PDF DOWNLOAD Bobcat 453 Operation & Maintenance Manual 6724163

4 5 3 EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

Operation & Maintenance Manual (S/N 561811001 & Above)

6724163 (11–96) Revised (9–98)

Printed in U.S.A.

© Melroe Company 1998

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

Untrained operators can cause injury or death.

W–2001–1285 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

B–10731

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

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.

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–6591

Never exceed rated operating capacity.

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

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

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

Never carry riders.

Never modify equipment.

Use only attachments approved

by Melroe Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer 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 (BICSTM) OSW03–0698

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

SAFETY

OPERATING INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

REFERENCE INFORMATION Write the correct information for YOUR Bobcat loader in the spaces below.

Always use these numbers when referring to your Bobcat loader.

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

TROUBLE– SHOOTING

MACHINE SIGN TRANSLATIONS

SPECIFICATIONS

NOTES:

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

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453 Bobcat Loader Operation & Maintenance Manual

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

British Standards Institute (BSI) is the Certified Registrar Melroe chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Melroe manufacturing plants and the Melroe corporate offices (Gwinner, Bismarck & Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance.

Continued certification is subject to periodic audits.

ISO 9001 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.

What does ISO 9001 mean to Bobcat Customers? It means that Melroe Company produces your Bobcat loader, Excavator or Spra–Coupe and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS 3974113

ENGINE OIL FILTER (6 Pack)

3885315

FUEL FILTER

897064

AIR CLEANER

6630156

RADIATOR CAP

6599543

HYDROSTATIC FILTER, #10 MICRON

6665228

BATTERY

6724094

PROPLYLENE GLYCOL ANTI–FREEZE, Premixed – [–34°F (–37°C)]

6724354

PROPLYLENE GLYCOL ANTI–FREEZE, Concentrate

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

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FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator necessary operating, servicing and preventive maintence instruction for the Bobcat loader. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

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SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service inofrmation 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.

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the operator cab on the right fender and in front of the seat [A].

Explanation of loader Serial Number: XXXX

M

P–04399

XXXX

B

Production Sequence (Series) Factory Use Only Model, Engine Version ENGINE SERIAL NUMBER The engine serial number is located on the engine fuel injection pump. [B].

B–06183

C

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

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BOBCAT SKID STEER LOADER IDENTIFICATION ◊ OPERATING LIGHTS

SEAT BAR GRAB HANDLES

OPERATOR HANDBOOK

STEERING LEVER

OPERATOR SEAT

SAFETY TREAD

TILT CYLINDER

BUCKET ◊ OPERATING LIGHTS

OPERATOR CAB (ROPS & FOPS)

UPRIGHTS LIFT ARM SUPPORT DEVICE LIFT ARMS

REAR DOOR

LIFT CYLINDER

TIRES*

B–14268 B–14269

◊ FACTORY OPTION OR FIELD ACCESSORY (Not Standard Equipment) * TIRES – Flotation tires (Optional) are shown. Bobcats are base–equipped with standard tires.

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

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

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OPTIONS AND ACCESSORIES 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

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.

Operator Cab 85 dBa Sound Package . . . . . . . . . . . . . . . . . . . .

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

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

Back–up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

Opt. & FA

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

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

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

Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA FA FA FA

Instrumentation Bobcat Operation Sensing System (BOSS®) . .

Opt.

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 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii MACHINE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, xv

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SAFETY

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

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

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

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

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

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

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

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

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

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

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

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

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

SI01–0698

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

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

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

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

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

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

I–2019–0284

W–2044–1285

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

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

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

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

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

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

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

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full load, or only part of a bucket load.

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

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

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer about Melroe Safety equipment.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A

P–10650

SI03–0398

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

AUXILIARY HYDRAULIC CONTROL

6702255

6708294

6708358

6707255

6708105

317 kg

700 LBS.

6708555

6705434

6579510

6564806

6702302

6710358

6565367

6702301

6579528

B–14239

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MACHINE SIGNS (DECALS) (Cont’d)

6577754

6707786

6576048

6560573

6579511

6708212

6565990

Located inside the engine compartment.

6711659

6707867

B–14269

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OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . 4 Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Seat Sensor Override (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Traction Lock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

OPERATING INSTRUCTIONS

ENGINE STOP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 HYDRAULIC CONTROLS Attachment Functions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Auxiliary Hydarulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Auxiliary Hydraulics (Option or Field Accessory) . . . . . . . . . . . . . . . . . . . . . . . 9 Bucket Position Valve Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front Auxiliary Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front Auxiliary Hydraulics Continuous Operation (Detent) . . . . . . . . . . . . . 10 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear Auxiliary Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Emptying the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Digging Into the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Filling the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Leveling the Ground (Using Lift Arms in Float Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Warming the Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . 16 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,24 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1

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INSTRUMENT PANEL

A

The following items are located on the instrument panel [A]:

5

1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Raised) Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 5.)

6

7

10

11

8 9

2. SEAT SENSOR OVERRIDE BUTTON (If Equipped) (Functions Only When The Seat Bar Is Down) Allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated. (See Page 4.)

4 1

3. IGNITION SWITCH – For starting, stopping the engine.

2

12

3 MC–02034

B

4. BEACON SWITCH (OPT.) – Controls the optional flashing beacon light.

5. LIGHT SWITCH (Option or Field Accessory) – Controls the work and travel lights.

6. PREHEAT BUTTON – For preheating the glow plugs before starting the engine.

1

7. BUCKET LEVEL SWITCH (Option or Field Accessory) – Controls the ON/OFF function of the optional bucket position valve.

P–09775

8. 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. 9. TRANSMISSION WARING LIGHT –Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON. 10. HOURMETER – Records the total operation hours of the loader.

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

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

ENGINE SPEED CONTROL The engine speed control (Item 1) [B] 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. ENGINE STOP CONTROL The engine stop control (Item 1) [C] is located below the front edge of the operator’s seat. Pull out on the engine stop control to stop the engine.

Push in on the control after the engine is stopped.

3

453 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 1.

The Bobcat Interlock Control System (BICS™) requires the operator to be seated in the operating position with the seat bar fully lowered before the lift, tilt and traction functions can be operated. The seat belt must be fastened any time you operate the loader.

A 1 2 3 4

The lift, tilt and traction drive functions are interlocked with the seat bar. The lift and tilt functions are interlocked with the seat.

5

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

There are five (5) green lights on the BICS™ System Controller and all must be lighted to operate the loader [A].

P–04242

B

The light functions are as follows [A]: 1. ON when operator is in the seat.

2. ON when the seat bar is in down position.

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

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

1

5. ON when the Controller is operating correctly.

NOTE: If any of the lights are off or blinking, see the troubleshooting chart on Page 52 of this manual or see inspection and maintenance instructions on Page 33.

B–14246

Seat Sensor Override (If Equipped) (Functions Only When The Seat Bar Is Down) Seat Sensor Override button (Item 1) [B] allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated.

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.

If seat indicator light on the BICS Controller does not go on, check for debris, dirt, or objects under or behind seat Lift Arm By–Pass Control

W–2151–0394

The lift arm by–pass control knob (Item 1) [B] 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) [B]. 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™).

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.

W–2045–1086

4

453 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont’d) 2.

A

Traction Lock Override There is a Traction Lock Override button (Item 1) [A] on the left hand instrument panel. It allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service.

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

1

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

P–09788

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.

B

PARKING BRAKE Engage the parking brake by pushing down on the top (toe) of the pedal [B]. The traction drive system will be locked.

MC–01914

P–09780

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

C MC–01914

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.

P–09779

5

453 Bobcat Loader Operation & Maintenance Manual

STEERING LEVERS

A

1

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

P–09781

B

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

FORWARD

REVERSE

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

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

FORWARD TRAVEL: Push both levers forward.

REVERSE TRAVEL: Pull both levers backward.

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

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

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

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

To increase travel speed, push the levers farther forward.

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

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

W–2002–1285

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.

PI–01849

6

453 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

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

1

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.

P–09785

W–2046–0595

B

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

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

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

SEAT BAR DOWN

2

Seat Bar

1

Interlock

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

3

Pedal Linkage

MC–01781

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.

• Move auxiliary control out of detent position.

W–2164–1294

C

SEAT BAR RAISED

Seat Bar

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

W–2105–1285

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

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

Refer to the Preventive Maintenance section for Seat Bar Restraint System Inspection & Maintenance. (See Page 33.)

MC–01781

7

453 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

A

Foot Pedals

3 1 2

P–04256

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

W–2002–1285

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

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

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

4

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

1

Lift Arm Float Position

5

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

P–04256

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

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

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

Bucket Position Valve Operation (Optional) The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in, prior to the upward lift cycle.

B–07440 B–07441

Bucket positioning functions automatically during the upward lift cycle only.

8

453 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (Option or Field Accessory) Auxiliary hydraulics [A] are not standard, but can be a Factory Option or installed as a Field Accessory.

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.

P–09777

B

W–2220–0396

Locked 2 1

Quick Couplers (Flush Face) 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 [A].

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.

P–09778

Rotate the ball release sleeve so that the locking pins (Item 1) [B] and the groove (Item 2) [B] do NOT align (Locked Position).

C 1

NOTE: If the locking pins and groove (Item 1) [C] are aligned, accidental disconnection is possible.

To Disconnect: Rotate the ball release sleeve so that the grooves are aligned with the pins (Item 1) [C] in the female coupler.

Holding the male coupler retract the sleeve on the female coupler until the couplers disconnect.

To Release

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

P–07965

9

453 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (Cont’d))

1

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.

P–09787

W–2220–0396

B

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

Raise the operator cab (See Page 30).

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

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

P–09777

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) [C].

C

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

Move the steering lever all the way to the right (Item 1) [C] to put the control valve into the detent 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 detent position before leaving the operator cab.

P–09776

10

453 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

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

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 Check Fuel Level Safety Tread & Safety Signs Bobcat Interlock Control System (BICS™)

B–06583

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

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that cetain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

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 [A].

W–2003–0797

B

6708212

11

453 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION

A

Read the Operation & Maintenance Manual and the Operator’s Handbook before operating the loader [A].

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

W–2001–0596 P–04246

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 [B].

B

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.

P–09786

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

C

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

N–15149

12

453 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

Lower the seat bar [A].

Be sure the parking brake is engaged.

All controls must be in the neutral position before you start the engine. (See Normal Starting Condition, Page 15.)

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

N–15148

B

N–15147

13

453 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE 3.

A

WRONG

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

W–2050–1285 B–03724

B

WRONG

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

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086 B–06578

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453 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d) 4.

Normal Starting Condition

A

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

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

Lower the seat bar [A].

P–09784

B

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

NEUTRAL POSITION

Set the engine speed control to half speed position (Item 2) [B].

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) [B].

1 1/2 SPEED

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

2 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.

ON POSITION

I–2034–0284

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

3

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

START POSITION

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

4 RUN POSITION

5 15

PI–02188 MC–02033

453 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

1

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

W–2071–1285

Cold Temperature Starting Condition P–09788

Also see Normal Starting Condition, Page 15. Turn the key switch to the RUN position.

B

Push the PREHEAT button (Item 1) [A] on the left side of the instrument panel to preheat the glow plugs.

Refer to the decal on the left side of the operator cab for operation of the preheat system [B].

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

If the temperature is below 32oF (0oC), use the following procedure to make starting the engine easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Oil Chart, Page 37.)

6705712

• Make sure the battery is at full charge.

• Install block or tank heater on the engine.

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

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

Pull up on the engine stop control to stop the engine.

Push down on the engine stop control after the engine has stopped.

16

453 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

A

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

Unapproved attachments can cause injury or death.

W–2052–1285 B–06587

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

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

The Rated Operating Capacity for this loader is shown on a label in the operator cab. (See the Specifications section, Page 61.)

AVOID INJURY OR DEATH

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.

Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

W–2053–0887

Exceeding the Rated Operating Capacity can cause the following problems [A]: 1. Steering the loader may be difficult.

B

2. Tires may wear faster.

2

3. There will be a loss of stability.

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

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

B–09054

Installation and Removal (Standard)

B–09044

C

The Bobcat is standard equipped with pin–type installation of attachments.

2

Install the pivot pins into the lower pivot holes in the bucket (Item 1) [B]. 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) [B].

1

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

Install the retainer and bolt (Item 2) [C]. Tighten bolt to 8–10 ft.–lbs. (10–13 Nm) torque

B–09073

17

B–09065

453 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installation and Removal (Bob–Tach – Option or Field Accessory) The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operator’s Manual to install other attachments.

PI–02590

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

B–06194

W–2054–1285

B

Pull the Bob–Tach levers all the way up.

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

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

PI–02591

Tilt the Bob–Tach backward until the bucket is off the ground [B]. Stop the engine.

B–06195

C

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

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both locked.

W–2045–1086

PI–02589

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

B–06196

D

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

W–2102–0588

1

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

Removal: Fully lower the bucket or attachment to the ground, stop the engine. Pull up on the Bob–Tach lever.

2

Tilt the bucket forward. Back the loader away from the bucket.

B–06197

18

453 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES

A

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

WITH BUCKET FULL

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

Going Down Slope

Loaders warmed up with moderate engine speed and light load have longest life.

1–2015–0284

B

B–14306

WITH BUCKET FULL

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

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

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

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

C

• 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.

WITH BUCKET EMPTY

Going Down Slope

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

D

W–2018–1187

B–09043

B–09042

WITH BUCKET EMPTY

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

Going Up Slope

19

B–09042

453 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (Cont’d)

A

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

P–04256

B–06719

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

B

P–04256

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

W–2056–1187

Drive backward away from the material.

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

B–06718

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

C

P–04256

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

W–2057–1285

B–06708

20

453 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

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

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

P–04256

B–06720

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

B

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

P–04256

B–06721

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

C

P–04256

B–06717

21

453 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

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

P–04256

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

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

B–06722

I–2005–1285

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

Backfilling P–04256

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

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

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

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

B–06724

22

453 Bobcat Loader Operation & Maintenance Manual

PARKING THE BOBCAT LOADER

A

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.

AVOID INJURY OR DEATH

MC–02099

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

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B

W–2045–1086

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.

LIFTING THE LOADER

B–06198

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point

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.

lift and operator cab.

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

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

W–2056–1187

W–2007–0497

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

Install the kit and lift the loader as shown [A].

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

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

23

453 Bobcat Loader Operation & Maintenance Manual

TRANSPORTING THE BOBCAT LOADER

A

453BICSOperation&MaintenanceManual#6724163S/N561811001&Above–OperatingInstructionsSection

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 [A] & [B].

Lower the bucket or attachment to the floor. Stop the engine.

Engage the parking brake.

Install chains at the front and rear of the loader as shown [A] & [B].

NOTE: Front and rear of the loader have similar slots in the frame for chain hooks [A].

B–06199

NOTE: Rear of the loader can be chained using the loop below the rear door [B].

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).

The towing chain (or cable) must be rated at 1–1/2 times the weight of the loader. (See Specification Page 61.)

• Turn the key switch to ON and press the Traction Lock Override button.

B–06200

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

B

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

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.

6707867

P–04031

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

I–2017–0389

24

453 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting the BICS™ System Controller (Engine STOPPED–Key ON) . . 33 Inspecting the Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspecting the Seat and Seat Bar Sensors (Engine RUNNING) . . . . . . . . . 33 Inspecting the Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . 33 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Proylene Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 38 ELECTRICAL SYSTEM Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replacing Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . 44 Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FUEL SYSTEM Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Replacement of the Hydraulic/Hydrostatic Filter Element . . . . . . . . . . . . . . 43 Removing the Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disengaging the Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engaging the Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 45 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

25

PREVENTIVE MAINTENANCE

453 Bobcat Loader Operation & Maintenance Manual

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

W–2003–0797 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–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

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

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

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

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

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

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

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

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

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

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

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

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

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

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

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

Lead–acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

26

MSW01–0698

453 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE 5.

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.

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

ITEM Engine Air Cleaner Engine Oil Engine Cooling System Tires Indicators, Gauges & Lights (Opt.) Seat Belt and Seat Bar

Safety Signs (Decals) and Safety Tread Lift Arm and Bob–Tach Pivot Pin and Wedges Engine Fuel Filter Hyd. Fluid, Hoses & Tubelines Bobcat Interlock Control System (BICS™) Battery Control Pedals & Steering Bob–Tach Wheel Nuts Parking Brake Alternator Belt Engine Fuel Filter Engine Oil & Filter Hydraulic Filter Element Spark Arrestor Muffler Drive Belts Steering Lever Pivots Engine Fuel Filter Hydraulic Reservoir Fill Cap (Breather) Final Drive Transmission (Chaincase) Hydraulic/Hydrostatic Reservoir Bobcat Interlock Control System (BICS™)

SERVICE REQUIRED

8–10

50

100

250 500 1000

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

Check the oil level & add oil as needed.

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

Check the air pressure & for damaged tires.

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

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

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

Lubricate with multi–purpose lithium based grease.

Remove the water from the filter.

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

Check BICS™ System Controller functions. Clean dirt, debris or objects from under or behind seat as required.

Check cables & electrolyte level.

Check for correct operation repair or adjust as needed.

Check locking levers & wedges for condition & operation.

Check for loose wheel nuts & tighten to 40–45 ft.–lbs.

(54–61 Nm) torque.

Check operation.

Check tension & adjust as needed.

Remove the water from the filter.

Replace oil & filter. Use CD or better grade oil and Melroe filter.

Replace filter element.

Clean the spark chamber.

Check all drive belts for condition and tension. Adjust as needed.

Lubricate the grease fittings and the oil hole in the steering shaft.

Replace filter element.

Replace the breather cap.

Replace the fluid.

Replace the fluid.

Check the lift arm bypass control

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.

27

453 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE 6.

A

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

W–2059–0598

1 P–09811

Engaging the Lift Arm Support Device Use the following procedure to use the lift arm support device.

B

Put jackstands under the rear corners of the loader.

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

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

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

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

P–09810

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod.

C

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

Raise the seat and move pedals until both pedals lock.

Install pin (Item 1) [C] into the rear of the lift arm support device below the cylinder rod.

Disengaging the Lift Arm Support Device

1

Remove the pin from the lift arm support device.

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

P–09808

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

D

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

Stop the engine.

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

Disconnect the spring from the bracket.

1

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

Connect spring to pin [A].

P–09807

28

453 Bobcat Loader Operation & Maintenance Manual

REAR DOOR 7.

A

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

W–2012–0497

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

Open the rear door.

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

W–2020–1285

P–09782

29

453 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB 8.

Emergency Exit

A

The front opening on the operator cab and rear window provides exits.

To exit through the rear window, use the following procedure: Pull on the tag at the rear window to remove the rubber cord [A].

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

Exit through the rear of the operator cab [B].

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.

P–09829

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.

B

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.

P–09774

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

C

1

W–2069–1285

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

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

Open the rear door. (See Page 29.)

If the lift arms must be up while raising the cab, install a lift arm support device. (See Page 28.)

P–09771

Remove the two (2) fasteners at the front corners of the operator cab [C].

Stand on the ground. Lift slowly until operator cab is all the way up [D].

D

The operator cab will lock in the raised position.

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.

P–09773

W–2014–0895

30

453 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d) 9.

Lowering the Operator Cab

A

Move the locking mechanism by pushing the lever inward from the locked position [A] and turning the lever until it stays in the unlocked position [B].

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

Avoid slippery surfaces when lowering the cab.

P–09823

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

B

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595 P–09825

Install the cab fasteners (including the washers or plates) and tighten the nuts. (See [C], Page 30.)

31

453 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM 10.

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.

A

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.

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.

Operate each foot pedal to check both the lift and tilt functions.

P–09790

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.

B

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

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

P–04400

Seat Bar Maintenance See the SERVICE SCHEDULE Page 27 and on the loader for correct service interval.

C

Clean any debris or dirt from the moving parts [A].

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

1

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

P–07528

32

453 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

Inspecting the BICS™ System Controller (Engine STOPPED – Key ON)

1 2

Sit in the operator’s seat. Turn key ON, lower the seat bar and disengage the parking brake. All five (5) BICS™ System Controller lights should be ON (Items 1, 2, 3, 4 & 5) [A].

3 4 5

Engage the parking brake, raise the seat bar fully. Seat bar light (Item 2) [A], valve light (Item 3) [A] and traction light (Item 4) should be OFF. Raise up slightly off the seat. Seat light (Item 1) [A] should be OFF.

P–09826

NOTE: Record what lights are blinking (if any) and number of blinks. Refer to Page 52.

B

Exit the loader and press traction lock override button.

Traction light (Item 4) [A] should be ON. Press override button again and traction light (Item 4) [A] should be OFF. Inspecting the Seat and Seat Bar Sensors (Engine RUNNING) Sit in the operator’s seat, lower the seat bar and engage the parking brake. Fasten the seat belt.

Start the engine and operate at low idle. While raising the lift arms, raise the seat bar fully. The lift arms should stop.

Repeat using the tilt function.

Clean area behind and under seat.

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

Operator Seat

C

Inspecting the Traction Lock (Engine RUNNING)

P–09824 P–09824

Sit in the operator’s seat.

Fasten the seat belt, disengage the parking brake, and raise the seat bar fully. Move the steering levers slowly forward and backward. The traction lock should be engaged. Lower the seat bar.

Seat Sensor

Seat 1 Spring

Seat Rail Cover

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 Raise the lift arms six (6) feet (2 m) off the ground. Stop the engine, pull and hold the by–pass control knob. Push the toe of the left foot pedal and the lift arms should lower slowly.

Maintenance

MC–02043

Clean any debris, dirt or objects from under or behind the operators seat [B] & [C]. The right side of the seat must move up and down.

AVOID INJURY OR DEATH

Clearance is necessary between the seat mount (Item 1) [C] and the seat pan, to allow the seat to move up and down freely. With adequate clearance, the seat sensor will be allowed to function properly.

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.

Inspect seat bar pivot area for tightness of linkage bolts.

W–2151–0394

Replace parts that are damaged. Use only genuine Melroe replacement parts.

33

453 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

See the SERVICE SCHEDULE Page 27 for the interval to service the air cleaner system.

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

1

Service the air cleaner as follows: Loosen the wing nut (Item 1) [A].

P–04265

Remove the cover (Item 1) [B], remove the dust cup (Item 2) [B]. Empty the debris from the dust cover.

B 3

Remove the wing nut (Item 3) [B] from the air filter.

2

1

P–04259

C Remove the air filter [C].

NOTE: Make sure all sealing surfaces are free of dirt and debris.

P–04266

34

453 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM

A

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

ON

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F°/C° +15o(–9o) o Down to –20 /–29o Below –20o/–29o

No. 2 100% 50% 0%

No. 1 0% 50% 100%

2

OFF

1

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

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

p–09831

Filling the Fuel Tank

B

Stop and cool the engine before adding fuel.

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

W–2063–0887

Remove the fuel fill cap [B].

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

P–09830

Install and tighten the fuel fill cap [B].

C

Fuel Filter

WRONG

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

See the SERVICE SCHEDULE Page 27 for the service interval when to remove the water from the fuel filter. Turn the fuel shut–off valve (Item 2) clockwise to shut–off the fuel supply [A].

B–06108

D

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

Open the shut–off valve (Item 2) [A].

See the SERVICE SCHEDULE Page 27 for the service interval when to replace the fuel filter.

Clean the area around the fuel filter. Close the shut–off valve [A].

Use a filter wrench to remove the fuel filter [D].

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

Install the new filter element.

1

Open the shut–off valve [A].

P–04264

35

453 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From the Fuel System

1

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.

Open the rear door. The engine must be cool.

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

P–04264

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

B

Tighten the vent plug.

Operate the hand pump until it feels solid [B].

1

B–06142

Move the engine speed control to minimum RPM. Open the valve (Item 1) [C] and squeeze the hand pump several times.

C

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

1

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

B–06113

W–2103–1285

36

453 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM 11.

Check the oil level every day.

A

Stop the engine and remove the dipstick (Item 1) [A].

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

2 1

Replacing Oil and Filter See the SERVICE SCHEDULE Page 27 for the service interval for replacing the engine oil and filter.

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

P–04257

B

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

Remove the filter (Item 2) [A].

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

Turn the oil fill cap (Item 1) [C] counterclockwise to remove the cap.

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

Oil Chart

P–04255 RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

C

+43 +49

SAE 40W or 20W–50 SAE 10W–30 SAE 15W–40 SAE 30W

1 * SAE 5W–30 SAE 20W–20 SAE 10W

P–04260

SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90 +100 +110 +120

F°

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

* Can be used ONLY when available with appropriate diesel rating.

Fill to capacity. (See SPECIFICATION Section, Page 61.)

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 filler cap (Item 1) [C].

NOTE: DO NOT overfill the crankcase.

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453 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM

A

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

Checking the Coolant Level

1

Open the rear door.

The coolant recovery tank (Item 1) [A] is located between the radiator and the right upright.

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

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

P–09816

B

Propylene Glycol Add premixed coolant; 43% water and 57% 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.

1

B–06393

C

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

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running • Tools are being used.

W–2070–1285

Cleaning the Cooling System Open the rear door.

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

P–09818

Removing Coolant from the Cooling System Open the rear door.

Raise the operator cab. (See Page 30.)

Connect a hose (Item 1) [B] to the valve to keep the coolant out of the engine compartment.

Remove the radiator cap [C].

Turn the valve so the lever is toward the outlet of the valve.

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453 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT ADJUSTMENT

A

Stop the engine.

Loosen the three mounting bolts (Item 1) [A] and move the alternator bracket. Set the belt tension to 1/4’’ (6 mm) movement between pulleys with 15 pounds (67 N) of force [B]. Tighten the three adjustment bolts.

1

1 P–04258

B

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

The electrical system is protected by 6 fuses.

P–04262

Fuse Location

C

The fuses are located under the fuse covers (Item 1) [C] located in the engine compartment.

1

P–04250

Electrical System Service

D

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

Install the terminal covers.

P–09588

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453 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting)

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).

P–04387

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

1–2023–1285

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.

Stop and cool the engine before adding fuel.

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

W–2063–0887

The ignition must be in the OFF position.

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

The battery must be 12 volt.

Connect one end of the first cable to the positive terminal (+) of the booster battery. Connect the other end of the same cable to the loader battery positive (+) terminal [A].

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

Never lean over battery while boosting, testing or charging.

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

Keep the cables away from moving parts.

Battery gas can explode and cause serious injury.

Start the engine.

W–2066–1296

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

Remove the cable connected to the loader battery.

Battery Removal and Installation

B

Open the rear door. Disconnect the negative (–) battery cable first (Item 1) [B].

1

Disconnect the positive (+) cable (Item 2) [B].

Remove the battery from the loader.

2

P–04261

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453 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

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

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.

SPARK ARRESTOR MUFFLER See the SERVICE SCHEDULE Page 27 for correct service interval. Do not operate the loader with a defective exhaust system.

P–09590

P–09589

B 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.

1

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.

P–04249

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

I–2022–0595

Stop the engine. Open 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.

Remove the plug (Item 1) [B] from the bottom of the muffler.

W–2011–1285

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

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

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–2050–1285

W–2068–1285

Start the engine.

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.

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

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453 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

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

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

1

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

A 10 micron filter element is installed on the left side of the engine compartment. This filter is used to clean the fluid for the hydrostatic transmission.

P–04257

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

B

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

Open the rear door. Remove the dipstick (Item 1) [A].

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.

B–09047

If the fluid level is not at the top mark, add the correct fluid to the reservoir until the level is correct.

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.

W–2072–0496

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453 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacement of the Hydraulic/Hydrostatic Filter Element See the SERVICE SCHEDULE Page 27 for the correct service interval.

1

Stop the engine. Open the rear door. Raise the operator cab. (See Page 28 for the correct procedure.) Clean the area around the filter housing. Remove the plug (Item 1) [A] from the filter housing (located on the outside of the loader at the right side).

After the fluid is drained from the filter, install the plug (Item 1) and tighten [A].

B–06104

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

B

Clean the surface of the filter housing head 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.

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.

1

Removing the Hydraulic/Hydrostatic Fluid

B–09052

See the SERVICE SCHEDULE Page 27 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

C

Stop the engine. Open the rear door.

Remove the fill cap/dipstick.

Loosen the nut (Item 1) [C] which fastens the fill tube to the loader frame.

1

Loosen the clamp at the fill tube, turn the fill tube down to drain the fluid from the reservoir [C].

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

P–04254

Replace the hydraulic filter element.

Add hydraulic/hydrostatic fluid to the reservoir. (See SPECIFICATIONS, Page 61 for the correct fluid.)

Do Not over–fill the reservoir.

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453 Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

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 SPECIFICATIONS, Page 61.)

Checking and Adding Oil Put the loader on a level surface.Remove the plug at the front of the chaincase [A]. 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.

AUXILIARY CONTROL LOCKBOLT The Auxiliary control has a lockbolt (Item 1) [B] that must be removed to use the optional auxiliary hydraulics.

B–09066

Raise the operator cab. (See Page 30.)

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

B

TIRE MAINTENANCE Wheel Nuts See the SERVICE SCHEDULE Page 27 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) .

1

Tire Rotation Check the tires regularly for wear, damage and pressure (See SPECIFICATIONS, Page 61 for the correct tire pressure).

P–09787

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 [C].

C

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.

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

C–01965

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

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453 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER 12.

Lubricate the loader as specified in the SERVICE SCHEDULE Page 27 for the best performance [A].

A

Record the operating hours each time you lubricate the Bobcat loader.Always use a good quality lithium–based multipurpose grease when lubricating the loader. Apply the lubricant until the extra grease shows.

6567875

B

Grease the pivot bearings at the end of the steering shaft [B]. See the SERVICE SCHEDULE Page 27 for the correct service interval.

B–06203

Add oil or grease as needed to the steering control shaft [C]. (Both sides).

B–06204

C

B–09084

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453 Bobcat Loader Operation & Maintenance Manual

BOB–TACH

A

453BICSOperation&MaintenanceManual#6724163S/N561811001&Above–PreventiveMaintenanceSection

Check the Bob–Tach for wear or damage.

Check for free movement of the wedges and the Bob–Tach lever.

1

Clean the Bob–Tach to keep the lever in good working condition.

Push down on the Bob–Tach lever (Item 1) [A] to engage the wedges.

B–06196

B

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

W–2102–0497

1

The wedges (Item 1) [B] must extend far enough to engage the holes in the attachment.

B–06197

PIVOT PINS

C

All pivot pins, lift arms and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [C] & [D].

Check that the lockbolts are tightened to 8–10 ft.–lbs.

(11–13 Nm) torque.

Do not over–tighten.

1 P–07161

D

1 P–4247

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453 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 50 TROUBLESHOOTING THE HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . 51

TROUBLE– SHOOTING

47

453 Bobcat Loader Operation & Maintenance Manual

48

453 Bobcat Loader Operation & Maintenance Manual

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

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance 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 Engine won’t turn over with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause for loss of charge.

39

Cables loose or dirty.

Clean and tighten the battery cables.

41

Damaged starter, solenoid or wiring.

Check the starting circuit.

Repair as needed.

DS

Wrong starting procedure.

Use correct starting procedure.

14

No fuel in tank.

Add fuel.

DS

Dirt or water in fuel system.

Repairs as needed.

35

Damaged fuel pump.

Make repairs as needed.

DS

Fuel filter is dirty.

Install a new filter.

35

Hole in fuel line.

Repair as needed.

DS

Wrong oil in engine.

See Oil Specifications.

37

Engine has lost compression.

Recondition the engine.

DS

Engine has overheated.

Check Cooling System.

38

Poor fuel quality.

Use fresh, good quality fuel.

35

Dirt, water or air in fuel system.

Clean and repair as needed.

35

DS = Dealer Service Only

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453 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE ENGINE (Cont’d) PROBLEM

CAUSE

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

Engine overheats.

CORRECTION

PAGE

Engine is hot.

Check cooling system.

38

Governor adjustment is wrong.

Check & make adjustment if needed.

DS

Dirty air cleaner.

Check air cleaner.

34

Engine has lost compression.

Recondition the engine.

DS

Cooling system is dirty. Air flow restricted.

Clean cooling system.

38

Engine shrouding damaged or missing.

Repair or replace.

DS

Engine is overheated.

Run at full throttle.

–

TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM No hydraulic action.

CAUSE

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

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.

16

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

42

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.

16

Damage to cylinder rods or seals.

Repair cylinders.

DS

Hydraulic cylinders leak fluid.

42

DS = Dealer Service Only

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453 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE HYDROSTATIC SYSTEM PROBLEM

CAUSE

CORRECTION

PAGE

No drive on both sides.

Hydraulic fluid is low.

Check fluid level. Add as needed.

42

10 micron filter is damaged.

Replace filter.

43

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.

64

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.

42

Pugged filter.

Install new filter element.

43

Low charge pressure.

Check by–pass valve.

DS

Bobcat is overloaded.

Use correct size attachment.

17

Hydrostatic transmission damaged.

Check hydrostatic system.

DS

No drive on one side.

Machine pulls to one side.

DS = Dealer Service Only

51

453 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 13.

Troubleshooting Chart 453BICSOperation&MaintenanceManual#6724163S/N561811001&Above–TroubleshootingSection

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

Flashing Indicator Means System Problem (See Your Bobcat Dealer for Service) Effect on Operation of Loader When Light Is Number of OFF Flashes Cause

Light ON

Light OFF

Seat

Operator in Seat

No Operator in Seat

Lift and tilt functions will not operate.

Seat Bar

Seat Bar Down

Seat Bar Up

Lift, tilt and traction functions will not operate.

3

Lift and tilt functions will not operate.

1 2

Valve

Traction

Control Valve Can Control Valve Be Used Cannot Be Used

Loader can be moved forward & backward.

Loader cannot be moved forward and backward.

Loader cannot be moved forward and backward.

2 3 2

3 3 1 2 3 4 5 6

Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Seat sensor circuit shorted to battery voltage*.

Seat sensor circuit shorted to ground Seat bar sensor circuit shorted to battery voltage*.

Seat bar sensor circuit shorted to ground.

Valve output circuit is open.

Valve output circuit shorted to battery voltage*.

Valve output circuit shorted to ground.

Valve output circuit is not grounded.

Traction lock hold coil circuit is open.

Traction lock hold coil circuit shorted to battery voltage*.

Traction lock hold coil circuit shorted to ground.

Traction lock pull coil circuit is open.

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

Traction lock pull coil circuit is shorted to ground.

Lift, tilt and traction functions will not operate.

NOTES: (1) If the seat 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.

(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat Sensor Override♦ can be used if the seat sensor cannot be activated. ♦ Only on later loaders, and early loaders which have had BICS Controller and switch replaced.

NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve and traction lights come on. (only loaders with BICS controller S/N’s above 200,000 will have this delay.) * Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage.

52

453 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 SERVICE SCHEUDLE (6708212) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 WARNING (6579528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 DANGER (6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 WARNING (6577754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 DANGER (6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an esential part of the loader. (See Page xiv & xv.) This section provides French and Spanish translations of the machine signs that are in English. The Operator’s Handbook is also available in a combination English, French, German, Spanish, Italian and Dutch editions.

–53–

453 Bobcat Loader Operation & Maintenance Manual

–54–

453 Bobcat Loader Operation & Maintenance Manual

IMPORTANTE (SPANISH) ESTA MAQUINA ESTA EQUIPADA POR LA FABRICA CON UN AMORTIGUADOR DE CHISPAS DEL SILENCIADOR, APROBADO POR EL SERVICIO DE SILVICULTURA DEL U.S.D.A. (DEPARTMENTO DE AGRICULTURA DE LOS ESTADOS UNIDOS).

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

IMPORTANT (FRENCH) CETTE CHARGEUSE EST EQUIPPEE A LA SORTIE DE L’USINE D’UN SILENCIEUX PARA–ETINCELLES APPROUVE PAR LE SERVICE DES EAUX ET FORETS DES ETATS–UNIS. IL EST INDISPENSABLE D’EFFECTUER UN ENTRETIEN REGULIER DE CE PARE–ETINCELLES AFIN DE LE GARDER EN BON ETAT DE MARCHE. L’ENTRETIEN CONSISTE A VIDER LA CHAMBRE A ETINCELLES TOUTES LES 100 HEURES DE MARCHE. SI CET ENGIN EST UTILISE SUR UN TERRAIN COUVERT D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, IL FAUT INSTALLER LE PARE–ETINCELLES ET LE GARDER EN BON ETAT DE MARCHE. CONSULTER LES APPLICABLES.

REGLEMENTATIONS

LOCALES

–55–

453 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

• Mantenga le puerta cerrada excepto para dar servicio.

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

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

• No use el cargador en lugares donde

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

• Todos los gases del escape pueden

matar. Ventile siempre el lugar de trabajo.

• No use nunca éter o líquido del arranque en los motores

• Les liquides sous pression peuvent pénétrer au travers de

• Escapes de líquido bajo presión pueden penetrat en la

• L’acide des batteries provoque de graves brûlures, porter

• El ácido de la batería puede causar quemaduras severas,

• Les batteries dégagent des gaz inflammables et

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

piel y causar heridas graves. Se requiere atención médica inmediata. Use gafas. Use cartón para revisar si hay fugas. use gafas. Si el ácido hace contacto con los ojos, la piel o la ropa, lávelos bién con agua. Si el contactor fuel en los ojos, lávelo bién y vaya al médico.

• Las baterias producen gas inflammable y explosivo.

la peau et causer de graves blessures. Consulter immédiatement un médecin Porter des lunettes de sécurité. Utiliser du carton pour repérer les fuites. des lunettes de sécurité. S’il entre en contact avec les yeux, la peau ou les vêtements, rincer généreusement à l’eau. Pour les yeux, appeler un médecin.

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

• En cas de démarrage par pontage, effectuer le dernier

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

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

• Para arranque con batería auxiliar, conecte de último el

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

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

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

un moteur diesel avec des bougies de préchauffage.

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

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

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

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non attachés et les vêtements à l’écart des contacts électriques, des pièces mobiles et brûlantes et de l’échappement.

• Ne pas utiliser la machine dans un endroit chargé de poussières ou de gaz explosifs, et où l’échappement risque de toucher des matériaux inflammables.

• Les gaz d’échappement peuvent être mortels. Toujours aérer.

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453 Bobcat Loader Operation & Maintenance Manual

PROGRAMA DE SERVICIO (SPANISH)

10.

CADA 10 HORAS 1. Aceite del Motor–Revise el nivel–no lo llene demasiado (Consulte el Manual del Operario para saber que aceite recominenda).

2. Filtro del Aire del Motor–Revise el medidor y/o el cuadrante. Dele servicio solamente cuando se necesite.

3. Sistema de refrigeración del motor–Eliminar suciedad del refrigerador, del radiador y de las rejillas.

Medir el nivel con el refrigerante frio. Completar con mezcla etilenglicol y agua (53/47).

4. Brazo de Elevación del Cargador, Cilindros, Pivote y Cuñas del Bob–Tach–Lubriquelos con grase de base de litio para uso múltiple (12 sitios).

5. Sistema de Aire del Motor–Revise para ver si hay fugas o componentes dañados.

6. En General–Verifique a ver si hay piezas flojas o rotas, daños en el cinturón de seguridad o en la cabina del operario, revise también el funcionamiento de los instrumentos, vea si hay tuercas flojas en las ruedas y fugas de aceite. Inspeccione el funcionamiento de la barra del aciento y arregle o reemplace la que sea necesario antes e poner a trabajar el cargador.

7. Cinturón de seguridad/Dispositivos de bloque de la barra de asiento y controles–Compruebe función.

Repare o reemplace como sea necesario. Limpie suciedad y escombros en las partes móviles.

8. Filtro del Combustible–Purgue el agua atrapada (Unicamente motor de diesel).

9. BICS–Verifique la función. Limpie la suciedad, escombros u objetos de abajo o de atrás del asiento tal como se requiere.

–57–

Llantas–Controle la presión de inflación. Infle las llantas hasta la presión. MAXIMA que se indica en la pared del costado de la llanta.

CADA 50 HORAS 1. Líquido Hidráulico–Revise el nivel del líquido. Vea el Manual del Operario para saber el líquido recomendado.

2. Caja de la Cadena–Revise el nivel del líquido. Vea su Manual del Operario para saber el líquido recomendado.

3. Batería–Revise su condición.

4. Mandos y Frenso–Verifique su funcionamiento, ajustelos si es necesario.

5. Aceite del motor (solo en las cargadoras 450)–Vaciar cuando el motor está a su temperatura de trabajo. Ver Manual de Utilización y de Mantenimiento.

CADA 100 HORAS 1. Silenciador con Amortiguador de Chispas–Desocupe la cámara de las chispas.

2. Sistema del Encendido–Si usa combustible que contine plomo, inspeccione las bujías y el sistema del encendido. Si usa combustible sin plomo, de servicio únicamente cuando sea necesario para mantener un encendido bueno y funcionamiento suave (Unicamente para Motores de Gasolina).

3. Vacie el aceite del motor cuando este está a su temperatura de trabajo. Ver Manual de Utilización y de Mantenimiento. (Cada 250 horas para 700 modelos con la KUBOTA motor.)

4. Inspeccione todas las correas de impulso–Verifique las condición y la tensión de todas las correas– Impulso del hidrostático, impulso de la bomba del agua, el alternador y el ventilador. Ajústelas y reemplácelas a media que sea necesario.

453 Bobcat Loader Operation & Maintenance Manual

5.

Sistema hidráulico/hidrostatico (solamente modelos 400 y 500)–Cambiar el filtro. Nota: El filtro ha de cambiarse antes si el inficador de aviso de la trasmision permanece encendido mas de 5 minutos despues de que el fluido hidráulico haya alcanzado su temperatura de trabajo.

CADA 250 HORAS (O CADA 12 MESES) 1. Filtro Final del Combustible–Reemplace el elemento del filtro.

2. Pivotes de la Palanca de la Dirección–Lubriquelos con grasa de base de litio para uso múltiple (2 sitios).

3. *Correa de transmisión. Comprobar si está desgastada o deteriorads. Ajustar si es necesario. *Inspeccione la nueva correa después de transcurridas

las primaras 50 horas de funcionamento. Ajustar si es necesario.

4. Transmisión (500 solamente)– Engrasar acoplamiento universal de la transmisión (modelo 500’s solamente).

Ver tipo de grasa en el Manual de Utilización y de Mantenimiento.

5. Sistema hidráulico/hidrostatico–Reemplazar el tapón respiradero del depósito hidráulico y cambiar el elemento del filtro. (853–reemplazar 2 elementos de filtro). Nota: El elemento filtrante deve ser cambiado antes si el indicador de la transmisión permanece encendido mas de 5 minutos despues de que el fluido hidráulico haya alcanzado su temperatura de trabajo.

CADA 1000 HORAS (O CADA 12 MESES) 1. Depósito hidráulico–Reemplazar el aceite. Véase tipo de aceite en el Manual de Utilización y de Mantenimiento.

2. Filtro de purge de los motores hidráulicos–Limpiar o cambiar si existen.

3. Cárter de la cadena– Vaciar y reemplazar el aceite.

Véase tipo de aceite en el Manual de Utilización y de Mantenimiento.

4. Cárter de engranajes del ventilador–Comprobar el nivel. Véase tipo de aceite en el Manual de Utilización y de Mantenimiento.

5. BICS–Comprobar el mando auxiliary de derivación de los brazos de elevación.

PROGRAMME D’ENTRETIEN (FRENCH) TOUTES LES 10 HEURES 1. Huile moteur–Contrôler le niveau–Ne pas dépasser le niveau (consulter le Manuel de l’Opérateur et d’Entretien

pour l’huile recommandée).

2. Filtre à air du moteur–Contrôler la jauge et/ou l’affichage.

Entretenir uniquement si nécessaire.

3. Circuit de refriudussenebt du moteur–Nettoyer les débris du refroidisseur d’huile, du radiateur et des grilles. Contrôler à froid le niveau de liquid de refroidissement et rajouter si nécessaire un mélange d’éthylène–glycol/eau à 53/47.

4. Bras de levage de la chargeuses, vérins, pivots et cale du Bob–Tach: lubrifier avec de la graisse tous usages à base de lithium (12 points).

5. Circuit d’air du moteur–Rechercher les fuites et les éléments endommagés.

6. Généralités–Rechercher les pièces desserrés ou brisées, voir si la ceinture de sécurité est endommagée de même que la cabine de l’opérateur, contrôler le fonctionnement des instruments, rechercher les écrous

de roue desserrés, les fuites d’huile, etc... Vérifier l’arceau de sécurité et réparer ou remplacer selon besoin avant d’utiliser la chargeuse.

7. Ceinture de sécurité/Verrouillages de barre de siège et de commandes–Fonction de vérification. Réparer ou remplacer selon les besoins. Nettoyer la saleté et les débris.

8. Filtre d’alimentation–Vidanger l’eau de condensation (moteur diesel uniquement).

9. BICS–Vérifiez le fontionnement. Nettoyez la saleté, les débris ou les objets se trouvant sous ou derrière le siège selon le besoin.

10. Pneus–Vérifiez la pression de gonflage. Gonflez les pneus à la pression MAXIMUM indiquée sur la paroi latérale des pneus.

TOUTES LES 50 HEURES 1. Huile hydraulique–Vérifier le niveau d’huile. Consulter le Manuel de l’Opérateur et d’Entretien pour l’huile.

2. Carter de chaînes–Vérifier le niveau. Consulter le Manuel de l’Opérateur et d’Entretien pour l’huile.

3. Batterie–Contrôler l’état de la batterie.

4. Commandes et freins–Contrôler le fontionnement et régler si nécessaire.

5. Huile moteur (série 450 uniquement)–Vidanger à chaud. Consulter le Manuel de l’Opérateur et d’Entretien.

TOUTES LES 100 HEURES 1. Silencieux para–étincelles–Vider la chambre à étincelles.

2. Circuit d’allumage–Si on utilise de carburant au plomb, vérifier les bougies et l’allumage. Si on utilise du carburant sans plomb, effectuer l’entretien uniquement selon besoin afin de maintenir de bonnes performances

au démarrage et un fonctionnement régulier (moteur à esence uniquement).

3. Huile moteur–Vidanger à chaud et changer le filtre.

Consulter le Manuel de l’Opérateur et d’Entretien.

(Toutes les 250 heures pour les séries 700 équipées d’un moteur KUBOTA.) 4. Contrôler tous les entraînements par courroie: hydrostatique, pomps á eau, alternateur et ventilateur;

vérifier l’état et la tension des courroies. Régler ou remplacer selon besoin.

5. Circuit hydraulique/hydrostatique (séries 400 et 500 uniquement)–Reemplacer l’élément du filtre. Remarque: L’élémentde filtre doit être remplacer plus tôt si le signal d’avertissement pour la transmission reste allumé plus de 5 minutes après que l’huile ne soit à temperáture.

TOUTES LES 250 HEURES (OU TOUS LES 12 MOIS) 1. Filtre d’alimentation final–Remplacer l’élément du filtre.

2. Pivots des leviers de direction–Lubrifier avec de la graisse tous usages à base de lithium (2 points).

3. Courroie de transmission–Vérifier et tendre si nécessaire. Vérifier la courroie de remplacement après 50 heures d’utilisation et régler si nécessaire.

4. Transmission (série 500 uniquement)–Graisser le cardan. Consulter le Manuel de l’Opérateur et d’Entretien.

5. Circuit hydraulique/hydrostatique–Remplacer le bouchon de reniflard du réservoir hydraulique et remplacer l’élément de filtre (853–remplacer deux (2) éléments de filtre). Remarque: L’élément de filtre doit être remplacé plus tôt si le signal d’avertissement de transmission reste allumé plus de 5 minutes après que le liquide hydraulicque soit à température.

TOUTES LES 1000 HEURES (OU TOUS LES 12 MOIS) 1. Réservoir hydraulique–Remplacer l’huile. Consulter le Manuel d’Opération et d’Entretien pour l’huile recommandée.

2. Filtre de drain de moteurs de transmission–Nettoyer ou remplacer si existant.

3. Carter de chaînes–Vidanger l’huile et la remplacer.

Consulter le Manuel de l’Opérateur et d’Entretien pour l’huile recommandée.

4. Réducteur du ventilateur–Contrôler le niveau d’huile.

Consulter le Manuel de l’Opérateur et d’entretien pour l’huile recommandée.

5. BICS–Vérifier le fonctionnement de la vanne de descente du bras de levage.

–58–

453 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

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

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

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

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

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

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA MELROE.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR MELROE COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE.

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

ANTES DE BAJARSE DEL CARGADOR POUR QUITTER LA CHARGEUSE: 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO. 2. PARE EL MOTOR.

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

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

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

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES.

–59–

453 Bobcat Loader Operation & Maintenance Manual

453BICSOperation&MaintenanceManual#6734163S/N561811001&Above–MachineTranslationsSection

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

PELIGRO (SPANISH)

LLEVE LA CARGA EN POSICION BAJA EL NO OBEDECER ESTA ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

EVITER DES BLESSURES OU LA MORT

LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL TOPE. • EL MOVER EL PIE DEL PEDAL O FALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOS BRAZOS DE ELEVACION.

TENIR LA CHARGE VERS LE BAS.

DANGER (FRENCH)

AVERTISSEMENT (FRENCH)

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

EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS DE LEVAGE RELEVÉS NE SONT PAS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

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

AVERTISSEMENT (FRENCH)

PELIGRO (SPANISH)

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

EVITE LA MUERTE

• EL FORZAR EL IMPLEMENTO CONTRA EL SUELO HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

JO DE LOS BRAZOS DE ELEVACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

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

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS SOUS LES BRAS OU LE VERIN DE LEVAGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

–60–

453 Bobcat Loader Operation & Maintenance Manual

14.

SPECIFICATIONS

CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 LOADER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 VIBRATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

SPECIFICATIONS

61–

453 Bobcat Loader Operation & Maintenance Manual

62–

453 Bobcat Loader Operation & Maintenance Manual

S Dimensions are given for loader equipped with standard tires and dirt bucket and may

SKID STEER LOADER SPECIFICATIONS

56.4 (1433)

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

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

99° ‘‘C”

33.9 (862)

38° 120.0 (3048) 92.4 (2347) 71.2 (1808)

15.0 (381) 71.5 (1816)

25°

26° 45.6 (1155)

5.9 (150)

‘‘B”

72.8 (1849)

STD. TIRES – 35.4 (900) FLOTATON – 43.3 (1100)

7.0 (180)

97.2 (2468)

‘‘A”

‘‘A”

28.4 (721)

‘‘B”

STD. TIRES – 29.4 (747) FLOTATION – 34.8 (884)

‘‘C”

6708828

36 in. BUCKET WIDTH – 35.48 in. (901 mm) 44 in. BUCKET WIDTH – 44.5 in. (1130 mm)

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 Rated Operating Capacity (SAE) . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . .

Operating Weight . . . . . . . . . . . . . . . . . . .

SAE Breakout Force – Lift . . . . . . . . . . . .

– Tilt . . . . . . . . . . . .

Axle Torque . . . . . . . . . . . . . . . . . . . . . . . .

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

CONTROLS Vehicle Steering . . . . . . . . . . . . . . . . . . . .

Loader Hydraulics: Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . .

Front Auxiliary (optional) . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . .

Service Brake . . . . . . . . . . . . . . . . . . . . .

453 600 lbs. (272 kg) 1431 lbs. (649,1 kg) 2501 lbs. (1134,5 kg) 1200 lbs. (544 kg) 1150 lbs. (522 kg) 1775 ft.–lbs. (2407 Nm) 0–5.2 MPH (8,4 km/hr.)

Direction and Speed controlled by two hand levers.

Secondary Brake . . . . . . . . . . . . . . . . . .

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

Controlled by separate foot pedals.

Controlled by lateral movement of RH steering lever.

Hand lever throttle; Key Type starter switch and shutdown.

Key activated glow plugs.

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

One of the hydrostatic transmissions Mechanical Disc, foot operated pedal.

ENGINE Make/Model . . . . . . . . . . . . . . . . . . . . . . . .

Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower(SAE Gross) . . . . . . . . . . . . .

(SAE Net) . . . . . . . . . . . . . . . .

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

Torque (SAE Gross) . . . . . . . . . . . . . . . . .

(SAE Net) . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Kubota/D750–B Diesel/Liquid 16.5 HP (12,3 kW) 15.0 HP(11,2 kW) 3000 RPM 33 ft.–lbs.(44,7 Nm)@ 1800 RPM 31 ft.–lbs. (42 Nm)@ 1800 RPM Three 46.5 cu.–in (762 cm3) 2.68/2.76 (68/70) Pressure System W/Filter External Dry replaceable paper cartridge Compression Diesel 63–

453 Bobcat Loader Operation & Maintenance Manual

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

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

System Relief at Quick Couplers . . . . . .

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

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

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

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

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

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

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

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

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

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

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

453 Engine driven, Gear type 6.8 GPM (25,7 L/min.) @ 3200 RPM 1400 to 1450 PSI (9653 to 9997,8 kPa) 10 micron replaceable cartridge in the hydrostatic pump charge line.

Double–acting 2.00 (50,8) 3.00 (76,2) 1.00 (25,4) 1.25 (31,8) 21.88 (555,8) 10.94 (277,9) 3–Spool series type, open center w/float detent on lift and detent on auxiliary.

SAE standard tubes, hoses & fittings 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 . . . . . . . . . . . . . . . . . . .

Lower Lift Arms . . . . . . . . . . . . . . . . . . . .

Bucket Dump . . . . . . . . . . . . . . . . . . . . . .

Bucket Rollback . . . . . . . . . . . . . . . . . . .

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

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

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

Instrumentation . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . .

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

5.0 Seconds 4.0 Seconds 3.0 Seconds 2.5 Seconds 37 amp open 12 Volt, 370 cold cranking amps @ 0° F (–18° C), 106 minute reserve capacity 12 Volt Straight Drive Gauges: Hourmeter, Voltmeter Eng. Temp. & Fuel (on tank) Warning Lights: Engine Oil Pressure & Temperature, Hyd. Oil Temp. & Pressure.

Hydrostatic 4 wheel drive Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing hydrostatic motors #60 endless roller chain & sprockets in sealed chaincase with oil lubrication

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . .

38.49:1 1.5 (38,1) (5) 7/16”

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

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

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

Hydraulic Reservoir . . . . . . . . . . . . . . . . . .

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

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

7 qts. (6,6 L) 6.5 gals. (24,6 L) 3.4 qts. (3,2 L) 5.3 qts. (5,0 L) 4.0 gals. (15,1 L) 3.0 gals. (11,4 L)

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

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

Recommended Pressure . . . . . . . . . . .

FLOOR PRESSURE Std. Tires–Rated Load . . . . . . . . . . . . . . . . . . .

Unloaded . . . . . . . . . . . . . . . . . . . . . .

Flot. Tires–Rated load . . . . . . . . . . . . . . . . . . . . .

Unloaded . . . . . . . . . . . . . . . . . . . . . . .

Revised Sept. 97

5.70–12, 4 ply rating 23 x 8.5–12, 4 or 6 ply rating Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

Front

Rear

Front

Rear

68 PSI (469 kPa) 49 PSI (338 kPa) 25 PSI (172 kPa) 14 PSI (97 kPa)

61 PSI (420 kPa) 67 PSI (462 kPa) 21 PSI ( 145 kPa) 25 PSI (172 kPa)

68 PSI (469 kPa) 49 PSI (338 kPa) 25 PSI (172 kPa) 14 PSI (97 kPa)

64 PSI (441kPa) 69 PSI (476 kPa) 23 PSI (159 kPa) 27 PSI (186 kPa)

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453 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES – For use on 453 Series Bobcat Loader These and other attachments are approved for use on this model Bobcat loader. Do not use unapproved attachments.

Attachments not manufactured by Melroe Company 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: BUCKETS

DESCRIPTION

Bob–Tach Mounted: 36 inch Dirt Bucket 36 inch Dirt Bucket w/6 teeth 44 inch Dirt Bucket 44 inch Dirt Bucket w/7 teeth 44 inch Utility Bucket 48 inch Utility Bucket Pin–On Type: 36 inch Dirt Bucket 44 inch Dirt Bucket 44 inch Utility Bucket 48 inch Utility Bucket Hydraulic Breaker (1250) (with Bob–Tach Only) 2 Position Frame (1560) 2 Position (1750S)

905B Backhoe (453 with Bob–Tach Only)

Bobcat backhoe attachments are designed for the pipeliner, municipal worker or contractor, for high production digging.

Frame

Up to 125 ft.–lb. impact energy class.

Bob–Tach mounted,. 2–position loader mounting frame for vertical and horizontal breaking. Quick–change tool system – variety of tools available. Low recoil operating cycle. *SPECIAL APPLICATIONS KIT WHICH INCLUDES A 1/2 INCH LEXAN FRONT DOOR WITH 1/4 INCH TOP AND REAR WINDOWS MUST BE USED WHEN OPERATING THE BOB–TACH MOUNTED HYDRAULIC BREAKER.

Utility Fork/Grapple Bob–Tach: 36’’ Fork 44’’ Fork Pin–On: 36’’ Utility Fork 44’’ Utility Fork Grapple Grapple

Cut down on daily hand chores and free up your time. The Bobcat Loader Utility Fork and Grapple is the ideal attachment for handling bundled material, loose straw, and manure.

Some attachments may not be available from your local dealer.

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453 Bobcat Loader Operation & Maintenance Manual

ADDITIONAL PUBLICATIONS

453BICSOperation&MaintenanceManual#6734163S/N561811001&Above–SpecificationsSection

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

OPERATOR’S HANDBOOK 6708358 SKID STEER LOADER OPERATOR TRAINING COURSE 6722720 –Introduces operator to step–by–step basics of Skid–Steer loader operation. Also available in Spanish P/N 6724036.

–gives basic operation instruction and safety warnings.

OPERATION & MAINTENANCE MANUAL 6724163 –complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

SAFETY VIDEO 6724793

–provides basic safety instructions.

Skid–Steer Loader

SAFETY MANUAL 6556500

EQUIPMENTMANUFACTURERS INSTITUTE 10S.RIVERSIDEPLAZACHICAGO,ILLINOIS60606–37100

SERVICE MANUAL 6724259 –complete maintenance and overhaul instructions for your BOBCAT loader.

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

PARTS MICROFICHE

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

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453 Bobcat Loader Operation & Maintenance Manual

WARRANTY 400–900 Series Bobcat Loaders The Melroe Company warrants to its authorized dealer and authorized dealers of Melroe Equipment, Ltd., who in turn warrants to the original buyer (owner) that each new Bobcat Loader will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

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

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

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

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

6570162 (1–96)

Printed in U.S.A.