Professional Documents
Culture Documents
Manual
S/N 527311001 & Above
S/N 527411001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6903151 (2-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START .....................................................10-01
RPM SENSOR.........................................................70-01
TIRE MAINTENANCE..............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HEATER
SPECIFICATIONS
SPECIFICATIONS
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to
service.
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.
SI SSL-0206 SM
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Figure 2
1
P-48387
DELIVERY REPORT
Figure 4
P-48677
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
FRONT
OPERATOR SEAT LIGHTS
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDERS FRONT AUXILIARY
QUICK COUPLERS
STEPS
BUCKET
STEPS
✝ BUCKET B-22498
● OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
◆ REAR AUXILIARY DEVICE
QUICK COUPLERS
LIFT ARM
REAR
GRILL LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
✽ TIRES B-22499
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Procedure
Figure 10-10-1
P-31849
Figure 10-10-3
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0903
Put the floor jack under the front of the loader [Figure 10-
WARNING 10-3].
Lift the front of the loader and put jack stands under the
Put jack stands under the front axles and rear
axle tubes [Figure 10-10-3].
corners of the frame before running the engine for
service. Failure to use jack stands can allow the
NOTE: Make sure the jack stands do not touch the
machine to fall or move and cause injury or death.
tires. Make sure tires clear floor or any
W-2017-0286
obstacles.
1
2
N-20525
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [Figure 10-20-2]
to the lift arm support device so there will be no
interference with the support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the seat bar and move pedals until both pedals
lock.
Figure 10-20-5
1 2
N-20524
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [Figure 10-20-3].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
N-20526
lock.
Install pin (Item 1) [Figure 10-20-3] into the rear of the lift Raise the support device into storage position and insert
arm support device below the cylinder rod. pin (Item 1) through lift arm support device (Item 2)
[Figure 10-20-5] and bracket. Connect spring to pin.
Removing The Lift Arm Support Device
Remove jack stands.
Figure 10-20-4
N-20523
Description
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
Figure 10-30-2
N-20120 P-54069
N-20520 N-20519
Always stop the engine before raising or lowering the
cab.
Loosen the nut (both sides) at the front corners of the
operator cab [Figure 10-30-2]. NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
Remove the nuts and plates [Figure 10-30-2] (both the grab handles to lower the cab.
sides).
Pull down on the bottom of the operator cab until it stops
Figure 10-30-3 at the latching mechanism [Figure 10-30-4].
Figure 10-30-5
P-54068
Emergency Exit
Figure 10-30-6
N-20171
Pull on the tag on the top of the rear window to remove Figure 10-30-9
the rubber cord [Figure 10-30-6].
Figure 10-30-7
X
P-30255
P-54070 Push the window out with your foot [Figure 10-30-9] at
any corner of the window.
Push the rear window out of the rear of the operator cab. Exit through the front door.
Procedure
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
N-19048 N-19073
Figure 10-40-1
N-20528D
1 N-20527D
Procedure
Figure 10-50-1
1
1
N-18409
Procedure
Figure 10-60-1
1
1
P-28793
Figure 10-60-3
N-20862
P-28823
Procedure (Cont'd)
WARNING
Figure 10-60-4
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
1 service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-5
P-28806
N-20861
Procedure (Cont'd)
Figure 10-60-6 1
2
3 1
P-43215
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.
Checking
Figure 10-80-1
1
2
N-18409
Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Removal And Installation
on Page 70-40-1.)
OUTER FILTER
Figure 10-80-3
1 P-43240
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
P-43239
INNER FILTER
Figure 10-80-6
1 P-43242
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
P-54003
Figure 10-90-3
P-54001
MAX
Open the rear door and remove the rear grill. (See
Removal And Installation on Page 50-60-1.) MIN
MAX
P-45106
Use air pressure or water pressure to clean the top of the
oil cooler [Figure 10-90-1].
WARNING
Do not use your bare hands to remove debris from P-54001
the oil cooler. Cooling fins are sharp and may cause
injury.
Open the rear door and raise the rear grill.
W-2460-0303
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
P-54001
Remove the cover from the coolant recovery tank. Fill the
tank until it is between the MIN and MAX marks on the
coolant recovery tank.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Fuel Specifications
Figure 10-100-2
WARNING WRONG
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause B-15602
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].
2 1
1
2
P-48076
P-48388
Open the rear door. Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.
(See SERVICE SCHEDULE on Page 10-70-1) for the
service interval for removing water from, or replacing the Squeeze the hand pump (priming bulb) (Item 2) [Figure
fuel filter. 10-100-4] until fuel flows from the vent with no air
bubbles.
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the Close the vent (Item 1) [Figure 10-100-4] on the fuel
filter. filter housing.
Remove the filter element (Item 2) [Figure 10-100-3]. Open the vent (Item 3) [Figure 10-100-4] on the fuel
injection pump.
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and Squeeze the hand pump (priming bulb) (Item 2) [Figure
hand tighten. 10-100-4] until the pump feels solid.
Remove the air from the fuel system. (See Removing Air Tighten the vent (Item 3) [Figure 10-100-4].
From The Fuel System on Page 10-100- 2.)
Start the engine.
Removing Air From The Fuel System
It may be necessary to open the vent (Item 3) [Figure 10-
100-4] briefly while the engine is running. Close the vent
when the engine runs smoothly.
WARNING
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
Figure 10-110-1
P-43249
P-43247
(See SERVICE SCHEDULE on Page 10-70-1.)for the
service interval for replacing the engine oil and filter.
Park the loader on level ground.
Run the engine until it is at operating temperature.
Check the engine oil level every day before starting the
engine for the work shift. Park the loader on level ground and stop the engine.
Open the rear door and remove the dipstick (Item 1) Open the rear door.
[Figure 10-110-1].
Remove the drain plug (Item 1) [Figure 10-110-2].
Keep the oil level between the marks on the dipstick. DO
NOT OVERFILL. Drain the oil into a container and dispose of used oil in an
environmentally safe manner.
Use a good quality motor oil that meets API Service
Classification of CD or better (See Oil Chart on Page 10-
110-1.)
Oil Chart
1
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-110-5
P-48079
P-1575
Add oil until it reaches the top mark (Item 1) [Figure 10-
110-5] on the dipstick. DO NOT OVERFILL.
Figure 10-120-1
2
1
P-28802
Lower the lift arms and tilt the Bob-Tach fully back.
Figure 10-120-2
P-54008
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received 2
immediately. 3
W-2145-0290
P-54188
P-54081
1
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Add the correct fluid to the reservoir until the fluid level is
between the marks on the dipstick. DO NOT fill above the
top mark on the dipstick.
Breather Cap
Figure 10-120-8
1
1
P-30011
(See SERVICE SCHEDULE on Page 10-70-1), for the NOTE: Be sure the rubber gasket (Item 2) [Figure 10-
correct service interval. 120-9] is installed on the cap.
Remove the breather cap (Item 1) [Figure 10-120-8]. Install the breather cap.
Checking And Adding Oil Remove the front chaincase cover.(See Front Cover
Removal And Installation on Page 40-30-2.)
Figure 10-130-1
Use a vacuum pump to extract the fluid from the chain
case.
P-3870
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
Figure 10-140-1
N-18460
Move the Bob-Tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-150-1]. Figure 10-150-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062
Figure 10-151-1
2
1
P-43832
2
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
2 Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
1
P-43831
Figure 10-151-4
Bob-Tach
Wedge
1
B-17460
If the wedge does not contact the lower edge of the hole Lubricate the wedges. (See SERVICE SCHEDULE on
[Figure 10-151-4], the attachment will be loose and can Page 10-70-1) and (See LUBRICATION OF THE
come off the Bob-Tach. BOBCAT LOADER on Page 10-160-1.)
Procedure
Figure 10-160-1
P-54011
N-20579
Procedure (Cont'd)
Figure 10-160-5
8 8
P-43829 P-43830
N-20573
Figure 10-160-6
6 P-43831
7
P1564
Procedure (Cont'd)
Figure 10-160-8
P-48500
Figure 10-160-9
N-20575
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-9].
Check that the lock nuts are tightened to 25-28 ft.-lb. (34-
38 N•m) torque.
Mounting
Rotating IMPORTANT
Figure 10-170-2 Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
Servicing
WARNING
Figure 10-180-1
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
(See SERVICE SCHEDULE on Page 10-70-1), for Close the rear door.
service interval for cleaning the spark arrestor muffler.
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.