Service Manual S70 Skid-Steer Loader · Never service the Bobcat Skid-Steer Loader without...

6986662 (2-08) Printed in U.S.A. © Bobcat Company 2008

Service ManualS70 Skid-Steer Loader

S/N A3W611001 & AboveS/N A3W711001 & Above

EQUIPPED WITHBOBCAT INTERLOCK

CONTROL SYSTEM (BICS)

MAINTENANCE SAFETY

WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operator’s Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0903

Never service the Bobcat Skid-Steer Loader without instructions.

Have good ventilation whenwelding or grinding paintedparts.Wear dust mask when grindingpainted parts. Toxic dust and gascan be produced.Avoid exhaust fume leaks whichcan kill without warning. Exhaustsystem must be tightly sealed.

Stop, cool and clean engine offlammable materials beforechecking fluids.Never service or adjust loaderwith the engine running unlessinstructed to do so in themanual.Avoid contact with leakinghydraulic fluid or diesel fuelunder pressure. It can penetratethe skin or eyes.Never fill fuel tank with enginerunning, while smoking or whennear open flame.

Disconnecting or loosening anyhydraulic tubeline, hose, fitting,component or a part failure cancause lift arms to drop. Do not gounder lift arms when raisedunless supported by anapproved lift arm support device.Replace it if damaged.

Keep body, jewelry and clothingaway from moving parts,electrical contact, hot parts andexhaust.Wear eye protection to guardfrom battery acid, compressedsprings, fluids under pressureand flying debris when enginesare running or tools are used.Use eye protection approved fortype of welding.Keep rear door closed except forservice. Close and latch doorbefore operating the loader.

Never work on loader with liftarms up unless lift arms are heldby an approved lift arm supportdevice. Replace if damaged.Never modify equipment or addattachments not approved byBobcat Company.

Lead-acid batteries produceflammable and explosive gases.Keep arcs, sparks, flames andlighted tobacco away frombatteries.Batteries contain acid whichburns eyes or skin on contact.Wear protective clothing. If acidcontacts body, flush well withwater. For eye contact flush welland get immediate medicalattention.

Use the correct procedure to lift orlower operator cab.

Cleaning and maintenance arerequired daily.

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 & MaintenanceManual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcatreplacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW01-0805

WRONG

B-6590

WRONG

B-16102B-6580

WRONG

B-16102B-6589

WRONG

B-15280

WRONG

B-15231

WRONG

B-11799

B-10731a

CORRECT

B-12365

CORRECT

B-7469

CORRECT

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

ALPHABETICAL INDEX

AIR CLEANER ........................................................ 70-01AIR CLEANER SERVICE ....................................... 10-01ALTERNATOR ........................................................ 60-01AUXILIARY CONTROL LOCKBOLT....................... 10-01AUXILIARY HYDRAULIC INTERLOCK VALVE...... 20-01

BATTERY................................................................ 60-01BICS™ CONTROLLER (GATEWAY)..................... 60-01 BICS™ SYSTEM ................................................... 60-01BOB-TACH ............................................... 10-01, 50-01BRAKE.................................................................... 40-01

CAMSHAFT AND TIMING GEARS......................... 70-01CHAINCASE ........................................................... 40-01CHARGE PRESSURE............................................ 30-01CONTROLS ............................................................ 20-01CONTROL LEVERS ............................................... 50-01CONTROL PANEL.................................................. 50-01CONVERSIONS ............................................SPEC-01CRANKSHAFT AND PISTONS .............................. 70-01CYLINDER HEAD................................................... 70-01CYLINDER (LIFT) ............................................... 20-01CYLINDER (TILT) ............................................... 20-01

DRIVE BELT ........................................................... 30-01DRIVE COMPONENTS .......................................... 40-01

ELECTRICAL SYSTEM INFORMATION ................ 60-01ENGINE ................................................................. 70-01ENGINE COMPONENTS AND TESTING .............. 70-01ENGINE COOLING SYSTEM...................... 10-01, 70-01ENGINE INFORMATION ........................................ 70-01ENGINE LUBRICATION SYSTEM.......................... 10-01ENGINE SPEED CONTROL .................................. 70-01

FINAL DRIVE TRANSMISSION (CHAINCASE) ..... 10-01FLYWHEEL AND HOUSING ............................... 70-01FUEL SYSTEM ............................................ 10-01, 70-01FUEL TANK............................................................. 50-01

HEATER COIL ........................................................ 80-01HEATER FAN.......................................................... 80-01HEATER SWITCH................................................... 80-01HEATER SYSTEM.................................................. 80-01HEATER UNIT ........................................................ 80-01HEATER VALVE...................................................... 80-01HYDRAULIC CONNECTION SPECS................SPEC-01HYDRAULIC CONTROL VALVE............................. 20-01HYDRAULIC/HYDROSTAIC FILTER...................... 20-01HYDRAULIC/HYDROSTAIC FLUID SPECIFICATIONS ................................SPEC-01HYDRAULIC PUMP................................................ 20-01HYDRAULIC FLUID RESERVOIR.......................... 20-01HYDRAULIC SYSTEM INFORMATION.................. 20-01HYDRAULIC/HYDROSTATIC SYSTEM ................. 10-01HYDROSTATIC MOTOR .....................................30-01

HYDROSTATIC PUMP ........................................ 30-01HYDROSTATIC SYSTEM INFORMATION ..........30-01

INSTRUMENT PANEL.............................................60-01

LIFT ARMS..............................................................50-01LIFT ARM BY-PASS CONTROL VALVE..................20-01LIFT ARM SUPPORT DEVICE ............................10-01LIFTING AND BLOCKING THE LOADER...............10-01LIGHTS ................................................................60-01LOADER SPECIFICATIONS ............................. SPEC-01LOADER STORAGE AND RETURN TO SERVICE 10-01LUBRICATING THE LOADER.................................10-01LUBRICATION SYSTEM.........................................70-01

MAIN RELIEF VALVE ..............................................20-01MUFFLER................................................................70-01

OIL COOLER .......................................................20-01OPERATOR CAB .........................................10-01, 50-01OPERATOR SEAT...................................................50-01

PARKING BRAKE....................................................40-01PIVOT PINS ............................................................10-01

REAR DOOR...........................................................50-01REAR WINDOW ..................................................50-01RECONDITIONING THE ENGINE ..........................70-01REGULAR MAINTENANCE ....................................80-01REMOTE START SWITCH .................................10-01

SEAT BAR RESTRAINT SYSTEM..........................10-01SEAT BAR ...............................................................50-01SEAT BAR SENSOR...............................................60-01SERVICE SCHEDULE ............................................10-01SPARK ARRESTOR MUFFLER..............................10-01STARTER ................................................................60-01STEERING ..............................................................30-01

TIRE MAINTENANCE .............................................10-01TORQUE SPECIFICATIONS FOR BOLTS ....SPEC-01TOWING THE LOADER..........................................10-01TRACTION LOCK ...................................................60-01TRANSPORTING THE LOADER ON A TRAILER ..10-01TROUBLESHOOTING ............................................80-01

WINDOWS (REAR) .................................................50-01

I S70 Service Manual

CONTENTS

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . X

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

s

DRIVESYSTEM

MAIN

SYSTEM AND

SAFETY &

HYDROSTATIC

MAIN FRAME

SYSTEM

SYSTEMDRIVE

ELECTRICAL

MAINTENANCE

SYSTEM &ANALYSIS

SERVICEENGINE

HEATER

HYDRAULICSYSTEM

SPECIFICATIONS

II S70 Service Manual

FOREWORDThis manual is for the Bobcat loader excavator mechanic. It provides necessary servicing and adjustment procedures forthe Bobcat loader and its component parts and systems. Refer to the for operating instructions, starting procedure, dailychecks, etc.

A general inspection of the following items must be made after the loader has had service or repair:

1. Check that the ROPS/FOPS(Including side screens) is ingood condition and is notmodified.

9. The parking brake mustfunction correctly.

2. Check that ROPS mountinghardware is tightened and isMelroe approved.

10. Enclosure door latches mustopen and close freely.

3. The seat belt must becorrectly installed, functionaland in good condition.

11. Bob-Tach wedges andlinkages must functioncorrectly and be in goodcondition.

4. The seat bar and pedalinterlocks must be correctlyadjusted, clean andlubricated.

12. Safety treads must be in goodcondition.

5. Check lift arm suport device,replace if damaged.

13. Check for correect function ofindicator lamps (Optional onsome models).

6. Machine signs must belegible and in the correctlocation.

14. Check hydraulic fluid level,engine oil level and fuelsupply.

7. Steering levers and footpedals must return to neutral.

15. Inspect for fuel, oil orhydraulic fluid leaks.

8. Check for correct funtion ofthe work lights.

16. Lubricate the loader.

III S70 Service Manual

17. Check the condition of thebattery and cables.

22. Operate the loader and checkall functions.

18. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.

23. Check for any fieldmodification not completed.

19. Check the electrical chargingsystem.

24. Check for correct function ofthe Bobcat Interlock ControlSystem (BICS™) before themachine is returned to thecustomer.

20. Check tires for wear andpressure.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

21. Inspect for loose or brokenparts or connections.

CALIFORNIAPROPOSITION 65 WARNING

Diesel engine exhaust and some of itsconstituents are known to the State of California

to cause cancer, birth defects and otherreproductive harm.

V S70 Service Manual

SAFETY INSTRUCTIONS

WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Operator’sHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs or service.Untrained operators and failure to follow instructionscan cause injury or death.

W-2003-0903

WARNINGWarnings on the machine and in the manuals are foryour safety. Failure to obey warnings can causeinjury or death.

W-2044-1285

IMPORTANTThis notice identifies procedures which must befollowed to avoid damage to the machine.

I-2019-0284

The following publications provide information on thesafe use and maintenance of the Bobcat machine andattachments:

• The Delivery Report is used to assure that completeinstructions have been given to the new owner andthat the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered withthe machine or attachment contains operatinginformation as well as routine maintenance andservice procedures. It is a part of the machine and canbe stored in a container provided on the machine.Replacement Operation & Maintenance Manuals canbe ordered from your Bobcat dealer.

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

• An Operator’s Handbook fastened to the operatorcab. It’s brief instructions are convenient to theoperator. The handbook is available from your dealerin an English edition or one of many other languages.See your Bobcat dealer for more information ontranslated versions.

• The AEM Safety Manual delivered with the machinegives general safety information.

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

• The Skid-Steer Loader Operator Training Course isavailable through your local dealer or atwww.training.bobcat.com or www.bobcat.com.This course is intended to provide rules and practicesof correct operation of the Skid-Steer Loader. Thecourse is available in English and Spanish versions.

• Service Safety Training Courses are available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com. They provide information forsafe and correct service procedures.

• The Skid-Steer Loader Safety Video is available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com.

SI SSL-1007 SM

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

Safety Alert Symbol

VII S70 Service Manual

FIRE PREVENTION

Maintenance

The machine and some attachments have componentsthat are at high temperatures under normal operatingconditions. The primary source of high temperatures isthe engine and exhaust system. The electrical system, ifdamaged or incorrectly maintained, can be a source ofarcs or sparks.

Flammable debris (leaves, straw, etc.) must be removedregularly. If flammable debris is allowed to accumulate, itcan cause a fire hazard. Clean often to avoid thisaccumulation. Flammable debris in the enginecompartment is a potential fire hazard.

The operator’s area, engine compartment and enginecooling system must be inspected every day and cleanedif necessary to prevent fire hazards and overheating.

All fuels, most lubricants and some coolants mixtures areflammable. Flammable fluids that are leaking or spilledonto hot surfaces or onto electrical components cancause a fire.

Operation

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

Electrical

Check all electrical wiring and connections for damage.Keep the battery terminals clean and tight. Repair orreplace any damaged part or wires that are loose orfrayed.

Battery gas can explode and cause serious injury. Usethe procedure in the Operation & Maintenance Manualfor connecting the battery and for jump staring. Do notjump start or charge a frozen or damaged battery. Keepany open flames or sparks away from batteries. Do notsmoke in battery charging area.

Hydraulic System

Check hydraulic tubes, hoses and fittings for damageand leakage. Never use open flame or bare skin to checkfor leaks. Hydraulic tubes and hoses must be properlyrouted and have adequate support and secure clamps.Tighten or replace any parts that show leakage.

Always clean fluid spills. Do not use gasoline or dieselfuel for cleaning parts. Use commercial nonflammablesolvents.

Fueling

Stop the engine and let it cool before adding fuel. Nosmoking! Do not refuel a machine near open flames orsparks. Fill the fuel tank outdoors.

Starting

Do not use ether or starting fluids on any engine that hasglow plugs. These starting aids can cause explosion andinjure you or bystanders.

Use the procedure in the Operation & MaintenanceManual for connecting the battery and for jump starting.

Spark Arrestor Exhaust System

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

Check the spark arrestor exhaust system regularly tomake sure it is maintained and working properly. Use theprocedure in the Operation & Maintenance Manual forcleaning the spark arrestor muffler (if equipped).

SI SSL-1007 SM

VIII S70 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnectthe battery, and disconnect the wiring from the Bobcatcontrollers before welding. Cover rubber hoses, batteryand all other flammable parts. Keep a fire extinguishernear the machine when welding.

Have good ventilation when grinding or welding paintedparts. Wear dust mask when grinding painted parts.Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such ashoods, fenders or covers can be flammable or explosive.Repair such components in a well ventilated area awayfrom open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits arelocated and how to use them. Inspect the fireextinguisher and service the fire extinguisher regularly.Obey the recommendations on the instructions plate.

SI SSL-1007 SM

IX S70 Service Manual

SERIAL NUMBER LOCATIONS

Always use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation.

Bobcat Loader Serial Number

Figure 1

The loader serial number plate is located on the inside ofthe operator cab on the right fender and in front of theseat [Figure 1].

Explanation of loader Serial Number:

Engine Serial Number

Figure 2

The engine serial number is located on the engine fuelinjection pump [Figure 2].

DELIVERY REPORT

Figure 3

The Delivery Report must be filled out by the dealer andsigned by the owner or operator when the Bobcat loaderis delivered. An explanation of the form must be given tothe owner. Make sure it is filled out completely [Figure3].

XXXX XXXXX

Model/ Engine Version Production Sequence (Series)

P-4399

P-37954

B-16315

X S70 Service Manual

BOBCAT LOADER IDENTIFICATION

B-23703

OPERATORHANDBOOK

OPERATOR SEAT

TILT CYLINDER

◆OPERATING LIGHTS

SEAT BAR

GRAB HANDLES

STEERING LEVER

SAFETY TREAD

STEPS

†BUCKET

B-23704

◆OPERATING LIGHT

REAR DOOR

•OPERATOR CAB (ROPS/FOPS)

UPRIGHTS

LIFT ARM SUPPORT DEVICE

LIFT ARMS

LIFT CYLINDERTIRES*

FACTORY OPTIONAL 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, per SAE J1040 and ISO 3471, and Falling Object Protective Structureper SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standardoperator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

10-01 S70 Service Manual

SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . 10-140-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . 10-90-2

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . 10-110-1Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Removing And Replacing Oil And Filter. . . . . . . . . . . . . . 10-110-1

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . 10-120-1Removing And Replacing Hydraulic / Hydrostatic Filter . 10-120-2Removing And Replacing Hydraulic / Hydrostatic Fluid. . 10-120-3

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . 10-210-1Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Continued On Next Page

SAFETY &

SYSTEMDRIVE

ELECTRICAL

MAINTENANCE

SYSTEM &ANALYSIS

ENGINESERVICE

SPECIFICATIONS

10-02 S70 Service Manual

SAFETY AND MAINTENANCE (CONT’D)

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-190-1

REMOTE START TOOL-MEL 1563 . . . . . . . . . . . . . . . . . . . . 10-60-1Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-60-1Service Tool Harness Communicator - MEL1566 . . . . . . . 10-60-2Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-60-2

REMOTE START TOOL (SERVICE TOOL) KIT -6689779 . . . 10-61-1Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-61-4Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-61-3Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-61-2

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . 10-200-1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . 10-220-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . 10-40-1Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEESTANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPECSECTION) UNLESS OTHERWISE SPECIFIED.

10-10-1 S70 Service Manual

LIFTING AND BLOCKING THE LOADER

Procedure

WARNINGAVOID INJURY OR DEATH

Instructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Operator’sHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs or service.Untrained operators and failure to follow instructionscan cause injury or death.

W-2003-0807

Figure 10-10-1

WARNINGPut jackstands under the front axles and rear cornersof the frame before running the engine for service.Failure to use jackstands can allow the machine tofall or move and cause injury or death.

W-2017-0286

Figure 10-10-2

Always park the loader on a level surface.

Put a floor jack under the rear of the loader [Figure 10-10-2].

Lift the rear of the loader and install jackstands [Figure10-10-2].

Figure 10-10-3

Put the floor jack under the front of the loader [Figure 10-10-3].

Lift the front of the loader and put jackstands under theloader frame.

NOTE: Make sure the jackstands do not touch thetires.

B-7023A

P-34920

P7289


LIFT ARM SUPPORT DEVICE

Installing

Maintenance and service work can be done with the liftarms lowered. If the lift arms are raised, use the followingprocedures to engage and disengage an approved liftarm support device.

WARNINGNever work on a machine with the attachment raisedunless secured by an approved support device.Failure to use an approved support device can causethe lift arms, boom or attachment to fall and causeserious injury or death.

W-2059-1007

WARNINGRepair the support device if damaged or if parts aremissing. Using a damaged support device or withmissing parts can cause lift arms or boom to fallcausing serious injury or death.

W-2271-1007

Figure 10-20-1

Put jackstands under the rear corners of the loader frame(Inset) [Figure 10-20-1].

Disconnect the spring from the lift arm support deviceretaining pin (Item 1) [Figure 10-20-1], hold the supportdevice and remove the retaining pin.

Figure 10-20-2

Lower the lift arm support device to the top of the liftcylinder. Fasten the free end of the spring (Item 1)[Figure 10-20-2] to the lift arms support device so therewill be no interference with the support deviceengagement.

With the operator in the seat, seat belt fastened and seatbar lowered, start the engine, press the green PRESSTO OPERATE Button.

P-19458

1

P-9773

P-81991

1


LIFT ARM SUPPORT DEVICE (CONT’D)

Installing (Cont’d)

Figure 10-20-3

Start the engine and raise the lift arms until the lift armsupport device drops onto the lift cylinder rod (Item 1)[Figure 10-20-3].

Lower the lift arms slowly until the support device is heldbetween the lift arm and the lift cylinder. Stop the engine.Raise the seat bar and move both pedals until bothpedals lock.

Install pin (Item 2) [Figure 10-20-3] into the rear of the liftarm support device below the cylinder rod.

Removing

Figure 10-20-4

Remove the retaining pin (Item 1) [Figure 10-20-4] fromthe lift arm support device.

Figure 10-20-5

Connect the spring from the lift arm support device to thetubeline bracket (Item 1) [Figure 10-20-5] on the liftarms.

With the operator in the seat, seat belt fastened and seatbar lowered, start the engine, press the green PRESSTO OPERATE Button.

Raise the lift arms a small amount. The spring will lift thesupport device off the lift cylinder rod.

Lower the lift arms and stop the engine.

Raise the seat bar, disconnect the seat belt and move thepedals until both pedals lock.

Disconnect the spring from the bracket.

N-20524BP-54470A

1

2

P-9808

1

P-9807

1


LIFT ARM SUPPORT DEVICE (CONT’D)

Removing (Cont’d)

Figure 10-20-6

Raise the support device into storage position and insertthe pin through the lift arm support device and bracket(Item 1) [Figure 10-20-6].

Connect the spring to the pin [Figure 10-20-6]

Remove the jackstands.

P-19458

1


OPERATOR CAB

Description

The Bobcat Loader has an operator cab (ROPS andFOPS) as standard equipment to protect the operatorfrom rollover and falling objects. Check with your dealer ifthe operator cab has been damaged. The seat belt mustbe worn for rollover protection.

ROPS / FOPS - Roll Over Protective Structure per ISO3471, and Falling Object Protective Structure per ISO3449, Level I.

Level I - Protection from falling bricks, small concreteblocks, and hand tools encountered in operations suchas highway maintenance, landscaping, and otherconstruction sites.

WARNINGNever modify operator cab by welding, grinding,drilling holes or adding attachments unlessinstructed to do so by Bobcat Company. Changes tothe cab can cause loss of operator protection fromrollover and falling objects, and result in injury ordeath.

W-2069-0200

Raising

Always stop the engine before raising or lowering thecab.

Stop the loader on a level surface and lower the lift arms.If the lift arms must be up while raising the operator cab,install the lift arm support device. (See LIFT ARMSUPPORT DEVICE on Page 10-20-1.)

Figure 10-30-1

Install jackstands (Item 1) [Figure 10-30-1] under therear corners of the loader frame.

Figure 10-30-2

Remove the nut and plate (Items 1&2) [Figure 10-30-2]on the inside front corner of the cab (Both sides).

P-81921

1

1

S4011

2

1

S4012

2

1


OPERATOR CAB (CONT’D)

Raising (Cont’d)

Figure 10-30-3

Lift on the grab handle and bottom of the operator cabslowly until the cab is all the way up and the latchingmechanism engages [Figure 10-30-3].

Lowering


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

W-2205-1207

Always stop the engine before raising or lowering thecab.

Figure 10-30-4

Hold the operator cab. Release the locking mechanismby pushing the lever (Item 1) in from the locked position(Item 2) and turning the lever until it stays in the unlockedposition (Item 3) [Figure 10-30-4].

REMOVE YOUR HAND FROM THE HOLE BEFORELOWERING THE OPERATOR CAB.

Stand on the ground and pull the cab down. Avoidslippery surfaces.

NOTE: The weight of the cab increases whenequipped with options and accessories suchas cab door, heater, air conditioning, etc. Inthese cases, the cab may need to be raisedslightly from the latch to be able to release thelatch.

NOTE: Always use the grab handles (once you canreach them) to lower the cab.

Figure 10-30-5

Install the plates and nuts (Items 1&2) [Figure 10-30-5](both sides).

Tighten the nuts to 40-45 ft.-lb. (54-61 N•m) torque.

P-81970

P-37062P-37061

1

2

2

SXXXXS4012

1

2

SXXXXS4011

1

2



Lowering (Cont’d)

If equipped with a heater, do the following:

NOTE: The heater hose connectors will disconnectwhen the cab is raised. The heater hoseconnectors must be reconnected for theheater to work after the cab is lowered andsecured.

Move the seat as far forward as needed to access theheater hose connectors that are loacted at the rear of thecab.

Figure 10-30-6

From behind the operator’s seat, push the two heaterquick connectors (Item 1) [Figure 10-30-6] into theheater couplers.

P-74920

1

1



Emergency Exit

The front opening on the operator cab and rear windowprovide exits.

Rear Window (If Equipped)

Figure 10-30-7

Pull on the tag (Item 1) [Figure 10-30-7] at the top of therear window to remove the rubber cord.

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

Figure 10-30-8

Exit throught the rear of the cab [Figure 10-30-8].

Front Door (If Equipped)

NOTE: When an Operator Cab Enclosure Kit isinstalled, the window of the front door can beused as an emetgency exit [Figure 10-30-9].

NOTE: If the loader has a special Application Door Kitinstalled, the window of the front door is NOTan emergency exit.

Figure 10-30-9

Pull the plastic loop (Item 1) [Figure 10-30-9] at the topof the window in the front door to remove the rubber cord.

Figure 10-30-10

Push the window out with your foot at any corner of thewindow (Item 2) [Figure 10-30-10].

Exit through the door.

P-64994S4046

P-19463

N-20171

1

6707852


TRANSPORTING THE LOADER ON A TRAILER

Loading And Unloading

WARNINGAVOID SERIOUS INJURY OR DEATH

Adequately designed ramps of sufficient strength areneeded to support the weight of the machine whenloading onto a transport vehicle. Wood ramps canbreak and cause personal injury.

W-2058-0807

Be sure the transport and towing vehicles are ofadequate size and capacity for the weight of the loader.

Figure 10-40-1

A loader with an empty bucket or no attachment must beloaded backward onto the transport vehicle [Figure 10-40-1].

The rear of the trailer must be blocked or supported[Figure 10-40-1] when loading or unloading the loader toprevent the front end of the trailer from raising up.

Fastening

Figure 10-40-2

Use the following procedure to fasten the Bobcat Loaderto the transport vehicle to prevent the loader from movingduring sudden stops or when going up or down slopes[Figure 10-40-2].

• Lower the bucket or attachment to the floor.

• Stop the engine.

• Engage the parking brake.

• Install chains at the front and rear loader tie downpositions [Figure 10-40-2].

• Fasten each end of the chain to the transport vehicle.

B-23759

Support

P-81925

P-9927

P-9926C P-9926B


TRANSPORTING THE LOADER ON A TRAILER (CONT’D)

Fastening (Cont’d)

Figure 10-40-3

Fasten the rear of the loader as shown [Figure 10-40-3].

P-37628P-37627P-37626


TOWING THE LOADER

Procedure

Because of the design of the loader, there is not arecommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to movefor service (EXAMPLE: Move onto a transportvehicle.) without damage to the hydrostatic system.(The wheels will not turn.) There might be slight wearto the tires when the loader is skidded.

The towing chain (or cable) must be rated at 1 & 1/2times the weight of the loader.


REMOTE START TOOL-MEL 1563

Remote Start Tool - MEL1563

Tools that will be needed to complete the following stepsare:

MEL1563 - Remote Start ToolMEL1565 - Service Tool Harness ControlMEL1566 - Service Tool Harness Communicator(Computer Interface)

Figure 10-60-1

The remote start tool (Item 1) [Figure 10-60-1] isrequired when the service technician is checking thehydraulic/hydrostatic system or adjusting the steeringlinkage.

Figure 10-60-2

The traction lock switch (Item 1) [Figure 10-60-2] is usedto turn traction lock ON or OFF. Push the switch to theoverride postion. The switch will illuminate to indicatetraction lock OVERRIDE, in this position the wheels areable to turn.

The maximum flow/variable flow switch (Item 2) [Figure10-60-2] is used to activate the auxiliary hydraulics.Pressing the switch once will activate the auxiliaryhydraulics. Pressing the switch again will deactivate theauxiliary hydraulics. The switch is used when checkingpressures and flow rate.

The auxiliary pressure release (Item 3) [Figure 10-60-2]is not used.

P16114

1 P16117

1

2

3


REMOTE START TOOL-MEL1563 (CONT'D)

Service Tool Harness Control - MEL1565

Figure 10-60-3

The service tool harness control (Item 1) is used toconnect the remote start tool (Item 2) [Figure 10-60-3] tothe electrical system on the loader.

Figure 10-60-4

Remove the plug (Item 1) [Figure 10-60-4] from theloader harness connector.

Connect the service tool harness control to the loaderharness connector.

Figure 10-60-5

Loaders equipped with an attachment harness (Item 1)must disconnect the attachment harness from the loaderharness (Item 2) [Figure 10-60-5].

Connect the service tool harness to the ACD connectorand the loader harness connector. Make sure the cap ison the other connector when not being used.

NOTE: To monitor, diagnose or load new softwarethe Service PC must be connected to theRemote Start Tool.

Service Tool Harness Communicator - MEL1566

Figure 10-60-6

The service tool harness communicator (Item 1) isrequired to connect remote start tool to the Service PC(Item 2) [Figure 10-60-6].

P16114

2

1

P-82026

1

P-82028

1

2

P16119

1

2


REMOTE START TOOL KIT-MEL1563 (CONT’D)

Remote Start Procedure

The tool listed will be needed to do the followingprocedure:

MEL1563: Remote Start Tool Kit

Figure 10-60-7

The remote start tool (Item 1) [Figure 10-60-7] isrequired when the operator cab is in the raised positionfor service and the service technician needs to turn thekey switch on or start the engine. Example: adjusting thesteering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) andinstall an approved lift arm support device.

Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

Figure 10-60-8

Figure 10-60-9

Remove the plug (Item 1) [Figure 10-60-8] or disconnectthe attachment control harness (Item 1) [Figure 10-60-9]if connected.

P16115

1

P-82026

1

P-82028

1


REMOTE START TOOL KIT-MEL1563 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-60-10

Connect the remote start tool to the engine harnessconnector (Item 1) [Figure 10-60-10].

NOTE: The key switch on the right-hand sideoperator panel must be in the off position orthe Remote Start Kit will not operate.

NOTE: Make sure the cap (Item 2) [Figure 10-60-10] isinstalled on the second connector when not inuse.


With the 7-pin connector plugged into the loader andthe Remote Start Key Switch in the OFF position, theloader can still be started from the operator panelinside the cab. Placing the key switch of the remotestart tool in the run position disconnects theoperator panel key switch from the start circuit. If theservice technician will be working in the engine areait is important to remove the operator panel keys.

W-2357-0899

Figure 10-60-11

The remote start tool (Item 1) [Figure 10-60-11] hasthree rocker switches.P-82029

1

2

P16116

1


REMOTE START TOOL KIT-MEL1563 (CONT'D)


Figure 10-60-12

The traction lock switch (Item 1) [Figure 10-60-12] isused to turn traction lock on or off. Push the switch to theoverride position. The switch will illuminate to indicatetraction lock OVERRIDE, in this position the wheels areable to turn.

The maximum flow/variable flow switch (Item 2) [Figure10-60-2] is used to activate the auxiliary hydraulics.Pressing the switch once will activate the auxiliaryhydraulics. Pressing the switch again will deactivate theauxiliary hydraulics. The switch is used when checkingpressures and flow rate.

NOTE: With the engine off and the auxiliariesenabled, move the auxiliary controls left andright to relieve pressure.

The auxiliary pressure release (Item 3) [Figure 10-60-12]is not used.

Figure 10-60-13

Push the couplers on the front auxiliary block toward theblock and hold for five seconds to release the frontauxiliary pressure [Figure 10-60-13].

P16118

32 1

P-34661


REMOTE START TOOL (SERVICE TOOL) KIT -6689779

Description

The Remote Start Tool (Service Tool) Kit is a replacementtool for MEL 1563 Remote Start Tool and MEL 1400B -BOSS® Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,can be used to service older loaders with the BOSS®system using the supplied BOSS® Service Tool HarnessP/N 6689745.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,can be used to service newer loaders using the suppliedharness P/N 6689747.

A computer can be connected to the Remote Start Tool(Service Tool) for diagnostics and software updates usingthe computer harness P/N 6689746 in conjunction withthe loader harness.


REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 (CONT'D)

Remote Start Tool (Service Tool) - 6689778

Tools that will be needed to complete the following stepsare:

Order from Bobcat Parts P/N: 6689779 - Remote StartTool (Service Tool) Kit

Kit Includes:6689778 - Remote Start Tool (Service Tool)6689747 - Loader Service Tool Harness 6689746 - Computer Service Tool Harness6689745 - BOSS® Service Tool Harness

Figure 10-61-1

The remote start tool (Item 1) [Figure 10-61-1] isrequired when the service technician is checking thehydraulic / hydrostatic system or adjusting the steeringlinkage.

Figure 10-61-2

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-2] has five buttons.

The STOP button (Item 2) [Figure 10-61-2] is used tostop the Remote Start Tool (Service Tool) fromcommunicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-2] is used to turnthe Remote Start Tool (Service Tool) on and activates theloader ignition power. The button will illuminate toindicate the service tool is active.

The START button (Item 4) [Figure 10-61-2] is used tostart the loader engine.

The traction lock button (Item 5) [Figure 10-61-2] is usedto turn traction lock ON or OFF. Push the button and thebutton will illuminate indicating the traction lock isdisabled in which the wheels or tracks are able to turn.

The auxiliary button (Item 6) [Figure 10-61-2] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button a second time will turn the flow OFF. Thebutton is used when checking pressures and flow rate.

P-76678

1

P-76439

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5

6 4

3

1



Loader Service Tool Harness - 6689747

Figure 10-61-3

The loader service tool harness (Item 1) [Figure 10-61-3]is used to connect the remote start tool (service tool)(Item 2) [Figure 10-61-3] to the electrical system on theloader.

Figure 10-61-4

Loaders without an attachment control harness, removethe loader harness cap (Item 1) [Figure 10-61-4] andconnect the Loader Service Tool Harness from theRemote Start Tool (Service Tool).

Figure 10-61-5

Loaders with an attachment control harness (7 pin or 14pin), the attachment harness (Item 1) must bedisconnected from the loader harness (Item 2) [Figure10-61-5].

When the remote start procedure is completed, replacethe loader connector cap (Item 1) [Figure 10-61-4] orreconnect the attachment control harness to the loaderharness [Figure 10-61-5].

P-76678

2

1

P-82026

1

P-82028

1

2



Loader Service Tool Harness - 6689747 (Cont’d)

Figure 10-61-6

NOTE: The Remote Start Tool (Service Tool)connection harness has two connectors (Item1) and (Item 3). The main connector (Item 1)[Figure 10-61-6] is always used for connectionto the loader harness.

The second connector (Item 3) [Figure 10-61-6] is used for attachment ACD upgrades orattachment operational diagnostics only. Thisconnector has a cap that must be installedwhen connector is not being used.

Connect the Remote Start Tool (Service Tool) connector(Item 1) to the loader harness connector (Item 2) and theother Remote Start Tool (Service Tool) connector to theACD harness connector (Item 3) [Figure 10-61-6].

NOTE: The right instrument panel (Key Switch orKeyless) must be in the off position or theRemote Start Tool (Service Tool) will notoperate.

Computer Service Tool Harness - 6689746

Figure 10-61-7

The computer service tool harness (Item 1) [Figure 10-61-7] is required to connect remote start tool (servicetool) to the Service PC (Item 2) [Figure 10-61-7].

P-82029

1

2

3

P-76454

P-76450

1

2



Remote Start Procedure


With the 7-pin connector plugged into the loader andRemote Start Tool RUN button is not illuminated, theloader can still be started from the operator panelinside the cab.

Pressing the RUN button on the Remote Start Tooldisconnects the operator panel from the start circuit.If the service technician will be working in the enginearea it is important to remove the operator panel keyor lock the keypad with a unique password.

W-2647-0707

The tool listed will be needed to do the followingprocedure:

6689779: Remote Start Tool (Service Tool) Kit

Figure 10-61-8

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-8] is required when the operator cab is in the raisedposition for service and the service technician needs toturn on the loader or start the engine. Example: adjustingthe steering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) andinstall an approved lift arm support device.

Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

Figure 10-61-9

Loaders without an attachment control harness, removethe loader harness cap (Item 1) [Figure 10-61-9] andconnect the Loader Service Tool Harness from theRemote Start Tool (Service Tool).

Figure 10-61-10

Loaders with an attachment control harness (7 pin or 14pin), the attachment harness (Item 1) must bedisconnected from the loader harness (Item 2) [Figure10-61-10].

When the remote start procedure is completed, replacethe loader connector cap (Item 1) [Figure 10-61-10] orreconnect the attachment control harness to the loaderharness [Figure 10-61-10].

P-76450

1

P-82026

1

P-82028

1

2




Figure 10-61-11

NOTE: The Remote Start Tool (Service Tool)connection harness has two connectors (Item1) and (Item 3). The main connector (Item 1)[Figure 10-61-11] is always used forconnection to the loader harness.

The second connector (Item 3) [Figure 10-61-11] is used for attachment ACD upgrades orattachment operational diagnostics only. Thisconnector has a cap attached to it to preventdamage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector(Item 1) to the loader harness connector (Item 2) and theother Remote Start Tool (Service Tool) connector to theACD harness connector (Item 3) [Figure 10-61-11].

NOTE: The right instrument panel (Key Switch orKeyless) must be in the off position or theRemote Start Tool (Service Tool) will notoperate.

Figure 10-61-12

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-12] has five buttons.

The STOP button (Item 2) [Figure 10-61-12] is used tostop the Remote Start Tool (Service Tool) fromcommunicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-12] is used toturn the Remote Start Tool (Service Tool) on andactivates the loader ignition power. The button willilluminate to indicate the service tool is active.

The START button (Item 4) [Figure 10-61-12] is used tostart the loader engine.

The traction lock button (Item 5) [Figure 10-61-12] isused to turn traction lock ON or OFF. Push the button andthe button will illuminate indicating the traction lock isdisabled in which the wheels or tracks are able to turn.

The auxiliary button (Item 6) [Figure 10-61-12] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button a second time will turn the flow OFF. Thebutton is used when checking pressures and flow rate.

P-82029

2

3

1

P-76454

P-76439

2

5

6 4

3

1




Figure 10-61-13

The gear icon with the left facing arrows (Item 1) [Figure10-61-13] will illuminate and blink when the RUN key ispressed and the loader is communicating with the servicetool.

The computer icon with the right facing arrows (Item 2)[Figure 10-61-13] will illuminate and blink when theRemote Start Tool (Service Tool) is transmitting data toand from the computer.

NOTE: To relieve the pressure at the front auxiliaries(if equipped) turn engine off and enableauxiliaries. Move the auxiliary controls leftand right to relieve pressure.

Figure 10-61-14

Push the couplers on the front auxiliary block toward theblock and hold for five seconds to release the frontauxiliary pressure [Figure 10-61-14].P-76441

1 2

P-34661


SERVICE SCHEDULE

Chart

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

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 8-10 50 100 150■

250■

500 ■ 1000

Engine Oil Check the oil level and add as needed. Do not overfill.

Engine Air Filter and Air System

Check condition indicator. Service only when required. Check for leaks and damaged components.

Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level COLD and add premixed coolant as needed.

Fuel Filter Remove the trapped water.

Lift Arms, Cylinders, Bob-Tach Pivot Pins and Wedges

Lubricate with multi-purpose lithium based grease.

Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on sidewall of tire.

Seat Bar, Control Interlocks, Seat Belt

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

Bobcat Interlock Control Systems (BICS)

Check for correct function. Lift and Tilt functions MUST NOT operate with seat bar raised. See details in this Manual.

Safety Signs and Safety Treads

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

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

Indicators and Lights Check for correct operation of all indicators and lights.

Heater Filter (If Equipped) Clean or replace filter as needed.

Hydraulic Fluid, Hoses and Tubelines

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

Final Drive Trans. (Chaincase),

Check oil level and add oil as needed.

Foot Pedals and Steering Levers

Check for correct operation. Repair or adjust as needed.

Parking Brake Check operation.

Wheel Nuts Check for loose wheel nuts and tighten to correct torque.(See TIRE MAINTENANCE on Page 10-170-1.)

❏

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

Spark Arrestor Muffler Empty Spark Chamber.

Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. 150 hours ✵

Alternator Belt Check tension and adjust as needed.

Fuel Filter Replace filter element.

Steering Shaft Grease fittings.

Engine/Hydrostatic Drive Belt

Check for wear or damage. Adjust or replace as needed. ❍

Bobcat Interlock Control System (BICS)

Check the function of the lift arm bypass control.

Hydraulic Reservoir Breather Cap

Replace the reservoir breather cap.

Hyd./Hydro. Filter Replace the filter element. ●

Final Drive Trans. (Chaincase)

Replace the fluid.

Hydraulic Reservoir Replace the fluid.

Coolant Replace the coolant Every 2 years

WARNING

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

❏ Check every 8-10 hours for the first 50 hours, then as scheduled.✵ First oil and filter change must occur at 50 hours, then as scheduled.❍ Inspect new belt after first 50 hours, then as scheduled.● Replace the hydraulic / hydrostatic filter element after the first 50 hours; thereafter when the transmission warning light comes ON while operating or as scheduled.■ Or every 12 months.


AIR CLEANER SERVICE

Replacing Filter Elements

Figure 10-80-1

Replace the large (outer) filter element only when the redring shows in the window of the condition indicator (Item1) [Figure 10-80-1].

NOTE: Before replacing the filter element, push thebutton on the condition indicator (Item 2)[Figure 10-80-1]. Start the engine. If the redring does not show, do not replace the filterelement.

Outer Filter

Open the evacuator valve (Item 3) [Figure 10-80-1] toget rid of large particles of dust and dirt.

Remove the dust cover by lifting the lever (Item 4)[Figure 10-80-1].

Figure 10-80-2

Pull the element straight out (Item 1) [Figure 10-80-2].

Install a new outer element.

Install the dust cover (Item 2) [Figure 10-80-1].

Check the air intake hose and the air cleaner housing fordamage. Make sure all connections are tight.

Inner Filter

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

Figure 10-80-3

Remove the inner filter (Item 1) [Figure 10-80-3].

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

Install a new inner element.

Install the outer element.

Install the dust cover [Figure 10-80-1].

P-81988

1 2

4

4

3

P-81987

1

P-81986

1


ENGINE COOLING SYSTEM

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

Cleaning

Open the rear door.

NOTE: Be careful when raising and lowering the reargrill so that it does not fall on the radiator anddamage the fins.

Figure 10-90-1

Use low air pressure or water pressure to clean the top ofthe radiator (Item 1) [Figure 10-90-1].

Check the cooling system for leaks.

Lower the rear grill and close the rear door.

Checking Level

Open the rear door.


Wear safety glasses to prevent eye injury when anyof the following conditions exist:• When fluids are under pressure.• Flying debris or loose material is present.• Engine is running.• Tools are being used.

W-2019-0907

Figure 10-90-2

Remove the coolant fill cap (Item 1) [Figure 10-90-2].Check the coolant level. The level markers are on thetank. Coolant must be at the bottom marker when theengine is cold and on the top marker when hot.

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

Close the rear door before operating the loader.

IMPORTANTAVOID ENGINE DAMAGE

Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling systemefficiency and may cause serious premature enginedamage.

Too little antifreeze reduces the additives whichprotect the internal engine components; reduces theboiling point and freeze protection of the system.

Always add a premixed solution. Adding full strengthconcentrated coolant can cause serious prematureengine damage.

I-2124-0497

P-81981

1

P-81981

1

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