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Operation & Maintenance Manual

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

6900372 (8–98) Revised (5–01)

Printed in U.S.A.

OPERATOR SAFETY WARNINGS CORRECT Operator must have instructions before running the machine. Untrained operators can cause injury or death. W–2001–1285 B–10731

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

Never use the loader without instructions. See machine signs

CORRECT

WRONG

CORRECT

(decals), Operation & Maintenance

Manual and Handbook.

B–7403

B–13552

B–13553

Always use the seat bar and fasten seat belt snugly. Always keep feet on the pedals or foot rest 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

B–6578

B–13554

B–13555

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

B–6587

B–13557

B–13558

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 about 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 pedals. 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 OSW01–0698 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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 . . . . . . .

SYSTEMS ANALYSIS

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

773 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 Melroe 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 3974896

ENGINE OIL FILTER (6 Pack)

6667352

FUEL FILTER

6598492

AIR CLEANER, OUTER

6598362

AIR CLEANER, INNER

6646678

RADIATOR CAP

6661248

HYDROSTATIC FILTER,

6665031

BATTERY

6724094

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

6724354

PROPYLENE 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.

773 Bobcat Loader Operation & Maintenance Manual

FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer. SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

iii

773 Bobcat Loader Operation & Maintenance Manual

SERIAL NUMBER INFORMATION Sometimes changes are made to a loader which will affect the way you must operate the controls, or it might affect maintenance & service procedures. These changes are identified by serial numbers (below). Identification in other parts of this manual may be made by Early Model Loaders OR Later Model Loaders. Description of Change and Loader Serial Number

Identification & Details of Change

Auxiliary Hydraulic Deactivation 5096 40053 & Above (Later Model Loaders) . . . . . These loaders have an Auxiliary Hydraulic Deactivation feature which deactivates the auxiliary hydraulics when the seat bar is raised. 5096 40052 & Below (Early Model Loaders) . . . . . These loaders do not have the Auxiliary Hydraulic Deactivation feature. Lift Arm By–Pass Control 5096 40660 & Above (Later Model Loaders) . . . . . These loaders use a procedure to lower the lift arms which which involves only the use of the Lift Arm By–Pass Control knob 5096 40659 & Below (Early Model Loaders) . . . . .. .These loaders use a procedure to lower the lift arms which involves the use of the Lift Arm By–Pass Control knob and left foot pedal (or mechanical hand controls)

773 Bobcat Loader Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. LOADER SERIAL NUMBER The loader serial number plate is located on the loader frame as shown [A]. Explanation of loader Serial Number: XXXX

P–10621

XXXXX

Module 2. – Production Sequence (Series) Module 1. – Model / Engine Combination 1. The four digit Model / Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the loader was manufactured. See SERIAL NUMBER INFORMATION, Page iv for Serial Numbers relating to this manual.

P–10560

ENGINE SERIAL NUMBER The engine serial number is in the location shown [B]. 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].

773 Bobcat Loader Operation & Maintenance Manual

BOBCAT LOADER IDENTIFICATION ◊ FRONT LIGHTS SEAT BAR GRAB HANDLES

OPERATOR SEAT WITH SEAT BELT

STEERING LEVER ◊ REAR AUXILIARY QUICK COUPLERS

TILT CYLINDER

BUCKET

STABILIZER ROD

◊ FRONT AUXILIARY QUICK COUPLERS BUCKET STEPS

SAFETY TREAD

◊ REAR WINDOW LIFT ARM LINK

OPERATOR CAB (ROPS & FOPS)

REAR GRILL LIFT ARM ◊ TAIL LIGHT

LIFT CYLINDER LIFT ARM SUPPORT DEVICE

◊ REAR LIGHT

REAR DOOR * TIRES ◊ *

B–15012 B–15013

OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) TIRES – The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section for available tires. BUCKET – Several different buckets and other attachments are available for the Bobcat loader. ROPS, FOPS – Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). vi

773 Bobcat Loader Operation & Maintenance Manual

OPTIONS AND ACCESSORIES Model 773 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 Glow Plug Preheat system Tires, 10–16.5, 8PR Bobcat Heavy Duty Below is a list of some equipment available as a Factory Installed Option or as a Field Installed Accessory from your Bobcat Loader dealer. See your Bobcat dealer for other available accessories and attachments. Tires 10–16.5, 8PR Bobcat Heavy Duty (Machine Width – 60 inches) . . . . . . . . . 31 x 15.5–15, 8PR Ultra Grip Tread . . . . . 7.50 x 15 Air Boss Segmented Tires . . . . 10 x 16.5 Air Boss Segmented Tires . . . .

Instrumentation Opt. & FA Opt. & FA FA FA

Bobcat Operation Sensing System (BOSS®) . . . . . . . . . . . . . . . . . . Keyless Start System . . . . . . . . . . . . . . . . .

Opt. FA

Hydraulics Operator Cab Sound Cab (Reduces Noise at Operator’s Ear) . . . . . . . . . . . . . . . . . . . . Deluxe Cab . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Lights (Front & Rear) . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back–up Alarm . . . . . . . . . . . . . . . . . . . . . . . Top Window . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window . . . . . . . . . . . . . . . . . . . . . . . . Cab Enclosure and Heater . . . . . . . . . . . . . Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . Hand Control Conversion . . . . . . . . . . . . . . Cover Kit (Pedals Area) . . . . . . . . . . . . . . . Cover Kit (Hydraulic Reservoir Area) . . . . Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . Strobe or Rotating Beacon Light . . . . . . . . 3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . Special Applications Kit* . . . . . . . . . . . . . . . Suspension Seat . . . . . . . . . . . . . . . . . . . . . Rear Window Wiper . . . . . . . . . . . . . . . . . . Large Operator Seat Bar Kit . . . . . . . . . . .

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

Front Auxiliary Hydraulics . . . . . . . . . . . . . Rear Auxiliary Hydraulics . . . . . . . . . . . . . . Hydraulic Bucket Positioning (Includes On/Off Selection) . . . . . . . . . .

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

Other Catalytic Exhaust Purifier . . . . . . . . . . . . . . Engine Block Heater . . . . . . . . . . . . . . . . . . Single Point Lift or Four Point Lift . . . . . . . Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . Radiator Screen Kit . . . . . . . . . . . . . . . . . . . Rear Door Bumpers . . . . . . . . . . . . . . . . . . Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . . Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterweight Kit . . . . . . . . . . . . . . . . . . . .

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

Opt. = Factory Installed Option FA = Field Accessory N/A = Not Available * Includes 1/2 inch Lexan Front Door; 1/4 inch Lexan Top & Rear Windows

Specifications subject to change without notice

vii

773 Bobcat Loader Operation & Maintenance Manual

viii

773 Bobcat Loader Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi, xii FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, xv

SAFETY

773 Bobcat Loader Operation & Maintenance Manual

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

773 Bobcat Loader Operation & Maintenance Manual

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. SI02–0598 xii

773 Bobcat Loader Operation & Maintenance Manual

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].

P–10650

SI03–0398

xiii

773 Bobcat Loader Operation & Maintenance Manual

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

6708105 (Non–BOSS Only) 6703723 Foot Pedals 6703724 Hand Control 6708021 Foot Pedals 6708158 Hand Control

6577754 (3)

6705720 6703726 Mechanical Hand Control 6717043 6707255 (Advanced Hand Control Only)

OR 6561376 6706809

6711840

6557565

6579510 Foot Pedals 6703725 Hand Control

*6579528

6710358

6579509

6561383 6579639

* Decal located behind lift arm crossmember.

B–15012

xiv

773 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (Cont’d)

6560573 6578368

6565990

6708929 (2)

6706557

6715563

6709030 Spring Loaded Idler

6707867 6705220 Fixed Mount Idler

6579511

6707786

Located inside the engine compartment. B–15013

773 Bobcat Loader Operation & Maintenance Manual

773Operation&MaintenanceManual#6900372–ContentsSection

xvi

773 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . 8 Auxiliary Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Seat Sensor Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Traction Lock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

OPERATING INSTRUCTIONS

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Advanced Hand Controls (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Attachment Functions Control (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 19 Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auxiliary Hydraulics Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Momentary Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Bucket Position Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 16 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Front Auxiliary Hydraulics Continuous Operation . . . . . . . . . . . . . . . . . . . . . 18 Front Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hand Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rear Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Front Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rear Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Quick Couplers (Flush Face) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BOSS® Option Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,6 With BOSS® (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 With BOSS® (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Without BOSS® (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Without BOSS® (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Continued On Next Page

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773 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS (Cont’d) LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FOOT PEDALS Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . 31 HAND CONTROLS Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . 34 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) . . . . 14 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 12 SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) . . 13 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Normal Starting (With BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Normal Starting (Without BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cold Temperature Starting (With BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cold Temperature Starting (Without BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . 23 Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . 25 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Forward, Reverse, Normal Turn, Fast Turn . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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773 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

Front Panel Without BOSS

Without BOSS® (Early Models)

1. TRACTION LOCK OVERRIDE BUTTON – Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 9.)

12 11

6 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 9.)

4 3

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

4. HAZARD INDICATORS (FA) – Both indicators blink when the hazard switch is ON. 5. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON.

MC–02034

6. ENGINE WARNING LIGHT – Low oil pressure or high coolant temperature. Stop the engine if the light comes ON. 7. BEACON SWITCH (FA) – Controls the available flashing beacon light. 8. HAZARD SWITCH (FA) – Controls the available hazard indicators. 9. LIGHT SWITCH (Opt/FA) – Controls the available work and travel lights. 10. PREHEAT SWITCH – For preheating the glow plugs before starting the engine. 11. BUCKET LEVEL SWITCH (Opt/FA) – Controls the ON/OFF function of the available bucket position valve. 12. HOURMETER – Records the total operating hours of the loader. 13. VOLTMETER – Shows the condition of the battery and the rate of charge. 14. FUEL GAUGE – Shows the amount of fuel in the fuel tank. 15. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature. 16. AUXILIARY HYDRAULICS SWITCH (Opt/FA) – For engaging the available auxiliary hydraulics (front or rear). Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

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773 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

Front Panel With BOSS

With BOSS® (Early Models)

1. TRACTION LOCK OVERRIDE BUTTON – Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 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 9.)

5 3

4 11

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

2 4. HAZARD INDICATORS (FA) – Both indicators blink when the hazard switch is ON.

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

MC–02035

6. BEACON SWITCH (Opt/FA) – Controls the available flashing beacon light. 7. HAZARD SWITCH (Opt/FA) – Controls the available hazard indicators. 8. LIGHT SWITCH (Opt./FA.) – Controls the available work and travel lights. 9. BUCKET LEVEL SWITCH (Opt/FA) – Controls the ON/OFF function of the available bucket position valve. 10. BOSS DISPLAY PANEL – Display panel for BOSS system and functions. (See Ref. 1 thru 13, Page 7.) 11. AUXILIARY HYDRAULICS SWITCH (Opt/FA) – For engaging the available auxiliary hydraulics (front or rear).

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

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773 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL Without BOSS® [A]: (Later Models) 1. TRACTION LOCK OVERRIDE BUTTON – Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 9.)

Without BOSS

11 10

8 5

4 12

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

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

13 N–17061

Side Console

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

P–10466

6. BUCKET LEVEL SWITCH (Opt/FA) – Controls the ON/OFF function of the available bucket position valve. 7. LIGHT SWITCH (Opt/FA) – Controls the available work and travel lights. 8. PREHEAT BUTTON – For preheating the engine (glow plugs) before starting the engine.

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

P–10742

10. FUEL GAUGE – Shows the amount of fuel in the fuel tank. 11. VOLTMETER – Shows the condition of the battery and the rate of charge. 12. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature. 13. AUXILIARY HYDRAULICS SWITCH (Opt/FA) – For engaging the available auxiliary hydraulics (front or rear). Side Console* – [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer. 2. HAZARD SWITCH/HAZARD INDICATORS (Opt/FA) – Controls the available hazard lights. (Hazard Lights is a separate available accessory.) Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, work lights, etc. 3. BEACON OR STROBE SWITCH (Opt/FA) – Controls the available flashing beacon or strobe light. * Can be installed if you have a Deluxe Cab or a Cab Enclosure installed. See your Bobcat loader dealer. Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

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773 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL (Cont’d)

With BOSS® [A]: (Later Models)

With BOSS

5 6

1. TRACTION LOCK OVERRIDE BUTTON – Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 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 9.)

4 3

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

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

8 P–10490

Side Console 2

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

P–10489

6. BUCKET LEVEL SWITCH (Opt/FA) – Controls the ON/OFF function of the available bucket position valve. 7. BOSS DISPLAY PANEL – Display panel for BOSS system and functions. (See Ref. 1 thru 13, Page 7.)

8. AUXILIARY HYDRAULICS SWITCH (Opt/FA) – For engaging the available auxiliary hydraulics (front or rear).

P–10742

Side Console* – [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer. 2. HAZARD SWITCH/HAZARD INDICATORS (Opt/FA) – Controls the available hazard lights. (Hazard Lights is a separate available accessory.) Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc. 3. BEACON OR STROBE SWITCH (Opt/FA) – Controls the available flashing beacon or strobe light.

* Can be installed if you have a Deluxe Cab or a Cab Enclosure installed. See your Bobcat loader dealer. Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

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773 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL (Cont’d)

BOSS Option Display Panel [A] 1. FUEL LEVEL – Shows the amount of fuel in the tank. Flashing pump symbol indicates low fuel level. (H2O symbol is non–functional.) (See WARNING SYMBOL) 2. BATTERY VOLTAGE – Shows the condition of the battery and charge rate. It will also indicate a WARNING for high or low voltage (See WARNING SYMBOL). 3. ENGINE OIL PRESSURE – Shows engine oil pressure. Flashing symbol indicates low oil pressure (See WARNING and SHUTDOWN SYMBOL). 4. ENGINE COOLANT TEMPERATURE / LEVEL – Shows engine coolant temperature and/or low coolant level (See WARNING and SHUTDOWN SYMBOL). 5. SHUTDOWN SYMBOL – This symbol is associated with any SHUTDOWN condition. When this symbol comes ON the SHUTDOWN will occur in 30 seconds. During SHUTDOWN the buzzer will sound continuously and the symbol will flash until the key switch is turned OFF.

NOTE: The engine can be restarted for 30–second periods to move the loader after a SHUTDOWN condition. 6. WARNING SYMBOL – The symbol will be ON when any WARNING or SHUTDOWN is activated. The warning symbol is also used to indicate a WARNING if there is no related symbol on the display. During a WARNING, the buzzer will beep three times and the symbol will be ON continuously. 7. HOURMETER – Records the total operating hours of the loader. The five character code will display the operating hours to the nearest tenth. When WARNING or SHUTDOWN occurs, an alpha–numeric code will be displayed in the hourmeter area to inform the operator of the problem (See SYSTEMS ANALYSIS, Page 79). During a WARNING or SHUTDOWN the hourmeter symbol is not visible. 8. CHARGE PRESSURE AND FILTER CONDITION – Flashing symbol indicates low fluid charge pressure (See SHUTDOWN SYMBOL). If arrows are ON with gear/drop, it is fluid charge pressure. This symbol will also indicate a clogged hydraulic fluid filter. 9. AIR FILTER CONDITION – This symbol will indicate a clogged air filter element. 10. GLOW PLUG (Diesel) – The symbol will be ON when the glow plugs are energized. The hourmeter will also contain characters GLOXX where XX indicates the remaining time the glow plugs will be ON. Time remaining will count down in increments. 11. ENGINE SPEED – This symbol will indicate an engine overspeed (See WARNING and SHUTDOWN SYMBOL). BRAKE INDICATOR LIGHT 12. PARKING (Non–Functional) . 13. HYDRAULIC FLUID TEMPERATURE – This symbol will indicate a high fluid temperature. (See WARNING or SHUTDOWN SYMBOL above).

MC–02320

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773 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

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

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.

The BICS controller is located inside the cab; behind and to the right of the operator’s seat [A]. There are five green lights on the BICS controller and all must be ON to operate the loader.

P–10157

The light functions are as follows [A]: 1. SEAT – ON when operator is in the seat. 2. SEAT BAR – ON when the seat bar is in down position. 3. VALVE – ON when lift and tilt hydraulic functions can be used.

AVOID INJURY OR DEATH

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

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.

5. POWER – ON when the controller is operating correctly. NOTE: If any of the lights are off or blinking, see SYSTEMS ANALYSIS, BICS Troubleshooting Chart Page 79 or see BICS Inspection and Maintenance Instructions Page 51.

W–2151–0394

Lift Arm By–Pass Control 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. Early Model Loaders: (See SERIAL NUMBER INFORMATION, Page iv.) 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] up. Push the top (toe) of the left (lift) pedal (or move the left hand control toward the operator). The lift arms will slowly lower.

Later Model Loaders: (See SERIAL NUMBER INFORMATION, Page iv.) With the operator in the seat, seat belt fastened and the seat bar fully lowered, turn the lift arm by–pass control knob (Item 1) [A] clockwise 1/4 turn. Then, pull up and hold the lift arm by–pass control until the lift arms slowly lower.

P–10559

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773 Bobcat Loader Operation & Maintenance Manual

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

Traction Lock Override (Functions Only When The Seat Bar Is Raised) There is a traction lock override button (Item 1) [A] on the left hand instrument panel which will allow you to use the steering levers to move the loader forward and backward when using the backhoe attachment or for service. • Press the button once to unlock traction drive (green traction light on BICS controller will be ON).

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

N–16884

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.

Without BOSS

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

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. If seat indicator light on the BICS Controller does not go on, check for debris, dirt, or objects under or behind seat.

P–10467

Auxiliary Hydraulic System

With BOSS

Later Model Loaders Only: (See SERIAL NUMBER INFORMATION, Page iv.) When the operator is seated and raises the seat bar, the auxiliary hydraulic system will deactivate. Press the auxiliary hydraulics switch (Item 1) [B] and [C] to reselect operating mode. (See Auxiliary Hydraulics Page 17.)

P–10487

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773 Bobcat Loader Operation & Maintenance Manual

ENGINE SPEED CONTROL

The lever (Item 1) [A] is at the right side of the operator’s seat. Engine speed is controlled by moving the lever forward to increase the engine RPM and backward to decrease the engine RPM.

P–10565

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

MC–01914

P–03990

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

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.

MC–01914

P–03989

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773 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 or footrests. W–2261–0397

P–04132

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

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

FORWARD

REVERSE

The steering levers control forward and reverse travel and turning of the loader [B]. Forward Travel – Push both levers forward. Reverse Travel – Pull both levers backward. Normal Turning – Move one lever farther forward than the other. Fast Turning – Push one lever forward and pull the other lever backward. For slow travel speed, push the steering levers forward only a small amount.

LEFT TURN

RIGHT TURN

LEFT FAST TURN

RIGHT FAST TURN

To increase travel speed, push both levers farther forward. For maximum pushing force, push the levers forward only a small amount with the engine at full RPM. STOPPING THE BOBCAT LOADER When the steering levers are moved to the NEUTRAL POSITION, the hydrostatic transmission will act as a service brake to stop the loader.

PI–01849

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773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

The seat bar restraint system has a pivoting, spring assist seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals.

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the NEUTRAL POSITION.

P–07638

AVOID INJURY OR DEATH

When operating the machine: • Keep the seat belt fastened snugly. • The seat bar must be lowered. • Keep your feet on the foot pedals or footrests.

SEAT BAR DOWN 2

Seat Bar

W–2261–0397

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

1 Interlock

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.

Pedal Linkage 3

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.

Interlock Shield

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

MC–01668

SEAT BAR RAISED Seat Bar

Interlock

W–2328–0798

Interlock Shield

When the seat bar is raised, spring forces raise the interlocks [C]. The foot pedals will not pivot when the interlock is up.

MC–01668

Refer to the SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance Page 48. –12–

773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)

Mechanical Hand Controls 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 functions.

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 hand controls. When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION. P–03563

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 footrests.

SEAT BAR DOWN

W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Mechanical Hand Controls) Move the hand controls until both lock. The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up. Service the system if hand controls do not lock correctly.

1 Hand Control Linkage

W–2322–0698

Seat Bar

Interlock Interlock Shield

The spring loaded interlocks (Item 1) [B] control the locking and unlocking functions of the hand controls. The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the hand controls 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 hand control linkages (Item 3) [B] from the interlocks.

MC–01950

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

AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

SEAT BAR RAISED Seat Bar

Interlock Shield

Interlock

W–2263–0597

When the seat bar is raised, spring forces raise the interlocks [C]. The hand controls will not function when the interlock is up. Refer to SEAT BAR RESTRAINT SYSTEM Inspection and Maintenance Page 49. –13–

MC–01950

773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

When the seat bar is down, the lift, tilt, and traction drive functions can be operated. When the seat bar is up, the lift, tilt, and traction drive functions are deactivated. P–13721

Refer to SEAT BAR RESTRAINT SYSTEM Inspection and Maintenance Page 50.

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly. • The seat bar must be lowered. • Keep your feet on the foot rests. W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate. W–2321–0698

–14–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

Foot Pedals

3 2 1

B–12830

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 B–13559

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

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

Lift Arm Float Position

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

B–12830

Use the float position of the lift arms to level loose material while driving backward. Push the bottom of the lift pedal to unlock from the float position. Tilt Operation The right pedal controls the action of the bucket. Push the top (toe) (Item 4) [A] of the pedal to tilt the bucket forward. Push the bottom of the pedal (heel) (Item 5) [A] to tilt the bucket backward. Bucket Position Valve Operation (If Equipped)

B–13560

The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle. Bucket positioning functions automatically during the upward lift cycle only. The bucket positioning function can be turned OFF with the bucket level switch (See Page 3, 4, 5 & 6).

–15–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d) Hand Controls (Mechanical and Advanced Hand Controls)

A 1 2

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

P–13252

P–13253

W–2152–0594

Put your feet on the footrests and KEEP THEM THERE for comfort and safety any time you operate the loader. Two hand levers [A] control the hydraulic cylinders for the lift and tilt functions. Lift Arm Operation The left hand lever controls the lift arms. Move the left hand lever away (Item 1) [A] from the operator to raise the lift arms.

B–13559

Move the left hand lever toward (Item 2) [A] the operator to lower the lift arms. Lift Arm Float Position Move the left hand lever all the way toward the operator (Item 2) [A] until it locks into float position.

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

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

P–13252

P–13253

Tilt Operation The right hand lever controls the action of the bucket. Move the right hand lever away (Item 3) [A] from the operator to tilt the bucket forward. Move the right hand lever toward (Item 4) [A] the operator to tilt the bucket backward. Bucket Position Valve Operation (If Equipped) The function of the bucket positioning valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle. B–13560

Bucket positioning functions automatically during the upward lift cycle only. The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Page 3,4,5 and 6). Advanced Hand Controls (AHC) (If Equipped) AHC is only available on later model loaders. AHC operation is the same as mechanical hand controls above. Two lights (Item 1) [B] on the left handle are always ON when the AHC is functioning correctly. If lights are blinking or do not come ON, see Advanced Hand Controls Troubleshooting Chart Page 79.

–16–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

Auxiliary Hydraulics (If Equipped)

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers. W–2220–0396

P–10567

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].

Locked

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

To Release 3

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

P–10566

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

FRONT AUXILIARY QUICK COUPLERS

REAR AUXILIARY QUICK COUPLERS

Hold the male coupler. Retract the sleeve on the female coupler until the couplers disconnect. Auxiliary hydraulics [C] are not standard, but can be a Factory Option or a Field Installed Accessory. A loader without front or rear auxiliary hydraulics will not have switches in the control handles. P–10567

–17–

N–15171

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.)

Auxiliary Hydraulics (If Equipped) (Cont’d)

Without BOSS

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

With BOSS

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

• Continuous Operation Press the Auxiliary Hydraulics Switch (Item 1) [A] a second time. Both lights (Items 2 & 3) [A] will be ON.

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

3 P–10466

P–10489

TWO–SWITCH HANDLES

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

NOTE: Later Model Loaders Only (See SERIAL NUMBER INFORMATION page iv.): When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System (Front and Rear) will deactivate. Press the Auxiliary Hydraulics Switch (Item 1) [A] to reselect operating mode.

Left Steering Lever

Right Steering Lever

FRONT Auxiliary Hydraulics Operation (RIGHT Steering Lever) P–02154

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

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

P–02152

DELUXE HANDLES 1

FRONT Auxiliary Hydraulics Continuous Operation (RIGHT Steering Lever) • Set the Auxiliary Hydraulics Switch for Continuous Operation. (See above.)

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

Left Steering Lever

Right Steering Lever

P–13255

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

D REAR Auxiliary Hydraulics Operation (LEFT Steering Lever)

P–13254

REAR AUXILIARY QUICK COUPLERS

• Set the Auxiliary Hydraulics Switch for Momentary or Continuous Operation (See above). • Push the switch (Item 3) [B] & [C] to the right or left to change the fluid flow direction to the rear quick couplers [D]. (EXAMPLE: Raise and lower rear stabilizers.)

N–15171

–18–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.) Attachment Functions Control (If Equipped) (Attachment Control Kit Required) (Item 1) [A]

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

The following are examples only, consult Attachment Operation & Maintenance Manual: Switch (Item 1) [B] . . . Left/Right Turn Signals Switch (Item 2) [B] . . . Left Moldboard Up/Down Switch (Item 3) [B] . . . Right Moldboard Up/Down Switch (Item 4) [B] . . . Water Spray

N–00334

DELUXE HANDLES

1 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

Left Steering Lever

Right Steering Lever

P–13255

Relieving Hydraulic Pressure Hydraulic pressure in the auxiliary hydraulic system can make it difficult to connect to the quick couplers. To make connecting and disconnecting attachments easier, the hydraulic pressure can be relieved at the front or rear quick couplers.

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

Without BOSS

P–13254

With BOSS

1 2

Early Model Loaders With the engine running, press the Auxiliary Hydraulics Switch (Item 1) [C] to engage the auxiliary hydraulics. The light (Item 2) [C] will come ON.

3 P–10466

P–10489

Foot Pedal Loaders: Push the heel of the tilt pedal so the hydraulic fluid goes over the main relief pressure. At the same time push switch (Item 5) [B] back and forth several times to relieve the pressure at the quick couplers. Release the tilt pedal. Stop the engine. Hand Control Loaders: Move the right hand lever toward the operator so the hydraulic fluid goes over the main relief pressure and at the same time, push switch (Item 5) [B] back and forth several time to relieve the pressure at the rear quick couplers. Release the hand control so that it returns to NEUTRAL POSITION (center). Stop the engine. Later Model Loaders The pressure relieving procedure is the same as Front Quick Couplers above. –19–

773 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The Service Schedule [A] is a guide for correct maintenance of the Bobcat loader. It is located inside the rear door of the loader and also in the MACHINE SIGN TRANSLATION Section Page 85. Daily Inspection and Maintenance: • Engine Oil Level • Hydraulic/Hydrostatic Fluid Level • Engine Air Filter, Air System for Damage or Leaks • Engine Coolant Level, System for Damage or Leaks • Operator Cab, Seat Belt, Seat Bar, Pedal or Hand Control Interlocks & Mounting Hardware • Grease Pivot Pins (Lift Arms, Bob–Tach, Cylinders, Bob–Tach Wedges • Tires for Wear or Damage and Correct Air Pressure • Fuel Filter, Remove Trapped Water • Loose or Broken Parts • Safety Treads and Safety Signs (Decals) • Bobcat Interlock Control System (BICS™) • Lift Arm Support Device

6715563

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

Operator must have instructions before running the machine. Untrained operators can cause injury or death. W–2001–0596

B 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

GETTING READY FOR OPERATION Read the Operation & Maintenance Manual and the Operator’s Handbook (Item 1) [B] before operating the loader. The Operation & Maintenance Manual and other manuals can be kept in a box (Item 2) [B] provided at the right hand side of the operator seat.

P–10561

–20–

773 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [A]. 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. See your Bobcat loader dealer for replacement treads.

P–10591

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

P–10562

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [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 P–10586

–21–

773 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

Lower the seat bar [A]. Be sure the parking brake is engaged. Put controls in the NEUTRAL POSITION before you start the engine.

P–10587

Keep your hands on the steering levers and feet on the foot pedals (or footrests) while seated in the loader [B].

P–10588

STARTING THE ENGINE

WRONG

B–03724

B–06578

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 [C]. W–2050–1285

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

Normal Starting (Without BOSS®) Adjust the seat position, fasten the seat belt and lower the seat bar [D]. Engage the parking brake.

P–10587

–22–

773 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

NEUTRAL POSITION

Normal Starting (Without BOSS®) (Cont’d) Put the hydraulic controls and steering levers in NEUTRAL POSITION (center) (Item 1) [A].

Set the engine speed control to the 1/2 SPEED position (Item 2) [A].

1/2 SPEED

Turn the key switch to the ON POSITION (Item 3) [A]. The engine and transmission warning lights will be ON when the key switch is on and the engine is stopped (Item 3) [A].

2 ON POSITION

Turn the key switch to START POSITION (Item 4) [A] and release it when the engine starts. NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

3 START POSITION

4 RUN POSITION

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.

PI–02188

I–2034–0284

When you release the key, it will return to the RUN POSITION (Item 5) [A]. STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF. NOTE: Upon failed start, if the key switch is turned OFF, wait for at least three seconds before turning the key switch ON to reset the fuel timer module. Cold Temperature Starting (Without BOSS®)

MC–2033

Early Models Without BOSS

Later Models Without BOSS

1 1

See Normal Starting. Turn the key switch to the RUN POSITION.

MC–02034

Push the preheat switch (Item 1) [B] on the left side of the instrument panel.

P–16964

The decal [C] on the left side of the operator cab shows the correct amount of time to hold the preheat switch. Follow the steps under Normal Starting and repeat the Preheat procedure until the engine starts. If the temperature is below 32°F. (0°C.), perform the following to make starting the engine easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Engine Lubrication System Page 58.) • Make sure the battery is fully charged. • Install an engine heater, available from your Bobcat loader dealer.

6713715

–23–

773 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

Normal Starting (With BOSS®) Adjust the seat position, fasten the seat belt and lower the seat bar [A].

Put the hydraulic controls and steering levers in NEUTRAL POSITION (center) (Item 1) [B].

P–10587

Be sure the parking brake is engaged.

Set the engine speed control to 1/2 SPEED position (Item 2) [B]. Turn the key switch to the ON POSITION, one beep will sound and the display symbols will be ON [C]. Turn the key switch to START POSITION. (See Cold Temperature Starting.) Release the key when the engine starts.

NEUTRAL POSITION

1 1/2 SPEED

NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

PI–02188

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses. I–2034–0284

When the key switch is turned ON, watch the alpha numeric display for SERVICE CODES. These codes are from the previous work shift when a WARNING may have occurred. (See SYSTEMS ANALYSIS Page 79.) The codes may be viewed again by turning the key switch OFF and then ON again without starting the engine. After the engine has been started, the BOSS controller will clear all codes from memory. The codes will not appear again unless the problem reoccurs. 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.

MC–02320

–24–

773 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

Cold Temperature Starting (With BOSS®)

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death. W–2071–1285

See Normal Starting. Turn the key switch to the ON POSITION. The glow plug symbol (Preheat) will be ON (Item 1) [A]. NOTE: If the display is showing SERVICE CODES, the timing of the glow plug activation may not be visible on the display. However, the glow plugs will be energized.

Characters on the display will be GLOXX where XX will indicate the remaining time the glow plugs will be energized. The following chart shows the time glow plugs will be energized.

MC–02042

Turn the key switch to the START POSITION and release when the engine starts. If the engine does not start, turn the key switch to the OFF POSITION and ON again. This will start the glow plug cycle again. When the engine is running, slowly move the engine speed control forward to increase engine RPM.

OFF POSITION

If the starting temperature is below 32°F. (0°C.), perform the following to make starting easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See ENGINE LUBRICATION SYSTEM Page 58.) • Make sure the battery is fully charged. • Install an engine heater. See your Bobcat loader dealer.

N–16961

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 loader (cold), more warm up time is needed. When the temperature is below –20°F. (–30°C.), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F. (–18°C.) if possible.

STOPPING THE ENGINE Pull the engine speed control fully backward to decrease the engine speed. Turn the key switch to the OFF POSITION [B].

I–2007–1285

–25–

773 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

WRONG

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 decal in the operator cab. (See SPECIFICATIONS Page 95.) The rated operating capacity is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used, the load center moves forward and reduces the rated operating capacity. If very dense material is loaded, the volume must be reduced.

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

W–2053–0887

Exceeding the rated operating capacity [A] can cause the following problems: 1. Steering the loader may be difficult.

2. Tires will wear faster.

WEIGHT OF LOADS LBS. (KG) (Without counterweights)

670(1475)

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. Maximum load to be carried when using a pallet fork is shown in figure [B].

555(1230)

3. There will be a loss of stability.

15.75 (400)

See your Bobcat loader dealer for more information about pallet forks and other available attachments.

24.00 (610)

CENTER OF LOAD LOCATION Inches (mm) 6712931 6712931 6712932 6712932

–26–

773 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d) Installing The Bucket Or Attachment The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments. Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

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

W–2054–1285

Fasten the seat belt, lower the seat bar and start the engine. Release the parking brake. Lower the lift arms and tilt the Bob–Tach forward.

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

Be sure the Bob–Tach levers do not hit the bucket. Tilt the Bob–Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [B]. Stop the engine and exit the loader.

N–17024

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Foot Pedal Controls) Move pedals until both lock. • (Mechanical Hand Controls) Move the hand controls until both lock. The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up. Service the system if hand controls do not lock correctly.

N–17025

• (Advanced Hand Controls) Move the hand

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

W–2323–0698

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

N–17028

The levers will contact the frame as shown (Item 1) [C] when locked. If the levers do not engage in the locked position, see your Bobcat loader dealer for maintenance.

N–17027

–27–

773 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

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

1 N–17022

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

N–17023

Removing The Bucket Or Attachment

Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit (See Relieving Hydraulic Pressure, Page 19). Raise the seat bar, unfasten the seat belt, set the parking brake and exit the loader. Pull the Bob–Tach levers [C] all the way up. Disconnect the hydraulic hoses, if necessary. Enter the loader.

N–17026

Fasten the seat belt, lower the seat bar and start the engine

Release the parking brake. Lower the lift arms and tilt the Bob–Tach forward. Move the loader backward, away from the bucket or attachment [D].

N–17024

–28–

773 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE

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

WITH BUCKET FULL

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

Going Up Slope

Machines warmed up with moderate engine speed and light load have longer life. I–2015–0284

B–13563

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 slowly. New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area. With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B]. With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

Going Down Slope

B–13563

WITH BUCKET EMPTY

• Keep the lift arms as low as possible. • Do not travel or turn with the lift arms up. • Turn on level ground. • Go up and down slopes, not across them. • Keep the heavy end of the machine uphill. • Do not overload the machine. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

Going Down Slope

B–13564

W–2018–1187

WITH BUCKET EMPTY

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

Going Up Slope

–29–

B–13565

773 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (FOOT PEDALS)

Filling the Bucket Push down on the top of the lift pedal until the lift arms are all the way down.

B–12830

Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A].

B–13566

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

B B–12830

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.

B–13567

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

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.

B–12830

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

W–2057–0694 B–13568

–30–

773 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (FOOT PEDALS) (Cont’d)

Digging Into the Ground Put the lift arms all the way down. B–12830

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

B–13569

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

B–12830

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 to put the lift arms in float position [C].

B–13570

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. B–12830

Never drive forward when the hydraulic control for lift arms is in float position. I–2005–1285

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

B–13571

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773 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (FOOT PEDALS) (Cont’d)

Backfilling 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 [A].

B–12830

Tilt the bucket forward as soon as it is past the edge of the hole [A]. If necessary, raise the lift arms to empty the bucket. PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground. Lower the lift arms fully and put the attachment flat on the ground. B–13572

Pull the engine speed control lever all the way backward. Turn the key switch to the OFF POSITION.

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

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.

–32–

773 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (HAND CONTROLS)

Filling The Bucket Move the left hand lever toward the operator until the lift arms are all the way down. Move the right hand away from the operator to put the cutting edge of the bucket on the ground [A].

P–13252

P–13253

B–13566

Drive slowly forward into the material. Move the right hand lever toward the operator to raise the front of the bucket [B].

P–13252

P–13253

W–2056–1187

Drive backward away from the material.

B–13567

Emptying The Bucket

Move the left hand lever away from the operator to raise the bucket over the truck box or bin [C]. Drive forward slowly until the bucket is over the top of the truck box or bin. Move the right hand lever away from the operator 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.

P–13252

P–13253

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death. W–2057–0694 B–13568

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773 Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURE

(HAND

CONTROLS)

Digging Into The Ground Put the lift arms all the way down. Move the right hand lever away from the operator 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–13252

Move the right hand lever toward the operator a small amount to increase traction and keep an even digging depth. 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 hand lever while driving forward slowly.

P–13253

B–13569

Move the right hand lever toward the operator to tilt the bucket backwards as far as it will go when the bucket is full [B].

P–13252

P–13253

B–13570

Leveling The Ground (Using Lift Arms In Float Position)

Move the left hand lever all the way down and in until the hand lever is in the locked position to put the lift arms in a float position [C]. Move the right hand lever 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.

P–13252

P–13253

Never drive forward when the hydraulic control for lift arms is in float position. I–2005–1285

Drive backward to level loose material. Move the left hand lever upward to unlock from the float position.

B–13571

–34–

773 Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURE

(HAND

CONTROLS)

Backfilling 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 [A]. Tilt the bucket forward as soon as it is past the edge of the hole [A]. If necessary, raise the lift arms to empty the bucket.

P–13252

P–13253

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground. Lower the lift arms fully and put the attachment flat on the ground. Pull the engine speed control all the way backward. Turn the key switch to the OFF POSITION.

B–13572

AVOID INJURY OR DEATH When operating the machine:

• Keep the seat belt fastened snugly. • The seat bar must be lowered. • Keep your feet on the foot rests. W–2179–0694

• (Advanced Hand Controls) Move the hand

W–2302–0698

Engage the parking brake. Lift the seat bar. Make sure the hand controls are in the locked position (mechanical only). Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

–35–

773 Bobcat Loader Operation & Maintenance Manual

TRANSPORTING THE BOBCAT LOADER

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

SUPPORT

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

P–10643

Be sure the transport and towing vehicles are of adequate size and capacity (See SPECIFICATIONS Page 95, for weight of loader.). The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up. Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B]. • Lower the bucket or attachment to the floor.

P–10638

• Stop the engine.

P–05077

• Engage the parking brake. • Install chains at the front and rear loader tie down positions (Inset) [B]. • Fasten each end of the chain to the transport vehicle. 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 SPECIFICATIONS Page 95.) • Turn the key switch to ON and press the traction lock override button. • Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

6707867

P–10646

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

–36–

773 Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

Single Point Lift

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

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

MC–01822

within 15 feet (5 meters) while lifting the machine. 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 as explained in the Instructions with the kit and attach lift as shown [A]. The single point lift, supplied by Melroe Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

–37–

773 Bobcat Loader Operation & Maintenance Manual

773Operation&MaintenanceManual#6900372–OperatingInstructionsSection

–38–

773 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . 51 Inspecting Deactivation Of The Auxiliary Hydraulics System . . . . . . . . . . . 51 Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Inspecting The BICS™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Inspecting The Seat And Seat Bar Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Inspecting The Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

PREVENTIVE MAINTENANCE

DRIVE BELT (FIXED MOUNT IDLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Adjusting The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Replacing The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 DRIVE BELT (SPRING LOADED IDLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adjusting The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Replacing The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Cleaning Battery Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . 70 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Continued On Next Page –39–

773 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 75 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) . . . . 50 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 48 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) . . 49 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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773 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

B–10731

B–13573

B–13561

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

B–13574

B–3724

B–13575

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

CORRECT

B–13576

B–13577

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. –41–

MSW03–0698

773 Bobcat Loader Operation & Maintenance Manual

–42–

773 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. 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 Oil Engine Air Filter and Air System Engine Cooling System Tires Seat Belt, Seat Bar, Foot Pedal or Hand Control Interlocks Safety Signs and Safety Tread Indicators & Lights (Opt.) Operator Cab Lift Arms, Cyl., Bob–Tach Pivot Pins and Wedges Fuel Filter Bobcat Interlock Control System (BICSTM) Hydraulic Fluid, Hoses and Tubelines Final Drive Trans.(Chaincase) Foot Pedals, Hand Controls, and Steering Levers Wheel Nuts Parking Brake Spark Arrestor Muffler Battery Steering Shaft Engine/Hydros. Drive Belt Fan Drive Gearbox Alternator Belt Engine Oil and Filter Fuel Filter Hydraulic Reservoir Breather Cap Hydraulic Reservoir Final Drive Trans.(Chaincase) Hydraulic/Hydrostatic Filter Case Drain Filters Bobcat Interlock Control System (BICSTM)

SERVICE REQUIRED

8–10 50 100 250 500 1000

Check the oil level and add oil as needed. Check condition indicator or display panel. Service only when required. Check for leaks and damaged components. Clean debris from oil cooler, radiator and grill. Check coolant level in recovery tank (engine cold). Add coolant as needed. Check for damaged tires and correct air pressure. Check the condition of seat belt. Check the seat bar, and foot pedal interlocks or hand control interlocks. Clean dirt and debris from moving parts. Check for damaged signs (decals) and safety tread. Replace any signs or safety treads that are damaged or worn. Check for correct operation of all indicators & lights. Check the fastening bolts, washers & nuts. Check the condition of cab. Lubricate with multi–purpose lithium based grease. Remove the trapped water. Check BICSTM functions. Clean dirt, debris or objects from under and behind seat and around brake pedal as required. Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed. Check oil level. Check for correct operation. Repair or adjust as needed. Check for loose wheel nuts and tighten to 105–115 ft.–lbs. (142–156 Nm) torque. Check operation. Clean the spark chamber. Check cables, connections and electrolyte level. Add distilled water as needed Grease two fittings. * Check for wear or damage. Adjust as needed. Check gear lube level. Add as needed. Check belt tension and adjust as needed. Replace oil and filter. Use CD or better grade oil and Melroe filter. Replace the filter element. Replace the reservoir breather cap. Replace the fluid. Replace the fluid. Replace the filter element. Replace the filters. Check lift arm bypass control

Check wheel nut torque every 8 hours for the first 24 hours. Replace filter element after the first 50 hours and when the transmission warning light comes ON. Or every 12 months. Inspect the new belt after first 50 hours. First oil and filter change must occur at 50 hours; 250 hours thereafter. –43–

773 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

1 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 P–10589

Installing Lift Arm Support Device Put jackstands under the rear corners of the loader.

Remove the lift arm support device (Item 1) [A] from storage position.

The operator must be in the operator’s seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is installed. Start the engine, and raise the lift arms all the way up. Have a second person install the lift arm support device (Item 1) [B] over the rod of one of the lift cylinders.

P–10594

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death. W–2271–1197

The lift arm support device must be tight against the cylinder rod. The tabs of the lift arm support device must be under the cylinder as shown (Item 1) [C].

P–10592

Lower the lift arms slowly until the stop is held between the lift arms and lift cylinder [D].

Removing Lift Arm Support Device The operator must be in the operator’s seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is removed and the lift arms are lowered all the way. Start the engine, raise the lift arms all the way up. Have a second person remove the lift arm support device. Return the lift arm support device to storage position and secure with clamping knobs.

P–10593

Remove the jackstands. –44–

773 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection. ROPS/FOPS – Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. Level I – Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

P–10564

Level II – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

P–10563

Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE Page 44.) Loosen the nut (both sides) at the front corner of the operator cab [A]. Remove the nut and plate (both sides) [A]. With Mechanical Hand Controls Only: Disconnect the control linkage joint from the bottom hole (work position) and move to the TOP hole on the control handle (both sides) [B].Both control handles must be in the vertical position so there will be no cab interference with the steering levers when the operator cab is raised or lowered.

P–03470

Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [C].

P–10449

P–10595

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.

W–2069–1285

–45–

773 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

Lowering The Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab. Pull down on the bottom of the operator cab until it stops at the latching mechanism (Inset) [A]. Release the latching mechanism (Inset) [A] and pull the cab all the way down.

P–10599

P–10596

Install the plate and nut (both sides) [B].

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

P–10564

With Mechanical Hand Controls Only: Move the control linkage from the top hole to the BOTTOM hole (work position) on the control handle (both sides) [C].

P–03561

–46–

773 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

Emergency Exit The front opening on the operator cab and rear window provide exits. Rear Window Pull on the tag on the top of the rear window to remove the rubber cord [A].

P–00660

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

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

P–10598

Front Door

NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [C] Pull the plastic loop at the top of the window in the front door to remove the rubber cord [C].

P–09216

Push the window out with your foot [D].

Exit through the front door.

P–09217

–47–

773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt functions.

Clean (Both Sides)

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 functions are locked when returned to the NEUTRAL POSITION. P–10361

AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

AVOID INJURY OR DEATH Never operate loader without pedal lock shield 6705474 on both interlocks. Shields prevent feet from unlocking interlocks when leaving loader seat.

W–2263–0597

W–2162–1194

Inspecting the Seat Bar 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. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in NEUTRAL POSITION. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed. Pull the seat bar down, lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Interlock Shield

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

Clean (Both Sides)

Maintaining the Seat Bar See the SERVICE SCHEDULE, Page 43, and on the loader for correct service interval. Clean any debris or dirt from the moving parts [A] & [B]. Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm). If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

P–10569

–48–

773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt control functions.

Clean (Both Sides)

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 hand controls. When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION. P–10361

AVOID INJURY OR DEATH AVOID INJURY OR DEATH

The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

Never operate loader without interlock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat. W–2158–0594

W–2263–0597

Inspecting The Seat Bar 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 hand control to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

B Interlock Shield

Raise the seat bar. Try to move each hand control. The controls must be firmly locked in NEUTRAL POSITION. There must be no motion of the lift arms or tilt (bucket) when the controls are pushed.

Clean (Both Sides)

Pull the seat bar down, lower the lift arms. Operate the lift control. 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 put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the hand controls to be sure that the controls are firmly locked in the NEUTRAL POSITION. Unbuckle the seat belt.

P–01640

Maintaining The Seat Bar See the SERVICE SCHEDULE Page 43 for correct service interval. Clean any debris or dirt from the moving parts [A] & [B]. Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm). If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust hand control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

–49–

773 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

When the seat bar is down, the lift, tilt, and traction drive functions can be operated. When the seat bar is up, the lift, tilt, and traction drive functions are deactivated. P–13721

Inspecting The Seat Bar Sit in the operator’s seat. Turn the key ON and lower the seat bar. Both lights on the left handle should be ON.

Move each hand control back and forth. You should hear the zip,zip sound of the lift and tilt actuators moving the control valve spools (under the seat).

Clean (Both Sides)

Raise the seat bar fully. Both lights on the left handle should be OFF. Move each hand control back and forth. There must be no sound of the lift or tilt actuators. If either actuator makes a sound while the seat bar is raised, contact your dealer for service. Maintaining The Seat Bar P–10361

See the SERVICE SCHEDULE Page 43 for correct service interval. Clean any debris or dirt from the moving parts [B]. If the seat bar system does not function correctly replace parts that are worn or damaged. Use only genuine Bobcat replacement parts. 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. • (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate. W–2321–0698

–50–

773 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Inspecting The BICS™ Controller (Engine STOPPED – Key ON)

1 2

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

3 4 5

2. Engage the parking brake and raise the seat bar fully. Seat bar light (Item 2) [A], valve light (Item 3) [A] and traction light (Item 4) [A] should be OFF. 3. Raise up slightly off the seat. Seat light (Item 1) [A] should be OFF. P–10157

NOTE: Record what lights are blinking (if any) and number of blinks. Refer to Page 80. 4. 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. Later Model Loaders Only (See SERIAL NUMBER INFORMATION, Page iv.) Inspecting Deactivation of the Auxiliary Hydraulics System (Engine STOPPED – Key ON) 5. Sit in the operator’s seat. Lower the seat bar. Press the auxiliary hydraulics switch. The switch light will come ON. Raise the seat bar. The light should be OFF. Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 6. Sit in the operator’s seat. Lower the seat bar. Engage the parking brake. Fasten the seat belt. 7. 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. Inspecting The Traction Lock (Engine RUNNING) 8. 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. 9. 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 10. Raise the lift arms six feet (2 m) off the ground. Stop the engine. Later Model Loaders (See SERIAL NUMBER INFORMATION, Page iv.) Turn the lift arm by–pass control knob clockwise 1/4 turn. Then pull up and hold the lift arm by–pass control knob until the lift arms slowly lower. Early Model Loaders (See SERIAL NUMBER INFORMATION, Page iv.) With the operator in the seat, seat belt fastened and the seat bar fully lowered, pull and hold the by–pass control knob up. Push the top (toe) of the left (lift) pedal (or move the left hand control toward the operator). The lift arms will slowly lower. –51–

773 Bobcat Loader Operation & Maintenance Manual

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

Clean Behind And Under Seat

Inspecting the BICS™ Lock Valve (Advanced Hand Control Only) 1. Sit in the operator’s seat. Fasten the seat belt. Lower the seat bar. 2. Start the engine and raise the lift arms about 3 feet (1 meter) off the ground. 3. Turn the key OFF and wait for the engine to come to a complete stop. 4. Turn the key ON. Move the left hand control toward the operator. The lift arms should not lower.

P–10585

5. With the key on and bucket installed, move the right hand control away from the operator. The bucket should not tip forward.

Operator Seat

Maintenance Seat Sensor

Clean any debris, dirt or objects from under or behind the operator seat [A] & [B]. The rear of the seat must move up and down.

Seat 1 Spring

Seat Rail Cover

Inspect both seat rail covers [B] for wear or damage. Replace if necessary. Clearance is necessary under the seat spring (Item 1) [B] and the seat, to allow the seat to move up and down freely. With adequate clearance, the seat sensor will be allowed to function correctly.

MC–02043

Inspect seat bar pivot area for tightness of linkage bolts. Replace parts that are damaged. Use only genuine Bobcat replacement parts.

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. W–2151–0394

–52–

773 Bobcat Loader Operation & Maintenance Manual

REAR DOOR

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

P–10338

P–10356

W–2012–0290

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

W–2020–1285

Put your fingers into the slot in the rear door and pull on the latch handle [A]. Pull the rear door open. Push the door stop up into the top hinge before closing the rear door [A]. Close the rear door before operating the loader.

P–10328

Adjusting The Latch The door latch catch (Item 1) [B] can be adjusted side to side for alignment with the door latch mechanism.

The door latch mechanism (Item 2) [B] can be adjusted backward or forward for alignment with the door catch. Close the rear door before operating the loader.

P–10570

REAR GRILL

P–10339

Open the rear door.

Raise the rear grill [C]. P–10616

The rear grill is held open by the cylinder (Item 1) [C] on the right side of the rear grill. Lower the rear grill and close the rear door before operating the loader. P–10607

–53–

773 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

Replacing Filter Element

Without BOSS® – Condition Indicator: Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [A].

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [A]. Start the engine. If the red ring does not show, do not replace the filter element. Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

P–10308

With BOSS®: It is important to change the air filter element only when the service codes (on the BOSS® option display panel) shows the symbols [AF.2] [B].

MC–02320

Open the rear door.

Remove the dust cover wing nut (Item 1) [C].

P–10313

Remove the dust cover [D].

Remove the wing nut (Item 1) [D] from the large air filter element.

P–10314

–54–

773 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

Replacing Filter Element (Cont’d) Remove the large filter element [A]. NOTE: Be sure all sealing surfaces are free of dirt and debris. Install the new filter element and washer and tighten the wing nut.

NOTE: Be sure sealing washer is in place on each wing nut [B].

P–10312

Install the dust cover and tighten the wing nut.

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight. Only replace the inner filter element under the following conditions: •

Replace the inner filter element every third time the outer filter is replaced.

•

Press the button to remove the red ring in the condition indicator after the outer filter element has been replaced. Start the engine and run at full RPM. If the red ring shows again, replace the inner filter element.

•

BOSS Only: If the service codes show symbols AF.2 during full engine speed, replace the inner filter element only after the outer filter element has been changed.

P–10310

Remove the inner filter wing nut (Item 1) [B]. Remove the inner filter [C]. Install a new filter and tighten the wing nut. Close the rear door before operating the loader.

P–10309

–55–

773 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM

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

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°)

No. 2

No.1

+15°(9°) Down to –20° (–29°) Below –20° (29°)

100% 50% 0%

0% 50% 100%

Contact your fuel supplier for local recommendations.

P–10601

Filling the Fuel Tank

WRONG

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 (Item 1) [A]. 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].

B–13579

Install and tighten the fuel fill cap (Item 1) [A]. Fuel Filter

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

P–10571

See the SERVICE SCHEDULE, Page 43, for the service interval when to remove the water from the fuel filter and when to replace the fuel filter. Loosen the drain (Item 1) [C] at the bottom of the filter element to drain water from the filter. See the SERVICE SCHEDULE, Page 43, for the service interval when to replace the fuel filter. Remove the filter element (Item 2) [C]. Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove the air from the fuel system. (See Page 57.) –56–

773 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

Removing Air From The Fuel System

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

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.

P–10571

W–2072–0496

Open the vent (Item 1) [A] on the fuel filter housing. Operate the hand pump (priming bulb) (Item 2) [A] until fuel flows from the vent with no air bubbles. Close the vent (Item 1) [A] on the fuel filter housing. Open the vent (Item 3) [A] on the fuel injection pump. Operate the hand pump (priming bulb) (Item 2) [A] until the pump feels solid. Tighten the vent plug (Item 3) [A]. Start the engine. It may be necessary to open the vent plug (Item 3) [A] briefly until the engine runs smoothly.

–57–

773 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

Checking Engine Oil Check the engine oil level every day before starting the engine for the work shift.

Open the rear door 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 CD or better (See Oil Chart below). Install the dipstick and close the rear door. P–10574

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

C° –40

–34

–29

–23

–18

–13

–7

–1

+10

+15

+21

+27

+32

+38

+43 +49

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

* SAE 5W–30

SAE 20W–20 SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

F°

–20

–10

+10

+20

+30

+40

+50

+60

+70

+80

+90

P–10576

+100 +110 +120

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. Replacing Oil And Filter See the SERVICE SCHEDULE, Page 43, for the service interval for replacing the engine oil and filter. Run the engine until it is at operating temperature. Stop the engine. Open the rear door. Remove the drain plug (Item 1) [B]. Drain the oil into a container and dispose of used oil in an environmentally safe manner.

–58–

773 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

Replacing Oil And Filter (Cont’d)

Remove the oil filter (Item 1) [A]. Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten. Install and tighten the drain plug.

P–10576

Remove the filler cap (Item 1) [B].

Put oil in the engine. (See SPECIFICATIONS, Page 95, for capacity) [B] (See Oil Chart, Page 58.)

Start the engine and let it run for several minutes. Stop the engine and check for leaks at the oil filter and check the oil level.

P–10572

Add oil as needed if it is not at the top mark (Item 1) [C] on the dipstick. Install the dipstick and close the rear door.

P–01575

W–2103–1285

–59–

773 Bobcat Loader Operation & Maintenance Manual

ENGINE COOLING SYSTEM

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

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.

P–10607

W–2019–1285

Cleaning The Cooling System Open the rear door and raise the rear grill. Use air pressure or water pressure to clean the top of the oil cooler [A]. Raise the oil cooler and clean the top of the radiator [B]. Check cooling system for leaks. Lower the rear grill and close the rear door. P–10608

Checking The Coolant Level Open the rear door.

Check the coolant level in the coolant recovery tank (Item 1) [C]. The coolant recovery tank must be 1/3 full. Close the rear door before operating the loader.

AVOID ENGINE DAMAGE

P–10572

Always use the correct ratio of water to antifreeze. Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

–60–

773 Bobcat Loader Operation & Maintenance Manual

ENGINE COOLING SYSTEM (Cont’d) Replacing the Coolant

773Operation&MaintenanceManual#6900372–PreventiveMaintenanceSectionPart1of2

Do not remove radiator cap when the engine is hot. You can be seriously burned. W–2070–1285

Open the rear door and raise the rear grill. P–03964

Remove the radiator cap (Item 1) [A]. Connect a hose to the engine block drain valve (Item 1) [B]. Open the drain valve and drain the coolant into a container.

B 1

After all the coolant is removed, close the drain valve. Mix the coolant in a separate container. (See SPECIFICATIONS Page 95, for correct capacity.) NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol. Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low. See IMPORTANT Page 60. 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.

P–10574

Use a refractometer to check the condition of propylene glycol in your cooling system. Fill the radiator with the premixed coolant. Install the radiator cap. Fill the coolant recovery tank 1/3 full. Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant to the recovery tank as needed. Lower the rear grill and close the rear door. ALTERNATOR BELT Adjusting The Alternator Belt

Stop the engine. Raise the operator cab. (See Raising The Operator Cab Page 45.)

Loosen the alternator mounting bolt (Item 1) [C]. Loosen the adjustment bolt (Item 2) [C]. Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span with 15 lbs. (66 N) of force. Tighten the adjustment bolt and mounting bolt.

Lower the operator cab. (See Lowering The Operator Cab Page 46.)

P–03877

–61–

773 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

Description The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again. Cleaning Battery Terminals The battery cables must be clean and tight. Check the electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution [A].

P–00742

Put grease on the battery terminals and cable ends to prevent corrosion.

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

P–10579

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W–2065–1296

1 Fuse Location The electrical system is protected by eight fuses (Inset) [B] located in the fuse block (Item 1) [B]. Remove the fuse block covers to check or replace the fuses. Fuses protect the electrical system from an overload.

P–10578

The decal inside the rear door shows the fuse sizes used in loader circuits [C].

AUX.

6707786

–62–

773 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

Using A Booster Battery (Jump Starting) If it is necessary to use a booster 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.

1 2

The key switch must be in the OFF POSITION. The booster battery must be 12 volt.

P–10644

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

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

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W–2065–1296

2 P–10645

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury.

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery). • Extra battery cables (booster cables) are connected wrong. I–2023–1285

W–2066–1296

Connect the end of the first cable (Item 1) [A] to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 1) [B] to the positive terminal on the loader starter (battery for early models). Connect the end of the second cable (Item 2) [A] to the negative (–) terminal of the booster battery. Connect the other end of the same cable (Item 2) [B] to the engine. Keep cables away from moving parts. Start the engine After the engine has started, remove the ground (–) cable (Item 2) [B] first. Remove the cable from the positive terminal (Item 1) [B].

–63–

773 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

Removing And Installing The Battery

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

Remove the battery hold down clamp (Item 2) [A].

P–10637

Disconnect the positive (+) battery cable (Item 1) [B].

P–10641

Remove the battery from the loader [C].

P–03873

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

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. Close the rear door before operating the loader.

P–09589

–64–

P–09590

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

Checking And Adding Fluid Use only recommended fluid in the hydraulic system. (See SPECIFICATIONS Page 95.)

Stop the loader on a level surface, Lower the lift arms and tilt the Bob–Tach fully back.

Stop the engine. Remove the dipstick (Item 1) [A]. P–10597

The fluid level must be between the marks on the dipstick [B].

If fluid is needed, remove the fill cap (Item 2) [A].

P–10303

Clean the hydraulic reservoir fill screen [C]. Add the fluid as needed to bring the level to the top mark on the dipstick [B]. Install the fill cap.

P–10600

Replacing Hydraulic/Hydrostatic Filter

See the SERVICE SCHEDULE Page 43 for the correct service interval. Open the rear door. Remove the filter element (Item 1) [D]. Clean the surface of the filter housing where the element seal contacts the housing.

Put clean oil on the rubber seal of the filter element. Install and hand tighten the filter element. P–10575

Close the rear door before operating the loader. –65–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

Replacing Hydraulic Fluid See the SERVICE SCHEDULE Page 43, for the service interval.

1 CD–12250

The fluid must also be replaced if it becomes contaminated or after major repairs. Remove the reservoir fill cap (Item 1) [A]. NOTE: Be sure the rubber gasket is installed on the fill cap [A]. Raise the operator cab. (See Raising The Operator Cab Page 45.)

P–10597

Disconnect the hose (Item 1) [B] from the case drain filter located on the reservoir. Use a plug and cap on the filter and case drain hose to prevent leakage.

Disconnect the hose (Item 1) [C] from the case drain filter located on the left drive motor. Use a plug and cap on the filter and case drain hose to prevent leakage.

Remove the case drain filters (Item 2) [B] & [C] and drain the fluid into a container. Replace the hydraulic/hydrostatic filter element. (See Page 63.) Replace both hydrostatic motor case drain filters (Item 2) [B] & [C].

When all the fluid is removed from the reservoir, reconnect the hose to case drain filter on the reservoir.

P–10603

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.

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

1 P–10602

W–2145–0290

Lower the operator cab (See Lowering the Operator Cab Page 46.) Start the engine and operate the loader hydraulic controls. Stop the engine and check for leaks. Check the fluid level in the reservoir and add as needed.

–66–

773 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

Breather Cap See the SERVICE SCHEDULE Page 43, for the correct service interval.

Raise the operator cab (See Raising The Operator Cab Page 45.) Remove the breather cap (Item 1) [A].

P–10604

NOTE: Be sure the rubber gasket (Item 1) [B] is installed on the fill cap.

Clean the filter (Item 2) [B] in the breather cap.

Be sure the baffle washer (Item 3) [B] is installed in the hydraulic reservoir. Replace the breather cap at regular intervals. (See the SERVICE SCHEDULE Page 43.) Lower the operator cab (See Lowering The Operator Cab Page 46.)

1 3

P–10605

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773 Bobcat Loader Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

See the SERVICE SCHEDULE, Page 43, for service interval for cleaning the spark arrestor muffler. Do not operate the loader with a defective exhaust system.

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.

P–10577

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

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

W–2050–1285

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

I–2022–0595

Stop the engine. Open the rear door and raise the rear grill.

W–2011–1285

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.

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

W–2068–1285

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W–2006–0284

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. This will force contaminants out through the cleanout hole. Stop the engine. Install and tighten the plug. Lower the rear grill and close the rear door.

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773 Bobcat Loader Operation & Maintenance Manual

TIRE MAINTENANCE

Wheel Nuts See the SERVICE SCHEDULE Page 43, for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) torque [A]. Tire Rotation Check the tires regularly for wear, damage and pressure. (See SPECIFICATIONS Page 95 for the correct tire pressure.) 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 [B]. It is important to keep the same size tires on each side of the loader. 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.

P–10628

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 Mounting 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.

B–09976

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 excessive 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. 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

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

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773 Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

Checking And Adding Oil

The chaincase contains the final drive sprockets and chains. Use the same type of oil as the hydraulic/hydrostatic system. (See SPECIFICATIONS Page 95.) Stop the loader on a level surface. Stop the engine. Remove the plug (Item 1) [A] from the front of the chaincase housing.

P–03870

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. Removing Oil From The Chaincase Remove the cover (Item 1) [B] which is installed over the drain plug at the bottom rear of the chaincase.

P–01616

Remove the drain plug (Item 1) [C] and drain the oil into a container. Check the drain plug and replace as necessary.

P–01619

FAN GEARBOX See the SERVICE SCHEDULE Page 43, for the correct service interval.

Checking And Maintaining Raise the operator cab. (See Raising The Operator Cab Page 45.) Remove the plug (Item 1) [D] to check the lubricant level. If the level is low, add SAE 90W gear lube through the check plug hole until the lubricant flows from the hole. Install and tighten the plug.

Lower the operator cab. (See Lowering The Operator Cab Page 46.)

P–03975

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773 Bobcat Loader Operation & Maintenance Manual

DRIVE BELT (Spring Loaded Idler)

Adjusting The Drive Belt Stop the engine. Open the rear door. Disconnect the negative (–) cable from the battery. Remove the belt shield fasteners (Item 1) [A]. Remove the belt shield (Item 2) [A].

P–03967

The belt tensioner is located between the flywheel and pump pulley.

Loosen the bolt (Item 1) [C] on the spring loaded drive idler.

NOTE: The pointer will be at the 1 o’clock position (Item 2) [C] when the belt tensioner is not under spring tension.

P–08760

Push the idler pulley against the belt, using a pry bar [D]. The pointer will be at the 3 o’clock position (Item 1) [D] when the idler pulley is against the stop (maximum movement).

P–08761

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773 Bobcat Loader Operation & Maintenance Manual

DRIVE BELT (Spring Loaded Idler) (Cont’d)

Adjusting The Drive Belt (Cont’d)

Raise the idler assembly slightly so that the pulley is operating on spring tension and not against the stop. Tighten the mounting bolt (Item 1) [A] to 25–28 ft.lbs. (34–38 Nm) torque. NOTE: Do not set the idler against the travel stop in the 3 o’clock position. Run the engine for a few minutes. Stop the engine and recheck the pointer position.

P–08762

Readjust if necessary.

After the idler has been in service, readjust when the pointer reaches the 1 o’clock position. Install the belt shield using the fasteners. Reconnect the negative (–) battery cable. Close the rear door. Replacing The Drive Belt Stop the engine. Open the rear door. Raise the operator cab. (See Raising The Operator Cab Page 45.)

P–03969

Remove the fan drive belt (Item 1) [C].

Remove the negative (–) cable from the battery. The battery may be removed for additional working clearance. (See Removing The Battery Page 64.)

Remove the belt shield fasteners. Remove the belt shield [B]. The belt tensioner is located between the flywheel and pump pulley. Loosen and remove the bolt (Item 2) [C] from the belt tensioner. Remove the belt tensioner assembly. Remove the drive belt from the pump pulley and flywheel.

P–08760

Remove the drive belt from the loader [D].

Install the new drive belt. Install the belt tensioner assembly. Install the fan drive belt. Adjust the drive belt. (See Page 73.) Reinstall previously removed components and connect the negative (–) cable to the battery. Lower the operator cab. (See Lowering The Operator Cab Page 46.) Close the rear door before operating the loader.

P–04064

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773 Bobcat Loader Operation & Maintenance Manual

DRIVE BELT (Fixed Mount Idler)

Adjusting The Drive Belt You will need the following tools:

MEL1405 – Bar MEL1406 – Spring Scale See the SERVICE SCHEDULE Page 43 for the service interval. You will be adjusting the belt idler on the belt between the engine flywheel and the hydrostatic pump pulley.

Stop the engine. Open the rear door.

P–01617

Disconnect the negative (–) battery cable.

Remove the three belt shield fasteners (Item 1) [A]. Remove the belt shield [B].

P–03394

Loosen the mounting bolt (Item 1) [C] on the belt idler.

Use the end of the tool (MEL1405) to move the pulley down (see inset) [C]. Tighten the bolt (Item 1) [C].

1 P–01662

P–01618

Install the Belt Tension Bar (MEL1405) on the drive belt [D].

The pin (Item 1) [D] must be pulled tight against the engine drive pulley. Put a mark on the cast flange just below the tool handle (Item 2) [D].

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773 Bobcat Loader Operation & Maintenance Manual

DRIVE BELT (Fixed Mount Idler) (Cont’d)

Adjusting The Drive Belt (Cont’d) Install a spring scale on the tool handle. The line of pull on the spring scale must be at a right angle (perpendicular) to the tool handle as shown [A]. NEW BELT: A new belt is one with a 1/2 hour or less operating time. With 15 lbs. (67 N) of force, the tool should move 1.250 inches (32 mm) (the width of the tool handle). NOTE: When a NEW belt is installed, run the engine for approximately 5 minutes. Then the belt tension must be checked and adjusted to 15 lbs. (67 N) spring scale force.

P–03396

USED BELT: With 12 lbs. (53 N) of force, the tool should move 1.250 inches (32 mm) (the width of the tool handle).

Close the rear door before operating the loader. Replacing The Drive Belt Stop the engine. Open the rear door. Raise the operator cab. (See Raising The Operator Cab Page 45.) Remove the fan drive belt. Remove the negative (–) cable from the battery. The battery may be removed for additional working clearance. (See Removing The Battery Page 64.)

P–03394

Remove the belt shield fasteners.

Remove the belt shield [B]. Remove the bolt (Item 1) [C].

Remove the belt idler assembly.

P–01618

Remove the drive belt from the pump pulley and flywheel. Remove the drive belt from the loader [D].

Install the new drive belt. Install the belt idler assembly. Reinstall the fan drive belt. Adjust the drive belt. (See Adjusting The Drive Belt Page 73.) Reinstall previously removed components and reconnect the negative (–) cable. Lower the operator cab. (See Lowering The Operator Cab Page 46.) Close the rear door before operating the loader.

P–01615

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773 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER Lubricate the loader as specified in the SERVICE SCHEDULE, Page 43, for the best performance of the loader.

A 1

Record the operating hours each time you lubricate the Bobcat loader. Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply lubricant until extra grease shows. Lubricate the following locations on the loader: 1. Stabilizer Rod – Front (Both Sides) [A]

P–10619

2. Stabilizer Rod – Rear (Both Sides) [B].

3. Lift Cylinder Rod End (Both Sides) [B]. 4. Lift Cylinder Base End (Both Sides) [B].

4 P–10640

5. Tilt Cylinder Base End [C].

P–10620

P–10622

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773 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

6. Tilt Cylinder Rod End. [A].

6 P–10625

7. Bob–Tach Wedge (Both Sides) [B].

P–10626

8. Bob–Tach Pivot Pin (Both Sides) [C].

8 P–10635

9. Lift Arm Pivot Pin (Both Sides) [D].

10. Lift Arm Link Pivot Pin (Both Sides) [D].

P–10621

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773 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

11. 250 Hours: Steering Lever Shaft (2) [A].

P–01533

PIVOT PINS

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [B]. Check that the lock nuts are tightened to 18–20 ft.–lbs. (24–27 Nm) torque.

P–10620

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773 Bobcat Loader Operation & Maintenance Manual

BOB–TACH

773Operation&MaintenanceManual#6900372–PreventiveMaintenanceSectionPart2of2

Inspection and Maintenance Move the Bob–Tach levers to engage the wedges [A]. The levers and wedges must move freely.

The wedges must extend through the holes in the attachment mounting frame (Item 1) [A]. N–17022

N–17027

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

The spring loaded wedge (Item 1) [A] must contact the lower edge of the hole in the attachment (Item 1) [B] and [C]. If the wedge does not contact the lower edge of the hole [B] and [C], the attachment will be loose and can come off the Bob–Tach.

N–17023

Bob–Tach Wedge

Wedge Must Contact Lower Edge Of Hole In The Attachment

Inspect the mounting frame on the attachment and the Bob–Tach, linkages and wedges for excessive wear or damage [D]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. Lubricate the wedges (See SERVICE SCHEDULE, Page 43 and LUBRICATION OF THE BOBCAT LOADER, Page 75).

TS–01062

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773 Bobcat Loader Operation & Maintenance Manual

SYSTEMS ANALYSIS ADVANCED HAND CONTROLS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 MONITOR SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SERVICE CODES (BOSS Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SYSTEMS ANALYSIS

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773 Bobcat Loader Operation & Maintenance Manual

SERVICE CODES The following list contains the BOSS defect codes which can occur. These codes are transmitted to the instrument panel display. Some service procedures for correcting the problems can be found in this manual and other procedures must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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

SUBJECT

DISPLAY READS

CONDITION

Engine Coolant Level

ECL 1

SHUTDOWN, No Coolant

Engine Coolant Temp.

EC–1.1 EC–2.1

SHUTDOWN, Engine Temperature WARNING, Engine Temperature

EC 3 EC 4 EC 5 EC 7

Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range

EP 1 EP 2 EP 3

SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected

Engine Speed

EP 4 EP 5 EP 7 ES 1

Wiring Shorted High Sensor Voltage Sensor Out Of Range SHUTDOWN, Engine Speed Too High

Air Filter

ES–2.1 ES–6 ES–7 AF 2

WARNING, Engine Speed Slightly High Sensor No Signal Sensor Out Of Range WARNING, Restriction Too High

AF 6 b–2.1 b–2.2 FUEL2

Sensor No Signal WARNING, Bad Battery WARNING, Battery Voltage WARNING, Low Level

FUEL3 FUEL4 FUEL5

Wiring Not Connected Wiring Shorted High Sensor Voltage

FUEL7

Sensor Out Of Range

Engine Oil Pressure

Battery Fuel Level

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773 Bobcat Loader Operation & Maintenance Manual

SUBJECT

DISPLAY READS

CONDITION

Hydrostatic Charge Filter Conditions

HF1–2 HF1–6

WARNING, High Restriction (1st Filter) Sensor No Signal

Return Filter Condition (853, 863, 873 Only)

HF2–2 HF2–6

WARNING, High Restriction Sensor No Signal

Hydrostatic Fluid

HP 1 HP 2 HP 3 HP 4 HP 5 HP 7 HC 1 HC 2 HC 3 HC 4 HC 5 HC 7

SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range SHUTDOWN, Temperature WARNING, Temperature Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range

Hydrostatic Fluid Temperature

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773 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 773Operation&MaintenanceManual#6900372–SystemsAnalysisSection

Troubleshooting Chart The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller lights are off or flashing. Have service procedures 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.

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.

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.

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773 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SERVICE SCHEDULE (6708212) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 WARNING (6579510 Foot Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 WARNING (6703725 Hand Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 WARNING (6579528, 6577754, 6579639, 6579509) . . . . . . . . . . . . . . . . . . . 93

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.

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773 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

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773 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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773 Bobcat Loader Operation & Maintenance Manual

Translations not available at time of printing.

–89–

773 Bobcat Loader Operation & Maintenance Manual

Translations not available at time of printing.

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773 Bobcat Loader Operation & Maintenance Manual

Solamente con control de piso

Commande au pied seulement

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.

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Solamente con control de mano

Commande à la main seulement

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.

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. MANTENGA LOS PIES EN LOS PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE. ANTES DE BAJARSE DEL CARGADOR 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR MELROE COMPANY. MAINTENIR LES PIEDS SUR LES PEDALES. DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT. POUR QUITTER LA CHARGEUSE: 1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL.

2. PARE EL MOTOR 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.

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4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES. 773 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE 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.

PELIGRO (SPANISH) EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

AVERTISSEMENT (FRENCH)

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.

EVITER DES BLESSURES OU LA MORT TENIR LA CHARGE VERS LE BAS. LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

DANGER (FRENCH) 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) 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.

PELIGRO (SPANISH) 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.

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773Operation&MaintenanceManual#6900372–MachineSignTranslationsSection

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SPECIFICATIONS ADDITIONAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 FLOOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 MELROE APPROVED ATTACHMENTS AND ACCESSORIES . . . . . . . . . . 99 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

SPECIFICATIONS

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•

SKID STEER LOADER SPECIFICATIONS

78.3 (1989)

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. • Where applicable, specification conform to SAE or ISO standards and are subject to change without notice. 93°

‘‘C” 46.8 (1189)

43° 28.9 (734)

76.3 (1938)

62.1 (1577) ‘‘B”

26°

25° 40.6 (1030) 101.7 (2583) 130.1 (3305)

7.5 (191)

‘‘A”

‘‘A” ‘‘B”

148.7 (3777) 115.0 (2921) 87.5 (2223)

10 – 16.5 TIRES – 66.0 in. (1676mm) or 60.0 in. (1524mm) 31 – 15.5 x 15 TIRES – 66.0 in. (1676mm) 10 – 16.5 TIRES – 54.5 in. (1383mm) or 48.5 in. (1231mm) 31 – 15.5 x 15 TIRES – 50.0 in. (1270mm)

‘‘C”

8.6 (218) MC–1525

60 in. BUCKET WIDTH – 61.0 in. (1549mm) 66 in. BUCKET WIDTH – 68.1 in. (1731mm)

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) . . . . . . . . . . . . Rear Auxiliary (Optional) . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . .

1700 lbs. (770 kg) 3800 lbs. (1720 kg) 5476 lbs. (2480 kg) 3040 lbs. (1379 kg) 3200 lbs. (1452 kg) 4400 ft.–lbs. (5966 Nm) 0–7.0 MPH (11,2 km/hr.) Direction and Speed controlled by two hand levers.

Secondary Brake . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Controlled by separate foot pedals or optional hand controls. Controlled by electrical switch on RH steering lever. Controlled by electrical switch on LH steering lever. Hand lever throttle: Key–Type starter switch and shutdown. Glow Plug– Rocker Switch activated. BOSS activated glow plugs (If so equipped). Two independent hydrostatic systems controlled by two hand operated steering levers. One of the hydrostatic transmissions Mechanical Disc, foot operated pedal.

ENGINE Make/Model . . . . . . . . . . . . . . . . . . . . . . . . Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . Horsepower (SAE) . . . . . . . . . . . . . . . . . . Maximum Governed RPM . . . . . . . . . . . . Torque @ 1600 RPM (SAE) . . . . . . . . . . Number of Cylinders . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota/V2203E Diesel/Liquid Gross: 50 HP (37 kW) Net: 46 HP (34 kW) 2800 RPM Gross: 114 ft.–lbs. (154 Nm) Net: 102.5 ft.–lbs. (138 Nm) Four 134.0 cu. in. (2195 cm3) 3.43/3.64 (87.0/92.4) Pressure System W/Filter External Dry replaceable cartridge w/safety element Diesel–Compression

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

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773 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 . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Driven, Gear Type 15.0 GPM (56 L/min.) @ 2850 RPM 3000 to 3050 PSI (20600 to 21029,7 kPa) Full flow replaceable, 3 micron synthetic media element Doubleacting; Tilt cylinder has custioning feature on dump & rollback 2.25 (57,2) 3.50 (88,9) 1.50 (38,1) 1.50 (38,1) 26.00 (660,4) 14.50 (368,3) 3–spool, open center type w/float detent on lift and electrically controlled auxiliary spool. SAE standard tubes, hoses & fittings Bobcat Fluid (P/N 6563328); If fluid is not available, use 10W–30/10W–40 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 . . . . . . . . . . . . . . . . . . . . .

3.49 Seconds 2.84 Seconds 1.93 Seconds 1.64 Seconds Belt driven, 55 amp, open 12 volt, 625 cold cranking amps. @ 0°F. (–18°C); 160 minute reserve capacity at 25 amps. 12 volt, Gear Reduction Type; 3.62 HP (2,7 kW) Gauges:Hourmeter, Fuel, Voltmeter, Engine Temperature. Warning lights: Engine Temperature, Engine Oil Pressure, Hydraulic Oil

Temperature & Pressure, Hydraulic Filter. Optional BOSS System Monitors; Engine Coolant Temperature, Engine Oil Pressure, Engine Coolant Level, Hydraulic System Temperature & Pressure, Hydraulic & Air Filters, RPM, Battery Condition,

Fuel Level & Machine Hours. Displays visual warnings & sounds audible alarm. Also controls automatic shutdown function and has diagnostic capability. DRIVE SYSTEM Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic 4 wheel drive Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors. #80 HS endless roller chain & sprockets in sealed chaincase with oil lubrication.

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . . Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . .

33:1 2.00 (50,8) (8) 9/16”

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil W/Filter . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . Hydraulic/Hydrostatic System . . . . . . . . . Chaincase Reservoir . . . . . . . . . . . . . . . .

13 qts. (12,3 L) 14 gals. (53,0 L) 7.5 qts. (7,1 L) 24.0 qts. (23,0 L) 8.5 gals. (32,2 L) 9 gals. (34,1 L)

TIRES Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . Terra Grip . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Pressure . . . . . . . . . . .

10–16.5, 8 ply rating 31 x 15.5–15, 8 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.

FLOOR PRESSURE . . . . . . . . . . . . . . . .

N/A

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773 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES – For use on 773 Series Bobcat Loaders 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 or other attachments. See your Bobcat 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: BUCKET DESCRIPTIONS 54 inch Construction – Industrial Bucket 54 inch Construction – Industrial with Teeth 60 inch Construction – Industrial Bucket 60 inch Construction – Industrial with Teeth 54 inch Dirt Bucket 54 inch Utility Bucket 60 inch Utility Bucket

Rear Stabilizer

54 inch Fertilizer Bucket 60 inch Fertilizer Bucket 66 inch Litter & Snow Bucket 78 inch Scraping Bucket

607 & 709 Backhoe

Angle Broom

(Recommended for use with backhoe)

Increase your backhoe performance. Increase your versatility in a wide range of jobs with a set of frame mounted Bobcat Loader rear stabilizers.

Industrial Grader Scarifier Kit Available

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

Econo–Grader

Turn your Bobcat loader into a high performance grading machine. Designed for use by landscaping, asphalt, curb and gutter and concrete flatwork contractors. Featuring a seven foot, six–way hydraulically controlled moldboard, operated with switches mounting on the loader’s steering levers for precise control.

Landscape Rake Model 5 A Model 6A

Break up lumpy soil, pick up rocks as small as 3/4’’, grade, level and scarify in close quarters with the Bobcat Landscape Rake. Use it for ground preparation, for seeding, sodding and lawn leveling. Pick up rocks or had–packed clumps of soil and dump them where you need them with the Bobcat Landscape Rake.

Two attachment options in one! Use it as an economical, but effective grader OR a box blade by utilizing locking end plates. Angle of the seven–foot moldboard is manually adjusted. Blade pitch adjusted by hydraulically tilting the Bob–Tach.

Put your Bobcat loader to work and clean up almost everything in sight with the hydraulically driven and controlled Angle Broom attachment. Use it to sweep driveways, sidewalks, parking lots, loading docks, warehouses, or countless other applications.

Sweeper – 60 inch – 72 inch

Cleans up construction sites. Cutting edge for scraping mud. Sweeps parking lots, warehouse, docks, etc. Sweeps and collects debris with one attachment.

Vibratory Roller

Combination Bucket

Pack and level smooth and easy. The Bobcat Loader Vibratory Roller features either a smooth or padded 48–inch wide drum. The roller provides up to 4156 pounds of force at 2153 vibrations per minute and is ideal for flatwork, trenching and asphalt patchwork contractors. A bolt–on smooth outer shell is also available for converting the padded drum to a smooth drum.

Perform a wide variety of job functions. The versatile Melroe Bobcat Combination Bucket is ideal for dozing, grappling, leveling, digging, loading and dumping.

Some attachments may not be available from your local dealer. –99–

773 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES (Cont’d) Scarifier (Bob–Tach Mount)

Auger

Trencher

Adjustable depth skids for presetting digging depth. Prepares hard–packed ground for digging or landscaping. One–to–seven–tooth versatility. Standard five–tooth unit with additional teeth available. Rips asphalt for removal.

Dig 6’’ – 36’’ holes with speed and plumbline accuracy. Utilizing Bobcat Loader hydraulics, the heavy–duty hydraulic auger bites in with low speed, high torque power. Because of a unique knuckle–joint design, the auger will dig vertical holes even though the Bobcat Loader is working on uneven terrain.

Versatile trenching ability. Use these Bobcat trencher attachments for a variety of jobs. The LT204 digs two or three feet deep and 4 to 12 inch trenching widths. The LT405 digs three to five feet deep and 5 to 12 inches wide. Hydraulic sideshift to get close to walls. Optional trench cleaner.

Industrial Bucket Grapple

Industrial Fork Grapple

Utility Fork/Grapple

Clamp onto heavy and odd–shaped objects, and move them with ease. The Bobcat Industrial Grapple is the ideal attachment for handling scrap, waste or pipe. It’s built strong for tough working conditions.

The Fork Grapple is perfect for handling irregular–shaped metal and other assorted scrap and heavy–duty agricultural applications.

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.

Pallet Fork

Hydraulic Breaker

Tiller

Move bulky or bagged materials in one load. Hook on a pallet fork and move your bagged or bulk material fast. Ideal for all kinds of farm chores and fertilizer handling. In industrial plants and landscaping, handle baled or pallet materials.

Up to 300 ft.–lb. impact energy class. Backhoe or loader mounting. 2–position loader mounting frame for vertical and horizontal breaking. Quick–change tool system – variety of tool system. Low recoil operating cycle.

Till and mix for seed or sod bed preparation. The Bobcat Tiller attachment is great for jobs such as breaking up clumps and mixing compost or other materials into existing soil. The Bobcat Tiller features: * 52–inch working width. * Tills at a maximum 6–inch depth. * Bi–directional rotation allows the loader to be driven forward or in reverse.

*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.

Brushcat Rotary Cutter

Level II FOPS Top Kit

For protection from falling trees, rocks for machines involved in site clearing, overhead demolition or forestry per ISO 3449. (Level I protection is provided with the standard cab).

Some attachments may not be available from your local dealer. –100–

773 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES (Cont’d) Box Scraper Approved by Melroe Company & Sold through Bobcat Loader Dealers

Longwood Grapple Approved by Melroe Company & Sold through Bobcat Loader Dealers

Bale Handler Approved by Melroe Company & Sold through Bobcat Loader Dealers

Grade, scarify, backfill or level. With this tool, a Bobcat Loader operator can grade, scarify, backfill or level in close quarters. Use it on road construction, lawn leveling, ripping hard packed soil or gravel, piling and leveling dirt, manure or other materials. Drag a load or doze it right where you need it.

Turn your Bobcat Loader into a high performance log handler. The Multitek Longwood Grapples are made of high quality steel providing strength and durability for rough working conditions.

Manage large round bales easily with the Bale Handler. It’s a handy and efficient way to move bales from the ground onto a trailer or into a bale feeder. The Bale Handler can be replaced with other attachments quickly, thanks to the Bob–TachTM mounting system.

Snow Blower Approved by Melroe Company & Sold through Bobcat Loader Dealers

Tree Transplanter Approved by Melroe Company & Sold through Bobcat Loader Dealers

Angle Blade Approved by Melroe Company & Sold through Bobcat Loader Dealers

Blow snow with this perfect winter clean–up tool. Blow snow off driveways, sidewalks or in those tight quarters where only a Bobcat skid–steer loader can manage. Powered from the Bobcat Loader auxiliary hydraulics. Rotational spout directs snow where you want it to go.

Turn your Bobcat Loader into a tree transplanter. The Caretree Transplanter will dig trees and also load them on a truck or trailer in minutes. It’s simple to operate with complete control from the operator’s seat.

Remove heavy snow from the surface, before it’s compacted. It’s the ideal attachment for cleaning sidewalks, driveways, parking lots, alleys, service stations and warehouse lots. Use a heavy duty version for dozing and backfilling dirt.

Rake Approved by Melroe Company & Sold through Bobcat Loader Dealers

Tracks Approved by Melroe Company & Sold through Bobcat Loader Dealers

Hydraulic Fork Positioner Approved by Melroe Company & Sold through Bobcat Loader Dealers

Turn your Bobcat Loader into a versatile landscape machine. The triple–duty York Rake rips up soil with scarifier teeth, blades down high spots and tills holes, and rakes the surface to remove big rocks and debris.

You’ll get better performance in sand, snow and mud. Float over soft, sandy, or muddy ground and get better traction on slippery surfaces with over–tire metal or rubber tracks.

Position pallet fork teeth from the operator’s seat. It uses loader auxiliary hydraulics to change teeth width to handle various pallet sizes.

*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.

Laser Approved by Melroe Company & Sold through Bobcat Loader Dealers

Use the laser option on your Bob–Tach mounted Grader attachment to increase grade preparation accuracy.

Some attachments may not be available from your local dealer. –101–

773 Bobcat Loader Operation & Maintenance Manual

ADDITIONAL PUBLICATIONS

773Operation&MaintenanceManual#6900372–SpecificationsSection

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

OPERATOR’S HANDBOOK 6708021 – Foot Pedal 6708158 – Hand Control 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 6900372 –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 6900092 –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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773 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.

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Printed in U.S.A.