Bobcat 442 Compact Excavator Operation & Maintenance Manual SN ADBR11001 & Above - PDF DOWNLOAD

Operation & Maintenance Manual 442 Compact Excavator

Dealer Copy -- Not for Resale

S/N ADBR11001 & Above

6987203 (5-09)

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Printed in U.S.A.

© Bobcat Company 2009

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OPERATOR SAFETY WARNINGS WARNING

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

W-2001-0502

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

CORRECT

WRONG

CORRECT

WRONG

P-90216

B-16674

B-16609

B-16675

without

Read machine signs, Operation & Maintenance Manual, and Operator’s Handbook.

Do not grasp control handles when entering canopy or cab.

Never operate without approved canopy or cab.

Never modify equipment.

Be sure controls are in neutral before starting.

Never use attachments not approved by Bobcat Company.

Sound horn and check behind machine before starting.

WRONG

WRONG

MC-1867

MC-1868

Use caution to avoid tipping - do not swing heavy load over side of track.

Keep bystanders out of maximum reach area.

Operate on flat, level ground.

CORRECT

Avoid steep areas or banks that could break away.

CORRECT

CORRECT

15° Maximum

15° Maximum

B-16676

Never exceed a slope to the side.

15°

MC-1878C

Never travel up a slope that exceeds 15°.

Do not travel or turn with bucket extended.

Never carry riders.

CORRECT

CORRECT

SAFETY EQUIPMENT 1. Seat Belt 2. Safety Signs (Decals) 3. Grab Handles 4. Slew Lock 5. Safety Tread

Stop 25° Maximum MC-1878B

MC-1859A

B-21928

Never exceed 25° when going down or backing up a slope.

To leave excavator, lower the attachment.

Fasten seat belt securely.

Stop the engine.

Operate controls only from operator’s seat.

OSW21-0409

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Never operate instructions.

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FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SAFETY & TRAINING RESOURCES

SAFETY & TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . XI OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1

OPERATING INSTRUCTIONS (OI)

MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . MST-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-1

PREVENTIVE MAINTENANCE (PM)

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-1 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1 REFERENCE INFORMATION Write the correct information for YOUR Excavator in the spaces below. Always use these numbers when referring to your Bobcat Excavator.

SPECIFICATIONS (SPEC)

Bobcat Excavator Serial Number Engine Serial Number

WARRANTY

NOTES

ALPHABETICAL INDEX

YOUR BOBCAT® EXCAVATOR DEALER: ADDRESS: PHONE:

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

Bobcat Company Europe Drève Richelle 167 B-1410 WATERLOO Belgium

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MACHINE SIGN TRANSLATIONS (MST)

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FOREWORD

FOREWORD

This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat Excavator. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR Bobcat Excavator. If you have any questions, see your Bobcat Excavator dealer.

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED . . . . . . . . . . . . . . . . V BUCKETS AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

SYSTEM SETUP & ANALYSIS

TRANSLATIONS

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Excavator Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

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FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . IX Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Buckets Available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Falling Object Guards (FOGS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . X Standard Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

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BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED

ISO 9001:2000 is an international standard that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001:2000 standard. The BSI registration certifies that Bobcat's manufacturing facilities in Gwinner and Bismarck, North Dakota (North America), Pontchateau (France), Dobris (Czech Republic) and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001:2000. Only certified assessors, like BSI, can grant registrations.

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

REGULAR MAINTENANCE ITEMS ENGINE OIL FILTER FUEL FILTER FUEL PRE-FILTER PRIMARY AIR FILTER SECONDARY AIR FILTER HYDRAULIC OIL FILTER CAB VENTILATION FILTER ALTERNATOR BELT AIR CONDITIONING BELT HYDRAULIC TANK/ ENGINE OIL DRAIN HOSE TRACK TENSIONER ADAPTER

5411656547 5411656301 5411657863 5501660912 5501660914 5368632568 5501661034 5411657150 1490953974 5366654556 1858000054

ENGINE OIL 6903105 SAE 15W40 CE/SG (12 qt.)

6903107 SAE 10W30 CE/SG (12 qt.)

6903109 SAE 30W CE/SG (12 qt.)

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

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

442 Operation & Maintenance Manual

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

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SERIAL NUMBER LOCATIONS

Engine Serial Number

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

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

Figure 2

1 Figure 1

1

P-56395

The engine serial number (Item 1) is located on the engine in the location shown [Figure 2].

P-56394

Dealer Copy -- Not for Resale

DELIVERY REPORT Figure 3

Excavator Serial Number The excavator serial number plate (Item 1) is located on the frame of the machine in the location shown [Figure 1].

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

/ B-16315

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

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

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

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EXCAVATOR IDENTIFICATION

ARM CYLINDER BOOM

ARM

OPERATOR HANDBOOK

MIRROR OPERATOR SEAT WITH SEAT BELT

BOOM CYLINDER

GRAB HANDLE BUCKET CYLINDER

RETURN TO TANK COUPLER

BUCKET BLADE CYLINDERS

RIGHT SIDE COVER AUXILARY COUPLERS REAR COVER

UPPERSTRUCTURE

BLADE TIEDOWN TRACK FRAME

TRACK B-16589 B-16590

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AUXILIARY COUPLERS

FEATURES, ACCESSORIES AND ATTACHMENTS Standard Items

Attachments

Model 442 Bobcat Excavators are equipped with the following standard items:

These and other attachments are approved for use on this model excavator. Do not use unapproved attachments. Attachments not manufactured by Bobcat may not be approved.

Enclosed Cab with Heater and Air Conditioning 92 inch (2330 mm) Dozer Blade 18 inch (450 mm) Rubber Tracks Two-Speed Travel Auxiliary Hydraulics Hydraulic and Travel Control Lockouts Horn Hydraulic Joystick Controls ISO/STD Control Pattern Selection Feature Suspension Seat

The versatile Bobcat Excavator quickly turns into a multijob machine with a variety of attachments.

See your Bobcat dealer for more details on these and other attachments and field accessories.

• • • • • • • • • • • • • • • •

Subject to change without notice.

Options and Accessories Below is a list of some equipment available from your Bobcat Excavator dealer as Dealer and/or Factory Installed Accessories and Factory Installed Options. See your Bobcat dealer for other available options, accessories and attachments.

• • • • • • • •

Enclosed Cab With Heater Flood Lights Security Ignition Radio Installation Kit Service Kit Blade Float Steel Track Travel Motion Alarm

Heavy duty trenching bucket Trenching bucket Grading bucket Auger Breaker Hydraulic Clamp 3-Tined Grapple Compactor Power Tilt Ripper 52 in. (1321 mm) Grading blade Hydro tilt Bucket Clam Packer wheel Rotating grapple Manual Spring Loaded Coupler

Buckets Available

BUCKET

Many bucket styles, widths and different capacities are available for a variety of different applications. See your Bobcat dealer for the correct bucket for your Bobcat Excavator and application.

• • • • • • • • •

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17.7 in. (450 mm) Bucket 17.7 in. (450 mm) Ejector Bucket 23.6 in. (600 mm) Bucket 31.5 in. (800 mm) Bucket 36.0 in. (914 mm) Trenching Bucket 59.0 in. (150 mm) Ditching Bucket 59.0 in. (150 mm) Swing Bucket 19.7 in. (500 mm) Clam Shell 39.0 in. (991 mm) Tilt Bucket

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• • • • • • • • • •

FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D)

Special Applications Kit Figure 5

Falling Object Guards (FOGS) Figure 4

SPECIAL APPLICATION KIT

OVERHEAD GUARD

Available for special applications that require protection from smaller objects that can fall on the cab or restrict material from entering cab openings [Figure 4] and [Figure 5].

P-92949

The excavator must have the overhead guard [Figure 4] installed to meet FOGS ISO 10262 - level 1.

The excavator must have the special applications kit [Figure 5] installed to meet the front guard requirements in FOGS ISO 10262 - level 1.

See your Bobcat Dealer for more information.

See your Bobcat Dealer for more information.

Special Applications Kit Inspection And Maintenance The Special Applications Kit must be regularly inspected and maintained. Inspect the screen for damage. Replace parts as necessary.

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P-92950

SAFETY & TRAINING RESOURCES FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . .XVI Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI

SAFETY & TRAINING RESOURCES

MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII PUBLICATIONS AND TRAINING MATERIALS . . . . . . . . . . . . . . .XIX SYSTEM SETUP & ANALYSIS Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

TRANSLATIONS

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•

An Operator’s Handbook is fastened to the operator cab of the excavator. It’s 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 AEM Safety Manual delivered with the machine gives general safety information.

•

The Compact Excavator Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Bobcat excavator. The course is available in English and Spanish versions.

•

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

•

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

Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat excavator is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat excavator usage.

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

The dealer explains the capabilities and restrictions of the Bobcat excavator and attachment for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments.

The attachments and buckets are designed for a Rated Lift Capacity. They are designed for secure fastening to the Bobcat excavator. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the machine attachment combination.

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

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

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

•

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

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

•

Call Before You Dig Dial 811 (USA Only) 1-888-258-0808 (USA & Canada)

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

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

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SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS (CONT’D)

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

Safe Operation Is The Operator’s Responsibility

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

Carefully read the message that follows.

A Qualified Operator Must Do The Following: Understand Regulations

WARNING

the

Written

Instructions,

Rules

and

•

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

•

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

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

W-2001-1285

•

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

•

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

•

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

•

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

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

I-2019-0284

DANGER The signal word DANGER on the machine and in the manuals indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Know the Work Conditions

D-1002-1107

•

Know the weight of the materials being handled.

Avoid exceeding the Rated Lift Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material.

•

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

•

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

•

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

WARNING The signal word WARNING on the machine and in the manuals indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

W-2044-1107

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

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

SI EXC-0208 XIV

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Have Training with Actual Operation

SAFETY INSTRUCTIONS (CONT’D)

FIRE PREVENTION

Avoid Silica Dust

Maintenance The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Cutting or drilling concrete containing sand or rock containing quartz may result in exposure to silica dust.

Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other job site Rules and Regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.

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

All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.

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

Electrical

Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed.

Battery gas can explode and cause serious injury. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting. Do not jump start or charge a frozen or damaged battery. Keep any open flames or sparks away from batteries. Do not smoke in battery charging area.

SI EXC-0208

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

FIRE PREVENTION (CONT’D)

Welding And Grinding

Hydraulic System

Always clean the machine and attachment, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

Check hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Hydraulic tubes and hoses must be properly routed and have adequate support and secure clamps.

Tighten or replace any parts that show leakage.

Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts.

Toxic dust or gas can be produced.

Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive.

Repair such components in a well ventilated area away from open flames or sparks.

Fueling

Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors.

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

Know where fire extinguishers and first aid kits are located and how to use them. Inspect the fire extinguisher and service the fire extinguisher regularly.

Obey the recommendations on the instructions plate.

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

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

Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Sl EXC-0208

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Fire Extinguishers

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

6813576

6807776

6589129

6813577 6813581

B-16589

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OPERATOR’S HANDBOOK 6901803

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

6811054 under right side cover 6804233 under right side cover

6813628 6813575

Dealer Copy -- Not for Resale

6594897

6813578 under rear cover

6595014 (2)

6813581

6595014 (2)

6589129

B-16590

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PUBLICATIONS AND TRAINING MATERIALS OPERATOR’S HANDBOOK

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

6901803 For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.bobcat.com; you can also order Operator and Service Training materials online through www.bobcatstore.com

- Gives basic operation instructions and safety warnings.

COMPACT EXCAVATOR OPERATOR TRAINING COURSE

OPERATION & MAINTENANCE MANUAL 6987203

6903186

- Complete instructions on the correct operation and the routine maintenance of the Bobcat Excavator.

EXCAVATOR SERVICE SAFETY COURSE

SERVICE MANUAL

6900916

6987204

- Introduces Service Technicians to step-by-step basics of proper and safe excavator maintenance and servicing procedures.

OPERATOR SAFETY VIDEO

- Complete maintenance instructions for your Bobcat Excavator.

6903181

SAFETY MANUAL 6570354

- Provides basic safety instructions.

OPERATOR SAFETY DVD

- Provide basic safety procedures and warnings for your Bobcat Excavator

6904762

Provides basic safety instructions contained in all Bobcat Safety Videos in both English and Spanish.

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- Introduces operator to step-by-step basics of Compact Excavator operation.

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OPERATING INSTRUCTIONS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-34 Bucket And Ripper Tooth Installation . . . . . . . . . . . . . . . . . . . . . OI-34 Bucket And Ripper Tooth Removal . . . . . . . . . . . . . . . . . . . . . . OI-35 Clamshell Bucket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-39 Clamshell Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-43 Clamshell Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-42 Fastening The Clamshell Bucket To The Transport Vehicle . . . OI-46 Lifting The Clamshell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-45 Manual Spring Loaded Coupler Attachment Installation . . . . . . OI-49 Manual Spring Loaded Coupler Attachment Removal . . . . . . . . OI-51 Manual Spring Loaded Coupler Installation . . . . . . . . . . . . . . . . OI-47 Manual Spring Loaded Coupler Removal . . . . . . . . . . . . . . . . . OI-48 Tilt Bucket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-36 Tilt Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-38 Tilt Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-37

OPERATING INSTRUCTIONS (OI)

BOOM SWING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-25 Daily Inspection And Maintenance. . . . . . . . . . . . . . . . . . . . . . . OI-26 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-14 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-14 HYDRAULIC CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-16 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-17 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Relieving Hydraulic Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Upperstructure Slew Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-23 INSTRUMENTS AND CONSOLES. . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Left Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Raising And Lowering The Left Console . . . . . . . . . . . . . . . . . . . OI-6 Right Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-4 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-61 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-61 Continued On Next Page

OI-1 25 of 166

442 Operation & Maintenance Manual

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BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24

OPERATING INSTRUCTIONS (CONT’D) MOTION ALARM SYSTEM (IF EQUIPPED). . . . . . . . . . . . . . . . . . . OI-15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-15

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 Front Window Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Heating, Ventilation And Air Conditioning Duct . . . . . . . . . . . . . . OI-11 Wiper/Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-27 Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-30 Entering And Exiting The Excavator . . . . . . . . . . . . . . . . . . . . . . OI-27 Operation And Maintenance Manual And Operator’s Handbook Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-27 Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-28 Seat Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-29 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-31 Cold Temperature Starting Procedure . . . . . . . . . . . . . . . . . . . . . OI-32 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-31 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . OI-33 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-33 TOWING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-60 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-60 TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . OI-62 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-62 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-62 TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 OI-2 26 of 166

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-52 Backfilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-57 Boom Swing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-56 Driving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-57 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-54 Lifting A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-53 Operating In Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-60 Operating On Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-52 Operating On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-58

Figure OI-3

INSTRUMENTS AND CONSOLES Left Console Figure OI-1

1

3

3 4

2

5 2 1

P-56396

P-56397

Left Control Lever (Joystick) - (Item 1) [Figure OI-1] (See HYDRAULIC CONTROLS on Page OI-16.)

ISO/STD Selector Switch - (Item 2) [Figure OI-3] Push the switch to the rear for STD operation (the switch is illuminated). Push the switch to the front for ISO operation (the switch is not illuminated).

Upperstructure Swing Brake - (Item 2) [Figure OI-1] Press the button on the control lever to assist in stopping the upperstructure swing function. (See Upperstructure Slew Brake on Page OI-23.)

(Item 3) [Figure OI-3]. Not used for this model.

Switch - (Item 3) [Figure OI-1] Not used for this model.

Switch - (Item 4) [Figure OI-1] Not used for this model.

Arm Rest (Adjustable) - (Item 5) [Figure OI-1].

Figure OI-2

1

P-58213

Switch - (Item 1) [Figure OI-2]. Not used for this model.

27 of 166

OI-3

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Battery Disconnect Switch - (Item 1) [Figure OI-3] Turn the key 1/4 turn counterclockwise and remove the key to disconnect the battery from the electrical system.

Install the key and turn 1/4 turn clockwise to connect the battery to the electrical system.

INSTRUMENTS AND CONSOLES (CONT’D)

Figure OI-6

Right Console

5

Figure OI-4

6

1

7 8

3 4

2

9 2

10 1

3 4 11 P-32715

Boom Load Indicator - (Item 1) [Figure OI-6]. Shows load on boom cylinder circuit when lifting.

P-32713

Fuel Gauge - (Item 3) [Figure OI-6]. Shows the amount of fuel in the tank.

Horn - (Item 2) [Figure OI-4] Press the button on the control lever to sound the horn.

Hourmeter - (Item 4) [Figure OI-6]. Displays the total operating hours on the excavator.

Momentary Hydraulic Switch - (Item 3) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

Battery Charge Indicator - (Item 5) [Figure OI-6]. Light will illuminate when the voltage is out of range.

Momentary Hydraulic Switch - (Item 4) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

Air Intake Heater - (Item 6) [Figure OI-6]. Light will illuminate when the air intake heater is energized.

Figure OI-5

Engine Oil Pressure Indicator - (Item 7) [Figure OI-6].

Light will illuminate when the engine oil pressure is low.

2

Air Filter Indicator - (Item 8) [Figure OI-6]. Light will illuminate when the air flow becomes restricted.

1

Hydraulic Oil Filter Indicator - (Item 9) [Figure OI-6].

Light will illuminate when the hydraulic oil filter is becoming plugged.

Hydraulic Oil Level Indicator - (Item 10) [Figure OI-6].

Light will illuminate when the hydraulic oil level in the tank is low.

P-32711

Start / Run Switch - (Item 11) [Figure OI-6]. Starts and stops the excavator engine.

Switch - (Item 1) [Figure OI-5]. Not used for this model.

Arm Rest (Adjustable) - (Item 2) [Figure OI-5].

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OI-4

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Engine Temperature Gauge - (Item 2) [Figure OI-6].

Shows the engine coolant temperature.

Right Control Lever (Joystick) - (Item 1) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

INSTRUMENTS AND CONSOLES (CONT’D)

Figure OI-8

Right Console (Cont’d) 1

Figure OI-7 1

2

3

2

3

4

5

6

4 7 8

P-56405

Heater Fan Switch - (Item 1) [Figure OI-7]. Three speed fan motor control.

Auxiliary Hydraulic Mode Switch - (Item 2) [Figure OI8]. Press this switch when using the hydraulic breaker.

(The switch will be illuminated.)

Wiper/Washer Switch - (Item 2) [Figure OI-7]. Starts and stops the wiper motor. Press and hold the bottom of the switch to activate the washer.

Float Switch - (Item 3) [Figure OI-8]. Press this switch to put the blade in the float position. (The switch will be illuminated.)

Rotating Beacon (If equipped) - (Item 3) [Figure OI-7].

Overload Warning Switch - (Item 4) [Figure OI-8].

Press this switch to engage the overload warning alarm.

(The switch will be illuminated.) The warning alarm will sound when the boom/arm/bucket functions are being overloaded.

Light Switch - (Item 4) [Figure OI-7]. Press the switch to turn on the cab/boom work light.

Motion Alarm (If equipped) - (Item 5) [Figure OI-8].

(Item 6) [Figure OI-8]. Not used for this model.

Engine Speed Control Lever - (Item 7) [Figure OI-8].

Controls the RPM of the engine. Push the lever forward for low speed. Pull the lever back to increase engine speed.

Temperature Control Lever - (Item 8) [Figure OI-8].

Push the lever forward to increase the cab temperatures; backward to decrease temperature.

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OI-5

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Two Speed Travel Control Switch - (Item 1) [Figure OI8]. Engages and disengages high range travel speed.

(The switch will be illuminated in high range.)

P-56399

INSTRUMENTS AND CONSOLES (CONT’D)

Raising And Lowering The Left Console

Right Console (Cont’d)

Raise the console before exiting the cab.

Figure OI-9

Figure OI-11

2

1

1

P-58140

Air Conditioning / Fan Motor Switch - (Item 1) [Figure OI-9]. Turns on the air conditioning; three speed fan switch.

Pull up on the handle (Item 1) [Figure OI-11]. The lift spring will assist in raising the console.

Lower the console before operating the excavator.

Air Conditioning Temperature Control - (Item 2) [Figure OI-9]. Turn the switch clockwise to decrease cab temperatures, counterclockwise to increase cab temperatures.

Push down on the handle (Item 1) [Figure OI-11] until the console is in the down position.

Figure OI-10

NOTE: When the console is raised, the hydraulic and traction systems are locked and will not operate.

1

P-32880

Auxiliary Power Outlet - (Item 1) [Figure OI-10] - 12 volt.

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OI-6

442 Operation & Maintenance Manual

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P-32906

OPERATOR CAB Description The excavator has an operator cab as standard equipment.

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

W-2069-0200

Cab Door

Dealer Copy -- Not for Resale

The start key can be used to lock the cab door.

Push the door all the way open until the latch engages to hold the door in the open position.

Figure OI-12

1

P-32677

Pull down on the latch (Item 1) [Figure OI-12] to release the door.

31 of 166

OI-7

442 Operation & Maintenance Manual

OPERATOR CAB (CONT’D)

Opening The Front Window

Front Window

NOTE: The right hand latch is shown. The procedure is the same for both latches.

Figure OI-13 Figure OI-15

Unlock 1 Lock 1 P-32882 P-32684

Turn the two latches (Item 1) [Figure OI-15] to the unlocked position.

Figure OI-16

1 P-32881

The front window is equipped with a wiper (Item 1) [Figure OI-13] and moveable sunvisor (Item 1) [Figure OI-14].

P-32983

Use both window grab handles to pull the top of the window in [Figure OI-16].

Continue moving the window in and up over the operator's head.

32 of 166

OI-8

442 Operation & Maintenance Manual

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Figure OI-14

OPERATOR CAB (CONT’D)

Figure OI-19

Front Window (Cont’d) Figure OI-17

Unlock

Lock

1

Unlock Lock

P-32685

6 Rotate the two latches (Item 1) [Figure OI-19] to the locked position.

P-32683

The front window may be opened approximately 4 in.

(181 mm).

Closing The Front Window Figure OI-20 Figure OI-18

Unlock Lock

1 1

P-32976 P-32682

Pull back on the window until the locks (Item 1) [Figure OI-20] engage the slots in the window hinge.

Rotate the two latches (Item 1) [Figure OI-18] to the unlocked position.

Use both window grab handles to pull the window down [Figure OI-18].

33 of 166

OI-9

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Front Window Ventilation Turn the two latches (Item 1) [Figure OI-17] to the locked position.

OPERATOR CAB (CONT’D) Right Side Windows Opening the right side window Figure OI-21

1

Dealer Copy -- Not for Resale

P-56401

Press the window latch (Item 1) [Figure OI-21] together and slide the window to the rear of the excavator.

Wiper/Washer Fluid Reservoir Figure OI-22

1

P-32602

The reservoir (Item 1) [Figure OI-22] is located behind the operators seat on the left side of the excavator.

Use an antifreeze temperatures.

34 of 166

washer

solution

in

freezing

OI-10

442 Operation & Maintenance Manual

OPERATOR CAB (CONT’D)

Figure OI-25

Heating, Ventilation And Air Conditioning Duct The cab fresh air vent is located behind the operators seat.

1 Figure OI-23

Open

Close P-32879

There are three heat vents (Item 1) [Figure OI-24] & [Figure OI-25].

1

Figure OI-26 1 1

Move the lever (Item 1) [Figure OI-23] to the right to close the vent.

Move the lever (Item 1) [Figure OI-23] to the left to open the vent.

Figure OI-24

1

P-58141

There are two air conditioning ducts (Item 1) [Figure OI26].

Turn the vents to direct air as desired.

P-32675

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OI-11

442 Operation & Maintenance Manual

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P-32676

TRAVEL CONTROLS

Turning

Description

Right Turn

The travel control levers control the movement of the excavator.

Figure OI-28

Forward And Reverse Travel NOTE: The following procedures describe forward, reverse, left & right as seated in the operator's seat.

Figure OI-27

1

Push the left steering lever forward to turn right [Figure OI-28] while traveling forward.

Figure OI-29

2

P-32716

Put the blade so that it is at the front of the machine (as you sit in the operator's seat). Slowly move both steering levers* (Item 1) [Figure OI-27] forward for forward travel; backward for reverse travel. * Steering can also be controlled with foot pedals (Item 2) [Figure OI-27].

B-19993

WARNING •

•

Pull the left steering lever backward to turn right [Figure OI-29] while traveling backward.

AVOID INJURY OR DEATH Check the blade location before traveling. When the blade is to the rear, operate the steering levers/foot pedals in the opposite direction to when the blade is in the front.

Move the steering levers/foot pedals slowly.

Abrupt lever motion will cause the machine to jerk.

W-2235-0396

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OI-12

442 Operation & Maintenance Manual

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B-19992

TRAVEL CONTROLS (CONT’D)

Figure OI-32

Turning (Cont’d) Counter-Rotation Right Turn Figure OI-30

B-19990

Pull the right steering lever backward to turn left while traveling backward [Figure OI-32].

Counter-Rotation Left Turn

B-19988

Dealer Copy -- Not for Resale

Figure OI-33 Push the left steering lever forward and pull the right steering lever backward [Figure OI-30].

Left Turn Figure OI-31

B-19991

Push the right steering lever forward and pull the left steering lever backward [Figure OI-33] B-19989

Push the right steering lever forward to turn left while traveling forward [Figure OI-31].

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OI-13

442 Operation & Maintenance Manual

EMERGENCY EXIT

Front Window

The left door, right side window and front window provide exits.

NOTE: If the excavator has a FOGS Kit installed, the front window is NOT an emergency exit.

Right Side Window

Figure OI-36

Figure OI-34

Unlock

Lock

1

1

P-32684

Turn the two latches (Item 1) [Figure OI-36] to the unlocked position.

Press the right side window latch (Item 1) [Figure OI-34] together and slide the window to the rear of the excavator.

Figure OI-37

Figure OI-35

P-32983

Use both window grab handles to pull the top of the window in [Figure OI-37].

P-32908

Exit through the window [Figure OI-35].

38 of 166

Continue moving the window in and up over the operator's head.

OI-14

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

P-56400

MOTION ALARM SYSTEM (IF EQUIPPED) Operation

WARNING

Figure OI-38

This machine is equipped with a motion alarm.

ALARM MUST SOUND! when operating forward or backward.

1

Failure to maintain a clear view in the direction of travel could result in serious injury or death.

The operator is responsible for the safe operation of this machine.

W-2786-0309

P-36618

If alarm does not sound or for adjustment instructions, see inspection and maintenance instructions for the motion alarm system in the preventive maintenance section of this manual. (See MOTION ALARM SYSTEM (IF EQUIPPED) on Page PM-8.)

This excavator may be equipped with a motion alarm system. The motion alarm (Item 1) [Figure OI-38] is located under the cab on the front of the excavator frame.

Figure OI-39

1 P-56399

The motion alarm ON / OFF switch (item 1) [Figure OI39] must be in the ON position for the alarm to function.

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OI-15

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

The motion alarm will sound when the operator moves the travel control levers in the either the forward or reverse direction.

HYDRAULIC CONTROLS

Right Control Lever (Joystick)

Description

Figure OI-41

The work equipment (boom, arm, bucket, and upperstructure slew) is operated by using the right and left control levers (joysticks).

Standard Control Pattern Left Control Lever (Joystick)

P-32713A

The right lever is used to operate the arm and bucket [Figure OI-41].

1.

2.

3.

4.

5.

6.

7.

8.

P-32673A

The left lever is used to operate the boom and slew the upperstructure [Figure OI-40].

1.

2.

3.

4.

5.

6.

7.

8.

Boom lower Boom lower and slew right Slew right Boom raise and slew right Boom raise Boom raise and slew left Slew left Boom lower and slew left

Arm out Arm out and bucket dump Bucket dump Arm in and bucket dump Arm in Arm in and bucket curl Bucket curl Arm out and bucket curl

WARNING AVOID INJURY OR DEATH Before leaving the machine: • Lower the work equipment to the ground.

• Lower the blade to the ground.

• Stop the engine & remove the key.

W-2196-0595

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OI-16

442 Operation & Maintenance Manual

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Figure OI-40

HYDRAULIC CONTROLS (CONT’D)

Right Control Lever (Joystick)

ISO Control Pattern

Figure OI-43

Left Control Lever (Joystick)

P-32713B

P-32673B

The right lever is used to operate the boom and bucket [Figure OI-43].

The left lever is used to operate the arm and to slew the upperstructure [Figure OI-42].

1.

2.

3.

4.

5.

6.

7.

8.

1.

2.

3.

4.

5.

6.

7.

8.

Arm out Arm out and slew right Slew right Arm in and slew right Arm in Arm in and slew left Slew left Arm out and slew left

Boom lower Boom lower and bucket dump Bucket dump Boom raise and bucket dump Boom raise Boom raise and bucket curl Bucket curl Boom lower and bucket curl

WARNING AVOID INJURY OR DEATH Before leaving the machine: • Lower the work equipment to the ground.

• Lower the blade to the ground.

• Stop the engine & remove the key.

W-2196-0595

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OI-17

442 Operation & Maintenance Manual

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Figure OI-42

HYDRAULIC CONTROLS (CONT’D)

Figure OI-45

Quick Couplers The excavator and attachments are equipped with thread together and poppet style couplers.

The excavator has quick couplers installed on both sides of the arm.

Figure OI-44

1 2

P-32834A

The female quick couplers (Item 1) [Figure OI-44] & [Figure OI-45] are used for standard auxiliary hydraulic functions (hydraulic breaker, clamshell, bucket rotation and swing bucket).

2

1

The male quick couplers (Item 2) [Figure OI-44] & [Figure OI-45] are used for dual auxiliary hydraulic functions (opening and closing the clamshell bucket).

P-32836A

The female quick coupler (Item 3) [Figure OI-45] is a direct to tank return line.

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

Be careful when connecting and disconnecting quick couplers.

W-2220-0396

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442 Operation & Maintenance Manual

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3

HYDRAULIC CONTROLS (CONT’D)

Thread the couplers (Item 1) from the attachment to the couplers (Item 2) [Figure OI-47] on the excavator.

Tighten the couplers until fully seated.

Quick Couplers (Cont’d) To Connect:

Figure OI-48

Figure OI-46

1

1

2

P-32981 P-32840

Dealer Copy -- Not for Resale

Figure OI-49

Remove any dirt or debris from the surface of both the male and female couplers. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced. Remove the protective caps (Item 1) [Figure OI-46].

3

Figure OI-47

2

3 1 P-32982

Example: Connect the clamshell bucket rotation to the female couplers (Item 1) [Figure OI-48] & [Figure OI49].

2

Connect the clamshell bucket open/close cylinder to the male quick couplers (Item 2) [Figure OI-48] & [Figure OI-49].

Thread the protective caps (Item 3) [Figure OI-49] together.

1

P-32980A

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442 Operation & Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

Figure OI-51

Quick Couplers (Cont’d) Figure OI-50

1 1 2

1 P-32841

Install the protective caps (Item 1) [Figure OI-51] on the quick couplers.

P-32835

Dealer Copy -- Not for Resale

Connect the return to tank line from the attachment to the female (poppet style) quick coupler (Item 1) [Figure OI50] (if required).

Turn the diverter valve (Item 2) [Figure OI-50] to direct hydraulic flow to the auxiliary quick couplers for clamshell open / close functions bucket.

NOTE: The bucket cylinder is inoperable when the diverter valve is turned for dual auxiliary hydraulic operation.

To Disconnect Unthread the couplers on the attachment from the excavator. Remove the return to tank line (if installed) from the female coupler (Item 1) [Figure OI-50].

Turn the diverter valve (Item 2) [Figure OI-50] back to restore hydraulic flow to the bucket cylinder.

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HYDRAULIC CONTROLS (CONT’D)

Figure OI-53

Auxiliary Hydraulics Figure OI-52 2

1 1

P-32714

For proper hydraulic breaker operation, press the switch (Item 1) [Figure OI-53]. The switch will be illuminated.

The switch allows full hydraulic flow to the right side coupler for breaker operation.

P-32713

The switches (Item 1 & 2) [Figure OI-52] are used for hydraulic powered attachments (such as a clamshell bucket).

Dealer Copy -- Not for Resale

Figure OI-54 1

Push and hold the switch (Item 1) [Figure OI-52] to provide hydraulic flow to the quick couplers. Release the switch to stop hydraulic flow.

2

Push and hold the switch (Item 2) [Figure OI-52] to reverse the direction of flow to the quick couplers.

Release the switch to stop hydraulic flow.

P-32713

Press and hold the switch (Item 1) [Figure OI-54] to provide hydraulic flow to the hydraulic breaker. Release the switch to stop hydraulic flow.

NOTE: Left side of the switch (Item 2) [Figure OI-54] is inoperable when the hydraulic breaker operation switch (Item 1) [Figure OI-53] is activated.

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HYDRAULIC CONTROLS (CONT’D) Relieving Hydraulic Pressure Stop the engine and turn the key to the RUN position.

Figure OI-55

1

Dealer Copy -- Not for Resale

P-56399

Press the hydraulic breaker switch (Item 1) [Figure OI55] OFF. The light is not illuminated.

Figure OI-56

1 1

P-32713

Press the switches (Item 1) [Figure OI-56] on the right control lever several times to relieve the hydraulic pressure.

Turn the key to the OFF position.

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HYDRAULIC CONTROLS (CONT’D) Upperstructure Slew Brake Figure OI-57

1

P-32673

47 of 166

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When slewing the upperstructure while working on a slope, push and hold the slew brake button (Item 1) [Figure OI-57] until the slew circuit is engaged. Release the button when the upperstructure starts to slew. This will prevent the upperstructure from drifting when the slew circuit is first engaged.

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442 Operation & Maintenance Manual

BLADE CONTROL LEVER

BOOM SWING PEDAL

Operation

Operation

Figure OI-58

Push the left side of the pedal (Item 2) [Figure OI-58] to swing the boom to the left.

Push the right side of the pedal (Item 2) [Figure OI-58] to swing the boom to the right.

1

Figure OI-60

2 P-32716

Pull the lever (Item 1) [Figure OI-58] backward to raise the blade.

B-16610A

NOTE: Keep the blade lowered when digging to help stabilize the excavator.

NOTE: The purpose of the boom swing pedal is to offset the boom with respect to the upperstructure for digging close to a structure [Figure OI-60].

Figure OI-59

1

P-32714

Push the switch (Item 1) [Figure OI-59] to put the blade in the float position (the switch will be illuminated).

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442 Operation & Maintenance Manual

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Push the lever (Item 1) [Figure OI-58] forward to lower the blade.

DAILY INSPECTION

Dealer Copy -- Not for Resale

Figure OI-61

6814224

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DAILY INSPECTION (CONT’D) Daily Inspection And Maintenance

WARNING

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [Figure OI-61] is a guide for correct maintenance of the Bobcat Excavator. It is located inside the rear door of the excavator and also in this manual.

AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

Check the following items before each day of operation: Operator Cab and mounting hardware.

•

Seat belt and mounting hardware.

•

Damaged decals, replace as needed.

•

Indicator lights for proper operation.

•

Check control console lockout.

•

Air cleaner and intake hoses.

•

Engine oil level and for engine leaks.

•

Engine coolant level and for leaks.

•

Hydraulic fluid level and system for leaks.

•

Grease all pivot points.

•

Cylinder and attachment pivot points.

•

Drain water and sediment from fuel tank and filter.

•

Track tension.

•

Repair broken and loose parts.

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W-2003-0807

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

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

IMPORTANT •

•

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 12 inches (300 mm) from the decal. Wash from the center of the decal toward the edges.

I-2226-0104

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442 Operation & Maintenance Manual

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•

PRE-STARTING PROCEDURE

Entering And Exiting The Excavator

Operation And Maintenance Manual And Operator’s Handbook Locations

Figure OI-63

Figure OI-62

1

P-32904

2

Read and understand the Operation & Maintenance Manual (Item 1) (located in the compartment behind the operator seat) and the Operator's Handbook (Item 2) [Figure OI-62] before operating.

WARNING AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

W-2003-0807

IMPORTANT •

•

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 12 inches (300 mm) from the decal. Wash from the center of the decal toward the edges.

I-2226-0104

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442 Operation & Maintenance Manual

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Use the grab handles and the tracks to enter the excavator [Figure OI-63].

P-33986

PRE-STARTING PROCEDURE (CONT’D)

Figure OI-66

Seat Adjustment Figure OI-64

2

3 1

4 P-32678

1 Turn the adjustment knob (Item 1) [Figure OI-66] to adjust the lumbar support in the seat back.

5 P-32680

Figure OI-67

Pull up on the lever (Item 2) [Figure OI-64] to adjust the bottom of the seat forward or backward.

1

Pull up on the lever (Item 3) [Figure OI-64] to adjust the incline of the seat bottom.

Turn the adjustment knob (Item 4) until the operators weight is shown in the window (Item 5) [Figure OI-64].

The seat is adjustable from 110 lb. (50 kg) to 285 lb. (130 Kg).

Figure OI-65

P-32671

Raise the arm rest (Item 1) [Figure OI-67].

NOTE: The right arm rest is shown. The procedure is the same for the left arm rest.

1

P-32679

Pull up on the lever (Item 1) [Figure OI-65] to change the incline of the seat back.

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Pull up on the lever (Item 1) [Figure OI-64] to adjust the seat forward or backward.

PRE-STARTING PROCEDURE (CONT’D)

Seat Belt Adjustment

Seat Adjustment (Cont’d)

Figure OI-70

Figure OI-68

1

1

P-32907 P-32672

Fasten the seat belt (Item 1) [Figure OI-70].

Dealer Copy -- Not for Resale

Rotate the adjustment wheel (Item 1) [Figure OI-68] to raise or lower the arm rests.

Figure OI-69

1

P-32857

Adjust the mirror (Item 1) [Figure OI-69].

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442 Operation & Maintenance Manual

PRE-STARTING PROCEDURE (CONT’D) Control Console Figure OI-71

P-32906

Dealer Copy -- Not for Resale

Lower the control console [Figure OI-71].

NOTE: There is a control lock switch in the left console which deactivates the hydraulic control levers (joysticks) and the traction drive system when the control console is in the raised position. The console must be in the down position for the hydraulic control levers (joysticks) and traction system to operate.

NOTE: If the control lock switch does not deactivate the control levers and the traction system when console is raised, see your Bobcat dealer for service.

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442 Operation & Maintenance Manual

STARTING THE ENGINE

Figure OI-74

Key Switch Perform the Pre-Starting Procedure. (See STARTING PROCEDURE on Page OI-27.)

Stop

PRE-

Run/Preheat

WARNING • •

Start

AVOID INJURY OR DEATH Fasten seat belt, start and operate only from the operator’s seat.

Never wear loose clothing when working near machine.

1

B-16666

W-2135-1108

Turn the key (Item 2) [Figure OI-73] & (Item 1) [Figure OI-74] to the RUN/PREHEAT position.

Figure OI-72

1 1

P-32716

Put the control levers (Item 1) [Figure OI-72] in the neutral position.

P-32715

The air intake heater light (Item 1) [Figure OI-75] will be illuminated, showing the air intake heater is on. Wait for the light to go off. When the air intake heater light goes out, turn the key to the start position and release the key when the engine starts. The key will return to the run position.

Figure OI-73

2

Stop the engine if the warning lights and alarm do not go off. Check for the cause before starting the engine again.

1 Low Speed

Turn the key switch OFF to stop the engine.

High Speed P-32714

Move the engine speed control (Item 1) [Figure OI-73] fully forward to the low speed position.

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Figure OI-75

STARTING THE ENGINE (CONT’D)

Figure OI-77

Cold Temperature Starting Procedure 1

IMPORTANT Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

I-2034-0700 P-32715

If the temperature is below freezing, 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 Oil Chart on Page PM-18.)

When the light goes out, turn the key to the start position and release the key when the engine starts. The key will return to the run position. When the engine speed increases, move the speed control lever to the low speed position until the engine warms up. Turn the key switch off to stop the engine.

Make sure the battery if fully charged.

NOTE: If the battery is discharged (but not frozen) a booster battery can be used to jump start the excavator. (See Using A Booster Battery (Jump Starting) on Page PM-27.)

IMPORTANT

Install an engine heater.

Figure OI-76

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

2

I-2034-0700

1

IMPORTANT

Low Speed

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

High Speed

I-2015-0284

P-32714

Move the speed control lever (Item 1) [Figure OI-76] back to the high speed position.

WARNING

Turn the key (Item 2) [Figure OI-76] to the RUN/ PREHEAT position.

AVOID INJURY OR DEATH Do not use ether with glow plug (preheat) systems.

Explosion can result which can cause injury, death, or severe engine damage.

W-2071-0907

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442 Operation & Maintenance Manual

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The air intake heater light (Item 1) [Figure OI-77] will be illuminated showing the air intake heater is on. Wait for the light to go off.

STOPPING THE ENGINE AND LEAVING THE EXCAVATOR

Figure OI-80

Procedure Stop the machine on level ground. Lower the work equipment and the blade to the ground.

Figure OI-78

2

P-32904

1 Low Speed

Use the grab handles and the tracks to exit the excavator [Figure OI-80]. Do not jump.

High Speed

Dealer Copy -- Not for Resale

P-32714

Move the engine speed control (Item 1) [Figure OI-78] fully forward to the low speed position.

Let the engine run at idle speed for five minutes before stopping the engine.

Figure OI-79 Stop Run/Preheat

Start

1

B-16666

Turn the key switch (Item 1) [Figure OI-79] to the STOP position.

Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel. Raise the control console and exit the machine.

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442 Operation & Maintenance Manual

Figure OI-83

ATTACHMENTS Bucket And Ripper Tooth Installation

WARNING

1

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

1

W-2052-0907 P-32913

Figure OI-81 Install the cotter pins (Item 1) [Figure OI-83].

1

WARNING

2

Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

3 4

W-2119-0788

3

P-32833

Figure OI-84 Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-81] in to the bucket mount.

Install the pins (Item 3) [Figure OI-81].

The pins must seat against the anti-rotation stops (Item 4) [Figure OI-81].

1

Figure OI-82 1

P-36506

1

The excavator is shown with the ripper tooth installed [Figure OI-84].

1

P-32831

Install the washers (Item 1) [Figure OI-82].

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442 Operation & Maintenance Manual

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4

ATTACHMENTS (CONT’D)

Figure OI-87

Bucket And Ripper Tooth Removal 3

Stop the excavator on a flat level surface. Put the bucket on the ground.

Figure OI-85

2

1 1 P-32832

1

Remove the pins (Item 1) [Figure OI-87].

1

Retract the bucket link (Item 2) and raise the arm (Item 3) [Figure OI-87].

Dealer Copy -- Not for Resale

P-32913

Remove the cotter pins (Item 1) [Figure OI-85] from both pins.

Figure OI-86

1

1 P-32831

Remove the washers (Item 1) [Figure OI-86] from both pins.

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442 Operation & Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-89

Tilt Bucket Installation

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

2 1

W-2052-0907 P-65778

Figure OI-88 Install the pins (Item 1) [Figure OI-89].

The pins must seat against the anti-rotation stops (Item 2) [Figure OI-89].

1

Dealer Copy -- Not for Resale

Figure OI-90

2

P-65777

1

Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-88] in to the bucket mount.

1 P-65780

Install the pin lock clips (Item 1) [Figure OI-90].

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442 Operation & Maintenance Manual

ATTACHMENTS (CONT’D)

Tilt Bucket Removal

Tilt Bucket Installation (Cont’d)

Relieve hydraulic pressure. (See Relieving Hydraulic Pressure on Page OI-22.)

Figure OI-91 Remove the hydraulic hoses (Item 1) [Figure OI-91] from the excavator quick couplers.

Figure OI-92

1

1 1

2 1 P-65784

Install the hydraulic hoses (Item 1) [Figure OI-91] from the bucket to the excavator quick couplers.

P-65779

Remove the lock clips (Item 1) and pins (Item 2) [Figure OI-92].

Figure OI-93

2

1

P-65777

Retract the bucket link (Item 1) and raise the arm (Item 2) [Figure OI-93].

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442 Operation & Maintenance Manual

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2

ATTACHMENTS (CONT’D)

Figure OI-95

Tilt Bucket Operation NOTE: The side to side movement of the tilt bucket can be slowed by adjusting the auxiliary hydraulic flow. (See Auxiliary Hydraulics on Page OI-21.)

Figure OI-94

2

P-65782

P-32713

Push and hold the switch (Item 1) [Figure OI-94] to swing the bucket to the left [Figure OI-95]. Release the button when the correct position of the bucket is obtained.

P-65777

WARNING

Push and hold the switch (Item 2) [Figure OI-94] to swing to the right [Figure OI-96]. Release the button when the correct position of the bucket is obtained.

Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

(See Auxiliary Hydraulics on Page OI-21.)

W-2119-0788

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Figure OI-96

1

ATTACHMENTS (CONT’D)

Figure OI-99

Clamshell Bucket Installation Figure OI-97

1 1

P-36425

Dealer Copy -- Not for Resale

Rotate the retainer (Item 1) [Figure OI-99] around the front of the arm.

P-36423

Fully retract the bucket cylinder (Item 1) [Figure OI-97].

Figure OI-98

1

P-36425

Install the bucket link retainer (Item 1) [Figure OI-98] through the pivot pin mount.

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ATTACHMENTS (CONT’D)

Figure OI-101

Clamshell Bucket Installation (Cont’d) Figure OI-100

1 1

P-36433

Figure OI-102 P-36427

1

P-36434

Turn the valves (Item 1) [Figure OI-101] & [Figure OI102] (on both sides of the arm) clockwise, to divert hydraulic flow from the bucket cylinder to the secondary front auxiliary quick couplers.

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Install the retainer pin (Item 1) [Figure OI-100].

ATTACHMENTS (CONT’D)

Figure OI-105

Clamshell Bucket Installation (Cont’d) Figure OI-103 2

1 2

1

P-36512

Install the retaining plate (Item 1) in the groove (Item 2) [Figure OI-105] of the pivot pin.

P-36510

Lower the arm (Item 2) [Figure OI-103] into the mount.

Figure OI-104 1

P-36513

1 Install the bolts (Item 1) [Figure OI-106].

Tighten the bolts to 48 - 55 ft.-lb. (65 - 75 N•m) torque.

P-36511

Install the pivot pin (Item 1) [Figure OI-104].

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442 Operation & Maintenance Manual

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Figure OI-106 Position the clamshell with the hose mounts (Item 1) [Figure OI-103] up, and the bottom of the clamshell towards the blade.

ATTACHMENT (CONT’D)

Figure OI-109

Clamshell Bucket Installation (Cont’d) Figure OI-107

1 2

3

1 1 1

P-36513

Remove the bolts (Item 1), retainer plate (Item 2) and pivot pin (Item 3) [Figure OI-109].

P-36514A

Figure OI-110

Clamshell Bucket Removal Figure OI-108 1

P-36510

Raise the arm (Item 1) [Figure OI-110]

P-36515

Lower the clamshell to the ground. Use the boom and arm functions to position the clamshell as shown [Figure OI-108].

Remove the hydraulic hoses from the excavator quick couplers.

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Install the hydraulic hoses (Item 1) [Figure OI-107] from the clamshell to the excavator quick couplers.

ATTACHMENT (CONT’D)

Figure OI-113

Clamshell Bucket Operation

WARNING Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

W-2119-0788

Figure OI-111

P-36508

Move the right joystick to the right (Item 2) [Figure OI111] to open the clamshell [Figure OI-113].

1

Dealer Copy -- Not for Resale

2

P-32713

Figure OI-112

P-36507

Move the right joystick to the left (Item 1) [Figure OI-111] to close the clamshell [Figure OI-112].

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442 Operation & Maintenance Manual

Figure OI-116

ATTACHMENTS (CONT’D) Clamshell Bucket Operation (Cont’d) Figure OI-114

2 1

P-36509

Push and hold the switch (Item 2) [Figure OI-114] to rotate the bucket in the clockwise direction [Figure OI116]. (See Auxiliary Hydraulics on Page OI-21.)

P-32713

Dealer Copy -- Not for Resale

Figure OI-115

P-36509

Push and hold the switch (Item 1) [Figure OI-114] to rotate the bucket in the counterclockwise direction [Figure OI-115].

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442 Operation & Maintenance Manual

ATTACHMENTS (CONT’D) Lifting The Clamshell Bucket NOTE: Use chains that are in good condition and of adequate size to lift the attachment.

Figure OI-117

1

1

Dealer Copy -- Not for Resale

P-36422

Figure OI-118

1

1

P-36421

Install the chains (Item 1) [Figure OI-117] & [Figure OI118] around the pivot of the clamshell bucket.

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442 Operation & Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-121

Fastening The Clamshell Bucket To The Transport Vehicle Figure OI-119

P-36418

Fasten the chains to the clamshell bucket [Figure OI119], [Figure OI-120], & [Figure OI-121].

P-36419

Use chain binders to prevent the attachment from moving during transport.

Secure the hydraulic hoses to the attachment.

P-36420

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Figure OI-120

ATTACHMENTS (CONT’D)

Figure OI-123

Manual Spring Loaded Coupler Installation Remove the bucket. (See Bucket And Ripper Tooth Removal on Page OI-35.)

WARNING

1

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

P-65759

Install the pins (Item 1) [Figure OI-123].

W-2052-0907

Figure OI-124 1

1 2

2

2

1

P-65758

Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-122] in to the coupler mount.

P-65760

Install the retainer bolts (Item 1) and nuts (Item 2) [Figure OI-124].

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442 Operation & Maintenance Manual

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NOTE: Align the pin retainer hole with the hole in the casting.

Figure OI-122

ATTACHMENTS (CONT’D)

Figure OI-127

Manual Spring Loaded Coupler Removal Figure OI-125 2

2

1 1 P-65758

2

1

Retract the bucket link (Item 1) and raise the arm (Item 2) [Figure OI-127].

P-65760

Dealer Copy -- Not for Resale

Remove the nuts (Item 1) and retainer bolts (Item 2) [Figure OI-125].

Figure OI-126

1

P-65759

Remove the pins (Item 1) [Figure OI-126].

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ATTACHMENTS (CONT’D)

Using the release bar (Item 1), rotate the locking hooks (Item 2) [Figure OI-129] upwards to the unlock position.

Manual Spring Loaded Coupler Attachment Installation

Figure OI-130

1

WARNING Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

W-2119-0788

Figure OI-128

2

Install the lock pin (Item 1) and retainer pin (Item 2) [Figure OI-130] to hold the locking hooks in the open position. Remove the release bar.

Figure OI-131 3 1 2 P-65773B

Insert the release bar (Item 1) into the manual spring loaded coupler. Remove the retainer pin (Item 2). Rotate the release bar (Item 1) upward slightly and remove the lock pin (Item 3) [Figure OI-128].

1 2

Figure OI-129 P-65766

Enter the machine, fasten the seat belt and start the engine.

1

Position the front hooks (Item 1) over the front pin (Item 2) [Figure OI-131] of the attachment.

2 P-65762

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P-65764

ATTACHMENTS (CONT’D)

Figure OI-134

Manual Spring Loaded Coupler Attachment Installation (Cont'd) Figure OI-132

1 2 1 P-65771

Rotate the locking hooks (Item 1) downward, cupping (engaging) the attachment pin (Item 2) [Figure OI-134].

2 P-65767

Extend the bucket cylinder (curl in) the coupler until the rear pin of the attachment (Item 1) is firmly seated in the coupler (Item 2) [Figure OI-132].

Continue to curl the coupler and attachment until the weight of the attachment is supported by the coupler.

1

Stop the engine and exit the machine.

Figure OI-133

2

3

P-65773

Install the locking pin (Item 1) and retainer pin (Item 2) [Figure OI-135] and remove the release bar.

Check for secure attachment. Never operate without retainer pins (Item 2) [Figure OI-135] installed.

1

2 P-65770

Reinsert the release bar (Item 1) and rotate the locking hooks (Item 2) [Figure OI-133] upwards slightly.

Remove the retainer pin and the locking pin (Item 3) [Figure OI-133].

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Figure OI-135

ATTACHMENTS (CONT’D)

Figure OI-138

Manual Spring Loaded Coupler Attachment Removal Figure OI-136

3

1

P-65769

2 1

Position the attachment flat on the ground.

Enter the machine, fasten the seat belt and start the engine.

Stop the engine and exit the machine.

Figure OI-139 Remove the retainer pin (Item 1) [Figure OI-136].

Insert the release bar (Item 2) and rotate the release bar upward slightly and remove the locking pin (Item 3) [Figure OI-136].

Figure OI-137 3

1

P-65765

Retract the bucket cylinder and move the arm forward until the manual spring loaded coupler is clear of the attachment [Figure OI-139].

2

P-65770

Using the release bar (Item 1), rotate the locking hooks (Item 2) upwards to the unlock position and install the locking pin (Item 3) [Figure OI-137].

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Install the retainer pin (Item 1) [Figure OI-138] to hold the locking hooks in the open position. Remove the release bar.

P-65773A

OPERATING PROCEDURE

Operating On Public Roads

Inspect The Work Area

When operating on a public road or highway, always follow local regulations. For example: A slow moving vehicle (SMV) sign, or direction signals may be required.

Before beginning operation, inspect the work area for unsafe conditions.

Check with utility companies for underground electrical, water, gas lines, etc. Work slowly in areas of underground utilities.

Look for sharp drop-offs or rough terrain. Have underground utility lines (gas, water, sewer, irrigation, etc.) located and marked.

Remove objects or other construction material that could damage the excavator or cause personal injury.

WARNING

Lowering The Work Equipment (Engine STOPPED) AVOID INJURY OR DEATH Do not exceed Rated Operating Capacity (ROC).

Excessive load can cause tipping or loss of control.

The hydraulic control levers (joysticks) control the movement of the boom, arm, bucket and upperstructure slew functions.

W-2053-0903

The left console must be in the locked down position, and the key switch in the ON position.

Dealer Copy -- Not for Resale

Figure OI-140

1

P-32906

Push down on the handle (Item 1) [Figure OI-140] and lock the console in the down position.

Use the control lever (joystick) to lower the boom.

NOTE: If the engine stops, the boom / bucket (attachments) can be lowered to the ground using hydraulic pressure in the accumulator.

The control console must be in the locked down position, and the key switch in the ON position.

Use the control lever (joystick) to lower the boom.

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OPERATING PROCEDURE (CONT’D) Lifting A Load Do not exceed the rated load capacity. (See LIFT CHART (6813628) on Page MST-4.)

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

W-2374-0500

Extend the bucket cylinder completely and lower the boom to the ground. Stop the engine.

Wrap the chain assembly around the bucket mounting plate.

Dealer Copy -- Not for Resale

Figure OI-141

B-16613

Make sure the load is evenly weighted and centered on the lifting chain, and is secured to prevent the load from shifting [Figure OI-141].

Lift and position the load. When the load is in position and tension is removed from the lift chain (secondary lift system), remove the secondary lift system.

WARNING AVOID INJURY OR DEATH Keep objects balanced and as close to the backhoe and ground as possible when lifting with the backhoe. Swing lifted objects slowly. Always lower objects to the ground before leaving the machine.

W-2115-0189

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OPERATING PROCEDURE (CONT’D)

Figure OI-144

Excavating

WARNING AVOID INJURY OR DEATH Check area to be excavated for overhead or underground lines such as electrical, gas, oil, water, etc. CALL 1-888-258-0808 and consult local utilities before digging. Extreme caution must be used in areas where utility lines are present.

W-2116-0903 TS-2062

Lower the blade to provide stability.

Raise the boom, retract the arm and curl the bucket [Figure OI-144].

Figure OI-142

NOTE: Do not allow the bucket teeth to contact the ground when swinging the upperstructure.

WARNING Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

TS-2064

Extend the arm, lower the boom and open the bucket [Figure OI-142].

W-2119-0788

Figure OI-143

WARNING AVOID INJURY OR DEATH Check area to be excavated for overhead or underground electrical power lines. Keep a safe distance from electrical power lines.

LINE VOLTAGE

TS-2063

MINIMUM APPROACH DISTANCE

50 kV

At least 10 ft. (3m)

230 kV

At least 16 ft. (5m)

740 kV

At least 33 ft. (10m) W-2757-0908

Retract the arm, while lowering boom and curling the bucket [Figure OI-143].

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Rotate the upperstructure.

OPERATING PROCEDURE (CONT’D)

Figure OI-147

Excavating (Cont’d)

WRONG

Figure OI-145

TS-2061

Do not use the bucket as a breaker or pile driver. It is better to excavate hard or rocky ground after breaking it with other equipment. This will reduce damage to the excavator.

NA1421A

Do not move the excavator while the bucket is in the ground.

Look in the direction of rotation and make sure there are no bystanders in the work area before rotating the upperstructure [Figure OI-145].

Dig only by moving the boom and arm toward the excavator.

Figure OI-146

Do not back dig (digging by moving the boom and arm away from the excavator). Damage to the attachments may occur.

B-16611

Extend the arm and uncurl the bucket to dump the material into a pile or truck [Figure OI-146].

IMPORTANT Avoid operating hydraulics over relief pressure.

Failure to do so will overheat hydraulic components.

I-2213-0402

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Do not dig under the excavator [Figure OI-147].

OPERATING PROCEDURE (CONT’D)

Figure OI-150

Boom Swing Figure OI-148

6

B-16632A

Swing the upperstructure, offset the boom to the right [Figure OI-148], center [Figure OI-149], and left [Figure OI-150] to dig a square hole the width of the machine without repositioning the excavator.

B-16612A

Figure OI-149

Dealer Copy -- Not for Resale

Figure OI-151

B-16631A B-16610A

The boom offset allows the operator to dig close to buildings and other structures [Figure OI-151].

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OPERATING PROCEDURE (CONT’D)

Driving The Excavator

Backfilling

When operating on uneven ground, operate as slow as possible and avoid sudden changes in direction.

Figure OI-152

Avoid traveling over objects such as rocks, trees, stumps, etc.

When working on wet or soft ground, put planks on the ground to provide a solid base to travel on and prevent the excavator from getting stuck.

Figure OI-153

B-16633

B-16634

If one or both tracks have become stuck in soft or wet ground, raise one track at a time by turning the upperstructure and pushing the bucket against the ground [Figure OI-153].

Put planks under the tracks and drive the excavator to dry ground.

Figure OI-154

B-16635

The bucket may also be used to pull the excavator. Raise the blade, extend the arm and lower the boom. Operate the boom and arm in a digging manner [Figure OI-154].

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Use the blade to backfill the trench or hole after excavating [Figure OI-152].

OPERATING PROCEDURE (CONT’D)

WARNING

Operating On Slopes

WARNING

• •

• • •

AVOID INJURY OR DEATH Do not travel across or up slopes that are over 15 degrees.

Do not travel down or back up slopes that exceed 25 degrees.

Look in the direction of travel.

•

AVOID INJURY OR DEATH Avoid steep areas or banks that could break away.

Keep boom centered and attachments as low as possible when traveling on slopes or in rough conditions. Look in the direction of travel.

Always fasten seat belt.

W-2498-0304

Figure OI-156

W-2497-0304

Traveling Up Slopes When going down a slope, control the speed with the steering levers and the speed control lever.

Figure OI-155

12 in.

(304 mm) Maximum 15° Maximum TS-2067

Figure OI-157 Traveling On Side Slopes

25° Maximum TS-2068

When going down grades that exceed 15 degrees, put the machine in the position shown, and run the engine slowly [Figure OI-155].

Operate as slow as possible and avoid sudden changes in lever direction.

Avoid traveling over objects such as rocks, trees, stumps, etc.

15° Maximum

Stop the machine before moving the upper equipment controls. Never allow the blade to strike a solid object.

Damage to the blade or hydraulic cylinder can result.

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B-16676

When traveling up slopes or on side slopes that are 15 degrees or less, position the machine as shown and run the engine slow [Figure OI-156] & [Figure OI-157].

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Traveling Down or Backing Up Slopes

OPERATING PROCEDURE (CONT’D)

Figure OI-159

Operating On Slopes (Cont’d)

1

1

Figure OI-158 Recommended Position For Working On A Slope

P-32716

When operating on a slope, level a work area [Figure OI158] before beginning.

When the engine stops on a slope, move the steering levers to the neutral position. Lower the boom/bucket to the ground.

If this is not possible, the following procedures should be used:

NOTE: If the engine stops, the boom / bucket (attachments) can be lowered to the ground using hydraulic pressure which is stored in the accumulator.

Do not work on slopes which are over 15 degrees.

Use a slow work cycle. Avoid working with the tracks across the slope. This will reduce stability and increase the tendency for the machine to slide.

Position the excavator with the blade downhill and lowered.

The console must be in the down position, and the key switch in the ON position.

Use the control lever to lower the boom.

Avoid swinging or extending the bucket more than necessary in a down hill direction. When you must swing the bucket downhill, keep the arm low and skid the bucket downhill.

Start the engine and resume operation.

When working with the bucket on the uphill side, keep the bucket as close to the ground as possible. Dump the spoil far enough away from the trench or hole to prevent the possibility of a cave in.

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To brake the machine when going down a slope, move the steering levers (Item 1) [Figure OI-159] to the NEUTRAL position. This will engage the hydrostatic braking.

B-16758

OPERATING PROCEDURE (CONT’D)

TOWING THE EXCAVATOR

Operating In Water

Procedure

Mud and water should be removed from the machine before parking. In freezing temperatures, park the machine on boards or concrete to prevent the track or undercarriage from freezing to the ground and preventing machine movement.

There is not a recommended towing procedure for the excavators.

•

The excavator can be lifted onto the transport vehicle.

•

The excavator can be skidded a short distance move for service (EXAMPLE: Move onto a transport vehicle) without damage to the hydraulic system. (The tracks will not turn.) There might be slight wear to the tracks when the excavator is skidded.

•

The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the excavator. (See Performance Specifications on Page SPEC-4.)

Figure OI-160

Dealer Copy -- Not for Resale

Water Level B-16664

Do not operate or immerse the excavator in water higher than the bottom of the swing circle [Figure OI-160].

Grease the excavator when it has been operated or immersed in water for a period of time. Greasing forces the water out of the lubrication areas.

Water must be removed from the cylinder rods. If water freezes to the cylinder rod, the cylinder seals can be damaged when the rod is retracted.

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LIFTING THE EXCAVATOR

Figure OI-162

Procedure Figure OI-161 2

2

1 1

B-16594

Fully extend the cylinders of the bucket, arm & boom so that the excavator is in the position shown [Figure OI161].

Fasten a chain to the boom (Item 2) [Figure OI-161] & [Figure OI-162] and up to a lifting fixture.

Raise the blade all the way.

Put the all control levers in neutral.

Stop the engine and exit the excavator.

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Fasten chains to the ends of the blade (Item 1) [Figure OI-161] & [Figure OI-162] and up to a lifting fixture above the cab. The lifting fixture must extend over the sides of the cab to prevent the chains from hitting the cab.

P-32909

TRANSPORTING THE EXCAVATOR ON A TRAILER

Fastening

Loading And Unloading

Figure OI-164

When transporting the machine, observe the rules, motor vehicle laws and vehicle limit ordinances. Use a transport and towing vehicle of adequate length and capacity.

1

Secure the parking brakes and block the wheels of the transport vehicle.

Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck bed and be sure ramp angle does not exceed 15 degrees.

Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width, and can support the weight of the machine.

P-32598

Determine the direction of the track movement before moving the machine (blade forward).

Figure OI-163

1

P-32603

Fasten chains to the front corners of the blade (Item 1) [Figure OI-164] and to the tie down loop at the rear track frame (Item 1) [Figure OI-165] to prevent it from moving when going up or down slopes, or during sudden stops.

P-32599

Use chain binders to tighten the chains and then safely tie the chain binder levers to prevent loosening.

Move the machine forward onto the transport vehicle [Figure OI-163].

WARNING

Do not change direction of the machine while it is on the ramps.

AVOID SERIOUS INJURY OR DEATH 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.

Lower the boom, arm and bucket to the transport vehicle.

Lower the blade to the transport vehicle.

Stop the engine and remove the key (if equipped).

W-2058-0807

Put blocks at the front and rear of the tracks.

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Figure OI-165

The rear of the trailer must be blocked or supported when loading or unloading the excavator to prevent the front of the transport vehicle from raising.

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 AIR CONDITIONING COMPRESSOR BELT . . . . . . . . . . . . . . . . . . . . . PM-32 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-32 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6

PREVENTIVE MAINTENANCE

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-21 Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-21 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-21 Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-22 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . . . . . PM-19 EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . PM-50 Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-50 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-50 FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 FRESH AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Fuel Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . PM-16 Pre-Filter Removal And Installation (If Equipped) . . . . . . . . . . . . . . . PM-15 Continued On Next Page

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ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-24 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-24 Fuse And Relay Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-29 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . PM-27

PREVENTIVE MAINTENANCE (CONT’D) HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 Diagnostic Couplers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-37 Hydraulic Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 Hydraulic Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-34 LUBRICATING THE ATTACHMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-48 Clamshell Bucket Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-49 Tilt Bucket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-48 LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-44 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-44

MOTION ALARM SYSTEM (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . PM-8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 REAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-38 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-41 Rubber Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-38 Steel Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-40 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-43 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-43 Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-43

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MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-3

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0807 instructions can cause injury or death.

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

CORRECT

CORRECT

P-90216

B-14148

B-14142

Bobcat without

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

Never service the Hydraulic Excavator instructions.

B-14147

B-14141

B-14145

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.

Exhaust system must be tightly sealed. Exhaust Fumes can kill without warning.

Always lower the bucket and blade to the ground before doing any maintenance.

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

WRONG

WRONG

WRONG

B-14146

B-14143

B-6589

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

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

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

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

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

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

Use eye protection approved for type of welding.

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

Lead-acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

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

MSW20-0409

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PM-3

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

CORRECT

Dealer Copy -- Not for Resale 90 of 166

PM-4

442 Operation & Maintenance Manual

SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals.

Instructions areearly necessary before operating or servicing machine. Read and Failure to do so will result in excessive wear and understand the Operation & Maintenance Manual, Operator’s Handbook and failures. The service schedule is a guide for correct signs (decals) on machine. Follow warnings and instructions in the manuals maintenance of the Bobcat Excavator. when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

WARNING

SERVICE SCHEDULE ITEM

SERVICE REQUIRED

Engine Coolant

Check coolant level. Add coolant as needed.

Engine Oil

Check engine oil level and add as needed.

HOURS 8-10

50

100

250

500

z 1000

Hydraulic Fluid Hoses Tube lines and Check the hydraulic fluid level and add as needed. Check Reservoir Breather Cap for damage and leaks. Repair or replaced as needed.

Check and adjust track tension.

Indicators and Lights

Check for correct operation of indicators and lights.

Horn and Motion Alarm *

Check for correct operation and repair as needed.

Operator Cab

Check cab condition and hardware.

Seat Belt

Check seat belt condition and mounting hardware

Safety Signs (Decals)

Check for damaged signs (decals). Replace as needed.

Pivot Points

Grease all machinery pivot points.

Fuel Tank & Filter

Drain water and sediment from fuel tank and filter.

Console Lockout

Check control console lockout for proper operation.

Swing Circle & Pinion

Grease swing circle and swing pinion.

Door Hinges

Grease door hinges.

Battery

Check battery, cables and electrolyte level.

Belts

Check and adjust belts.

Travel Motors

Check oil level in both travel motors.

Hydraulic Oil Cooler, Radiator, A/C Condenser and Cab Ventilation Filter

Clean radiator / oil cooler fins. Clean A/C condenser.

Clean / replace cab filter.

Hydraulic Filter

Replace hydraulic filter.

Engine Oil & Filter

Replace engine oil and filter.

Air Filter Intake

Check / clean air filter intake

Alternator & Starter

Check alternator and starter connections.

Fuel Filters

Replace diesel fuel pre-filter and filter.

Engine Valves

Check and adjust engine valve clearance.

Travel Motors

Replace oil in both travel motors.

Dealer Copy -- Not for Resale

Track Tension

Hydraulic System

Replace hydraulic fluid and filter. Clean reservoir.

Engine Coolant

Drain and flush cooling system. Replace coolant.

Every 2 years

* If equipped Service at first 50 hours, then as scheduled Service at first 100 hours, then as scheduled zService at 1000 hours or every six months

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PM-5

442 Operation & Maintenance Manual

CONTROL CONSOLE LOCKOUTS Inspection And Maintenance Figure PM-1

P-32673

Dealer Copy -- Not for Resale

When the left console is raised [Figure PM-1], the hydraulic control levers (joysticks) and traction system must not function.

Sit in the operator's seat, fasten the seat belt and start the engine.

Raise the left console.

Move the joystick control levers. There should be no movement of the boom, arm, slew or bucket.

Move the steering control levers. There should be no movement of the excavator tracks.

Service the system if these controls do not deactivate when the left control console is raised. (See your Bobcat dealer for service.)

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PM-6

442 Operation & Maintenance Manual

SEAT BELT

Figure PM-2

Inspection And Maintenance

WARNING Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

Check the seat belt daily for correct function.

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty/dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), or hardware.

B-22283

The items below are referenced in [Figure PM-2].

1. Check the seat belt webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn, deformed or buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your machine.

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PM-7

442 Operation & Maintenance Manual

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Inspect the seat belt system thoroughly yearly or more often if the machine is exposed to severe environmental conditions or applications.

MOTION ALARM SYSTEM (IF EQUIPPED)

Adjustment

Description

Figure PM-4

This excavator may be equipped with a motion alarm system. The motion alarm will sound when the operator moves the travel control levers in the either the forward or reverse direction.

Inspecting Figure PM-3

P-32912

1

Figure PM-5

P-36633

2

1

1

1

1

Inspect for damaged or missing motion alarm decal (Item 1) [Figure PM-3]. Replace if required.

Sit in the operator’s seat. Turn excavator key to ON position but do not start the engine.

1

Move the travel control levers in the forward direction.

The motion alarm must sound. Move the travel control levers in the reverse direction. The motion alarm must sound.

1

1

1

1

1

1

P-32911

Turn excavator key to OFF position.

Remove the eleven bolts (Item 1) and cover (Item 2) [Figure PM-5].

The motion alarm is located under the cab on the front of the excavator frame.

Installation: Tighten the bolts to 18 - 19 ft.-lb. (24 - 26 N•m) torque.

NOTE: The excavator will need to be moved slightly in both the forward and reverse direction to test the motion alarm. Keep all bystanders away from machine during test.

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PM-8

442 Operation & Maintenance Manual

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To increase or decrease the alarm sensitivity, position the excavator as shown [Figure PM-4].

MOTION ALARM SYSTEM (IF EQUIPPED) (CONT’D) Adjustment (Cont’d) Figure PM-6 1 3

4

2

P-36631

Dealer Copy -- Not for Resale

Adjustment screw identification: (Item 1) [Figure PM-6] Left Forward Travel (Item 2) [Figure PM-6] Left Reverse Travel (Item 3) [Figure PM-6] Right Forward Travel (Item 4) [Figure PM-6] Right Reverse Travel Turn the adjustment screws counterclockwise to increase motion alarm sensitivity.

Turn the adjustment screws clockwise to decrease motion alarm sensitivity.

Install the cover.

Inspect the motion alarm system for proper function after adjustment.

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442 Operation & Maintenance Manual

REAR COVER

RIGHT SIDE COVER

Opening And Closing

Opening And Closing Figure PM-8

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

W-2012-0497

1

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

P-56407

Figure PM-7

Lower the right side cover and push down firmly to close the rear cover.

NOTE: The start key can be used to lock the right side cover.

1

P-56406

Push the latch (Item 1) [Figure PM-7] and raise the rear cover.

Lower the rear cover and push down firmly to close the rear cover.

NOTE: The start key can be used to lock the rear cover.

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PM-10

442 Operation & Maintenance Manual

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Push the latch (Item 1) [Figure PM-8] and raise the right side cover.

W-2020-1285

AIR CLEANER SERVICE

Replacing Filter Elements

Daily Check

Outer Filter

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Unlatch the air filter cover latches (Item 2) [Figure PM10].

Figure PM-9

Remove the air filter cover (Item 3) [Figure PM-10].

Figure PM-11 1

1

P-32689

If the air filter condition indicator (Item 1) [Figure PM-9] is illuminated, the outer filter element needs to be replaced.

Remove the outer filter (Item 1) [Figure PM-11].

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

Check the housing for damage.

Figure PM-10

Clean the housing and seal surface. Do not use compressed air.

Install the outer filter.

2

2

Install the cover.

3

1

P-32688

Open the right side cover to inspect the air intake (Item 1) [Figure PM-10] for damage or restrictions. (See RIGHT SIDE COVER on Page PM-10.)

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PM-11

442 Operation & Maintenance Manual

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P-32713

AIR CLEANER (CONT’D) Replacing Filter Elements (Cont’d) Inner Filter Replace the inner filter every third time the outer filter has been replaced.

Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated.

Remove the air cleaner cover and outer filter.

Figure PM-12

Dealer Copy -- Not for Resale

1

2

1

P-32690

Pry up on the ends of the air filter (Item 1). Pull the air filter (Item 2) [Figure PM-12] out of the housing.

Discard the inner air filter after it has been removed.

Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris.

Figure PM-13

1

P-32691

Install the new inner filter (Item 1) [Figure PM-13]. Install the outer filter and air cleaner cover.

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PM-12

442 Operation & Maintenance Manual

FRESH AIR FILTER

Figure PM-16

Removal And Installation See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

1

1 Figure PM-14

1

2

1

P-32910

Remove the four bolts (Item 1) [Figure PM-16].

Remove the filter (Item 2) [Figure PM-16].

Dealer Copy -- Not for Resale

P-32912

Position the excavator as shown [Figure PM-14].

Figure PM-15

1

1

1

2

1

1

1

P-32911

Remove the eleven bolts (Item 1) [Figure PM-15] and washers.

Installation: Tighten the bolts to 18 - 19 ft.-lb. (24 - 26 N•m) torque.

Remove the cover (Item 2) [Figure PM-15].

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PM-13

442 Operation & Maintenance Manual

Biodiesel Blend Fuel

Fuel Specifications

Biodiesel blend fuel has unique qualities that should be considered before using in this machine:

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

•

Cold weather conditions can lead to plugged fuel system components and hard starting.

The following is a suggested blending guideline which should prevent fuel gelling during freezing temperatures:

•

Biodiesel blend fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components.

•

Use of biodiesel blend fuel may result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

•

Shorter maintenance intervals may be required, such as cleaning the fuel system and replacing fuel filters and fuel lines.

•

Using biodiesel blended fuels containing more than five percent biodiesel can affect engine life and cause deterioration of hoses, tubelines, injectors, injector pump and seals.

TEMPERATURE F° (C°)

NO. 2

NO. 1

+15° (9°)

100%

0%

Down to -20° (-29°)

50%

50%

Below -20° (-29°)

0%

100%

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel must be used in this machine.

The following fuels may also be used in this machine: •

Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.

•

Biodiesel Blend Fuel - Must contain no more than five percent biodiesel mixed with low sulfur or ultra low sulfur petroleum based diesel. This is commonly marketed as B5 blended diesel fuel.

Apply the following guidelines if biodiesel blend fuel is used:

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

W-2063-0807

WARNING AVOID INJURY OR DEATH 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.

•

Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank.

•

Ensure that the fuel tank cap is securely tightened.

•

Biodiesel blend fuel can damage painted surfaces, remove all spilled fuel from painted surfaces immediately.

•

Drain all water from the fuel filter daily before operating the machine.

•

Do not exceed engine oil change interval. Extended oil change intervals can cause engine damage.

•

Before vehicle storage; drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long term stability and should not be stored for more than three months.

W-2103-0508

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PM-14

442 Operation & Maintenance Manual

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FUEL SYSTEM

FUEL SYSTEM (CONT’D)

WARNING

Filling The Fuel Tank Figure PM-17

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

W-2063-0807

Pre-Filter Removal And Installation (If Equipped) Figure PM-19 1

P-32697

1

Open the rear cover and remove the fuel fill cap (Item 1) [Figure PM-17].

NOTE: The fuel fill cap can be locked. Use the fuel fill cap key to lock and unlock the cap.

Figure PM-18

P-56410

Loosen the hose clamps (Item 1) and remove the filter (Item 2) [Figure PM-19] (if equipped).

1

P-32698

Check the condition of the fill strainer screen (Item 1) [Figure PM-18]. Clean or replace as necessary.

Use a clean, approved safety container to add fuel. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! Install and tighten the fuel fill cap. Close the rear cover.

See Service Schedule for the service interval when to remove water from the fuel pre-filter or replace the fuel pre-filter and fuel filter. (See SERVICE SCHEDULE on Page PM-5.)

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442 Operation & Maintenance Manual

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2

FUEL SYSTEM (CONT’D) Fuel Filter Removal And Installation See Service Schedule for the service interval when to replace the fuel filter. (See SERVICE SCHEDULE on Page PM-5.)

Clean the area around the filter.

Figure PM-20

1

Dealer Copy -- Not for Resale

2

P-92951

Remove the filter (Item 1) [Figure PM-20].

Put clean oil on the seal of the new filter.

Install the filter and hand tighten.

NOTE: If air needs to be bled from the fuel system, a manual pump (Item 2) [Figure PM-20] can be used to pump fuel through the fuel system.

Pull out and push in on the knob until a strong resistance is felt and pressure has been built up. Start the engine and run at low idle until any air is removed from the fuel system.

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442 Operation & Maintenance Manual

FUEL SYSTEM (CONT’D)

Figure PM-23

Draining The Fuel Tank Figure PM-21

1

P-32902

Position the excavator as shown [Figure PM-21].

WARNING

Figure PM-22

AVOID INJURY OR DEATH 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.

W-2103-0508

1

P-32903

Remove the cap (Item 1) [Figure PM-22] from the drain.

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442 Operation & Maintenance Manual

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Open the drain (Item 1) [Figure PM-23] and drain the fuel into a container.

P-32901

ENGINE LUBRICATION SYSTEM

Oil Chart

Checking Engine Oil

Figure PM-25

Check the engine oil after every 8-10 hours of operation and before starting the engine for the work shift.

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

Figure PM-24

P-56411

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CI-4 OR BETTER) [1] Synthetic Oil - Use recommendation from Synthetic Oil Manufacturer.

Open the right side cover and remove the dipstick (Item 1) [Figure PM-24].

Keep the oil level between the marks on the dipstick.

Use a good quality engine oil that meets the correct API Service Classification. See oil chart [Figure PM-25].

Use a good quality motor oil that meets the correct API Service Classification. (See REGULAR MAINTENANCE ITEMS on Page V.)

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PM-18

442 Operation & Maintenance Manual

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1

ENGINE LUBRICATION SYSTEM (CONT’D)

Figure PM-28

Removing And Replacing Oil And Filter See Service Schedule for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page PM-5.)

1

Figure PM-26

P-32886

Install the drain hose (Item 1) [Figure PM-28] on the oil pan. Tighten the hose until oil starts to drain from the oil pan.

Recycle or dispose of used oil in an environmentally safe manner.

Rotate the upperstructure so the right side is positioned between the tracks [Figure PM-26]. Run the engine until it is at operating temperature. Stop the engine.

Open the right side cover.

Figure PM-27

1

P-32885

Remove the cap (Item 1) [Figure PM-27].

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PM-19

442 Operation & Maintenance Manual

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Drain the oil in a container.

P-32884

ENGINE LUBRICATION SYSTEM (CONT’D) Removing And Replacing Oil And Filter (Cont’d) Figure PM-29

2

3 1 P-56411

Dealer Copy -- Not for Resale

Remove the oil filter (Item 1) [Figure PM-29] and clean the filter housing surface.

Use a genuine Bobcat replacement oil filter.

Put clean engine oil on the filter gasket. Install the filter and hand tighten.

Remove the drain hose and install the cap on the oil pan after the oil has been completely drained.

Remove the fill cap (Item 2) [Figure PM-29].

Put oil in the engine. (See REGULAR MAINTENANCE ITEMS on Page V.) (See Capacities on Page SPEC-6.)

Install the fill cap.

Start the engine and let it run for several minutes.

Stop the engine. Check for leaks at the oil filter. Check the oil level on the dipstick (Item 3) [Figure PM-29].

Add oil as needed if it is not at the top mark on the dipstick.

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PM-20

442 Operation & Maintenance Manual

ENGINE COOLING SYSTEM

Figure PM-31

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

1

Open the right side cover.

Use air pressure or water pressure to clean the radiator/ oil cooler. Be careful not to damage the fins when cleaning.

Checking Level

P-32844

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

W-2070-1203

IMPORTANT

Open the right side cover.

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Figure PM-30

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

1

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 P-32693

WARNING

Check the coolant level in the surge tank (Item 1) [Figure PM-30].

NOTE: There is a sight gauge located on the surge tank that can also be used for checking the coolant level.

AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W-2019-0907

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PM-21

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

The surge tank (Item 1) [Figure PM-31] must be half full when the engine is cold.

ENGINE COOLING SYSTEM (CONT’D)

NOTE: The plug is located next to the alternator mount bracket.

Removing And Replacing Coolant Drain the coolant from the engine.

See Service Schedule for the correct service interval to replace the coolant. (See SERVICE SCHEDULE on Page PM-5.)

Figure PM-34

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

1

W-2070-1203

Figure PM-32 P-32847

1

Drain the coolant from the engine.

After the coolant is removed, install the plug (Item 1) [Figure PM-33] and lower radiator hose (Item 1) [Figure PM-34].

Recycle or dispose of the used coolant in an environmentally safe manner.

P-32693

Mix the coolant in a separate container.

When the engine is cool, loosen and remove the radiator cap (Item 1) [Figure PM-32].

NOTE: The excavator is factory filled with ethylene glycol coolant.

Figure PM-33

Add premixed coolant, 50% water and 50% ethylene glycol to the reservoir if the coolant level is low.

One gallon (3,8 L) of ethylene glycol mixed with one gallon (3,8 L) of water is the correct mixture of coolant to provide a -34°F (-37°C) freeze protection.

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

1 Fill the radiator with the premixed coolant. Install the radiator cap.

Run the engine until it is at operating temperature.

Stop the engine.

P-32849

Remove the plug (Item 1) [Figure PM-33] from the back side of the engine block.

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PM-22

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Remove the lower radiator hose (Item 1) [Figure PM-34].

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant (Cont’d) Figure PM-35

1

P-32844

Dealer Copy -- Not for Resale

Check the coolant level (COLD) in the surge tank (Item 1) [Figure PM-35] when cool.

Add coolant to the tank as needed.

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PM-23

442 Operation & Maintenance Manual

ELECTRICAL SYSTEM

WARNING

Description Figure PM-36

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

1

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.

1

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

2

W-2065-0807 P-32706

Dealer Copy -- Not for Resale

Figure PM-37

P-32701

The excavator has a 12 volt, negative ground electrical system. The electrical system is protected by fuses located in the right console and beside the battery [Figure PM-36] & [Figure PM-37]. 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.

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.

Put Battery Saver P/N 6664458 or grease on the battery terminals and cable ends to prevent corrosion.

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PM-24

442 Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Figure PM-40

Fuse And Relay Location Figure PM-38

2

1

2 B-23196

The location and sizes are shown below [Figure PM-39] & [Figure PM-40].

REF.

To check or replace the fuses in the right console, remove the screws (Item 1) and remove the cover (Item 2) [Figure PM-38].

Figure PM-39

P-58260

DESCRIPTION

AMPER AGE

1

Key switch, interior light, security ignition (If equipped)

10A

2

Aux power outlet, radio, heater

15A

3

Rotating beacon (If equipped)

10A

4

Flood light (Front)

15S

5

Flood light (Back)

15A

6

Fuel pump

15A

7

Horn, panel light, security ignition (If equipped)

10A

8

Heater fan

15A

9

Wiper/washer, radio

15A

10

Hyd. oil level, hyd functions, overload warning

5A

11

Travel pressure switch

5A

12

Main hyd. system

5A

13

Left and right joystick

5A

14

Air conditioning box

10A

K1

Flood light (Front)

Relay

K2

Flood light (Rear)

Relay

K3

Open

Relay

K01 Switch power

Relay

Always replace fuses with the same type and capacity.

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PM-25

442 Operation & Maintenance Manual

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P-32706

ELECTRICAL SYSTEM (CONT’D)

Figure PM-43

Fuse And Relay Location (Cont’d) Figure PM-41

1

2

3

1 P-32705

Remove the covers (Item 1) [Figure PM-43] for access to the two fuses.

P-32701

Figure PM-44

2

1 Figure PM-42

3

B-23197

1 The location and sizes [Figure PM-43] & [Figure PM-44] are shown below.

P-32702

Remove the battery compartment cover (Item 1) [Figure PM-42].

REF.

DESCRIPTION

AMPERAGE

1 (FA)

Main fuse

40

2 (FB)

Pre-Heat

50

3 (K03)

Intake air heat

relay

Always replace fuses with the same type and capacity.

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PM-26

442 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

To check or replace fuses beside the battery, pull up on and remove the floor mat (Item 1) [Figure PM-41].

ELECTRICAL SYSTEM (CONT’D)

Using A Booster Battery (Jump Starting)

Fuse And Relay Location (Cont’d)

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.

Open the right side cover.

Figure PM-45

Be sure the key switch is OFF. The booster battery must be 12 volt.

Figure PM-47

1 1

Figure PM-46 P-32701

Pull up on and remove the floor mat (Item 1) [Figure PM47].

Figure PM-48 1

1 P-56416

The location is shown below [Figure PM-45] & [Figure PM-46].

REF.

DESCRIPTION

AMPERAGE

1 (K02)

Starter, additional fueling

Relay

P-32702

Always replace relays with the same type and capacity.

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Remove the battery compartment cover (Item 1) [Figure PM-48].

PM-27

442 Operation & Maintenance Manual

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P-56417

ELECTRICAL SYSTEM (CONT’D)

Figure PM-49

Using a Booster Battery (Jump Starting) (Cont’d) 2

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

1

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.

P-32708

Connect one end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal (Item 1) [Figure PM-49] of the excavator battery.

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

Connect the end of the second cable to the negative (-) terminal of the booster battery. Connect the other end of the same cable to the excavator frame (Item 2) [Figure PM-49] (away from the battery).

WARNING

NOTE: (See Cold Temperature Starting Procedure on Page OI-32.)

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

Start the engine. After the engine has started, remove the ground (-) cable first (Item 2) [Figure PM-49].

Disconnect the cable from the excavator battery (Item 1) [Figure PM-49].

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

W-2066-0705

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W-2065-0807

ELECTRICAL SYSTEM (CONT’D)

Figure PM-50

Removing And Installing Battery

IMPORTANT 1 If jump starting the excavator from a second machine: When jump starting the excavator from a battery installed in a second machine, make sure the engine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

P-32701

I-2060-0906

Pull up on and remove the floormat (Item 1) [Figure PM50].

IMPORTANT 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.

1

I-2023-1285

P-32702

WARNING

Remove the battery compartment cover (Item 1) [Figure PM-51].

AVOID INJURY OR DEATH 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-2065-0807

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Figure PM-51

ELECTRICAL SYSTEM (CONT’D)

WARNING

Removing And Installing Battery (Cont’d) Figure PM-52

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

2

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.

1

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

W-2065-0807 P-32703

Dealer Copy -- Not for Resale

Disconnect the negative (-) cable (Item 1) [Figure PM52] first.

Disconnect the positive (+) cable (Item 2) [Figure PM52].

Figure PM-53

1

2

1

P-32704

Remove the nuts (Item 1) and remove the hold down clamp (Item 2) [Figure PM-53].

Remove the battery.

Always clean the terminals and the cable ends, even when installing a new battery.

Install the battery. Install the hold down clamp and tighten the bolts.

Connect the battery cables. Connect the negative (-) cable (Item 1) [Figure PM-52] last to prevent sparks.

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ALTERNATOR BELT

FAN BELT

Adjusting Belt Tension

Adjusting Belt Tension

Check the alternator belt deflection at the mid span of the belt between the crankshaft pulley and alternator pulley.

Figure PM-56

Apply approximately 33 lb. (45 mm) force to the belt. The belt should deflect 0.40 in. (10 mm).

Figure PM-54 1

1 1

Check the fan belt (Item 1) [Figure PM-56] deflection mid span of the belt between the crankshaft pulley and the fan pulley.

P-32846

Apply approximately 33 lb. (45 N) of force to the belt. The belt should deflect 0.40 in. (10 mm).

Figure PM-55 Figure PM-57

1

1

1

2

B-16596C B-16596C

Loosen the three alternator bolts (Item 1) [Figure PM-54] & [Figure PM-55] and rotate the alternator until the belt is correctly tensioned.

Loosen the two bolts (Item 1) [Figure PM-57] on the idler. Using a 1/2 inch socket wrench, rotate the idler until the belt is correctly tensioned.

Tighten the bolts.

Tighten the bolts.

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P-32845

AIR CONDITIONING COMPRESSOR BELT Adjusting Belt Tension Figure PM-58

2 1 2

P-92952

Dealer Copy -- Not for Resale

Check the air conditioning compressor belt deflection mid span of the belt between the crankshaft pulley and the compressor pulley (Item 1) [Figure PM-58].

Apply approximately 33 lb. (45 mm) force to the belt. The belt should deflect 0.40 in. (10 mm).

Loosen the bolts (Item 2) [Figure PM-58] and rotate the compressor until the belt is correctly tensioned.

Tighten the bolts.

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HYDRAULIC SYSTEM

Figure PM-60

Checking And Adding Hydraulic Oil Put the machine on a flat level surface.

Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine.

Open the rear cover.

1

Figure PM-59

P-32851

Add the correct oil to the reservoir until it is visible in the sight gauge. (See Capacities on Page SPEC-6.)

1

Check the breather cap and clean as necessary. Replace the cap if damaged.

P-32695

Install the reservoir cap.

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [Figure PM-59].

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Close the rear cover.

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Clean the surface around the reservoir (breather) cap and remove the cap from the reservoir (Item 1) [Figure PM-60].

HYDRAULIC SYSTEM (CONT’D)

Remove the drain hose and install the cap on the hydraulic reservoir.

Replacing The Hydraulic Oil Add fluid to the reservoir. (See Capacities on Page SPEC-6.)

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.

Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine.

Open the rear cover.

WARNING

Figure PM-61

AVOID INJURY OR DEATH 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.

1

WARNING AVOID INJURY OR DEATH 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-32899

Remove the cap (Item 1) [Figure PM-61] from the hydraulic reservoir drain.

Figure PM-62

W-2072-0807

1 P-32900

Install the drain hose (Item 1) [Figure PM-62] on the hydraulic reservoir. Tighten the hose until oil starts to drain from the reservoir.

Drain the fluid into a container.

Recycle or dispose of the fluid in an environmentally safe manner.

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HYDRAULIC SYSTEM (CONT’D)

Figure PM-65

Hydraulic Filter Removal See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

1

Open the rear cover.

Figure PM-63

1 P-58143

Dealer Copy -- Not for Resale

Remove the filter (Item 1) [Figure PM-65] from the filter bowl.

P-58219

Remove the filter cover (Item 1) [Figure PM-63] and spring.

Figure PM-64

1

P-58216

Remove the filter and filter bowl (Item 1) [Figure PM-64].

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HYDRAULIC SYSTEM (CONT’D)

Figure PM-68

Hydraulic Filter Installation Clean the filter bowl in clean solvent and dry with compressed air.

1 Figure PM-66

1 P-58143

Install the filter (Item 1) [Figure PM-68] in the filter bowl.

Figure PM-69

Inspect the O-ring (Item 1) [Figure PM-66] on the outside of the filter bowl. Replace the O-rings if damaged.

1

Figure PM-67

P-58216

Install the filter and filter bowl (Item 1) [Figure PM-69].

1

P-58217

Install the O-ring (Item 1) [Figure PM-67] in the bottom of the new filter.

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P-58142

HYDRAULIC SYSTEM (CONT’D)

Diagnostic Couplers

Hydraulic Filter Installation (Cont’d)

Open the rear cover and right side cover.

Figure PM-70

Figure PM-72

1

1 P-58218

P-58221

Inspect the O-ring (Item 1) [Figure PM-70]. Replace if damaged.

Dealer Copy -- Not for Resale

Figure PM-73

Figure PM-71

1

1

P-58220

The two diagnostic couplers (Item 1) [Figure PM-72] & [Figure PM-73] are located on the hydraulic circuitry.

P-58219

Install the spring and cover (Item 1) [Figure PM-71].

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The couplers can be used to check circuit pressures.

(Refer to the Service Manual.)

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442 Operation & Maintenance Manual

TRACK TENSION

Figure PM-74

Rubber Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. For the correct service interval (See SERVICE SCHEDULE on Page PM-5.)

1

NOTE: On new excavators or on excavators with new rubber tracks installed, check and adjust as needed the rubber track clearance two to three times on the first day of operation.

P-32889

Figure PM-75

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

W-2142-0903

1

Raise one side of the machine (approximately four inches) using the boom and arm.

P-32888

Raise the blade fully and install jackstands (Item 1) [Figure PM-74] & [Figure PM-75] under the blade and track frame. Lower the boom until all machine weight is on the jackstands.

Stop the engine.

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WARNING

TRACK TENSION (CONT’D) Rubber Track Clearance (Cont'd) Figure PM-76

1

P-32891

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Figure PM-77

Track Frame

0.787” (20 mm) Track Roller

Track B-14067

Measure the track sag at the third roller (Item 1) [Figure PM-76] from the front of the track frame. Do not get fingers in pinch points between the track and track roller.

Use a bolt or dowel of the appropriate size to check the gap between the contact edge of the roller and the top edge of the track guide lug [Figure PM-77].

Rubber track clearance 0.98 - 1.18 in. (25 - 30 mm).

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TRACK TENSION (CONT’D)

Figure PM-78

Steel Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. For the correct service interval (See SERVICE SCHEDULE on Page PM-5.)

WARNING

1

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

NOTE: On new excavators or on excavators with new steel tracks installed, check and adjust as needed the steel track clearance two to three times on the first day of operation.

Park the excavator on a flat and level surface.

Put a straight edge (Item 1) on the top of the track surface between the rear sprocket and the top idler wheel. Measure between the top of the track and the bottom of the straight edge [Figure PM-78].

Steel track clearance 0.79 in. (20 mm).

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TRACK TENSION (CONT’D)

Figure PM-81

Adjustment Figure PM-79 1 1 2

P-32893

Install the track tensioning adapter (Item 1) [Figure PM81] on the end of a grease gun.

P-32891

See your Bobcat dealer for replacement track tensioning adapter (P/N 1858000054).

Remove the bottom bolt and washer (Item 2) [Figure PM-79].

Figure PM-82

Dealer Copy -- Not for Resale

Loosen the top bolt (Item 1) [Figure PM-79].

Pivot the cover out of the way.

Figure PM-80

1

P-32894

1 Install the adapter (Item 1) [Figure PM-82] on the track tensioner.

P-32892

Remove the grease fitting adapter (Item 1) [Figure PM80] from the end of a grease gun.

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TRACK TENSION (CONT’D)

Figure PM-85

Adjustment (Cont’d) Figure PM-83

1

2

1

P-32974

To release track tension, loosen the tensioner (Item 1) [Figure PM-85]. Do not remove the tensioner.

P-32896

After track tension has been released, remove all grease from the tensioner area.

Repeat the procedure for the other track.

1

2

P-32895

Add grease to the track tensioner until the track tension indicator (Item 1) is flush with the cylinder edge (Item 2) [Figure PM-83] & [Figure PM-84].

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NOTE: Do not remove the tensioner (Item 1) [Figure PM-85] unless pressure is released.

Figure PM-84

TRAVEL MOTOR

Draining The Travel Motor

Checking Oil Level

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Figure PM-86 Figure PM-87 2

1 1 1

P-32898

Put the machine on a level surface with the plugs positioned as shown (Item 1 & 2) [Figure PM-86].

Put the machine on a level surface with the plugs positioned as shown (Item 1 & 2) [Figure PM-87].

Remove the plug (Item 1) [Figure PM-86]. the oil level should be at the bottom edge of the plug hole.

Remove both plugs (Items 1 & 2) [Figure PM-87] and drain into a container. Recycle or dispose of the fluid in an environmentally safe manner.

Remove the plug (Item 2) and add gear lube through the hole if the oil level is below the hole (Item 1) [Figure PM86]. (See Capacities on Page SPEC-6.)

After all the gear lube is removed, rotate the track motor to the position shown [Figure PM-86].

Install both plugs.

Add gear lube to the plug hole (Item 2) until the gear lube level is at the bottom edge of the plug hole (Item 1) [Figure PM-86] Install and tighten the plugs.

Repeat the procedure for the other side.

Repeat the procedure for the other side.

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P-32897

LUBRICATING THE EXCAVATOR

5. Left blade cylinder base end (1) [Figure PM-89]

Lubrication Locations

6. Left side blade pivot (1) [Figure PM-89]

See Service Schedule for the best performance of the machine. (See SERVICE SCHEDULE on Page PM-5.)

Figure PM-90

Always use a good quality lithium based multipurpose grease when lubricating the machine. Apply the lubricant until extra grease shows.

Lubricate the following locations on the excavator EVERY 8-10 HOURS:

7

Figure PM-88

P-32869

1

Dealer Copy -- Not for Resale

7. Boom pivot (1) [Figure PM-90]

3

Figure PM-91 2

P-32866 P-32898

Ref. Description (# of Fittings)

8

1. Right blade cylinder rod end (1) [Figure PM-88] 2. Right blade cylinder base end (1) [Figure PM-88] 3. Right side blade pivot (1) [Figure PM-88] P-32868 P-32868

Figure PM-89 8. Boom swing pivot (2) [Figure PM-91]

4

5 6

P-32867 P-32898

4. Left blade cylinder rod end (1) [Figure PM-89]

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LUBRICATING THE EXCAVATOR (CONT’D)

Figure PM-94

Lubrication Locations (Cont’d) Figure PM-92 13 12

9

10 P-32877 P-32876

12. Boom cylinder base end (1) [Figure PM-94] P-32878

13. Arm cylinder base end (1) [Figure PM-94] 9. Boom swing cylinder base end (1) [Figure PM-92]

Dealer Copy -- Not for Resale

Figure PM-95

10. Boom swing cylinder rod end (1) [Figure PM-92] Figure PM-93

14

11

P-32875

14. Arm cylinder rod end (1) [Figure PM-95] P-32877 P-32877

11. Boom cylinder rod end (1) [Figure PM-93]

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LUBRICATING THE EXCAVATOR (CONT’D)

Figure PM-98

Lubrication Locations (Cont’d) Figure PM-96 17

15

P-32872

17. Bucket cylinder rod end (1) [Figure PM-98] P-32874

Figure PM-99

Figure PM-97 18

20 16 19

P-32871

18. Bucket link pivot (1) [Figure PM-99] P-32873

19. Bucket pivot (1) [Figure PM-99] 16. Bucket cylinder base end (1) [Figure PM-97]

20. Bucket link (2) [Figure PM-99] Lubricate the following locations on the excavator EVERY 50 HOURS:

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15. Arm pivot (1) [Figure PM-96]

LUBRICATING THE EXCAVATOR (CONT’D) Lubrication Locations (Cont’d) Figure PM-100

21

22

P-32870

Dealer Copy -- Not for Resale

21. Swing circle bearing (1) [Figure PM-100] 22. Swing circle pinion (1) [Figure PM-100] Figure PM-101

23

23

P-32875

23. Door hinges (2) [Figure PM-101]

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LUBRICATING THE ATTACHMENTS Tilt Bucket Lubrication Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows.

Lubricate the following locations EVERY 8-10 HOURS: Figure PM-102

1

Dealer Copy -- Not for Resale

2

P-36530

1. Bucket pivot (1) [Figure PM-102] 2. Cylinder base end (1) [Figure PM-102] Figure PM-103

3

P-36531

3. Cylinder rod end (1) [Figure PM-103]

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LUBRICATING THE ATTACHMENTS (CONT’D)

Figure PM-105

Clamshell Bucket Lubrication Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows.

Lubricate the following locations EVERY 8-10 HOURS: Figure PM-104 2

P-36519

Figure PM-106 1

P-36518

1. Bucket pivot points (4) [Figure PM-104] 2 2 P-36520

2. Cylinder link pivots (5) [Figure PM-105] & [Figure PM-106]

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1

Return to Service

Storage

After the Bobcat Excavator has been in storage, it is necessary to follow a list of items to return the excavator to service.

Sometimes it may be necessary to store your Bobcat Excavator for an extend period of time. Below is a list of items to perform before storage.

•

Thoroughly clean the excavator including the engine compartment.

•

Lubricate the excavator.

•

Replace worn or damaged parts.

•

Drive the excavator onto planks in a dry protected shelter.

•

Lower the boom fully with the bucket flat on the ground.

•

Check the engine and hydraulic oil levels; check coolant level.

•

Install a fully charged battery.

•

Remove grease from exposed cylinder rods.

•

Check all belt tensions.

•

Be sure all shields and guards are in place.

•

Lubricate the excavator.

•

Remove cover from exhaust pipe opening.

•

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Put grease on any exposed cylinder rods.

•

Put fuel stabilizer in the fuel tank and run the engine a few minutes to circulate the stabilizer to the pump and fuel injectors.

•

Drive the excavator off of the planks.

•

Operate machine, check for correct function.

If biodiesel fuel has been used, perform the following:

•

Stop the engine and check for leaks. Repair as needed.

Drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Replace all fluids and filters (engine, hydraulic).

•

Replace all filters (i.e.: air cleaner, heater, etc.).

•

Put all controls in neutral position.

•

Remove the battery. Be sure the electrolyte level is correct then charge the battery. Store it in a cool dry place above freezing temperatures and charge it periodically during storage.

•

Cover the exhaust pipe opening.

•

Tag the machine to indicate that it is in storage condition.

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EXCAVATOR STORAGE AND RETURN TO SERVICE

MACHINE SIGN TRANSLATIONS COOLANT (6811054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-14 LIFT CHART (6813628) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-4 MECHANICAL SPRING LOADED COUPLER (7130241) . . . . . . . . . MST-15 SERVICE SCHEDULE (6814224). . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 UNDERCARRIAGE COMPONENTS (6589129). . . . . . . . . . . . . . . . . MST-14 WARNING (6813577) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6807776) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-10

MACHINE SIGN TRANSLATIONS

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WARNING (6813581, 6813576, 6804233) . . . . . . . . . . . . . . . . . . . . . MST-13

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WARNING (6813577)

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LIFT CHART (6813628)

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LIFT CHART (6813628) (CONT’D)

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LIFT CHART (6813628) (CONT’D)

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SERVICE SCHEDULE (6814224)

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SERVICE SCHEDULE (6813578) (CONT’D)

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SERVICE SCHEDULE (6813578) (CONT’D)

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WARNING (6807776)

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WARNING (6807776) (CONT’D)

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WARNING (6807776) (CONT’D)

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WARNING (6813581, 6813576, 6804233)

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COOLANT (6811054)

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UNDERCARRIAGE COMPONENTS (6589129)

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MECHANICAL SPRING LOADED COUPLER (7130241)

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MECHANICAL SPRING LOADED COUPLER (CONT’D) (7130241)

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SPECIFICATIONS

SPECIFICATIONS

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SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Excavator Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-7 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6

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SPECIFICATIONS Excavator Machine Dimensions 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.

171” (4340)

243” (6170) 164” (4160)

107” (2718)

104” (2641)

167” (4250)

286” (7260)

B-16592

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• •

SPECIFICATIONS (CONT’D) Performance Specifications Operating Weight w/cab (w/ 24 in. Bucket) and rubber track 16538 lb. (7502 kg) Steel tracks add 550 lb. (249 kg)

Add the following weights to the above, if equipped with any of these options

Travel Speed

Low 1.7 mph (2,7 km/hr.)

High 3.2 mph (5,2 km/hr.)

Boom Swing (Offset)

Left 63° Right 65°

Controls Steering

Two hand levers or foot pedals

Hydraulics

Two hand operated levers (joysticks) control boom, bucket, arm and cab swing

Auxiliary Hydraulics

Electric switches in joysticks

Brakes Travel Swing

Hydraulically released, spring loaded Hydrostatic swing drive acts as swing brake

Service

Spring loaded multi disc brake acting as parking brake when the control lever is in neutral

Engine Make/Model

Deutz TD2011LO4W Tier III

Fuel/Cooling

Diesel / Liquid

Horsepower, (SAE Net)

75.1 HP (56 Kw)

Maximum Governed RPM

2200 RPM

Torque @ 1500 RPM (SAE Net)

211 ft.-lb. (286 N•m)

Number Of Cylinders

4

Displacement

221 cu. in. (3.62 L)

Bore/Stroke

3.78 x 4.92 in. (96 x 125 mm)

Lubrication

Pressure System with Filter

Crankcase Ventilation Air Cleaner

Closed Breathing Dry replaceable paper dual cartridge

Ignition

Diesel-Compression

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Service & Parking

SPECIFICATIONS (CONT’D) Hydraulic System Boom, arm, bucket, auxiliary & travel functions 38 GPM (142 L/min.)

Hydraulic Circuit 2 (gear pump)

Swing, blade & boom swing function 16.37 GPM (62 L/min.)

Hydraulic Filter

Full flow replaceable, 3 micron synthetic media element

Control Valve

Six spool closed center Three spool open center

Fluid Type

Bobcat Fluid, Hydraulic / Hydrostatic 6903117 - (2.5 Gal.) 6903118 - (5 Gal.) 3603119 - (55 Gal.)

System Relief Pressure Travel Circuits Slew Circuit, Blade and Boom Offset Boom, Bucket, Arm, Auxiliary, Joystick Control Pressure

4060 PSI (280 bar) 3335 PSI (230 bar) 4060 PSI (280 bar) 508 PSI (35 bar)

Auxiliary Relief

4060 PSI (280 bar)

Arm Port Relief Base End And Rod End

4350 PSI (300 bar)

Boom Port Relief Base End And Rod End

2610 PSI (180 bar)

Bucket Port Relief Base End And Rod End

4350 PSI (300 bar)

Auxiliary Port Relief Base And Rod End

4350 PSI (300 bar)

Auxiliary (Second - If Equipped) Port Relief Base And Rod End

3626 PSI (250 bar)

Main Hydraulic Filter Bypass

50 PSI (3.4 bar)

Case Drain And Fan Motor Filter Bypass

50 PSI (3.4 bar)

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Hydraulic Circuit 1 (Piston Pump)

Hydraulic Cylinders Cylinder

Bore

Rod

Stroke

Boom

4.7 in. (120 mm)

2.4 in. (60 mm)

33.5 in. (850 mm)

Arm

4.5 in. (115 mm)

2.8 in. (70 mm)

26.4 in. (670 mm)

Bucket

3.5 in. (90 mm)

2.4 in. (60 mm)

28.3 in. (720 mm)

Boom Swing

4.1in. (105 mm)

2.4 in. (60 mm)

24.6 in. (625 mm)

Blade

3.9 in. (100 mm)

2.0 in. (50 mm)

7.9 in. (200 mm)

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SPECIFICATIONS (CONT’D) Hydraulic Cycle Times Bucket Curl

2.2 Seconds

Bucket Dump

2.7 Seconds

Arm Retract

3.5 Seconds

Arm Extend

4.2 Seconds

Boom Raise

6.5 Seconds

Boom Lower

5.9 Seconds

Boom Swing Left

9.7 Seconds

Boom Swing Right

9.7 Seconds

Blade Raise

2.2 Seconds

Blade Lower

2.2 Seconds

Slew

10 RPM

Starter

12 volts, gear reduction 4.2 HP (3,1 kW) reduction drive

Alternator

12 volts, 55 amps, open, negative ground

Battery

12 volts, 450 CCA @ 0° F (-18° C)

Drive System Final Drive

Each track is driven by an axial piston motor

Type of Reduction

Two stage planetary gear reduction

Gradability

30%

Undercarriage Crawler

Tractor design

Rollers

Sealed rollers with box section track roller frame

Track Adjusters

Grease type track adjusters with shock absorbing recoil spring

Capacities Fuel Tank

34.3 Gal. (130,0 L)

Hydraulic Reservoir Only (Center of Sight Glass)

Tank Cap 29 Gal. (110,0 L)

Hydraulic System (with Reservoir)

37 Gal. (140,0 L)

Cooling System

3.2 Gal. (12,0 L)

Engine Oil and Filter

10.6 qt. (10,0 L)

Final Drive (each)

1.9 qt. (1,8 L)

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Electrical System

SPECIFICATIONS (CONT’D) Tracks Type

Steel

Rubber

Width

18 in. (450 mm)

18 in. (450 mm)

No. of Shoes (Steel Track)

42 6 Bottom - 1 Top

6 Bottom - 1 Top

Ground Pressure

4.4 PSI (0.31 bar)

4.4 PSI (0.31 bar)

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No. of Track Rollers

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WARRANTY

WARRANTY

WARRANTY

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WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-3

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WARRANTY

WARRANTY Bobcat Excavators

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company’s option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement. Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors. The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, and other high-wear items.

This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6570375 (2-09)

Printed in U.S.A.

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Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Excavator will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) tracks for twelve (12) months on a prorated basis based on the remaining depth of the track at the time any defect is discovered, and (iii) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

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ALPHABETICAL INDEX AIR CLEANER SERVICE.................................................................PM-11 AIR CONDITIONING COMPRESSOR BELT .................................. PM-32 ALTERNATOR BELT ....................................................................... PM-31 ATTACHMENTS ................................................................................ OI-34 BLADE CONTROL LEVER ............................................................... OI-24 BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED ..............................V BOOM SWING PEDAL ..................................................................... OI-24 CONTROL CONSOLE LOCKOUTS ................................................. PM-6 DAILY INSPECTION ......................................................................... OI-25 DELIVERY REPORT..............................................................................VII

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ELECTRICAL SYSTEM .................................................................. PM-24 EMERGENCY EXIT .......................................................................... OI-14 ENGINE COOLING SYSTEM ......................................................... PM-21 ENGINE LUBRICATION SYSTEM.................................................. PM-18 ENGINE OIL.............................................................................................V EXCAVATOR IDENTIFICATION............................................................VIII EXCAVATOR STORAGE AND RETURN TO SERVICE ................. PM-50 FAN BELT........................................................................................ PM-31 FEATURES, ACCESSORIES AND ATTACHMENTS .............................IX FRESH AIR FILTER ........................................................................ PM-13 FUEL SYSTEM ............................................................................... PM-14 HYDRAULIC CONTROLS................................................................. OI-16 HYDRAULIC SYSTEM.................................................................... PM-33

ALPHABETICAL INDEX

INSTRUMENTS AND CONSOLES..................................................... OI-3 LIFTING THE EXCAVATOR .............................................................. OI-61 LUBRICATING THE ATTACHMENTS............................................. PM-48 LUBRICATING THE EXCAVATOR .................................................. PM-44 Continued On Next Page

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ALPHABETICAL INDEX (CONT’D) MACHINE SIGNS (DECALS).............................................................. XVII MAINTENANCE SAFETY ................................................................. PM-3 MOTION ALARM SYSTEM (IF EQUIPPED)..................................... OI-15 MOTION ALARM SYSTEM (IF EQUIPPED)..................................... PM-8 OPERATOR CAB ................................................................................ OI-7 OPERATING PROCEDURE ............................................................. OI-52 PRE-STARTING PROCEDURE ........................................................ OI-27 PUBLICATIONS AND TRAINING MATERIALS ................................... XIX

SAFETY INSTRUCTIONS ................................................................... XIII SEAT BELT........................................................................................ PM-7 SERIAL NUMBER LOCATIONS ........................................................... VII SERVICE SCHEDULE ...................................................................... PM-5 SPECIFICATIONS......................................................................... SPEC-3 STARTING THE ENGINE................................................................ PM-31 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR ......... OI-33 TOWING THE EXCAVATOR ............................................................. OI-60 TRACK TENSION ........................................................................... PM-38 TRANSPORTING THE EXCAVATOR ON A TRAILER ..................... OI-62 TRAVEL MOTOR ............................................................................ PM-43 TRAVEL CONTROLS........................................................................ OI-12 WARRANTY ........................................................................WARRANTY-3

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REAR COVER................................................................................. PM-10 REGULAR MAINTENANCE ITEMS........................................................ V RIGHT SIDE COVER ...................................................................... PM-10