Bobcat E80 Compact Excavator Operation & Maintenance Manual 7257778 (03-17)

EN

Operation & Maintenance Manual E80 Compact Excavator

S/N AET315001 & Above

7257778enGB (03-17) (A)

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Printed in Belgium Original Instructions

©2017 Bobcat Company. All rights reserved. EAC T2

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OPERATOR SAFETY WARNING 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-19792

B-19751

B-19754

without

Do not grasp control handles when entering cab.

Never operate instructions.

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

Avoid steep areas or banks that could break away.

Never use attachments not approved by Bobcat Company.

WRONG

WRONG

MS-1784

Operate on flat, level ground.

without

Never modify equipment.

Be sure controls are in neutral before starting.

Sound horn and check behind machine before starting.

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

Never operate approved cab.

MS1785

Keep bystanders out of maximum reach area.

 Maximum

CORRECT

CORRECT

B-19756

 Maximum MS-1786

Never exceed a 15 slope to the side.

Never travel up a slope that exceeds 15.

Do not travel or turn with bucket extended.

Never carry riders.

CORRECT

CORRECT

CORRECT

CORRECT

B-21928

NA-1421A

STOP  Maximum TS-2068A

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

NA-1435B

6808261

To leave excavator, lower the work equipment and the blade to the ground.

Fasten seat belt securely.

Operate controls only from operator’s seat.

Look in the direction of rotation and make sure no bystanders are in the work area.

Stop the engine.

SAFETY EQUIPMENT The Bobcat® excavator must be equipped with safety items necessary for each job. Ask your Bobcat dealer for information on the availability and safe use of attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. OPERATOR CAB (ROPS): Check condition and mounting hardware.

3. OPERATOR’S HANDBOOK: Must be in the cab.

4. LEFT HAND CONSOLE: When raised must deactivate the travel and hydraulic functions.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. GRAB HANDLES: Replace if damaged.

OSW78-EN-0117 7. INTEGRATED SLEW LOCK BRAKE.

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CONTENTS CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SYSTEM SETUP AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 REFERENCE INFORMATION Write the correct information for YOUR excavator in the spaces below. Always use these numbers when referring to your Bobcat excavator.

Bobcat Excavator  Serial Number Engine Serial Number

NOTES

YOUR BOBCAT EXCAVATOR DEALER: ADDRESS: PHONE:

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128 UNITED STATES OF AMERICA

Doosan Bobcat Manufacturing s.r.o. U Kodetky 1810 263 12 Dobris CZECH REPUBLIC

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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 dealer. This manual may illustrate options and accessories not installed on your excavator.

BOBCAT COMPANY IS IS0 9001 CERTIFIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 LUBRICANTS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Excavator Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Options And Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Buckets Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Top Guard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Special Application Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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BOBCAT COMPANY IS IS0 9001 CERTIFIED

ISO 9001 is an international standard that specifies requirements for a quality management system 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 at Bobcat's manufacturing facilities in Gwinner and Bismarck, North Dakota (U.S.A.), Pontchateau (France), Dobris (Czech Republic) and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota.

Only certified assessors, like BSI, can grant registrations.

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

REGULAR MAINTENANCE ITEMS ENGINE OIL FILTER 7004996

FUEL FILTER 7006269 FUEL FILTER, water separator 7005081

HYDRAULIC RETURN FILTER 7004884 HYDRAULIC STRAINER / SUCTION  FILTER 7006811 HYDRAULIC BREATHER  FILTER 7006806

AIR FILTER, Outer  7005000

BATTERY 7005712

AIR FILTER, Inner  7005001

RADIATOR CAP 7005051

NOTE: Always verify Part Numbers with your Bobcat dealer.

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LUBRICANTS AND FLUIDS

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SERIAL NUMBER LOCATIONS 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.

Excavator Serial Number

Engine Serial Number

Figure 1

Figure 3

1

1

P-86268

P-86914

The engine serial number (Item 1) [Figure 3] is located on the side of the engine.

The excavator serial number plate (Item 1) [Figure 1] is located on the swing frame on the front of the upperstructure.

DELIVERY REPORT Figure 2

Figure 4 Module 2 - Production Sequence (Series) Module 1 - Model / Engine Combination P-90175

Explanation of Excavator Serial Number [Figure 2]: 1. The four digit Model / Engine Combination Module number identifies the model number and engine combination.

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

B-16315

The delivery report [Figure 4] contains a list of items that must be explained or shown to the owner or operator by the dealer when the Bobcat excavator is delivered.

The delivery report must be reviewed and signed by the owner or operator and the dealer.

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EXCAVATOR IDENTIFICATION

2 1

24

14 15

16

4 13

23

17

3 5 6

12

9

18

11 7

21 8

10

ITEM

DESCRIPTION

19

22

20

ITEM

NA5962 NA5960

DESCRIPTION

1

Operator’s Handbook

16

Cab (ROPS / TOPS) [B]

2

Arm Cylinder

17

Rear Cover

3

Auxiliary Quick Couplers

18

Counterweight

4

Boom

19

Tracks [C]

5

Arm

20

Tie Downs (Both Sides)

6

Bucket Cylinder

21

Track Frames

7

Bucket Link

22

Blade

8

Bucket [A]

23

Right Side Cover

9

Boom Cylinder

24

Lift Point

10

Tie Downs / Lift Points

11

Blade Cylinder

12

Upperstructure

13

Control Levers (Joysticks)

14

Operator’s Seat with Seat Belt

15

Mirror

[A] BUCKET - Several different buckets and other attachments are available for the Bobcat excavator.

[B] ROPS / TOPS - Roll-Over Protective Structure per ISO 12117-2: 2008, and Tip-Over Protective Structure  per ISO 12117: 2000.

[C] TRACKS - Optional tracks are available.

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FEATURES, ACCESSORIES AND ATTACHMENTS Standard Items

Attachments

Model E80 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.

• • • • • • • • • • • • • • • • •

Cab (ROPS / TOPS) Cab with Heater and A/C Cab Mounted Lights 400 mm (15.75 in) Rubber Tracks 1980 mm (78.00 in) Blade Two-Speed Travel Auxiliary Hydraulics Hydraulic and Travel Control Lockout Work Lights - Boom and Frame Mounted Steel Track Engine Monitor with Shut Down Horn Hydraulic Joystick Controls Radio Ready Suspension Seat Advanced Diagnostics Second Auxiliary Hydraulic Lines

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.

• Auger • Breaker • Adapter • Tilt Bucket • Rotary Grinder • Hydraulic Clamp • Bucket Clam • Packer wheel Buckets Available

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.

• • • • • • • • • •

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.

Travel Motion Alarm Cab Mounted Lights Catalytic Exhaust Purifier Top and Front Guard Kit (FOGS) Strobe Beacon Third Auxiliary Hydraulic Lines Long Arm Blade Load Hold Rubber Tracks

Specifications subject to change without notice and standard items may vary.

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FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D) Top Guard Kit

Special Application Kit

Available for special applications that require protection from smaller objects that can fall on the cab and restrict material from entering cab.

The excavator must have the Front Guard Kit (Item 2) installed to meet the front guard requirements in ISO 10262. Inspect the screen for damage. Replace parts as necessary.

The excavator must have the top guard (Item 1) installed to meet the level 2 top guard requirements in ISO 10262.

See your Bobcat Dealer for availability.

1

2

B-27866

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SAFETY AND TRAINING RESOURCES SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pictorial Only Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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SAFETY INSTRUCTIONS

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.

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 motorway, 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 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.

•

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.

•

An Operator’s Handbook is fastened to the operator cab of the excavator. Its brief instructions are convenient to the operator. See your Bobcat dealer for more information on translated versions.

SI EXC DSN EMEA-0913

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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 and machine signs (decals).

•

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. For driving on public roads, the machine must be equipped as stipulated by the local regulations authorising operation on public roads in your specific country. Regulations may identify a hazard such as a utility line.

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

W-2001-0502

Have Training with Actual Operation

IMPORTANT

•

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

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

•

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.

I-2019-0284

Know the Work Conditions

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 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.

•

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.

D-1002-1107

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 DSN EMEA-0913

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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.

Use a respirator, water spray or other means to control dust.

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.

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 DSN EMEA-0913

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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 petrol or diesel fuel for cleaning parts. Use commercial non-flammable solvents.

Dust generated from repairing non-metallic 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

Fire Extinguishers

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.

Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations with higher Sulfur content. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

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.

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

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

SI EXC DSN EMEA-0913

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PUBLICATIONS AND TRAINING RESOURCES The following publications are also available for your Bobcat excavator. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK

For the latest information on Bobcat product and the Bobcat Company, visit our web site at Bobcat.com

6987304 Gives basic operation instructions and safety warnings

OPERATION & MAINTENANCE MANUAL 7257778enGB

Complete instructions on the correct operation and the routine maintenance of the Bobcat excavator

SERVICE MANUAL 6987194

Complete maintenance instructions for your Bobcat excavator

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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.

OPERATOR’S HANDBOOK

1

7169010 6987304 7136738 - If Equipped With Motion Alarm

RIGHT CONSOLE AREA

2

7120571 (2)

FOOT CONTROLS AREA

3 7169037 7193276 - If 7169036 Equipped w/ 6808872 (2) Arti Boom

7169007 (2)

6815993 (2)

7169018

4

7168039 (2)

LEFT FRONT UPPERSTRUCTURE AREA

5

7169020

6

7189181 7120577 B-23930A

MACHINE SIGNS (DECALS) (CONT’D) Follow the instructions on all the Machine Signs (Decals) that are on the excavator. Replace any damaged machine signs

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and be sure they are in the correct locations. Machine signs are available from your Bobcat excavator dealer.

7169014

7

7168996 - Standard Machines 7120570 ON RIGHT REAR WINDOW

ON RIGHT SIDE COVER

9

6533897 - Standard Machines

8

7169009

7169000 Short Arm 7169015 Long Arm

7318891

10

7120573

6595014

2

11

7120571 (2) 7185935 IN ENGINE COMPARTMENT

7120579

B-23931A

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs Safety signs are used to alert the equipment operator or maintenance person to hazards that may be encountered in the use and maintenance of the equipment. The location and description of the safety signs are detailed in this section. Please become familiarized with all safety signs installed on the machine / attachment.

NOTE: See the numbered MACHINE SIGNS (DECALS) on Page 20 and Machine Signs (Decals) (Cont’d) on Page 20 for the machine location of each corresponding numbered pictorial only decals as shown below.

1. Motion Alarm (7136738)

Vertical Configuration This safety sign is located on the right rear console.

HAZARD PANEL

AVOIDANCE PANEL

Horizontal Configuration

7136738

WARNING This machine is equipped with a motion alarm.

ALARM MUST SOUND! when operating forward or backward.

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

HAZARD PANEL

AVOIDANCE PANEL

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

W-2786-0309

The format consists of the hazard panel(s) and the avoidance panel(s): Hazard panels depict a potential hazard enclosed in a safety alert triangle.

Avoidance panels depict actions required to avoid the hazards.

A safety sign may contain more than one hazard panel and more than one avoidance panel.

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs (Cont’d) 2. Thrown Or Flying Objects (7120571)

4. Thrown Or Flying Objects (7168039)

This safety sign is located on the gas spring under the right side cover and on the front window.

This safety sign is located on the outside of both tracks.

7120571

7168039

WARNING WARNING

High pressure gas can cause serious injury or death.

Do not open. Opening cylinder can release rod.

W-2523-0106

High pressure grease can cause serious injury. Do not loosen grease fitting. Do not loosen bleed fitting more than 1 - 1/2 turns.

3. Crush Hazard (7169007) This safety sign is located on both sides of the boom.

Read and understand the Operation & Maintenance Manual for more information.

W-2516-0110

7169007

WARNING Keep away from the operating machine to avoid serious injury or death.

W-2520-0106

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs (Cont’d) 6. Transporting And Lifting (7120577)

5. High Pressure, Battery, Rotating Fan, Exhaust Gases and Service Schedule (7189181)

This safety sign is located on the front of the cab.

This safety sign is located on the right front corner of the upperstructure. For Service Schedule Information, (See SERVICE SCHEDULE on Page 97.)

7120577

WARNING Improper loading, transporting and lifting procedures can cause serious injury or death. Read and understand the Operation & Maintenance Manual prior to transporting or lifting the machine.

7189181G

W-2517-0110

WARNING Leaking fluids under pressure can enter the skin and cause serious injury or death. Immediate medical attention is required. Wear goggles. Use cardboard to check for leaks.

Battery makes flammable and explosive gas. Keep arcs, sparks, flames and lighted tobacco away. Keep away from electrical contacts Rotating fan can cause serious injury. Keep away from fan and moving parts. Do not operate with guard removed.

All exhaust gases can kill. Always ventilate.

Read and understand the Operation & Maintenance Manual for more information.

W-2522-0110

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs (Cont’d) 7. General Hazard (7168996 or 7193274)

8. Stay Away (7169009)

This safety sign is located inside the operator’s area on the right rear window. For Control Pattern Information (See TRAVEL CONTROLS on Page 47.)

This safety sign is located on both upper rear corners of the upperstructure.

7169009 7168996 OR 7193274

WARNING

WARNING • • •

Failure to obey warning signs and instructions can cause serious injury or death. Never use excavator without instructions. Read and understand the Operation & Maintenance Manual and Handbook.

AVOID INJURY OR DEATH Keep out of swing area or travel path.

Always look in the direction of travel.

Make sure swing area is clear of bystanders and objects.

W-2775-1208

Keep away from dropoffs, steep areas or banks that could break away.

Explosion or electrocution can occur if machine contacts utility lines or pipes. Check for overhead or underground lines before operating.

Keep bystanders away. No riders. Check location of blade for direction of travel before moving steering controls.

Failure to operate machine from the operator’s position can cause serious injury or death.

To Leave Excavator: 1. Lower attachment and blade to ground.

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

3. Raise control console.

W-2518-0110

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs (Cont’d) 9. Lift Capacity (7169000 or 7169015 or 7193275)

10. Hot Surfaces and Rotating Fan (7120579)

This safety sign is located on the right side cover.

This safety sign compartment.

is

located

inside

the

engine

7169000 OR 7169015 OR 7193275

WARNING Overload can tip the excavator and cause serious injury or death.

•

Do not lift or hold any load that exceeds these ratings at their specific load radii and height.

•

Total rated load is shown. The weight of all lifting devices must be deducted to determine the net load that can be lifted.

Read and understand the Operation & Maintenance Manual for more information.

W-2519-0110 7120579

WARNING Rotating fan blade can cause serious injury or death.

Keep away from fan and moving parts. Do not operate with guard removed.

Hot surfaces can cause injury. Do not touch. Allow to cool before servicing.

W-2521-0106

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MACHINE SIGNS (DECALS) (CONT’D) Pictorial Only Safety Signs (Cont’d) 11. Hot Surfaces (7185935) This safety sign is located in the engine compartment.

7185935

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

You can be seriously burned.

W-2070-1203

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OPERATING INSTRUCTIONS INSTRUMENTS AND CONSOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Cab Interior Light (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Left Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Right Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Indicator Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Upperstructure Slew Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Raising And Lowering The Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Two-Speed Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OPERATOR CAB (ROPS / TOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Right Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Heating, Ventilation And Air Conditioning Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Right Side Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 MOTION ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Auxiliary Hydraulics (One Way Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Auxiliary Hydraulics (Primary Auxiliaries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Secondary Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Third Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Relieve Hydraulic Pressure - One Way Flow (Excavator And Attachment) . . . . . . . . . . . . 52 Relieve Hydraulic Pressure - Primary Auxiliaries (Excavator And Attachment) . . . . . . . . . 52 Relieve Hydraulic Pressure - Secondary Auxiliaries (If Equipped) (Excavator And Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Relieve Hydraulic Pressure - Third Auxiliaries (If Equipped) (Excavator And Attachment) 53 Direct To Tank Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ENGINE SPEED CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Setting Engine Speed (RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Automatic Idle Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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BOOM SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 OVERLOAD WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Daily Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Operation & Maintenance Manual And Operator’s Handbook Locations . . . . . . . . . . . . . .59 Entering The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Warming The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . .65 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Emergency Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Installing And Removing The Attachment (Pin-On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Installing And Removing The Attachment (Quick Coupler, Lehnhoff® System) . . . . . . . . .68 Installing And Removing The Attachment (Quick Coupler, Klac™ System) . . . . . . . . . . . .71 Quick Coupler And Attachment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Inspect The Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Basic Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Lowering The Work Equipment (Engine STOPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Lifting A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Using The Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Boom Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Driving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Operating On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Operating In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Avoiding Track Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 TOWING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

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TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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INSTRUMENTS AND CONSOLES Cab Interior Light (If Equipped) Left Console [Figure 6]

Figure 5

REF. NO. 1 2

1 3

P-86248

Slide the switch (Item 1) [Figure 5] to turn the cab light ON or OFF. Left Console Figure 6

4

1 5

2

6

3

4

6

5

P-86215 P-86216

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DESCRIPTION

FUNCTION/OPERATION

Left Joystick

(See HYDRAULIC CONTROLS on Page 49.)

Horn Press lower button on left joystick to sound horn. (Key switch must be in ON position for horn to operate.) (The top two switches on the left joystick are not used for this model.)

Air Conditioner / Press A/C button to turn air Fan Motor conditioner ON, Press OFF button to turn A/C OFF and also turns the fan motor OFF. (When the A/C button is pressed to the ON position, the Fan motor speed must also be selected before the A/C will work. When both the A/C button and a fan speed button is pressed, the light above the A/C button will be ON.) Fan Speed Press Low - Medium - High button Select to select fan speed. (Light above button selected will be ON.) Temperature Press COOL button repeatedly to Control / Heater lower temperature / press WARM Activation button repeatedly to raise temperature. There are 24 positions to select the desired temperature range. (Lights above COOL / WARM buttons will show the temperature selected. Green lights indicate cool / red lights indicate warm.)  To activate HEAT, the OFF button must be pressed. Press the desired fan speed button, then repeatedly press the WARM button until the desired temperature is selected. To turn heater OFF, press the OFF button to turn the fan motor to OFF. Air Vent / Air Press the desired button to Flow Location control air flow to various areas in the cab. The icons on the buttons indicate the air flow location. (See Heating, Ventilation And Air Conditioning Ducting on Page 44.)

E80 Operation & Maintenance Manual

INSTRUMENTS AND CONSOLES (CONT’D) Right Console Figure 7

4

REF. DESCRIPTION NO.

8

7

9

10 11 17 12 13 14

7 15 17

6 8

16

9

18 2 5

3

10 1 11 19 STOP

5

ON

12

START

13

P-86211A

14 Right Console [Figure 7] REF. DESCRIPTION NO.

1 2

3

4

5

6

15

FUNCTION/OPERATION

Right Joystick (See HYDRAULIC CONTROLS on Page 49.)

Auxiliary Controls the fluid flow to the Hydraulic auxiliary hydraulic quick couplers Switch (attachment) (See Auxiliary Hydraulics (One Way Flow) on Page 51.)

Blade Control Blade Control: Controls raising and Lever lowering the blade. (See BLADE CONTROL LEVER on Page 54.)

16

17 18 19

Two-Speed Switch

Engages and disengages High Range Travel Speed. (See TwoSpeed Travel on Page 39.)

Auto Idle Engages and disengages the Switch automatic idle feature. (See Setting Engine Speed (RPM) on Page 54.)

Light Switch Press switch to centre position to OFF- ON - ON turn instrument panel lights ON, press switch fully to activate cab work lights and boom work lights.

Wiper Switch Press switch to centre position for OFF- ON - ON intermittent wiper mode, press switch fully for continuous wiper motion.

Press switch to spray washer fluid Window Washer on the front window. (Will only work Switch when the wiper switch is ON.) Radio ON / Turns the main power On or OFF to OFF Switch the radio. (The key switch must also be in the ON position for the radio to be powered.)

Overload Engages or disengages the Warning overload warning feature. (See OVERLOAD WARNING on Page 56.)

Beacon / Press switch to turn strobe / beacon Strobe Light light ON (if equipped).

Switch (OPTIONAL) Motion Alarm Engages or disengages the motion Cancel Switch alarm (if equipped). (See MOTION (OPTIONAL) ALARM SYSTEM on Page 46.)

Engine Move the switch to the emergency Emergency STOP position. Switch will return to Stop Switch the ON position when released.

NA Not used for this model.

Hourmeter Shows total hours of machine use.

Instrument (See Indicator Icons on Page 37.)

Panel

NOTE: Always turn key switch and all accessories to OFF position after the engine is stopped. The battery will discharge if the key is left ON.

Engine Speed Controls rpm of the engine. (See Control Dial Setting Engine Speed (RPM) on Page 54.)

Key Switch Always perform the PRESTARTING PROCEDURE before starting the engine. (See PRESTARTING PROCEDURE on Page 59.) and (See STARTING THE ENGINE on Page 62.)

Auxiliary 12 volt receptacle for accessories.

Power Outlet

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E80 Operation & Maintenance Manual

INSTRUMENTS AND CONSOLES (CONT’D) Indicator Icons The table below shows the Icons, their function and other important information.

FUNCTION

ICON / LIGHT

CONDITION

DESCRIPTION

1

REF.

System Voltage

OFF ON

--Warning

 Voltage out of range - Light will be ON when key is turned to the ON position with engine not started, light will go OFF after engine starts. If light is ON with engine running, shut engine OFF immediately an determine cause of problem.

2

Engine Oil Pressure

OFF ON

--Warning

 Oil pressure low - Light will be ON when key is turned to the ON position with engine not started, light will go OFF after engine starts. If light is ON with engine running, shut engine OFF immediately. If engine is operated with light ON, serious engine damage may occur.

3

Engine Air Filter

OFF ON

--Warning

 Indicates the air filter(s) needs servicing when light is ON.

4

Air Intake Heater

OFF ON

-----

 Air intake heater energized. In cold weather with the key in the ON position, the icon indicates the engine preheat feature is activated. When icon is OFF with the key in the ON position means the engine preheat cycle has finished and the engine can be started.

5

Low Fuel

OFF ON

--Warning

 Light ON when fuel in tank is approximately 10 L (2.6 U.S. gal) or less. Add fuel as soon as possible.

6

Engine Coolant Temperature

OFF ON

--Warning

 Light ON when engine temperature exceeds allowable limit. Alarm will sound and the engine rpm will automatically be reduced. Check engine temperature gauge, if indicator is in red zone on gauge, allow engine to idle until engine temperature reaches white zone. Continue to allow engine to idle for another few minutes. Stop engine and allow to cool before servicing.

7

Two-Speed Travel

OFF ON

-----

 Light ON when Two-Speed activated, High Range engaged. 

8

Working Lights

OFF ON

-----

 Light ON when working lights ON.

9

Engine Check

OFF ON

--Warning

 Light flashes when engine needs servicing. Stop engine and service as needed. (Light flashes a service code pattern to indicate problem.)

10

Overload Warning

OFF ON

--Warning

 When switch is activated - the light ON and alarm sounding indicates the load exceeds the maximum allowable limit (lift capacity exceeded). Reduce load immediately.

11 

Water In Fuel

OFF ON

--Warning

 Light ON when water in fuel filter is indicated. Drain water from fuel filter as soon as possible.

Figure 8

The right console contains the instrument panel with Function Icons [Figure 8].

1

Engine Coolant Temperature Gauge (Item 1) [Figure 8].

Gauge indicate engine coolant temperature and allowable operating range. WHITE area indicates coolant temperature is in normal operating range. RED area indicates engine coolant temperature is to high. When in RED area, engine rpm will automatically be reduced.

Allow engine to idle until engine temperature is in normal operating range. Stop the engine and allow coolant to cool and service as required.

2

3 3

Fuel Level Gauge (item 2) [Figure 8]. Shows amount of fuel in fuel tank.

Function Icons information.

(Item

3)

[Figure 8],

see

above

P-86955A

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INSTRUMENTS AND CONSOLES (CONT’D) Upperstructure Slew Brake

Raising And Lowering The Console

This excavator is equipped with an automatically applied slew brake integrated into the slew motor.

Raise the console before exiting the cab.

Figure 9

When the upperstructure slew circuit is engaged, hydraulic pressure unlocks the slew motor.

When the upperstructure slew circuit is disengaged, spring pressure applies the internal slew motor brake.

1 P-86320

Pull up on the console release handle (Item 1) [Figure 9].

Lower the console before operating the excavator.

Push down on the console release handle (Item 1) [Figure 9] until the latch is engaged.

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

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.

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INSTRUMENTS AND CONSOLES (CONT’D) Two-Speed Travel Figure 10

1

P-86211B

Press the bottom of the two-speed button (Item 1) [Figure 10] to engage the high range.

Figure 11

1

P-86955A

When high range is engaged, the two-speed travel icon (Item 1) [Figure 11] will illuminate.

Press the top of the two-speed button (Item 1) [Figure 10] to disengage.

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OPERATOR CAB (ROPS / TOPS) Description

Cab Door

The Bobcat excavator has an operator cab (ROPS / TOPS) as standard equipment to provide protection if the excavator is tipped over. The seat belt must be worn for ROPS / TOPS protection.

Figure 12

1 Check the ROPS / TOPS cab, mounting, and hardware for damage. Never modify the ROPS / TOPS cab.

Replace the cab and hardware if damaged. See your Bobcat dealer for parts.

2

ROPS / TOPS - Roll-Over Protective Structure per ISO 12117-2: 2008, and Tip-Over Protective Structure per ISO 12117: 2000.

WARNING

P-86952

The cab door can be locked (Item 1) [Figure 12] with the same key as the start switch.

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.

The door can be held in the open position. Push the door all the way open until the latch (Item 2) [Figure 12] engages to hold the door in the open position.

W-2069-0200

Figure 13

2 1 P-86238A

When the door is in the open position, push down on the latch (Item 1) [Figure 13] and close the door.

From inside the cab, open the door using handle (Item 2) [Figure 13].

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OPERATOR CAB (ROPS / TOPS) (CONT’D) Front Window Opening The Front Window Figure 16

Figure 14

2 1

1

P-86225

P-86954

When the window is fully raised, push up on the window slightly until the two latch pins (Item 1) (both sides) engage into the bracket (Item 2) [Figure 16] to lock the window in the open position. Pull down slightly on the window to make sure the latch pins are properly seated to hold the window securely in the open position.

Rotate the front window latch pins (Item 1) [Figure 14] (both sides).

Figure 15

Closing The Front Window Support the window while rotating both window latch pins (Item 1) [Figure 16] to the unlocked position.

Using both window grab handles, pull the window forward and down to the closed position [Figure 15].

When the window is fully lowered, push in on the window slightly until the two latch pins (Item 1) [Figure 14] (both sides) engage into the bracket to lock the window in the closed position.

P-86322

Use both window grab handles to pull the top of the window in [Figure 15].

Continue moving the window in and up over the operator’s head until the window is fully raised.

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OPERATOR CAB (ROPS / TOPS) (CONT’D) Front Wiper

Window Washer Reservoir

Figure 17

Figure 19

1 1

P-86249

P-86908

The window washer reservoir (Item 1) [Figure 19] is located under the front centre cover. (When the temperature is 0°C (32°F.) or lower, fill the washer reservoir with washer fluid specified for freezing conditions. If the washer bottle is filled with water, it will freeze and damage the washer reservoir.)

The front window is equipped with a wiper (Item 1) [Figure 17] and washer.

Figure 18 1

1

2

2

P-86945A

The wiper switch (Item 1) [Figure 18] has three positions, OFF, intermittent wiper mode and full speed.

The window washer switch (Item 2) activates the front window washer. (The wiper switch (Item 1) must be activated before the washer switch (Item 2) [Figure 18] will allow washer fluid to be sprayed on the front window.)

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OPERATOR CAB (ROPS / TOPS) (CONT’D) Right Side Window Opening The Right Front Window Figure 20

1 P-86228

Press the latch / handle (Item 1) [Figure 20] together and pull back on the latch / handle to open the right side window.

Closing The Right Front Window Push the latch / handle (Item 1) [Figure 20] forward until the latch / handle lock the window in the closed position.

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OPERATOR CAB (ROPS / TOPS) (CONT’D) Heating, Ventilation And Air Conditioning Ducting Figure 21

Figure 23

1 1

P-86229 P-86951

Figure 22 The excavator is equipped with seven air vents (Item 1) [Figure 21], [Figure 22] and [Figure 23] that can be adjusted to deflect air flow to the desired area of the cab.

Figure 24 1 1

P-86230

P-86953

Use one of the five buttons (Item 1) [Figure 24], located in the left console, to control which air ducts are active.

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EMERGENCY EXIT The door, the right side rear window and the front window provide emergency exits.

Right Side Rear Window Figure 27

Figure 25

1

P-86217

P-86325

If emergency exit requires breaking a window, use the supplied hammer (Item 1) [Figure 25] located on the left side of the operator cab.

Exit through the right rear side window [Figure 27].

Figure 26

Figure 28

Front Window

P-86218

P-86322

Open the front window and exit [Figure 28].

Remove the hammer from the storage position and strike the glass with the pointed end of the hammer [Figure 26].

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

Use the hammer to remove broken glass from the edge of the window before exiting.

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MOTION ALARM SYSTEM Operation Figure 29

WARNING This machine is equipped with a motion alarm.

ALARM MUST SOUND! when operating forward or backward.

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

1 With the switch (Item 1) [Figure 30] in the ON position, the motion alarm will sound when the operator moves the travel control levers in the either the forward or reverse direction.

P-86947

This excavator may be equipped with a motion alarm system. The motion alarm (Item 1) [Figure 29] is located inside the rear of the excavator.

If alarm does not sound (with the switch (Item 1) [Figure 30] in the ON position) 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 on Page 101.)

Figure 30

1

P-86211C

The motion alarm can be turned ON or OFF with the motion alarm cancel switch (Item 1) [Figure 30]. Press the bottom of the switch to turn the motion alarm ON, press the top of the switch to turn the motion alarm OFF.

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TRAVEL CONTROLS Description

Turning

The travel control levers control the movement of the excavator.

Right Turn Figure 32

Forward And Reverse Travel

Right Turn (Forward)

NOTE: The following procedures describe forward, reverse, left and right as seated in the operator’s seat.

Figure 31 1

FORWARD

1

NEUTRAL

REVERSE

B-19992

Push the left steering lever forward to turn right [Figure 32] while travelling forward.

Figure 33 2

2

P-86220

Right Turn (Reverse) 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 31] forward for forward travel; backward for reverse travel. * Travel can also be controlled with foot pedals (Item 2) [Figure 31].

WARNING B-19993

•

•

AVOID INJURY OR DEATH Check the blade location before travelling. 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.

Pull the left steering lever backward to turn right while travelling backward [Figure 33]

W-2235-EN-1009

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TRAVEL CONTROLS (CONT’D) Turning (Cont’d) Counter - Rotation Right Turn Figure 34

Figure 36

Counter - Rotation Right Turn

Left Turn (Reverse)

B-19988

B-19990

Push the left steering lever forward and pull the right steering lever backward [Figure 34].

Pull the right steering lever backward to turn left while travelling backward [Figure 36].

Left Turn

Counter - Rotation Left Turn

Figure 35

Figure 37 Counter - Rotation Left Turn

Left Turn (Forward)

B-19989

B-19991

Push the right steering lever forward to turn left [Figure 35] while travelling forward.

Push the right steering lever forward and pull the left steering lever backward [Figure 37].

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

Right Control Lever (Joystick) Figure 39

ISO Control Pattern Left Control Lever (Joystick) Figure 38

ISO CONTROL PATTERN

ISO CONTROL PATTERN

P-86214A

The right lever (joystick) is used to operate the boom and bucket [Figure 39].

P-86215A

1.

2.

3.

4.

5.

6.

7.

8.

The left lever (joystick) is used to operate the arm and slew the upperstructure [Figure 38].

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 and remove the key.

W-2196-0595

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HYDRAULIC CONTROLS (CONT’D) Quick Couplers To Disconnect:

WARNING

Figure 41

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.

1

2

W-2220-0396

Figure 40

N-15540

Hold the male coupler (Item 1). Retract the sleeve (Item 2) [Figure 41] on the female coupler until the couplers disconnect.

2

1 P-92920

Excavator and attachments use flush faced couplers (Item 1 and 2) [Figure 40]. The male flush face couplers are located on the right side of the arm (shown), the female coupler is located on the left side of the arm.

Coupler (Item 1) is for one way flow auxiliary hydraulics, coupler (Item 2) [Figure 40] is the secondary auxiliary hydraulics.

To Connect: Remove any dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage, or excessive wear, if any of these conditions exist, the coupler(s) (Item 1) [Figure 40] must be replaced.

Install the male coupler into the female coupler. Full connection is made when the ball release sleeve slides forward on the female coupler.

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HYDRAULIC CONTROLS (CONT’D) Auxiliary Hydraulics (One Way Flow)

Secondary Auxiliary Hydraulics (If Equipped)

Figure 42

Figure 44

1 1 2

P-86214

P-86215

Press and hold the Auxiliary Hydraulics button (Item 1) [Figure 42] on the right joystick to supply hydraulic flow / pressure to the female coupler.

The left joystick switches (Item 1 and 2) control the secondary auxiliary functions. Press switch (Item 1) to supply hydraulic flow and pressure to the female coupler.

Press switch (Item 2) [Figure 44] to supply hydraulic flow and pressure to the male coupler.

NOTE: The auxiliary hydraulic switch (Item 1) [Figure 42] is for one way flow to the female coupler, return flow through the male coupler only. If two way flow auxiliaries are required for the attachment, the primary auxiliary hydraulic function will be used. (See Below)

NOTE: For breaker applications, use the one way auxiliary hydraulic switch (Item 1) [Figure 42].

Auxiliary Hydraulics (Primary Auxiliaries) Figure 43 2 3

1

4

P-86917A

Release the pedal lock (Item 1) and pivot the heel of the pedal to the rear (Item 2) [Figure 43].

Push the toe of the pedal (Item 3) to supply hydraulic flow and pressure to the female coupler; push the heel of the pedal (Item 4) [Figure 43] to supply hydraulic flow and pressure to the male coupler.

NOTE: The primary auxiliary hydraulics and the one way flow auxiliary hydraulics use the same auxiliary hydraulic couplers.

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HYDRAULIC CONTROLS (CONT’D) Third Auxiliary Hydraulics

Relieve Hydraulic Pressure - One Way Flow (Excavator And Attachment)

Figure 45 Excavator: 1

Put the attachment flat on the ground.

Stop the engine and turn the key to ON. NOTE: The left console must be fully lowered for relieving hydraulic pressure.

2

Press the right joystick switch (Item 2) [Figure 46] several times.

Attachments:

P-92574

• Rotate the valve (Item 1) 1/4 turn clockwise (both sides) for the third auxiliary coupler (if equipped) (Item 2) function. Rotate the valve (Item 1) [Figure 45] (both sides) 1/4 turn anticlockwise for the bucket function.

Follow procedure above to release pressure in excavator.

•

Connect male coupler from attachment to female coupler of excavator then repeat procedure above.

This will release pressure in the attachment.

NOTE: The bucket function is not usable when the third auxiliary hydraulics are activated.

•

Connect the female coupler from the attachment.

Figure 46

Hydraulic pressure in the auxiliary hydraulic system can make it difficult to engage quick couplers to an attachment.

Relieve Hydraulic Pressure - Primary Auxiliaries (Excavator And Attachment) 2

Excavator: Put the attachment flat on the ground.

Stop the engine and turn the key to ON.

1

NOTE: The left console must be fully lowered for relieving hydraulic pressure.

P-86214

Press the auxiliary hydraulic pedal forward (Item 3) and back (Item 4) [Figure 43] several times.

Use the right joystick (Item 1) [Figure 46] (same as the bucket function). Move the joystick to the left for hydraulic flow to the female coupler. Move the joystick to the right for hydraulic flow to the male coupler.

Attachments:

NOTE: For breaker applications, use the one way auxiliary hydraulic switch (Item 2) [Figure 46].

•

Follow procedure above to release pressure in excavator.

•

Connect male coupler from attachment to female coupler of excavator then repeat procedure above.

This will release pressure in the attachment.

•

Connect the female coupler from the attachment.

Hydraulic pressure in the auxiliary hydraulic system can make it difficult to engage quick couplers to an attachment.

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HYDRAULIC CONTROLS (CONT’D) Direct To Tank Valve

Relieve Hydraulic Pressure - Secondary Auxiliaries (If Equipped) (Excavator And Attachment)

Figure 47 Excavator: Put the attachment flat on the ground.

Stop the engine and turn the key to ON. 1

NOTE: The left console must be fully lowered for relieving hydraulic pressure.

Press the left joystick switches (Item 1 and 2) [Figure 44] several times.

Attachments: • •

•

Follow procedure above to release pressure in excavator.

P-86913

Connect male coupler from attachment to female coupler of excavator then repeat procedure above.

This will release pressure in the attachment.

Figure 48

Connect the female coupler from the attachment.

Hydraulic pressure in the auxiliary hydraulic system can make it difficult to engage quick couplers to an attachment.

A

Relieve Hydraulic Pressure - Third Auxiliaries (If Equipped) (Excavator And Attachment)

B

Excavator: 1

Put the attachment flat on the ground.

NOTE: The valves (Item 1) [Figure 45] must be rotated to the third auxiliary position before hydraulic pressure can be relieved.

P-86909

Open the centre cover (Item 1) [Figure 47] to access the direct to tank valve.

Stop the engine and turn the key to ON.

The excavator is equipped with a direct to tank valve (Item 1) [Figure 48] that must be switched when using a breaker attachment.

NOTE: The left console must be fully lowered for relieving hydraulic pressure.

Move the right joystick (Item 2) [Figure 42] left and right several times.

Rotate the direct to tank valve (Item 1) [Figure 48] spool anticlockwise (A) for breaker operation and clockwise (B) for all other attachments.

Attachments: •

Follow procedure above to release pressure in excavator.

•

Connect male coupler from attachment to female coupler of excavator then repeat procedure above.

This will release pressure in the attachment.

•

Connect the female coupler from the attachment.

The direct to tank valve (Item 1) [Figure 48] when in the breaker positions, will direct most of the hydraulic return flow back to the hydraulic tank for less flow restriction and increase breaker performance. Some of the hydraulic return flow will still go through the hydraulic valve so that this oil goes through the hydraulic oil cooler to keep the hydraulic oil at the correct temperature.

Hydraulic pressure in the auxiliary hydraulic system can make it difficult to engage quick couplers to an attachment.

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BLADE CONTROL LEVER

ENGINE SPEED CONTROL DIAL

Operation

Setting Engine Speed (RPM)

Figure 49

Figure 50

2

HIGH IDLE

1

1

LOW IDLE 2

P-86213

P-86946A

Pull the lever backward to raise the blade (Item 1) [Figure 49].

The engine speed control dial (Item 1) [Figure 50] controls the engine rpm. Rotate the knob clockwise to increase engine rpm, anticlockwise to decrease engine rpm.

Push the lever forward to lower the blade (Item 2) [Figure 49].

Automatic Idle Feature NOTE: Keep the blade lowered for increased digging performance.

The auto idle feature (when engaged) will reduce the engine speed to low idle when the control levers (joystick, blade, travel, etc.) are in neutral and not used for approximately four seconds. The engine rpm will return to the set position as soon as any control lever is activated.

The automatic idle switch (Item 2) [Figure 50] is used to engage or disengage the automatic idle feature.

Press the bottom of the switch (Item 2) to engage automatic idle, press the top of the switch (Item 2) [Figure 50] to disengage automatic idle.

NOTE: When loading or unloading the machine or when operating in confined spaces, disengage the auto idle feature.

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BOOM SWING Operation Figure 51 3

2 1

4 P-86917B

Release the pedal lock (Item 1) and pivot the heel of the pedal to the rear (Item 2) [Figure 51].

Push the toe of the pedal (Item 3) to swing the boom to the right; push the heel of the pedal (Item 4) [Figure 51] to swing the boom to the left.

Figure 52

B-16610B

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 52].

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OVERLOAD WARNING Description The overload warning feature, when engaged, will alert the operator with a warning buzzer and overload icon on the instrument panel when the work group is overloaded.

If overload occurs, immediately bring the arm towards the machine, lower the boom and reduce the load before continuing operation.

Figure 54

Operation Figure 53

1

P-86955A

The icon (Item 1) [Figure 54] will illuminate and a buzzer will sound when the boom is overloaded.

If overload occurs, immediately bring the arm towards the machine, lower the boom and reduce the load before continuing operation.

1 P-86211D

Do not exceed the Rated Lift Capacity.

To engage the overload warning feature, press the switch (Item 1) [Figure 53]. The switch icon will be illuminated when engaged.

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

W-2374-0500

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DAILY INSPECTION Figure 55

7189181G

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DAILY INSPECTION (CONT’D) Daily Inspection And Maintenance Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [Figure 55] is a guide for correct maintenance of the Bobcat excavator. It is located on the right front corner of the excavator upperstructure and also in this manual.

IMPORTANT •

Check the following items before each day of operation: •

Operator Cab (ROPS / TOPS) and mounting hardware.

•

Seat belt and mounting hardware. Replace seat belt if damaged.

•

Check for damaged decals, replace as needed.

•

Check control console lockout.

•

Check X-Change™ System (if equipped) for damage or loose parts.

•

Air cleaner condition indicator and intake hoses/ clamps.

•

Engine oil level and engine for leaks.

•

Engine coolant level and engine for leaks.

•

Check engine area for flammable materials.

•

Check hydraulic fluid level and system for leaks.

•

Check indicator lights for correct operation.

•

Drain water and sediment from fuel tank and filter.

•

Check cylinder and attachment pivot points.

•

Check the track tension.

•

Repair broken and loose parts.

•

Clean cab heater filter (if equipped).

•

Check front horn and motion alarm (if equipped) for proper function.

•

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 300 mm (12 in) from the decal. Wash from the centre of the decal toward the edges.

I-2226-EN-0910

IMPORTANT This machine is factory equipped with a spark arrester exhaust system.

The spark arrester muffler, if equipped, must be cleaned to keep it in working condition. The spark arrester muffler must be serviced by dumping the spark chamber every 100 hours of operation.

On some models, the turbocharger functions as the spark arrester and must operate correctly for proper spark arrester function.

If this machine is operated on flammable forest, brush, or grass covered land, a spark arrester attached to the exhaust system may be required and must be maintained in working order. Refer to local laws and regulations for spark arrester requirements.

I-2284-EN-0909

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

W-2001-0502

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

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

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PRE-STARTING PROCEDURE Entering The Excavator

Operation & Maintenance Manual And Operator’s Handbook Locations

Figure 58 Figure 56

1

P-86245

Figure 57

1

P-86319

Use the grab handles, tracks and safety treads to enter the cab [Figure 58].

WARNING

P-89985

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.

Read and understand the Operation & Maintenance Manual (Item 1) [Figure 56] (located inside the storage box on the back of the operator’s seat) and the Operator’s Handbook (Item 1) [Figure 57] before operating.

W-2003-0807

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PRE-STARTING PROCEDURE (CONT’D) Seat Adjustment Figure 59

Figure 60

6

5

4

10

7

8 P-87300

1

Heated Seat (If Equipped). The optional heated seat has a switch (Item 10) [Figure 60] located on the left side of the seat. Press the top of the switch to activate the heated seat. Press the bottom of the switch to turn off.

2

3

9

Seat Belt P-86949A

Figure 61

Release the seat lever (Item 1) [Figure 59] to adjust the seat forward or backward.

Turn the handle (Item 2) to change the adjustment for operator weight. Turn the handle until the operator’s weight is shown in the window (Item 3) [Figure 59].

1

Release the lever (Item 4) [Figure 59] (on the back of the seat) to change the lumbar support.

Rotate the knob (Item 5) [Figure 59] (on the lower left side of the seat) to change the incline of the seat back.

Rotate the knob (Item 6) [Figure 59] (on both arm rest) to change the angle of the arm rest.

Release the lever (Item 7) [Figure 59] to change the position of the lower cushion forward or back.

1

Release the lever (Item 8) [Figure 59] to change the angle of the lower cushion.

2

The operator’s group (seat and left and right consoles) can be adjusted forward or backward. Adjust the operator’s group using the lever (Item 9) [Figure 59].

P-86323A

Fasten the seat belt (Item 1) [Figure 61].

To adjust seat height, sit in the seat and fasten the seat belt. Place your hands to the sides of the cab (not on the consoles) and lift up slowly with your arms and legs, raising the seat. The seat has four adjustment positions.

When the top position is reached, the seat will reset and allow the seat to go back to the lowest position.

Press the red button (Item 2) [Figure 61] to release the seat belt.

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PRE-STARTING PROCEDURE (CONT’D) Control Console

Mirror Adjustment

Figure 62

Figure 63

1 P-86320

P-86251

Lower the control console [Figure 62].

Adjust mirror (Item 1) [Figure 63] (if equipped).

NOTE: There is a control lock switch in the left console which deactivates the hydraulic control levers (joysticks and traction system) when the control console lock lever is raised.

The console must be in the locked 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 when the console lock lever is raised, see your Bobcat dealer for service.

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STARTING THE ENGINE Key Switch Figure 66

WARNING OFF • •

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

Never wear loose clothing when working near machine.

ON START 1

W-2135-1108

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page 59.)

Figure 64

P-86240

FORWARD 1

1

Turn the key (Item 1) [Figure 66] to the ON position. If preheating is required, the air intake heater will automatically cycle. (The preheat icon will be ON while air intake heater is activated).

NEUTRAL

REVERSE

Turn the key to START and release the key when the engine starts. It will return to the ON position [Figure 66].

P-86220A

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

Put control levers (Item 1) [Figure 64] in the neutral position.

Turn the key switch OFF to stop the engine.

Figure 65 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.

P-86229

I-2034-0700

Rotate the engine speed control dial (Item 1) [Figure 65] anticlockwise to low idle.

WARNING

WARNING

•

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

•

AVOID SERIOUS INJURY OR DEATH Engines can have hot parts and hot exhaust gas.

Keep flammable material away.

Do not use machines in atmosphere containing explosive dust or gases.

W-2051-0212

W-2050-0807

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STARTING THE ENGINE (CONT’D) Cold Temperature Starting Figure 68

WARNING OFF EXPLOSION CAN CAUSE SERIOUS INJURY, DEATH OR SEVERE ENGINE DAMAGE DO NOT use ether or starting fluid with glow plug or air intake heater systems.

ON START 1

W-2071-0415

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 ENGINE LUBRICATION SYSTEM on Page 111.)

P-86240

Turn the key to the ON position (Item 1) [Figure 68].

•

Make sure the battery is fully charged:

•

Install an engine heater, available from your Bobcat dealer.

Figure 69

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 118.)

Figure 67 1

1

P-86229 P-86955A

Rotate the engine speed control dial (Item 1) [Figure 67] half way between low and high engine speed.

The preheat icon (Item 1) [Figure 69] will come ON. The air intake heater will automatically cycle. When the icon goes off, turn the key to start.

IMPORTANT

Release the key when the engine starts, it will return to the ON position.

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.

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

When the engine speed increases, move the engine speed control dial (Item 1) [Figure 67] to low idle position until the engine warms.

I-2034-0700

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STARTING THE ENGINE (CONT’D) Warming The Hydraulic System

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

I-2007-0910

Let the engine run at least 5 minutes to warm the engine and hydraulic fluid before operating the excavator.

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STOPPING THE ENGINE AND LEAVING THE EXCAVATOR Procedure Figure 72

Figure 70

STOP ON START 1

P-86335

P-86240

Turn the key switch to STOP (Item 1) [Figure 72].

Stop the machine on level ground. Lower the work equipment and the blade to the ground [Figure 70].

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

Figure 71

Emergency Shut Off

1

Figure 73

STOP

1 P-86229

RUN

Rotate the engine speed control dial (Item 1) [Figure 71] to the low idle position.

Run the engine at idle speed for approximately 5 minutes to allow it to cool.

P-86944

In case of emergency, move the switch (Item 1) [Figure 73] in the STOP position.

The switch will return to the to the RUN position. Restart the engine using the start key.

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ATTACHMENTS Installing And Removing The Attachment (Pin-On) Installation Figure 75

NOTE: Installation and removal of the bucket is shown. The procedure is the same for other attachments. Disconnect any hydraulic lines that are operated by hydraulic power before removing the attachments (breakers, auger, etc.).

WARNING AVOID INJURY OR DEATH Stop the machine on a firm flat surface. When removing or installing attachments (such as a bucket), always have a second person in the operator’s seat, give clear signals and work carefully.

1

P-86916

W-2140-0189

Installing the arm (Item 1) [Figure 75] into the attachment.

Figure 74 1

Figure 76

1 2

3 P-86804 P-86253

Before installing the attachment, make sure the four Orings (Item 1) [Figure 74] are positioned over the attachment boss (as shown) so they are not damaged during installation.

Align the arm mounting hole with the attachment and install the pin (Item 1) [Figure 76].

Install the link (Item 2) in the attachment and align the mounting hole. Install the pin (Item 3) [Figure 76].

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Pin-On) (Cont’d) Removal

Figure 77

Park the excavator on a flat surface and lower the attachment fully.

1

Position the four O-rings (Item 1) [Figure 78] into the storage groove of the attachment so they do not get damaged during removal.

2

Remove the retainer bolts (Item 1) and nuts (Item 2) [Figure 77].

2

Remove the pins (Item 1 and 3) [Figure 76].

1 P-86252

WARNING

Install the two retainer bolts (Item 1) and jam nuts (Item 2) [Figure 77] and tighten the jam nuts.

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.

NOTE: The two retaining bolts (Item 1) [Figure 77] should rotate after the two jam nuts are installed. Install the first jam nut until the bolt is finger loose on the mount. Install the second jam nut and tighten the second jam nut against the first jam nut.

W-2052-0907

Figure 78

1

P-86255

Reposition the four O-rings (Item 1) [Figure 78] next to the arm.

Install grease in the grease fittings on the arm and bucket link pins.

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

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Lehnhoff® System) Installation NOTE: Installation and removal of the bucket is shown. The procedure is the same for other attachments. Disconnect any hydraulic lines that are operated by hydraulic power before removing any attachments (breaker, auger etc.).

Figure 80

1

WARNING

2

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.

S3014A

W-2052-0907

Engage the coupler hooks (Item 1) onto the attachment shaft (Item 2) [Figure 80].

Position the excavator so the excavator arm is above the attachment.

Figure 81

Fully retract the bucket cylinder.

Figure 79

1

2 1 2 S3015A

Extend (curl in) the bucket cylinder and slightly raise the boom until the coupler (Item 1) contacts the back of the attachment mount (Item 2) [Figure 81].

S3013A

Lower the coupler (Item 1) onto the attachment (Item 2) [Figure 79].

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Lehnhoff® System) (Cont’d) Installation (Cont’d) Figure 84

Figure 82

1

1 1 S3017A

S3020A

Stop the engine and exit the excavator.

Install the wrench (Item 1) [Figure 84] on the locking pins and turn anticlockwise until the locking pins are disengaged.

Use the supplied wrench (Item 1) [Figure 82] and turn the locking pins clockwise until they are fully engaged.

Figure 85

Engage the parking brake.

Removal Park the excavator on a level surface.

Figure 83

S3021A

Enter the excavator, fasten the seat belt and start the engine Lower the attachment until it is on the ground [Figure 85].

S3019A

Raise the boom and extend the bucket cylinder until the attachment it is slightly off the ground [Figure 83].

Engage the parking brake.

Stop the engine and exit the excavator.

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Lehnhoff® System) (Cont’d) Removal (Cont’d) Figure 86

1 2

S3022A

Retract the bucket cylinder to rotate the coupler (Item 1) out of the attachment mount (Item 2) [Figure 86].

Figure 87

1 2

S3023A

Move the arm out and raise the boom until the quick coupler (Item 1) is clear of the attachment (Item 2) [Figure 87].

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Klac™ System) Installation NOTE: Installation and removal of the bucket is shown. The procedure is the same for other attachments. Disconnect any hydraulic lines that are operated by hydraulic power before removing any attachments (breaker, auger etc.).

WARNING AVOID INJURY Keep fingers and hands out of pinch points when latching and unlatching the attachment quick coupler.

WARNING

W-2541-1106

Figure 89

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

Figure 88 Unlatched Position

Latched Position

P-72273

To unlatch the quick coupler, install the tool (Item 1) [Figure 89] and pull the handle. The latch will move completely forward. The latch will lock in the unlatched position.

1

1

Figure 90 P-72272

Fully retract the bucket cylinder.

Stop the engine and exit the excavator.

Inspect the quick coupler to make sure the latch is in the unlatched position (Item 1) [Figure 88].

1 2

If in the latched position, see [Figure 89] for additional information.

If the latch is in the unlatched position, proceed to [Figure 90].

P-72274

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

Position the quick coupler (Item 1) to the attachment (Item 2) [Figure 90].

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Klac™ System) (Cont’d) Installation (Cont’d) Figure 93

Figure 91 1

4

3

100

2

500 mm 20 in P-72275A

P-72277

There must be at least 100 between the quick coupler surface (Item 1) and the attachment mounting surface (Item 2) [Figure 91]. Extend the arm out to get the required angle for proper installation.

Raise the boom until there is approximately 500 mm (20.0 in) of clearance between the bottom of the attachment and the ground [Figure 93].

Figure 94

NOTE: There must be proper clearance (100 minimum) between the hook (Item 3) and the quick coupler (Item 4) [Figure 91]. Possible damage to the attachment hooks or the quick coupler could occur without proper clearance.

1

Figure 92 1 1

P-72278

2

2 Extend the bucket cylinder (Item 1) [Figure 94] fully.

Lower the attachment until it is flat on the ground.

Engage the parking brake.

P-72276

Stop the engine and exit the excavator.

Raise the boom and extend the arm until the hooks of the attachment (Item 1) engage the pins (Item 2) of the quick coupler [Figure 92].

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Klac™ System) (Cont’d) Installation (Cont’d) Figure 96

Figure 95 Fully Engaged

Not Engaged

2 1 1 1 2 2 P-72279

P-72286

If the latch is not engaged, install the tool (Item 1) in the hole (Item 2) [Figure 96] of the quick coupler and push down to unlatch the quick coupler. Remove the tool.

Enter the excavator, fasten the seat belt and start the engine. Raise the attachment 500 mm (20.0 in) off of the ground and fully extend the bucket cylinder. Lower the attachment until it is flat on the ground. Engage the parking brake. Stop the engine and exit the excavator.

Visually inspect the quick coupler latch (Item 1) to the bucket mount (Item 2) [Figure 95]. The latch must be fully engaged.

WARNING AVOID INJURY Keep fingers and hands out of pinch points when latching and unlatching the attachment quick coupler.

Again, visually inspect the quick coupler to make sure the latch (Item 1) [Figure 95] is fully engaged. If it is not fully engaged, remove the attachment and inspect both the quick coupler and the attachment for damage or debris.

(See [Figure 100] for Quick Coupler And Attachment Inspection information.)

W-2541-1106

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ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Quick Coupler, Klac™ System) (Cont’d) Removal Figure 98

WARNING AVOID INJURY Keep fingers and hands out of pinch points when latching and unlatching the attachment quick coupler.

W-2541-1106

Figure 97

1

P-72282

Retract the bucket cylinder fully and lower the boom [Figure 98] until the attachment is on the ground.

Figure 99

P-72281

Position the attachment flat on the ground.

Install the quick coupler tool (Item 1) into the hole (Item 2) [Figure 96] in the quick coupler.

Push down on the tool (Item 1) [Figure 97] to unlock the latch.

P-72274

Remove the tool.

Continue to lower the boom and move the arm towards the excavator until the quick coupler is clear of the attachment [Figure 99].

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

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ATTACHMENTS (CONT’D) Quick Coupler And Attachment Inspection Figure 100

2

1

P-72274

Inspect the quick coupler for wear or damage. Inspect the quick coupler pins (Item 1) and the hooks (Item 2) [Figure 100] (on the attachment) for wear or damage.

Repair or replace damaged parts.

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OPERATING PROCEDURE Inspect The Work Area

Lowering The Work Equipment (Engine STOPPED)

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

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

Look for sharp drop-offs or rough terrain. Have underground utility lines (petrol, water, sewer, irrigation, etc.) located and marked. Work slowly in areas of underground utilities.

The 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.

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

Figure 101

Always check ground conditions before starting your work: •

Inspect for signs of instability such as cracks or settlement.

•

Be aware of weather conditions that can affect ground stability.

•

Check for adequate traction if working on a slope.

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

P-86320

The console lock switch disengages the hydraulic control functions from the joysticks when the console is raised [Figure 101].

Run the engine at low idle speed to warm the engine and hydraulic system before operating the excavator.

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

IMPORTANT

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

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

I-2015-0284

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

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

Lower the control console lock lever to engage the hydraulic control functions of the joysticks [Figure 101].

Operating Near An Edge Or Water Keep the excavator as far back from the edge as possible and the excavator tracks perpendicular to the edge so that if part of the edge collapses, the excavator can be moved back.

Always move the excavator back at any indication the edge may be unstable.

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OPERATING PROCEDURE (CONT’D) Lifting A Load Do not exceed the Rated Lift Capacity.

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

W-2374-0500

NOTE: Load Holding Valves may be required for lifting objects. Check the local regulations in your area. See your Bobcat dealer for load holding valves for your model excavator.

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

Wrap the chain assembly around the bucket mounting plate.

Figure 102

B-16613

Make sure the load is evenly weighted and centred on the lifting chain, and is secured to prevent the load from shifting [Figure 102].

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

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OPERATING PROCEDURE (CONT’D) Using The Clamp When Using Secondary Auxiliary Hydraulics To Activate Clamp

Figure 103

Figure 104 2 3

1

4

P-86917A

Release the pedal lock (Item 1) and pivot the heel of the pedal to the rear (Item 2) [Figure 104].

Push the toe of the pedal (Item 3) to close the clamp; push the heel of the pedal (Item 4) [Figure 104] to open the clamp.

P-86912

NOTE: The primary auxiliary hydraulics and the one way flow auxiliary hydraulics use the same auxiliary hydraulic couplers.

The optional hydraulic clamp attachment gives the excavator a wider range of use and mobility for debris removal [Figure 103].

When Using Secondary Auxiliary Hydraulics To Activate Clamp

The hydraulic clamp cylinder is operated by the secondary auxiliary hydraulic system (if equipped).

Figure 105

The lifting clamp cylinder must be fully retracted when the machine is being used for excavating.

The lift capacities are reduced by 136 kg (300 lb) if the excavator is equipped with the optional hydraulic clamp.

1 2

WARNING P-86215

AVOID INJURY OR DEATH Check area to be excavated for overhead or underground lines such as electrical, gas, oil, water, etc. DIAL 811 (USA Only) or 1-888-258-0808 (USA & Canada) and consult local utilities before digging.

Extreme caution must be used in areas where utility lines are present.

The left joystick switches (Item 1 and 2) control the secondary auxiliary functions. Press switch (Item 1) to close the clamp. Press switch (Item 2) [Figure 105] to open the clamp.

W-2686-1007

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OPERATING PROCEDURE (CONT’D) Excavating Figure 108

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

W-2119-0910

Lower the blade for increased digging performance.

Figure 106

MS1854

Raise the boom, retract the arm and curl the bucket [Figure 108].

Rotate the upperstructure.

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

WARNING

MS1855

Extend the arm, lower the boom, and open the bucket [Figure 106].

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

Figure 107

VOLTAGE

MINIMUM DISTANCE

up to 50 kV

3 m (10 ft)

beyond 50 kV

5 m (17 ft) W-2757-EN-0513

MS1856

Retract the arm, while lowering boom and curling the bucket [Figure 107].

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OPERATING PROCEDURE (CONT’D) Excavating (Cont’d) Figure 111

Figure 109

WRONG

B-23542A

MS1857

Do not dig under the excavator [Figure 111].

Look in the direction of rotation and make sure there are no bystanders in the work area before rotating the upperstructure [Figure 109].

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.

Figure 110

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

B-16611

Extend the arm and uncurl the bucket to dump the material into a pile or truck [Figure 110].

IMPORTANT Avoid operating hydraulics over relief pressure.

Failure to do so will overheat hydraulic components.

I-2220-0503

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OPERATING PROCEDURE (CONT’D) Boom Swing Figure 115

Figure 112

B-16610B

B-16612A

Figure 113

The boom swing allows the operator to offset the boom and dig close to buildings and other structures [Figure 115].

B-16631A

Figure 114

B-16632A

Slew the upperstructure, swing the boom to the right [Figure 112], centre [Figure 113] and left [Figure 114] to dig a square hole the width of the machine without repositioning the excavator.

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OPERATING PROCEDURE (CONT’D) Backfilling

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

IMPORTANT

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

Avoid impacting objects with the blade. Damage to blade and undercarriage components may occur.

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.

I-2256-0507

Figure 116 Figure 117

B-16633

Plank

Use the blade to backfill the trench or hole after excavating [Figure 116].

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 117].

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

Figure 118

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 118].

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OPERATING PROCEDURE (CONT’D) Operating On Slopes

WARNING • • •

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.

• •

•

W-2497-0304

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

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

Always fasten seat belt.

W-2498-EN-1009

When going down a slope, control the speed with the steering levers and the engine speed control dial.

Figure 120 Travelling Up Slopes

Figure 119 Travelling Down or Backing Up Slopes 304 mm (12 in) Maximum

15 Maximum 25 Maximum MS1860

MS-1861

Figure 121 Travelling On Side Slopes

When going down grades that exceed 15 degrees, put the machine in the position shown, and run the engine slowly [Figure 119].

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

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

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.

15 Maximum B-19936

When travelling up slopes or on side slopes that are 15 degrees or less, position the machine as shown and run the engine slow [Figure 120] and [Figure 121].

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OPERATING PROCEDURE (CONT’D) Operating On Slopes (Cont’d) Figure 123

Figure 122 Recommended Position For Working On A Slope

1

1

Forward Neutral

Reverse

B-19935

P-86220A

To brake the machine when going down a slope, move the steering levers (Item 1) [Figure 123] to the NEUTRAL position. This will engage the hydrostatic braking.

When operating on a slope, level the work area before beginning [Figure 122].

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

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

Do not work on slopes which are over 15 degrees.

Use a slow work cycle.

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

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 locked down position, and the key switch in the ON position.

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.

Use the control lever to lower the boom.

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.

Start the engine and resume operation.

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OPERATING PROCEDURE (CONT’D) Operating In Water 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.

Figure 124

Maximum Water Level

B-16664

Do not operate or immerse the excavator in water higher than the bottom of the swing bearing [Figure 124].

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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OPERATING PROCEDURE (CONT’D) Avoiding Track Damage Driving over sharp objects should be avoided. If this is impossible, do not make turns while driving over sharp objects.

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.

Figure 127

Some Cause Of Track Damage: Figure 125

PI-13035

Incorrect track tension: When the rubber track is detracting, the idler or sprocket rides on the projections of the embedded metal [Figure 125] causing the embedded metal to be exposed to corrosion. (See TRACK TENSION on Page 128.)

B-17824

If rubber track is clogged with stones or foreign objects, these can get wedged between the sprocket / rollers and cause detracting and track stress.

When rubber tracks drive over sharp projections, intensive stress is applied to the lug side rubber surface, especially at the edges of embedded metals, causing cracks and cuts in the area around the embedded metals [Figure 127].

When moisture invades through cuts on the track, the embedded steel cords will corrode. The deterioration of the design strength may lead to the breaking of the steel cords.

Avoid extensive stress applied to the lug root where metals are embedded. Operators should try to avoid driving over stumps and ridges.

Figure 126 Cuts

PI-13045

When rubber tracks drive over projections or sharp objects in the field, the concentrated forces applied cause cuts on the lug side rubber surface [Figure 126]. In case of making turns on projections, the lug side rubber surface will have an even higher chance to be cut. If the cuts run through the embedded steel cords, it might result in the steel cords' breakage due to their corrosion.

Avoid quick turns on bumpy and rocky fields.

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TOWING THE EXCAVATOR Procedure 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 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 1.5 times the weight of the excavator. (See Performance on Page 156.)

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LIFTING THE EXCAVATOR Procedure Figure 129

Figure 128 2

1

1

1

P-86334A

S37585

Raise the blade fully.

Fasten chains to the ends of the blade (Item 1) [Figure 128] and [Figure 129] and up to a lifting device above the cab. Place protective material between the chains and the cab and the upperstructure to prevent damage.

Put all the control levers in neutral.

Figure 130

Fully extend the cylinders of the bucket, arm and boom so that the excavator is in the position as shown [Figure 128].

WARNING •

• • •

2 2

AVOID INJURY OR DEATH Use a lifting fixture with sufficient capacity for the weight of the excavator plus any added attachments.

Maintain center of gravity and balance when lifting.

Do not swing boom or upperstructure.

Never lift with operator on machine.

1

S37585

W-2434-0502 S37586

S37587

Fasten chains to the boom (Item 2) [Figure 128] and [Figure 130] and up to a lifting device above the cab.

Place protective material between the chains and the cab and the upperstructure to prevent damage.

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LIFTING THE EXCAVATOR (CONT’D) Procedure (Cont’d) Figure 131

45°

B-23947A

The maximum angle between the front and rear chains must not exceed 45° [Figure 131].

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TRANSPORTING THE EXCAVATOR ON A TRAILER Loading And Unloading 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.

Figure 132

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

Align the ramps with the centre 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.

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

P-86910A

NOTE: When loading or unloading the machine or when operating in confined spaces, disengage the auto idle feature.

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

Move the machine forward onto the transport vehicle [Figure 132].

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, bucket, and blade to the transport vehicle.

Stop the engine and remove the key.

W-2058-0807

Put blocks at the front and rear of the tracks.

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TRANSPORTING THE EXCAVATOR ON A TRAILER (CONT’D) Fastening Figure 135

Figure 133

1

P-49459 P-87269

When on the transport vehicle, loop the chains through the holes in the mounting frame.

Figure 134

Loop the chain (Item 1) [Figure 135] round the bucket link.

1

P-87267

NOTE: A clevis may be used at the chain holes for the chains to be routed through for clearance.

Fasten chains to both corners of the blade (Item 1) [Figure 133] and to the tie down loop at the rear of the track frame (Item 1) [Figure 134] to prevent it from moving when going up or down slopes or during sudden stops.

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

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PREVENTIVE MAINTENANCE MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Inspection Checkbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 MOTION ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 CENTRE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Removing And Replacing Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Checking Swing Motor Gear Box Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 Removing And Replacing Swing Motor Gear Box Fluid . . . . . . . . . . . . . . . . . . . . . . . . . .126 SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 AIR CONDITIONING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Pin-On Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Quick Coupler And Attachment Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . .134 TRACK ROLLER AND IDLER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

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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

CORRECT

P-90216

B-19964

B-19959

Never service the Bobcat Excavator without instructions.

Use the correct procedure to lift and support the excavator.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-19965

B-19960

B-19966

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-19962

B-19958

B-19798

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 protections approved for type of welding.

Keep tailgate closed except for service. Close and latch tailgate 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.

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MSW28-0409

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

Failure to do so will result in excessive wear and early failures.

WARNING

The service schedule is a guide for correct maintenance of the Bobcat excavator.

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

Every 10 Hours (Before Starting The Excavator) • • • • •

• • • • • • •

Engine Oil - Check level and add as needed. (See Page 111.)

Engine Air Filters and Air System - Check condition indicator. Service only when required. Check for leaks and damaged components. (See Page 105.)

Engine Cooling System - Check coolant level COLD and add premixed coolant as needed. (See Page 113.)

Fuel Filter - Remove the trapped water and sediment from fuel / water separator. (See Page 107.)

Seat Belt, Seat Belt Retractors, Seat Belt Mounting hardware, Control Console Lockout - Check the condition of seat belt and mounting hardware. Clean or replace seat belt retractors as needed. Check the control console lockout lever for proper operation. Clean dirt and debris from moving parts. (See Page 100.)

Motion Alarm - Check for proper function. (See Page 101.)

Operator Cab - Check the cab condition and mounting hardware. (See Page 40.)

Indicators and Lights - Check for correct operation of all indicators and lights. (See Page 35.)

Safety Signs - Check for damaged signs (decals). Replace any signs that are damaged. (See Page 20.)

Hydraulic Fluid - Check fluid level and add as needed. (See Page 120.)

Track Tension - Check tension and adjust as needed. (See Page 128.)

Swing Reduction Gearbox - Check fluid level and add as needed. (See Page 126.)

Every 50 Hours • • • • • •

Hydraulic Hoses and Tubelines - Check for damage and leaks. Repair or replace as needed.

Steering Levers and Joysticks - Check for correct operation. Repair as needed.

Swing Bearing - Grease swing bearing. Service every 10 hours when operating in water. (See Page 137.)

Blade, Boom Swing, Boom Swing Cylinder and Bucket Pivot Points - Add Grease. Service every 10 hours when operating in water. Service every 10 hours for the first 100 hours, then as scheduled. (See Page 137.)

Battery - Check cables, connections, and electrolyte level; add distilled water as needed. (See Page 115.)

Fuel Tank - Drain water and sediment from fuel tank. (See Page 107.)

Every 100 Hours • •

Spark Arrester Muffler - Clean spark chamber. (See Page 127.)

Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed. Service at first 50 hours, then as scheduled. (See Page 131.) and (See Page 133.)

Every 250 Hours Or Every 12 Months • • • •

Boom and Arm (Workgroup) Pivot Points - Add Grease. Service every 10 hours when operating in water. Service every 10 hours for the first 100 hours, then as scheduled. (See Page 137.)

Engine Oil and Filter - Service at first 50 hours, then as scheduled. Replace oil and filter. (See Page 111.)

Fuel / Water Separator Screen - Service at first 50 hours, then as scheduled. Replace as needed. (See Page 109.)

Travel Motors (Final Drive) - Check fluid level and add as needed. (See Page 130.)

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SERVICE SCHEDULE (CONT’D) Maintenance Intervals (Cont’d) Every 500 Hours Or Every 12 Months • • • • • • •

Swing Pinion - Grease swing pinion. (See Page 137.)

Cooling System - Clean debris from radiator, fuel cooler, hydraulic fluid cooler, air conditioning condenser (if equipped), and front and rear grille. (See Page 113.)

Fuel Filter - Replace filter element. (See Page 109.)

Hydraulic Filter and Hydraulic Reservoir Breather Cap - Service at first 250 hours, then as scheduled. Replace the primary hydraulic filter and the reservoir breather cap. (See Page 122.)

Belts and Idler - Service at first 100 hours, then as scheduled. Check condition. Replace as necessary. (See Page 131.) and (See Page 133.)

Alternator and Starter - Service at first 100 hours, then as scheduled. Check connections.

Heater and Air Conditioning Filters - Clean or replace filters as needed. (See Page 104.)

Every 1000 Hours •

Engine Valves - Adjust the engine valve clearance.

Every 1000 Hours Or Every 12 Months • • • • •

Swing Reduction Gear - Grease swing reduction gear. (See Page 137.)

Hydraulic Suction Filter - Service at first 250 hours, then as scheduled. Clean the hydraulic suction filter, replace as needed. (See Page 122.)

Travel Motors (Final Drive) - Service at first 100 hours, then as scheduled. Replace fluid. (See Page 130.)

Hydraulic Filter - Service at first 250 hours, then as scheduled. Replace the pilot filter. (See Page 122.)

Swing Reduction Gear - Service at first 100 hours, then as scheduled. Replace fluid. (See Page 130.)

Every 2000 Hours Or Every 12 Months •

Hydraulic Reservoir - Replace the hydraulic fluid. (See Page 125.)

Every 24 Months •

Coolant - Replace the coolant. (See Page 114.)

NOTE: The Inspection Checkbook can be ordered for you by your local dealer. Part number 7296478.

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SERVICE SCHEDULE (CONT’D)

CONTROL CONSOLE LOCKOUTS

Inspection Checkbook

Inspection And Maintenance

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures.

Figure 136

The service schedule is a guide for the correct maintenance of the Bobcat excavator.

The Inspection information:

Checkbook

contains

the

following

•

Doosan Bobcat EMEA s.r.o. Warranty Policy

•

Doosan Bobcat EMEA s.r.o. Extended Warranty Policy

The inspection checkbook has to be filled in by the Dealer for any maintenance and service work of your Bobcat machine. This book may be required anytime by an authorised dealer or by Bobcat Europe, should be a breakdown occur on the Bobcat equipment.

P-86321

When the left console is raised [Figure 136] the hydraulic control levers (joysticks and traction system) must not function.

Your dealer can order the Inspection Checkbook. Part Number: 7296478.

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 travel control levers. There should be no movement of the excavator.

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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E80 Operation & Maintenance Manual

SEAT BELT Inspection And Maintenance Figure 137

WARNING

1

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

3

W-2466-0703

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly at least once each year or more often if the machine is exposed to severe environmental conditions or applications.

2

4

Any seat belt system that shows cuts, fraying, extreme or unusual wear, significant discolourations due to ultraviolet UV exposure, dusty / dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), hardware or any other obvious problem should be replaced immediately.

The items below are referenced in [Figure 137].

1. Check the 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.

B-22283

2. Check the buckle and latch for correct operation.

Make sure latch plate is not excessively worn, deformed or buckle is not damaged or casing broken.

3. Check the retractor web storage device (if equipped) by extending webbing to determine if it looks correct and that it spools out and retracts webbing correctly.

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

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

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MOTION ALARM SYSTEM Description Figure 139

This excavator may be equipped with a motion alarm system. The motion alarm (when the motion alarm cancel switch is in the ON position) will sound when the operator moves the travel control levers in the either the forward or reverse direction. Slight movement of the steering levers in either the forward or reverse direction is required with hydraulic components before the motion alarm will sound.

Inspecting

1

Figure 138

P-86211C

Make sure the motion alarm switch (Item 1) [Figure 139] is in the ON position.

1

Move the travel control levers (one lever at a time) in the forward direction. The motion alarm must sound. Move the travel control levers (one lever at a time) in the reverse direction. The motion alarm must sound.

P-86951A

Return both levers to neutral and turn excavator key to OFF position. Exit the excavator. (See STOPPING THE ENGINE AND LEAVING THE EXCAVATOR on Page 65.)

Inspect for damaged or missing motion alarm decal (Item 1) [Figure 138]. Replace if required.

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.

Make sure there are no bystanders in the area.

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

W-2050-0807

Sit in the operator’s seat and fasten the seat belt. Start the engine. (See PRE-STARTING PROCEDURE on Page 59.)

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MOTION ALARM SYSTEM (CONT’D) Inspecting (Cont’d)

Adjusting Switch Position

The motion alarm is located inside the lower part of the engine compartment.

Stop the engine. Raise the operator cab. (See Service Manual for correct procedure.)

Figure 140

Figure 141

2

1 1

P-86915

P-86551

Inspect the motion alarm electrical connector (Item 1) and wire harness (Item 2) [Figure 140] for damage.

Repair or replace any damaged components.

The motion alarm switch (Item 1) [Figure 141] is hydraulic pressure activated and located under the operator cab in the motion alarm valve.

If the motion alarm switch requires adjustment, see the following information.

The switch (Item 1) [Figure 141] is non-adjustable. It must be fully installed into the valve housings and tightened.

Inspect the motion alarm system for proper function if switch is replaced.

WARNING This machine is equipped with a motion alarm.

ALARM MUST SOUND! when operating forward or backward.

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

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REAR COVER

RIGHT SIDE COVER

Opening And Closing

Opening And Closing

The hydraulic tank breather / filter and hydraulic oil fill cover is located under the rear cover.

Figure 144

Figure 142

1

1

P-86256

P-86257

Pull the latch (Item 1) [Figure 144] and raise the right side cover.

Use the start key to unlock and open the rear cover (Item 1) [Figure 142].

NOTE: The right side cover can be locked using the start key.

Close and lock the rear cover when the service procedure is completed.

Adjusting The Latch

CENTRE COVER

Figure 145

Opening And Closing The window washer bottle, breaker valve, circuit breaker, fusible links, some relays and the swing motor located under the centre cover.

1

Figure 143

2

P-86943

The right side cover latch (Item 1) [Figure 145] can be adjusted.

1 Loosen the nut (Item 2) [Figure 145] and adjust the latch. Tighten the nut after the adjustment is made.

P-86257

Close the right side cover before operating the excavator.

Use the start key to unlock and open the centre cover (Item 1) [Figure 143].

Close and lock the centre cover when the service procedure is completed.

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CAB FILTERS Cleaning And Maintenance See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Figure 148

The recirculation filter must be cleaned regularly. The filter is located below the operator seat.

Figure 146 1

1 P-87293

1

2

Installation: Install the filter with the arrows that indicate air flow direction (Item 1) [Figure 148] pointing toward the heater / A/C housing.

P-86942

The filter must be cleaned regularly.

Remove the four bolts (Item 1) from the cover (Item 2) [Figure 146].

Figure 147

2

1

P-87294

Remove the cover (Item 1) and pull up the filter (Item 2) [Figure 147] to remove from the cover.

Use low air pressure to clean the filter. Replace the filter when very dirty.

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AIR CLEANER SERVICE Outer Filter

See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Daily Check

Pull out on the three fasteners (Item 1) and remove the cover [Figure 150].

Figure 149

Clean the dust cup (Item 2) [Figure 150].

1

Figure 151

1

P-86955A

P-86262

Check the air cleaner condition indicator icon (Item 1) [Figure 149] in the instrument panel. If the icon stays ON after the engine is started, the filter needs to be replaced.

Pull the outer filter (Item 1) [Figure 151] from the air cleaner housing.

Replacing Filter Elements Check the housing for damage.

Open the right side cover to access the air cleaner for service. (See RIGHT SIDE COVER on Page 103.)

Clean the housing and the seal surface. DO NOT use compressed air.

Figure 150

Install a new filter.

1 Install the cover and engage the three fastener (Item 1) [Figure 150].

Make sure the dust evacuator cup (Item 3) [Figure 150] is in the down position as shown.

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

1

1 2 3 P-86260

Replace the inner filter every third time the outer filter is replaced or as indicated.

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AIR CLEANER SERVICE (CONT’D) Replacing Filter Elements (Cont’d) Inner Filter Only replace the inner filter under the following conditions: •

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

•

After the outer filter has been replaced, start the engine. If the air cleaner condition indicator icon (Item 1) [Figure 149] remains ON, replace the inner filter.

Figure 152

1

P-86261

Remove the air cleaner cover, the outer filter and the inner filter (Item 1) [Figure 152].

NOTE: Make sure all sealing surfaces are free of dirt and debris. DO NOT use compressed air.

Install the new inner filter (Item 1) [Figure 152].

Install the outer filter and the air cleaner cover.

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E80 Operation & Maintenance Manual

FUEL SYSTEM

Biodiesel Blend Fuel

Fuel Specifications

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

NOTE: Contact your local fuel supplier to receive recommendations for your region.

•

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

•

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.

Ultra low sulfur diesel fuel may also be used in this machine. Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur maximum.

•

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

The following is one suggested blending guideline that should prevent fuel gelling during cold temperatures:

•

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.

At a minimum, low sulfur diesel fuel must be used in this machine. Low sulfur is defined as 500 mg/kg (500 ppm) sulfur maximum.

U.S. Standard (ASTM D975) Use only clean, high quality diesel fuel, Grade Number 2-D or Grade Number 1-D.

TEMPERATURE

GRADE 2-D GRADE 1-D

Above -9°C (+15°F)

100%

0%

Down to -21°C (-5°F)

50%

50%

Below -21°C (-5°F)

0%

100%

Apply the following guidelines if biodiesel blend fuel is used:

NOTE: Biodiesel blend fuel may also be used in this machine. Biodiesel blend fuel must contain no more than five percent biodiesel mixed with ultra low sulfur petroleum based diesel.

This biodiesel blend fuel is commonly marketed as B5 blended diesel fuel. B5 blended diesel fuel must meet ASTM specifications.

•

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 stabiliser and run the engine for at least 30 minutes.

E.U. Standard (EN590) Use only clean, high quality diesel fuel that meets the specifications listed below: •

Low sulfur diesel fuel defined as 500 mg/kg (500 ppm) sulfur maximum.

•

Diesel fuel with cetane number of 51.0 and above.

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

Clean, high quality diesel fuel that meets the EN590 specification may also be used.

NOTE: Biodiesel blend fuel may also be used in this machine. Biodiesel blend fuel must contain no more than seven percent biodiesel mixed with ultra low sulfur petroleum based diesel.

This biodiesel blend fuel is commonly marketed as B7 blended diesel fuel. B7 blended diesel fuel must meet EN590 specifications.

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FUEL SYSTEM (CONT’D) Filling The Fuel Tank Figure 153

1

P-86941

Remove the fuel fill cap (Item 1) [Figure 153] located behind the left corner of the operator cab.

Figure 154

1

P-86263

Inspect the fuel strainer (Item 1) [Figure 154] for damage. Replace if damaged. Always have the fuel strainer installed when filling the fuel tank.

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.

Clean up any spilled fuel.

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FUEL SYSTEM (CONT’D) Fuel Filters Removing Water

Replacing Elements

See the SERVICE SCHEDULE for the service interval when to remove water from or replace the fuel filter. (See SERVICE SCHEDULE on Page 97.)

See the SERVICE SCHEDULE for the service interval when to replace the fuel filter. (See SERVICE SCHEDULE on Page 97.)

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

Fuel Water Separator Turn the shut off valve (Item 2) [Figure 155] clockwise to the closed position.

Figure 155

Remove the housing (Item 3) [Figure 155] and replace the screen.

2

CLOSED

Clean the area around the filter housing. Put clean oil on the seal of the new filter. Install the fuel filter and hand tighten.

OPEN

Turn the shut off valve (Item anticlockwise to the open position.

3

2)

[Figure 155]

Figure 156 1 P-86267A

1

Loosen the drain (Item 1) [Figure 155] at the bottom of the filter to drain water from the filter into a container.

Clean up any spilled fuel.

P-87986

Fuel Filter Turn the shut off valve (Item 2) [Figure 155] clock wise to the closed position.

Remove the filter (Item 1) [Figure 156].

Clean the area around the filter housing. Put clean oil on the seal of the new filter. Install the fuel filter and hand tighten.

Turn the shut off valve (Item anticlockwise to the open position.

2)

[Figure 155]

Remove the air from the fuel system. (See Removing Air From The Fuel System on Page 110.)

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FUEL SYSTEM (CONT’D) Draining The Fuel Tank See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

WARNING

Figure 157

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 doctor familiar with this injury.

1 1

W-2072-EN-0909

2 Removing Air From The Fuel System Turn the start key to the ON position for 10 - 15 seconds.

1

P-86315

The electric fuel pump will supply fuel under pressure and force air from the system.

Loosen one of the bolts and remove two bolts / washers (Item 1) and the access cover (Item 2) [Figure 157] from below the rear of the excavator. Rotate the cover out of the way.

Figure 158

1 P-86318

Install a drain hose on the drain valve (Item 1) [Figure 158] at the bottom of the fuel tank. Route the hose to a container.

Drain the fuel into a container. Tighten the drain valve after fuel has been removed.

Reuse, recycle or dispose of fuel in an environmentally safe manner.

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ENGINE LUBRICATION SYSTEM Checking And Adding Engine Oil

Engine Oil Chart

Check the engine oil every day before starting the engine for the work shift.

Figure 160 ENGINE OIL RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

Figure 159

1

P-86271

Open the right side cover and remove the dipstick (Item 1) [Figure 159].

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.

Keep the oil level between the marks on the dipstick.

Use good quality engine oil that meets API Service Classification of CI-4 or better [Figure 160].

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.

W-2103-0508

Install the dipstick and close the right side cover.

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ENGINE LUBRICATION SYSTEM (CONT’D) Removing And Replacing Oil And Filter Figure 163

See the SERVICE SCHEDULE for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page 97.)

Run the engine until it is at operating temperature. Rotate the upperstructure 90° for access to the bottom engine cover and the engine oil pan drain plug. Stop the engine.

Open the right side cover.

1

Figure 161 2

3

2

2 P-86272

Remove the oil filter (Item 1) [Figure 163] and clean the filter housing surface.

1

Use a genuine Bobcat replacement filter. Put clean oil on the filter gasket. Install the filter and hand tighten.

1

2

Install and tighten the plug (Item 1) [Figure 162].

P-86925

Figure 164

From under the machine, loosen the two bolts (Item 1) and remove four bolts / washers (Item 2) from the access cover (Item 3) [Figure 161] from below the engine area.

Remove the access cover.

1

Figure 162

P-86268

Remove the fill cap (Item 1) [Figure 164].

1

Put the correct amount of oil in the engine. (See Capacities on Page 158.)

Install the fill cap.

P-86924

Start the engine and let it run for several minutes.

Remove the plug (Item 1) [Figure 162] from the engine oil pan. Drain the oil into a container.

Stop the engine. Check for leaks at the oil filter. Check the oil level.

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

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

Reinstall the access cover (Item 3) [Figure 161] and tighten the bolts.

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

Cleaning Figure 166

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

Figure 165

MA X

1

MIN

1

P-86273

Check the coolant level in the coolant recovery tank (Item 1) [Figure 166].

P-86279

The coolant level must be between the MIN and MAX marks on the coolant recovery tank (Item 1) [Figure 166] when the engine is cold.

Use air pressure or water pressure to clean the radiator, oil cooler and the air conditioning condenser (Item 1) [Figure 165]. Be careful not to damage fins when cleaning.

NOTE: The cooling system is factory filled with ethylene glycol. DO NOT mix ethylene glycol with propylene glycol.

NOTE: Allow the cooling system and engine to cool before servicing or cleaning the cooling system.

Checking Level

IMPORTANT

WARNING

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

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

You can be seriously burned.

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

W-2070-1203

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

WARNING

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

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.

I-2124-0497

W-2019-0907

Open the right side cover.

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ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant Figure 168

See the SERVICE SCHEDULE for correct service intervals. (See SERVICE SCHEDULE on Page 97.)

Stop the engine. Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

1

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

You can be seriously burned.

W-2070-1203 P-86275

Figure 167

Open the drain valve (Item 1) [Figure 168] (located below the oil filter) and drain the coolant into the container.

After all the coolant is removed, close the drain valve.

1

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

Mix the coolant in a separate container. (See Capacities on Page 158.)

NOTE: The cooling system is factory filled with ethylene glycol. DO NOT mix ethylene glycol with propylene glycol.

P-86274

When the engine is cool, loosen and remove the radiator cap (Item 1) [Figure 167].

The correct mixture of coolant to provide a -37°C (-34°F) freeze protection is 4 L ethylene glycol mixed with 4 L of water OR 1 U.S. gal ethylene glycol mixed with 1 U.S. gal of water.

Rotate the upperstructure 90° to access the lower engine access cover. Remove the lower engine access cover so coolant can be drained into a container.

Add premixed coolant; 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low.

Run the engine until it is at operating temperature. Stop the engine. Check the coolant level and add as needed.

Be sure the radiator cap is tight.

Add coolant to the recovery tank as needed.

Reinstall the lower engine access cover.

Close the right side cover.

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ELECTRICAL SYSTEM Description

Fuse And Relay Location / Identification

Figure 169

A decal is on the cover to show location and amp ratings.

Remove the cover to check or replace the fuses.

Figure 170

1

1

2

3

4

5

6

9

10

11

12

13

14

7

8

P-86276

The excavator has a 12 volt, negative ground electrical system. The electrical system is protected by fuses located below the operator’s seat (Item 1) [Figure 169].

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.

B-23955

The fuse location and sizes are shown [Figure 170] and in the below chart.

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.

REF

DESCRIPTION

AMP

1 2 3 4

Warning Light, Motion Alarm Two-Speed, Console Lock, Cab Light Wiper, Washer Stereo, ECU, Air Conditioning Control Panel Instrument Panel Horn, Breaker Switch, Beacon / Strobe Light EGR Valve Starter Can Checker Power Plug Condenser Fan, Compressor Clutch Air Conditioner / Heater Fuel Pump, Hour Meter Work Light, Boom Light

10 10 10 10

5 6

WARNING

7 8 9 10 11 12 13 14

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.

10 10 10 10 15 15 20 20 20 30

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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ELECTRICAL SYSTEM (CONT’D) Fuse And Relay Location / Identification (Cont’d) Figure 172

Figure 171

1

2

3

4

5

6

7

8

9 10

1 11

12

2 3 P-86907

P-86246

The relays are shown in [Figure 171] and [Figure 172] and in the below chart. The relays are located behind the access panel that is located behind the operator’s seat.

A 60 amp circuit breaker (Item 1) and two fusible links (Item 2) 27 amp and (Item 3) [Figure 171] 45 amp are located under the front centre cover.

The 27 amp fusible link (Item 2) is for the start circuit and the 45 amp fusible link (Item 3) [Figure 171] is for the preheat circuit.

REF

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12

Breaker Switch Horn Lights (Boom) Blower (3) (High) Blower (2) (Med) Blower (1) (Lo) Compressor Additional Lights (Cab Work Lights) Rack (Speed Control) Main Preheat Starter

NOTE: Relays (Item 11 and 12) [Figure 171] are located under the centre cover.

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ELECTRICAL SYSTEM (CONT’D) Battery Maintenance Figure 174

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

Figure 173

1

2

1 P9589

P9590

The battery cables must be clean and tight [Figure 174].

Remove acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery saver grease to prevent corrosion.

P-92919

The battery is located in the right front corner of the machine.

Remove the two bolts and washers (Item 1), the retaining plate (Item 2) [Figure 173].

Check for broken or loose connections.

If the battery cables are removed for any reason, disconnect the negative (-) cable first. When installing the battery cables, make the last connection the negative (-) cable to the battery.

The original equipment battery is maintenance free. If a replacement battery is installed, check the electrolyte level in the battery.

If the electrolyte level is lower than 13 mm (0.50 in) above the plates, add distilled water only.

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.

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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ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting) NOTE: (See Cold Temperature Starting on Page 63.)

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.

IMPORTANT

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

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 excavator.

(Remove both cables from the battery.)

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

Open the right side cover.

Figure 175

I-2223-0903

WARNING

1

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.

P-86284

Figure 176 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

2

P-86285

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 175] of the battery.

Connect one end of the second cable to the negative (-) terminal of the booster battery. Connect the other end of the same cable to bolt (Item 2) [Figure 176] where the flywheel cover fastened to the engine.

Start the engine. After the engine has started, remove the ground (-) cable first (Item 2) [Figure 175].

Disconnect the cable from the battery (Item 1) [Figure 175].

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ELECTRICAL SYSTEM (CONT’D) Removing And Installing Battery Figure 178

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

Figure 177

1

2 1

1 1

1

5 3

5

4

6 2 P-92918

2 2 3

P-86287

Disconnect the negative (-) cable (Item 3) [Figure 178] first.

Remove the three plugs (Item 1) [Figure 177] and the bolts and washers.

Disconnect the positive (+) cable (Item 4) [Figure 178].

Loosen the three bolts (Item 2) and remove the cover (Item 3) [Figure 177].

Remove the two nuts (Item 5) and remove the hold-down clamp (Item 6) [Figure 178].

NOTE: There may be washers used as shims between the bolts (Item 2), the upperstructure and the cover (Item 3) [Figure 177].

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 3) [Figure 178] last to prevent sparks.

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.

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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HYDRAULIC SYSTEM Checking And Adding Hydraulic Oil Figure 180

Put the machine on a level surface.

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

3

3 Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

3

3

Figure 179 2

1

3

3

2

P-86906

2

Open the rear cover. (See REAR COVER on Page 103.)

1

NOTE: When removing the cover (Item 2), there is spring pressure under the cover. Push down on the cover while removing the bolts (Item 3) [Figure 180].

P-86295

Clean the surface around the reservoir (breather) cap (Item 1) and cover (Item 2) fully. Press down on the cover (Item 2) and remove the six bolts (Item 3) from the cover (Item 2) [Figure 180]. Remove the cover.

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) between the two red lines (Item 2) [Figure 179].

Add the correct fluid to the reservoir until it is visible in the sight gauge. (See LUBRICANTS AND FLUIDS on Page 8.)

WARNING

Check the O-ring under the cover (Item 2) [Figure 180].

Replace the O-ring if damaged.

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.

Reinstall the cover and align the bolt holes. Press down on the cover (Item 2) and install the six bolts (Item 3) [Figure 180]. Tighten the bolts.

W-2103-0508

Close the rear cover.

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HYDRAULIC SYSTEM (CONT’D) Hydraulic / Hydrostatic Fluid Chart Figure 181 RECOMMENDED ISO VISCOSITY GRADE (VG) AND VISCOSITY INDEX (VI)

TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE [1] Synthetic Fluid; VG 46; Minimum VI 150 [2] BOBCAT Hydraulic / Hydrostatic Fluid Use the correct hydraulic fluid shown in chart [Figure 181].

Add hydraulic fluid as needed to bring the level to the centre of sight gauge (Item 1) [Figure 179].

Reinstall the cover and align the bolt holes. Press down on the cover (Item 2) and install the four bolts (Item 3) [Figure 180]. Tighten the bolts.

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HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Filters Hydraulic Return Filter Figure 183

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.

1

W-2103-0508

2

See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Open the rear cover. (See REAR COVER on Page 103.)

P-86301

Figure 182 Remove the spring (Item 1) [Figure 183].

1

Inspect the O-ring (Item 2) [Figure 183] for damage.

Replace if damaged.

1

1

Figure 184

2 1

1 1

P-86906

1 NOTE: When removing the cover (Item 2), there is spring pressure under the cover. Push down on the cover while removing the bolts (Item 1) [Figure 182].

P-86302

Clean the surface around the cover (Item 2) [Figure 182] fully.

Remove the valve (Item 1) [Figure 184].

Press down on the cover (Item 2) and remove the six bolts (Item 1) [Figure 182] and remove the cover.

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HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Filters (Cont’d) Hydraulic Return Filter (Cont’d)

Hydraulic Suction Filter

Figure 185

Open the rear cover.

Figure 186

3

3

3

3 1

2

1

3

3

P-86303

P-86906

Remove the return filter (Item 1) [Figure 185].

NOTE: When removing the cover (Item 2), there is spring pressure under the cover. Push down on the cover while removing the bolts (Item 3) [Figure 186].

Install the new filter (Item 1) [Figure 185].

Reinstall the valve (Item 1) [Figure 184].

Reinstall the spring (Item 1) [Figure 183].

Clean the surface around the reservoir (breather) cap (Item 1) and cover (Item 2) fully. Remove the four bolts (Item 3) from the cover (Item 2) [Figure 186] and remove the cover.

Reinstall the cover and align the bolt holes. Press down on the cover (Item 2) and install the four bolts (Item 1) [Figure 182] and tighten the bolts.

Figure 187

2

1

P-86300

Remove the spring (Item 1) [Figure 187].

Lift up on the rod (Item 2) [Figure 187].

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HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Filters (Cont’d) Hydraulic Suction Filter (Cont’d)

Hydraulic Breather Filter

Figure 188

See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Open the rear cover. (See REAR COVER on Page 103.)

Figure 189

1

2 1 P-87308

Continue to lift up on the rod (Item 1) until the filter (Item 2) [Figure 188] is removed from the tank.

P-86906

NOTE: Before removing the filter (Item 2) [Figure 188] from the rod (Item 1) [Figure 188], measure the distance from the end of the rod to the end of the filter. Install the new filter to the same measured distance so that the spring (Item 1) [Figure 187] pressure will keep the filter installed correctly in the tank.

Remove the filter cap (Item 1) [Figure 189] by turning the cap anticlockwise.

Figure 190

NOTE: When installing the new filter (Item 2) [Figure 188] into the hydraulic tank, make sure to get the filter positioned over the outlet port at the bottom of the hydraulic tank.

1

P-86296

Remove and replace the breather filter (Item 1) [Figure 190].

Reinstall the cap (Item 1) [Figure 189].

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HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Figure 192

WARNING

1

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 doctor familiar with this injury.

2

P-86317

W-2072-EN-0909

Rotate the cover plate (Item 1) [Figure 192] to access the bottom of the hydraulic tank.

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

Open the rear cover. (See REAR COVER on Page 103.)

Remove the drain plug (Item 2) [Figure 192] from the bottom of the hydraulic tank.

Figure 191

Drain the fluid into a container.

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

1

1

Reinstall the drain plug (Item 2) [Figure 192].

Always replace the filters when changing the hydraulic oil. (See Removing And Replacing Hydraulic Filters on Page 122.)

1

2

P-86316

From below the rear of the excavator upperstructure, remove three bolts (Item 1) and loosen the fourth bolt (Item 2) [Figure 191].

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HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid (Cont’d)

Checking Swing Motor Gear Box Fluid Level

Figure 193

Figure 194

2 1 1

P-86927

P-86904

After the hydraulic fluid has been drained from the excavator or after the hydraulic pump has been serviced, the hydraulic pump must be flooded with hydraulic oil.

Allow sufficient time for the hydraulic fluid to gravity feed into the hydraulic pump before starting the machine.

Open the centre cover to access the swing motor.

Remove the vent plug (Item 1) [Figure 193] to see if hydraulic fluid is at the plug opening. If oil is present the pump has been flooded. Reinstall the vent plug.

Keep the oil level between the marks on the dipstick.

The swing motor gear box (Item 1) has a dipstick (Item 2) [Figure 194] for checking the swing motor gear box oil level.

Removing And Replacing Swing Motor Gear Box Fluid

If fluid is not at the plug opening, install the plug (Item 1).

Start the engine and run at low idle for one minute. Stop the engine. Remove the vent plug (Item 1) [Figure 193] and verify fluid is at the plug opening. Reinstall plug before operating.

Figure 195

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

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

1

Install new Bobcat hydraulic fluid. (See Hydraulic / Hydrostatic Fluid Chart on Page 121.) (See REGULAR MAINTENANCE ITEMS on Page 7.)

P-87254

The swing motor carrier drain plug is located below the engine area by the hydraulic tank drain plug.

Remove the plug (Item 1) [Figure 195] and drain the swing motor carrier. Reinstall the drain plug.

Remove the dipstick (Item 2) [Figure 194] and add gear lube (80W-90) until it is at the correct mark on the dipstick. (See REGULAR MAINTENANCE ITEMS on Page 7.)

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SPARK ARRESTER MUFFLER Cleaning Procedure See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Figure 196

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

1

W-2050-0807 P-91994

WARNING

Remove the plug (Item 1) [Figure 196] from the bottom of the muffler.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles.

Failure to obey can cause serious injury.

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. The carbon deposits will be forced out of the muffler plug hole (Item 1) [Figure 196].

W-2011-1285

Stop the engine. Install and tighten the plug.

WARNING

Close the right side cover.

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

W-2068-1285

WARNING When the engine is running during service, the steering levers must be in neutral.

Failure to do so can cause injury or death.

W-2203-0595

Do not operate the excavator with a defective exhaust system.

Stop the engine. Open the tailgate.

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TRACK TENSION NOTE: The wear of undercarriage parts vary with working conditions and types of soil conditions. Maintain the correct track tension by inspecting regularly. For the correct service interval (See SERVICE SCHEDULE on Page 97.)

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

Adjusting

W-2142-0903

Figure 197 Rubber Track Clearance Figure 199

10 - 15 mm (0.39 - 0.59 in) P-86926

Raise one side of the machine (approximately 101,6 mm [4 in]) using the boom and arm [Figure 197].

P-86332

Figure 200

Figure 198

Track Frame Track Frame

10 - 15 mm (0.39 - 0.59 in) 1

1 Track Track Roller Roller

P-86328A

Raise the blade fully and install jackstands under the blade and track frame (Item 1) [Figure 198]. Lower the boom until all machine weight is on the jackstands.

Track Track B-14067

Stop the engine.

Measure the clearance at the middle track roller. Do not get fingers into pinch points between the track and the track roller. Use a bolt or a dowel of the appropriate size to check the gap between the contact edge of the roller and the top edge of the track guide [Figure 199] and [Figure 200].

Rubber Track Clearance - 10 - 15 mm (0.39 - 0.59 in).

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TRACK TENSION (CONT’D) Adjusting (Cont’d) Steel Track Clearance Figure 202

Figure 201

1

2

Track Frame Frame Track

A

2

Track Track

1 B-15022

P-86333A

NOTE: The track tension grease fitting (Item 1) is installed into the end of the bleed fitting (Item 2). DO NOT loosen the grease fitting (Item 1), loosen the bleed fitting (Item 2) [Figure 202] ONLY (maximum of 1-1/2 turns) when releasing track pressure.

Measure the track clearance “A” at the middle track roller.

Do not get fingers into pinch points between the track and the track roller. Check the gap between the bottom edge of the track frame and the top surface of the track [Figure 201].

TERRAIN TYPE

DIMENSION “A”

Soil

140 - 150 mm (5.51 - 5.91 in)

Gravel, Sand, Soft Soil

150 - 160 mm (5.91 - 6.30 in)

Rock Bed

120 - 130 mm (4.72 - 5.12 in)

Add grease to the fitting (Item 1) [Figure 202] until the track tension is correct.

To release track pressure, loosen the bleed fitting (Item 2) [Figure 202] to release tension from the track.

NOTE: Do not loosen the grease fitting (Item 1) [Figure 202].

Repeat the procedure for the other side.

WARNING • •

HIGH PRESSURE GREASE CAN CAUSE SERIOUS INJURY Do not loosen grease fitting.

Do not loosen bleed fitting more than 1 - 1/2 turns.

W-2781-0109

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TRAVEL MOTOR Checking And Adding Oil

Removing And Replacing Oil

Figure 203

For the correct service SCHEDULE on Page 97.)

interval

(See

SERVICE

Park the excavator on a level surface with plugs (Item 1, 2 and 3) in the position shown. Remove plugs (Item 2 and 3) [Figure 203] and drain the lubricant into a container.

2 1

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.

3

P-86327

W-2103-0508

Park the excavator on a level surface with the plugs (Item 1, 2 and 3) [Figure 203] in the position as shown.

Install the bottom plug (Item 3). Add lubricant (80W-90) through the top plug (Item 2) until the lube level is at the bottom edge of the plug hole (Item 1) [Figure 203].

Remove the plug (Item 1) [Figure 203]. The lube level must be at the bottom edge of the hole.

Install the plugs (Item 1 and 2) [Figure 203].

Add lubricant (80W-90) through [Figure 203] if the lube level is low.

hole

(Item

2) Repeat the procedure for the opposite travel motor.

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ALTERNATOR BELT Belt Adjustment

Belt Replacement

See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Figure 206

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

Figure 204 1

1 P-86293

Loosen the alternator mounting bolt (located below the alternator). Loosen the bolt (Item 1) [Figure 206].

Remove the old belt and install a new belt.

P-86293

When belt tension is correct, tighten the alternator bolts.

Loosen the alternator mounting bolt (located below the alternator). Loosen the bolt (Item 1) [Figure 204].

WARNING

Figure 205 • • •

AVOID INJURY OR DEATH Do Not Operate with damaged or missing screens, shields or rubber deflectors.

Stop engine before cleaning or servicing.

Contact with moving parts or flying objects can cause injury or death.

W-2528-0406

P-86292

Press down on the belt midway between the fan pulley and the alternator pulley. The correct tension should allow the belt to deflect 10 mm (0.375 in) [Figure 205].

When belt tension is correct, tighten the alternator bolts.

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AIR CONDITIONING BELT Belt Adjustment See the SERVICE SCHEDULE for the correct service interval. (See SERVICE SCHEDULE on Page 97.)

Figure 209

Open the right side cover. (See RIGHT SIDE COVER on Page 103.)

2

Figure 207

1

3 2 3

1

P-86920

Press down on the belt midway between the crankshaft pulley and the compressor pulley. The correct tension should allow the belt to deflect 10 mm (0.375 in) [Figure 209].

P-86922

Loosen the lock nut (Item 1) and adjust the bolt (Item 2) [Figure 209] until the belt tension is correct.

The air conditioning belt will be adjusted using the bolt (Item 1) [Figure 207].

When belt tension is correct, tighten the lock nut (Item 1) [Figure 209].

Figure 208

Tighten the belt idler mounting bolt (Item 1) [Figure 208].

Reinstall the shield (Item 2) and the two bolts and washers (Item 3) [Figure 207].

1

WARNING • • •

P-86921

AVOID INJURY OR DEATH Do Not Operate with damaged or missing screens, shields or rubber deflectors.

Stop engine before cleaning or servicing.

Contact with moving parts or flying objects can cause injury or death.

W-2528-0406

NOTE: Belt shield removed for photo clarity in the following two photos.

Loosen the belt idler mounting bolt (Item 1) [Figure 208].

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AIR CONDITIONING BELT (CONT’D) Belt Replacement Figure 210

Figure 212

1 2 2

1

P-86922

P-86920

Remove the two bolts and washers (Item 1) and remove the shield (Item 2) [Figure 210].

Loosen the lock nut (Item 1) and the bolt (Item 2) [Figure 212] until the belt can be removed.

Figure 211

Install a new belt.

Adjust the bolt (Item 2) until the belt tension is correct.

Tighten the lock nut (Item 1) [Figure 212].

Tighten the belt idler mounting bolt (Item 1) [Figure 211].

1 Reinstall the shield (Item 2) and the two bolts and washers (Item 1) [Figure 210].

WARNING P-86921

• • •

Loosen the belt idler mounting bolt (Item 1) [Figure 211].

AVOID INJURY OR DEATH Do Not Operate with damaged or missing screens, shields or rubber deflectors.

Stop engine before cleaning or servicing.

Contact with moving parts or flying objects can cause injury or death.

W-2528-0406

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ATTACHMENT Pin-On Inspection And Maintenance

Quick Coupler And Attachment Inspection And Maintenance

Figure 213 Figure 215 2 2 2

2 2

1

1 1

P-86252 P-72274

Inspect the bucket pins (Item 1) and hardware (Item 2) [Figure 213] for wear or damage. Inspect the bucket (on the attachment) for wear or damage.

Inspect the quick coupler for wear or damage. Inspect the quick coupler pins (Item 1) and the hooks (Item 2) [Figure 215] (on the attachment) for wear or damage

Repair or replace damaged parts.

Repair or replace damaged parts.

Figure 214

1

1 P-86254

Inspect the four O-ring seals (Item 1) [Figure 214] for wear or damage.

Repair or replace damaged or missing parts.

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TRACK ROLLER AND IDLER LUBRICATION Procedure The track rollers and idlers require no maintenance. The bearings are a sealed design.

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BUCKET Bucket Teeth Removal And Installation Pin-On Buckets Figure 217

WARNING 2 Wear safety glasses to prevent eye injury when any of the following conditions exist: • Pressurised fluids and springs or other stored energy components.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

1

W-2505-EN-1009

Position the bucket so the bucket teeth are at a 30° angle up from the ground for accessibility to the teeth. Install a block under the bucket.

P-87320

Removal: Use a punch and a hammer and drive the retainer pin (Item 1) down and out the bottom of the tooth (Item 2) [Figure 217]. Remove the tooth from the shank.

Lower the boom until the bucket is fully on the ground and resting on the block.

Stop the engine and exit the excavator.

Figure 218 Figure 216 2 1

2

1

3

P-87316 P-87315

Remove the rubber retainer (Item 1) from the shank (Item 2) [Figure 218].

The bucket tooth (Item 1) has a unique retaining pin (Item 2) and rubber retainer (Item 3). The retaining pin (Item 2) must be installed as shown with the notch towards the rubber retainer (Item 3). The rubber retainer (Item 3) [Figure 216] will be installed into the shank before the tooth is installed on the shank.

Installation: Install the rubber retainer (Item 1) into the tooth shank (Item 2) [Figure 218].

Position the new tooth point (Item 2) [Figure 217] on the shank (Item 2) [Figure 218].

Install the retainer pin (Item 1) [Figure 218] until it is flush with the top of the tooth.

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LUBRICATION OF THE HYDRAULIC EXCAVATOR Lubrication Locations Figure 220

Lubricate the excavator as specified in the SERVICE SCHEDULE for the best performance of the machine.

(See SERVICE SCHEDULE on Page 97.)

Record the operating hours each time you lubricate the excavator.

4

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

Figure 219

1 P-86309

3

3

4. Boom Cylinder Base End (1) [Figure 220] Figure 221

5

2 P-86313

Ref Description (# of Fittings)

5

1. Blade Cylinder Rod End (1) 6 2. Blade Cylinder Base End (1) 3. Blade Pivots (2) [Figure 219]

P-86310

5. Boom Swing Pin (2) 6. Boom Swing Cylinder Rod End (1) [Figure 221]

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LUBRICATION OF THE HYDRAULIC EXCAVATOR (CONT’D) Lubrication Locations (Cont’d) Figure 222

Figure 224

7

9

P-86311

P-86308

7. Boom Pivot (1) [Figure 222]

9. Arm Cylinder Base End (1) [Figure 224]

Figure 223

Figure 225

10

8

P-87302A

P-86307

8. Boom Cylinder Rod End (1) [Figure 223]

10. Arm Pivot (1) [Figure 225]

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LUBRICATION OF THE HYDRAULIC EXCAVATOR (CONT’D) Lubrication Locations (Cont’d) Figure 226

Figure 228

11

15 12

15

16 P-86306

P-86304

11. Arm Cylinder Rod End (1)

15. Link Pivot Pin (2)

12. Bucket Cylinder Base End (1) [Figure 226]

16. Arm (1) [Figure 228]

Figure 227

Figure 229

20

13

19

18 17

14

P-86305

P-86905

13. Bucket Cylinder Rod End (1)

Lubricate the following locations on the hydraulic Excavator per the SERVICE SCHEDULE for the correct lubrication intervals. (See SERVICE SCHEDULE on Page 97.)

14. Bucket Link (1) [Figure 227]

17. Boom Swing Cylinder Base End (1) 18. Swing Motor Reduction Gear (1) 19. Slew Circle Bearing (1) 20. Slew Pinion (1). (Install 3 - 4 pumps of grease then rotate the upperstructure 90°. Install 3 - 4 pumps of grease and again rotate the upperstructure 90°.

Repeat this until the slew pinion has been greased at four positions.) [Figure 229].

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PIVOT PINS Inspection And Maintenance Figure 230

1

1

1

P-86923

The boom, arm and cylinders pivots have a large pin (Item 1) [Figure 230] held in position with a bolt and nut.

Check that the bolt and nut are securely tightened and are not damage. See your Bobcat dealer for replacement parts.

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EXCAVATOR STORAGE AND RETURN TO SERVICE Storage

Return 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.

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

•

Thoroughly clean the excavator including the engine compartment.

•

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

•

Lubricate the excavator.

•

Install a fully charged battery.

•

Replace worn or damaged parts.

•

Remove grease from exposed cylinder rods.

•

Drive the excavator onto planks in a dry protected shelter.

•

Check all belt tensions.

•

Be sure all shields and guards are in place.

•

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

•

Lubricate the excavator.

•

Remove cover from exhaust pipe opening.

•

Put grease on any exposed cylinder rods.

•

•

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

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

•

Drive the excavator off of the planks.

•

Operate machine, check for correct function.

•

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

If biodiesel fuel has been used, perform the following:  Drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabiliser 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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SYSTEM SETUP AND ANALYSIS DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 FLASHING PATTERNS OF ENGINE CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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DIAGNOSTIC SERVICE CODES Service Codes List The error codes will be displayed on the instrument panel as a flashing light sequences on icon (Item 1) [Figure 231].

Figure 231

See the following chart for the codes, the conditions and the flashing sequence.

Flash Examples: (4) 4 long flashes, (4-1) four long flashes followed by one short flash, (4-4) four long flashes followed by four short flash.

See [Figure 231] for additional information on following the flashing code sequence.

1

P-86955A

FLASHES

ITEM

CONDITIONS

OPERATION WHEN FAILURE OCCURS

ACTION

4

Coolant temperature sensor failure

Sensor voltage is 4.8 V or more, or 0.2 V or less.

Engine runs with a coolant temperature of Correct 30°C failure.

5

Accelerator sensor failure

Sensor voltage is 4.6 V or more, or 0.2 V or less.

[Without optional back-up accelerator Correct sensor] failure.

Engine runs at 1500 rpm. (Option can change) [With optional back-up accelerator sensor] Select back-up accelerator sensor: No limitation Back-up accelerator sensor failure: Engine runs at 1500 rpm. (Option can change)

6

Speed sensor failure

Engine start signal (E8) is on, but [With optional back-up speed sensor] Turn key the engine speed is zero.

Back-up speed sensor becomes active; OFF. speed is limited to 1800 rpm.(Option can Engine speed decreases by 480 change) rpm or more in 40 ms.

Back-up speed sensor failed: Engine stops. [Without optional back-up speed sensor] Engine stops.

7

Rack position sensor failure

Correlation between rack actuator Engine runs with limited output and speed. Turn key output and rack position exceeds (Rack position control is inactive and speed OFF. threshold upper limit by 0.32 control is active). seconds or more.

Correlation between rack actuator output and rack position exceeds threshold upper limit by 0.16 seconds or more.

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DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) FLASHES

ITEM

8

Rack actuator failure

CONDITIONS

OPERATION WHEN FAILURE OCCURS

Rack actuator current is too high. Engine stops.

ACTION Turn key OFF.

Rack actuator current is too low.

Engine accelerates with minimum rack actuator output Engine stalls while rack position sensor is failed.

9

Over speed

Idling engine speed exceeds high Engine stops. idling speed plus 600 rpm.

Turn key OFF.

1-1

Back-up speed Engine start signal (E8) is on, but Engine continues to run while main speed Turn key sensor failure the engine speed is zero. sensor is used.

OFF. Back-up speed sensor failed: Engine stops.

Engine speed decreases by 480 rpm or more in 40 ms.

1-2

CAN communication packets CAN communication cannot be received. failure

Last value is retained. Back-up sensor becomes active.

1-3

EGR valve failure

Engine runs with limited output (92%) and Turn key speed (1800 rpm) OFF.

Low status is detected even though port is off.

Correct failure.

High status is detected even though port is on.

1-4

CSD solenoid valve failure

High status is detected even though port is off.

Engine continues to run with port being off. Turn key OFF.

Low status is detected even though port is on.

1-5

Air heater relay High status is detected even failure though port is off.

Engine runs with air heater relay being off. Turn key OFF.

Low status is detected even though port is on.

1-6

Main relay failure

Power is not shut off even though Engine runs normally. main relay is off.

Correct failure. Or turn key OFF.

1-7

Rack actuator relay failure

Low status is detected even though port is off.

Engine stops.

Turn key OFF.

High status is detected even though port is on.

1-8

Back-up accelerator sensor failure

Sensor voltage is 4.6 V or more, or 0.2V or less.

Engine continues to run while main accelerator sensor is used.

Main accelerator sensor failure: Engine runs at 1500 rpm. (Option can change)

Correct failure.

1-9

Atmospheric pressure sensor failure

Sensor voltage is 4.6 V or more, or 0.2 V or less.

Atmospheric pressure compensation is canceled.

Turn key OFF.

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DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) FLASHES

ITEM

2-1

Oil pressure switch failure

2-2

Charge switch Charge switch fails to turn on failure when engine is off.

Engine runs normally.

Turn key OFF.

2-3

Power supply voltage abnormal

E-ECU supply voltage exceeds 10.0 V.

Engine runs normally.

Correct failure.

Sensor 5V failure

Monitoring voltage is approx. 0 V. Engine runs normally.

Turn key OFF.

2-4

CONDITIONS

OPERATION WHEN FAILURE OCCURS

ACTION

Oil pressure switch fails to turn on Engine runs normally. (Option can change) Turn key when engine is off.

OFF.

E-ECU supply voltage exceeds 16.0 V. Monitoring voltage is 4.5 V or less.

Monitoring voltage is 5.5 V or more.

2-5

E-ECU E-ECU temperature exceeds Engine runs normally. (Option can change) Correct overheat alarm 105°C. failure.

Alarm is canceled when E-ECU temperature decreases to 100°C. (option can change)

3-1

Oil pressure low

3-2

Charge failure Charge switch fails to turn off when engine is running.

3-3

Coolant temperature abnormal

3-4

Air cleaner Air cleaner switch turns on. blockage alarm

Engine runs normally. (Option can change) Turn key OFF.

3-5

Oily water separator alarm

Oily water separator switch turns on.

Engine runs normally. (Option can change) Turn key OFF.

3-6

Coolant temperature high alarm

Coolant temperature is 115°C or Engine runs normally. higher. alarm is canceled when Coolant temperature decreases to 110°C. (Option can change)

4-1

E-ECU failure Flash ROM suffers checksum [ROM error] error.

4-1

E-ECU failure Reading /Writing fails.

Engine runs normally.

[EEPROM EEPROM suffers checksum error. error]

Turn key OFF.

4-1

E-ECU failure E-ECU fails to communicate with [EEPROM sub CPU. failure]

Engine runs normally.

Turn key OFF.

4-1

E-ECU failure Map format is invalid.

[Mapping error]

Engine stops.

Turn key OFF.

4-1

E-ECU failure Sensor voltage is 4.6 V or more, or 1.0 V or less.

[E-ECU temperature sensor failure]

Engine runs normally.

Correct failure.

Oil pressure switch fails to turn off Engine runs normally. (Option can change) Correct when engine is running. failure.

Engine runs normally.

Coolant temperature switch turns Engine runs normally. (Option can change) Turn key on.

OFF.

Engine stops.

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Turn key OFF.

Correct failure.

Turn key OFF.

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FLASHING PATTERNS OF ENGINE CHECK LAMP When detecting these failures, the E-ECU (Engine control unit) flashes the engine check lamp to alert the operator to the occurrence of failure conditions. The engine check lamp will illuminate for 2 seconds when the E-ECU is power on. This allows checking if the E-ECU is supplied with power normally.

Flashing patterns of the engine check lamp are shown in [Figure 231]. When accelerator sensor failure (flashing 5 time) and EGR valve failure (flashing 1 - 3 times) occur, the engine check lamp flashes as shown in [Figure 231]. When two or more failures have occurred simultaneously, the engine check lamp scrolls through all the failure modes, then repeats.

Figure 232

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SPECIFICATIONS EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 (E80) Excavator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 (E80) Excavator Machine Dimensions - Standard Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 152 (E80) Excavator Machine Dimensions - Long Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 (E80) Rated Lift Capacity - Standard Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 (E80) Rated Lift Capacity - Long Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s) are provided for comparison purposes only and are subject to change without notice. Specification(s) for your individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions, and other factors.

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EXCAVATOR SPECIFICATIONS (E80) Excavator Dimensions •

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

70°

55°

6167 mm (242.8 in)

2266mm (89.2 in) 1030 mm (40.5 in)

1370 mm (54.0 in)

923 mm (36.3 in)

1298 mm (51.1 in)

4797 mm (188.8 in)

737 mm (29.0 in)

2605 mm (102.6 in)

450 mm (17.7 in) 1850 mm (72.8 in)

2085 mm (82.1 in)

648 mm (25.5 in) 362 mm (14.3 in)

2200 mm (86.6 in) 2850 mm (112.2 in)

2300 mm (90.6 in)

3282 mm (129.2 in)

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410 mm (17.6 in) 1912 mm (75.3 in)

446 mm (17.3 in)

MS2791

E80 Operation & Maintenance Manual

EXCAVATOR SPECIFICATIONS (CONT’D) (E80) Excavator Machine Dimensions - Standard Arm •

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

2500 mm (98.4 in)

6715 mm  (264.4 in)

4720 mm (185.8 in)

3220 mm (126.7 in)

4150 mm (163.4 in)

6965 mm (274.2 in) MS2792A

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EXCAVATOR SPECIFICATIONS (CONT’D) (E80) Excavator Machine Dimensions - Long Arm •

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

2700 mm (106.3 in)

7070 mm (278.3 in)

5085 mm (200.2 in)

3730 mm (146.9 in)

4675 mm (184.0 in)

7480 mm (294.5 in) MS2792A

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EXCAVATOR SPECIFICATIONS (CONT’D) (E80) Rated Lift Capacity - Standard Arm

7169000-V

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EXCAVATOR SPECIFICATIONS (CONT’D) (E80) Rated Lift Capacity - Long Arm

7169015-V

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EXCAVATOR SPECIFICATIONS (CONT’D) Performance Operating weight w/ cab, steel tracks and 610 mm (24 in) bucket

8380 kg (18475 lb)

If equipped with long arm, add:

60 kg (133 lb)

Travel Speed

Low Range 2,9 km/h (1.8 mph) High Range 4,6 km/h (2.9 mph)

Digging Force (per ISO 6015) Arm (Standard) Arm (Long Arm Option) Bucket

40855 N (9185 lbf) 34068 N (7659 lbf) 54623 N (12280 lbf)

Boom Swing (Offset)

Left 70° Right 55°

Controls Steering

Two hand levers or foot pedals.

Hydraulics

Two hand operated levers (joysticks) control boom, bucket, arm and upperstructure slew.

Auxiliary Hydraulics Auxiliary Pressure Release

Electric switch in right joystick, right pedal and electric switches in left joystick (if equipped) Right pedal and electric switches in left joystick (if equipped)

Engine

Engine speed control dial, key type start switch

Starting Aid Brakes Travel Service & Parking Swing Service Holding

Air Intake Heater - activated by key switch

Hydraulic lock in motor circuit Automatically applied slew brake integrated in slew motor Automatically applied slew brake integrated in slew motor

Engine Make / Model

Yanmar 4TNV98-ESDB8

Fuel / Cooling

Diesel / Liquid (Antifreeze mixture)

Horsepower (SAE Gross) Torque

40.7 kW (54.6 hp) 223 - 243 N•m (164.5 - 179.1 ft-lb) @ 1300 rpm

Number Of Cylinders

4

Displacement

3.319 L (202.5 in3)

Bore / Stroke

98 x 110 mm (3.85 x 4.33 in)

Lubrication

Pressure System with Filter

Crankcase Ventilation

Closed Breather

Air Cleaner

Dual dry replaceable paper cartridges

Ignition

Diesel Compression

Low Idle

1050 rpm

High Idle

2150 rpm

Engine Coolant

Ethylene Glycol / water mixture (50% EG / 50% water)

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EXCAVATOR SPECIFICATIONS (CONT’D) Hydraulic System Pump Type

Engine driven, variable displacement dual piston pump with pressure compensating, load sensing and torque limiter controls.

Two gear pumps.

Piston Pump Capacity

70 Lpm (2 @ 18.5 U.S. gpm)

Gear Pump Capacity

70 Lpm (18.5 U.S. gpm)

Gear Pump Capacity

9,9 Lpm (2.6 U.S. gpm)

Auxiliary Flow

120 Lpm (31.7 U.S. gpm)

Control Valve

12 spool closed centre

System Relief Pressure Travel Circuits

27503 kPa (275 bar) (3989 psi)

Slew Circuit

21601 kPa (216 bar) (3133 psi)

Boom, Arm, Bucket, Boom Swing, Blade, Auxiliary Hydraulics

29503 kPa (295 bar) (4279 psi)

Joystick Control Pressure

2944 kPa (29,4 bar) (427 psi)

Arm Port Relief, Base And Rod End

30999 kPa (310 bar) (4496 psi)

Boom Port Relief, Base End And Rod End

30999 kPa (310 bar) (4496 psi)

Bucket Port Relief, Base End Rod End

30999 kPa (310 bar) (4496 psi)

Primary Auxiliary Port Relief

21001 kPa (210 bar) (3046 psi)

Secondary Auxiliary Port Relief (If Equipped)

25000 kPa (250 bar) (3626 psi)

Swing Motor Cross Port Relief Valves

21994 kPa (220 bar) (3190 psi)

Hydraulic Filter Bypass

145 kPa (1,5 bar) (21 psi)

Hydraulic Cylinders Cylinder

Bore

Rod

Stroke

Boom (cushion up)

115 mm (4.52 in)

75 mm (2.95 in)

775 mm (30.51 in)

Arm

100 mm (3.94 in)

65 mm (2.56 in)

866 mm (34.88 in)

Bucket (cushion extend / retract)

85 mm (3.35 in)

55 mm (2.17 in)

690 mm (27.17 in)

Boom Swing (cushion left/ right)

110 mm (4.33 in)

60 mm (2.36 in)

738 mm (29.05 in)

Blade

100 mm (3.94 in)

60 mm (2.36 in)

149 mm (5.87 in)

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EXCAVATOR SPECIFICATIONS (CONT’D) Hydraulic Cycle Times Boom

Raise 3.2 Seconds

Lower 3.0 Seconds

Arm

Retract 3.8 Seconds

Extend 2.9 Seconds

Bucket

Curl 3.3 Seconds

Dump 2.1 Seconds

Blade

Raise 2.4 Seconds

Lower 2.9 Seconds

Boom Swing

Left 6.9 Seconds

Right 8.6 Seconds

Electrical Starting Aid

Air Intake Heater

Alternator

12 volt, 60 Amp open frame w/ internal regulator

Battery

12 volt - 750 CCA @ -18°C (0°F)

Starter

12 volt gear reduction 3.0 kW (4.0 hp)

Instrumentation

Fuel gauge, audible alarm, visual warning for engine functions and hourmeter

Drive System Final Drive

Each track is independently driven by an Axial Piston Motor

Type of Reduction

Two-stage planetary gear reduction

Slew System Slew Motor

Axial Piston Motor

Slew Circle

Single row shear type ball bearing with internal gear

Slew Speed

9.8 rpm

Undercarriage Crawler Track Design

Sealed track rollers with boxed section track, Roller frame, Grease type track adjuster

Capacities Fuel Tank

110 L (29.1 U.S. gal)

Hydraulic Reservoir Only (Centre of Sight Glass)

87 L (23.0 U.S. gal)

Hydraulic System (with Reservoir)

127 L (35.5 U.S. gal)

Cooling System

10,0 L (10.6 qt)

Engine Oil and Filter

11,6 L (12.25 qt)

Final Drive (each)

1,4 L (1.5 qt) 80W90 gear lube

Swing Motor Reduction Drive

1,5 L (16 qt) 80W90 gear lube

Air Conditioning Refrigerant (R-134a)

0,65 kg (1.4 lb)

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EXCAVATOR SPECIFICATIONS (CONT’D) Tracks Type

Rubber

Steel

Width

450 mm (17.7 in)

450 mm (17.7 in)

Number Of Shoes

Single Assembly

39

5

5

Number of Track Rollers (per side) Ground Pressure Ground Pressure

39 kPa (0,39 bar) (5.66 psi)

Fuel Consumption Fuel Consumption

8,14 L/hr (2.15 gph)

NOTE: The engine fuel consumption chart is to be used as a guideline only. The actual results may vary.

Estimated fuel consumption is based on testing by Bobcat Company in high duty cycle digging applications.

Environmental Vibration Levels

Uncertainties (If Applicable)

Whole body vibration (ISO 2631-1) (limit 0,5 m/s2)

0,32 m/s2

-------

Hand-arm vibration (ISO 5349-1) (limit 2,5 m/s2)

1,11 m/s2

-------

Machine equipped with optional HVAC (air condition) contains fluorinated greenhouse gas (F-gas) F-gas type

HFC-134a

F-gas mass (kg)

0.77

CO2 equivalent (t)

1.10

GWP

1430

Temperature Range Operation and storage

-17° - +43°C (-1.3° - +109.4°F)

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WARRANTY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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WARRANTY

WARRANTY BOBCAT EXCAVATORS Doosan Bobcat EMEA s.r.o. (“Doosan”) warrants to its authorized dealers who in turn warrants to the customer that each new Bobcat Excavator will be free from defects in material and workmanship for twelve (12) months from the date of delivery to the customer or 2000 hours of machine usage, whichever occurs first. During the warranty period, the authorized Doosan dealer shall repair or replace, at Doosan’s option, without charge for parts, labour and travel of technicians, any part of the Doosan product which fails because of defects in material or workmanship. The customer shall provide the authorized Doosan dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Doosan may, at its option, request failed parts to be returned to the factory or to any other designated location. Transportation of the Doosan product to the authorized Doosan dealer for warranty work is not the responsibility of Doosan. Service schedules must adhere to prescribed intervals and Bobcat genuine parts/lubricants must be used. The warranty does not apply to tyres, tracks or other accessories not manufactured by Doosan. For coverage on engines, consult with your Bobcat Dealer. For these non-covered items, the customer shall refer solely to the warranty, if any, of the respective manufacturers thereof, in accordance with the respective manufacturers warranty statement. Some Doosan parts are covered pro-rata depending on the expected life-time of the part.

Coverage for batteries, air-conditioning refill, couplers and ignition system parts (glow plugs, fuel injection pumps, injectors) is reduced as failures generally originate from factors not under Doosan’s control such as, but not limited to, prolonged storage, abuse or fuel quality. Reduced coverage is, depending on the component, limited from 50 to 500 operating hours. The warranty does not cover: (i) Oils and lubricants, coolant fluids, filter elements, brake linings, tune-up parts, bulbs, fuses, alternator fan belts, drive belts, pins, bushings and other high-wear items. (ii) Damages resulting from abuse, accidents, alterations, use of the product with any bucket or attachment not approved by Doosan, air flow obstructions, or failure to maintain or use the Doosan product according to the instructions applicable to it. (iii) Ground engaging parts such as bucket teeth and cutting edges. (iv) Fuel or hydraulic system cleaning, engine tune-up, brake inspection or adjustment. (v) Adjustments or slight defects which generally do not affect the stability or reliability of the machine.

DOOSAN EXCLUDES OTHER CONDITIONS, WARRANTIES OR REPRESENTATIONS OF ALL KINDS, EXPRESSED OR IMPLIED, STATUTORY OR OTHERWISE (EXCEPT THAT OF TITLE) INCLUDING ALL IMPLIED WARRANTIES AND CONDITIONS RELATING TO MERCHANTABILITY, SATISFACTORY QUALITY AND FITNESS FOR A PARTICULAR PURPOSE. CORRECTIONS BY DOOSAN OF NONCONFORMITIES WHETHER PATENT OR LATENT, IN THE MANNER AND FOR THE TIME PERIOD PROVIDED ABOVE, SHALL CONSTITUTE FULFILLMENT OF ALL LIABILITIES OF DOOSAN FOR SUCH NONCONFORMITIES, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE WITH RESPECT TO OR ARISING OUT OF SUCH PRODUCT. THE REMEDIES OF THE END-USER/OWNER SET FORTH UNDER THE PROVISIONS OF THE WARRANTY OUTLINED ABOVE ARE EXCLUSIVE AND THE TOTAL LIABILITY OF DOOSAN INCLUDING ANY HOLDING, SUBSIDIARY, ASSOCIATED OR AFFILIATED COMPANY OR DISTRIBUTOR WITH RESPECT TO THIS SALE OR THE PRODUCT AND SERVICE FURNISHED HEREUNDER IN CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM DELIVERY, INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED BY OR FURNISHED UNDER THIS SALE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED. DOOSAN INCLUDING ANY HOLDING, SUBSIDIARY, ASSOCIATED OR AFFILIATED COMPANY AND DISTRIBUTOR SHALL IN NO EVENT BE LIABLE TO THE END-USER/OWNER, ANY SUCCESSORS IN INTEREST OR ANY BENEFICIARY OR ASSIGNEE RELATING TO THIS SALE FOR ANY CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES ARISING OUT OF THIS SALE OR BY ANY BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE PRODUCT UNDER THIS SALE, WHETHER BASED UPON LOSS OF USE, LOST PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NON-OPERATION, INCREASED EXPENSES OF OPERATION OR CLAIMS OF USER OR CUSTOMERS OF THE USER FOR SERVICE INTERRUPTION WHETHER OR NOT SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.

Printed in Belgium

4700003enGB (01-17)

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ALPHABETICAL INDEX AIR CLEANER SERVICE . . . . . . . . . . . . . 105 AIR CONDITIONING BELT . . . . . . . . . . . . 132 ALTERNATOR BELT . . . . . . . . . . . . . . . . . 131 ATTACHMENT . . . . . . . . . . . . . . . . . . . . . 134 ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . 66 BLADE CONTROL LEVER . . . . . . . . . . . . . 54 BOBCAT COMPANY IS IS0 9001 CERTIFIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 BOOM SWING . . . . . . . . . . . . . . . . . . . . . . . 55 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . 136 CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . 104 CENTRE COVER . . . . . . . . . . . . . . . . . . . 103 CONTROL CONSOLE LOCKOUTS . . . . . . 99 DAILY INSPECTION . . . . . . . . . . . . . . . . . . 57 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 9 DIAGNOSTIC SERVICE CODES . . . . . . . 145 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 115 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . 45 ENGINE COOLING SYSTEM . . . . . . . . . . 113 ENGINE LUBRICATION SYSTEM . . . . . . 111 ENGINE SPEED CONTROL DIAL . . . . . . . 54 EXCAVATOR IDENTIFICATION . . . . . . . . . . 10 EXCAVATOR SPECIFICATIONS . . . . . . . . 151 EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 141 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . 11 FIRE PREVENTION . . . . . . . . . . . . . . . . . . 17 FLASHING PATTERNS OF ENGINE CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . 107 HYDRAULIC CONTROLS . . . . . . . . . . . . . . 49 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . 120 INSTRUMENTS AND CONSOLES . . . . . . . 35 LIFTING THE EXCAVATOR . . . . . . . . . . . . . 88 LUBRICANTS AND FLUIDS . . . . . . . . . . . . . 8 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . 137 MACHINE SIGNS (DECALS) . . . . . . . . . . . 20 MAINTENANCE SAFETY . . . . . . . . . . . . . . 95 MOTION ALARM SYSTEM . . . . . . . . . . . . 101 MOTION ALARM SYSTEM . . . . . . . . . . . . . 46 OPERATING PROCEDURE . . . . . . . . . . . . 76 OPERATOR CAB (ROPS / TOPS) . . . . . . . . 40 OPERATOR SAFETY WARNING . . . . . . . . . 1 OVERLOAD WARNING . . . . . . . . . . . . . . . . 56 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . 140 165 of 168

PRE-STARTING PROCEDURE . . . . . . . . . .59 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . .19 REAR COVER . . . . . . . . . . . . . . . . . . . . . .103 REGULAR MAINTENANCE ITEMS . . . . . . .7 RIGHT SIDE COVER . . . . . . . . . . . . . . . . .103 SAFETY INSTRUCTIONS . . . . . . . . . . . . . .15 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . .100 SERIAL NUMBER LOCATIONS . . . . . . . . . .9 SERVICE SCHEDULE . . . . . . . . . . . . . . . . .97 SPARK ARRESTER MUFFLER . . . . . . . . .127 STARTING THE ENGINE . . . . . . . . . . . . . .62 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . .65 TOWING THE EXCAVATOR . . . . . . . . . . . .87 TRACK ROLLER AND IDLER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 TRACK TENSION . . . . . . . . . . . . . . . . . . .128 TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . .90 TRAVEL CONTROLS . . . . . . . . . . . . . . . . .47 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . .130 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . .163

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Bobcat®, the Bobcat logo and the colours of the Bobcat machine are registered trademarks of Bobcat Company in the United States and various other countries.

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