Bobcat Excavator 316 Operation & Maintenance Manual 6902283

S/N 522811001 & Above S/N 522911001 & Above

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

6902283 (12-05) Revised (5-12) (5)

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Printed in U.S.A.

©Bobcat Company 2005

Dealer Copy -- Not for Resale

Operation & Maintenance Manual

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OPERATOR SAFETY WARNINGS WARNING

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

W-2001-1285

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

B-10731a

MC-1862a

MC-1859a

MC-1865a

without

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

Do not grasp control handles when entering canopy or cab.

TS-2074

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

Operate on flat, level ground.

CORRECT

Avoid steep areas or banks that could break away.

Never modify equipment.

Be sure controls are in neutral before starting.

Sound horn and check behind machine before starting.

WRONG

Never operate without approved canopy or cab.

WRONG

TS-2075

Never use attachments not approved by Bobcat Company.

CORRECT

CORRECT

15° Max.

15° Max.

MC-1865b

Keep bystanders out of maximum reach area.

Never exceed a slope to the side.

Do not travel or turn with bucket extended.

Always expand the tracks when working on slopes or in rough conditions.

Never carry riders.

CORRECT

15°

CORRECT

TS-2067A

Never travel up a slope that exceeds 15°.

SAFETY EQUIPMENT The machine must be equipped with safety items necessary for each job.

Ask your dealer for information on the safe use of attachments and accessories.

25° Max. TS-2068a

B-21928

MC-1859a

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

Fasten seat belt securely.

To leave excavator, lower the attachment.

Operate controls only from operator’s seat.

Stop the engine.

1. SEAT BELT 2. SLEW LOCK 3. CANOPY (TOPS) 4. MACHINE SAFETY SIGNS 5. SAFETY TREADS 6. CONTROL LOCKOUT LEVERS OSW22-0805

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Never operate instructions.

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FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

SAFETY

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1

OPERATING INSTRUCTIONS

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

PREVENTIVE MAINTENANCE

CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust And Some Of Its Constituents Are Known To The State Of California To Cause Cancer, Birth Defects And Other Reproductive Harm.

MACHINE SIGN TRANSLATIONS Dealer Copy -- Not for Resale

REFERENCE INFORMATION Write the correct information for YOUR exca vator in the spaces below. Always use these numbers when referring to your Bobcat product.

SPECIFICATIONS

Excavator Serial Number Engine Serial Number

NOTES:

YOUR BOBCAT DEALER: ADDRESS: PHONE:

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

Bobcat Company Europe J. Huysmanslaan 59 B-1651 LOT Belgium

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FOREWORD

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

BOBCAT COMPANY IS ISO 9001 CERTIFIED . . . . . . . . . . . . . . . . V DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII EXCAVATOR SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . VII FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . IX Standard Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

SYSTEM SETUP & ANALYSIS

REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . V

Dealer Copy -- Not for Resale

MOTOR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

TRANSLATIONS

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

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BOBCAT COMPANY IS ISO 9001 CERTIFIED

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

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

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

Diesel Engine Exhaust And Some Of Its Constituents Are Known To The State Of California To Cause Cancer, Birth Defects And Other Reproductive Harm.

MACHINE SIGN TRANSLATIONS

REGULAR MAINTENANCE ITEMS ENGINE OIL FILTER 6671057

BATTERY NTS2-71000 FLUID, Hydraulic/Hydrostatic 6903117 - (2.5 Gal.) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

FUEL FILTER 15393-43019

AIR FILTER 19167-1108-0

RADIATOR CAP 16861-7202-0

HYDROSTATIC FILTER 12514-1102

ETHYLENE GLYCOL ANTI-FREEZE, (PURCHASE LOCALLY)

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

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

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

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

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

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CALIFORNIA PROPOSITION 65 WARNING

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SERIAL NUMBER LOCATIONS

ENGINE SERIAL NUMBER

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

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

Figure 2

1

Figure 1

P-39940

The engine serial number is located on top of the valve cover (Item 1) [Figure 2].

P-43315

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DELIVERY REPORT Figure 3

EXCAVATOR SERIAL NUMBER The excavator serial number plate is located on the lef t front corner of the swing frame [Figure 1].

Explanation of excavator Serial Number: XXXX XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination B-16315

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

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

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

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MACHINE IDENTIFICATION

CANOPY (With TOPS Approval) OPERATOR SEAT ARM CYLINDER BOOM AUXILIARY HYDRAULICS

CONTROL LOCKOUT LEVERS

BOOM CYLINDER

B-19805

FRONT LIGHT

BUCKET CYLINDER

SEAT BELT

BUCKET

BLADE TRACKS B-19797

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ENGINE COVER

ARM

FEATURES AND ACCESSORIES Standard Items Model 316 Bobcat Excavators are equipped with the following items: • • • • • • • • • • • •

Adjustable Cushion Seat Auxiliary Hydraulics Boom Light Control Lockouts Canopy (With TOPS Approval) Expandable Tracks Horn Instrumentation: Hourmeter, Glow Plug, Battery Charge, Engine Oil Pressure Indicator Lights Locking Engine Cover Seat Belt Spark Arrestor Exhaust System Upperstructure Slew Lock

Dealer Copy -- Not for Resale

Specifications subject to change without notice.

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SAFETY MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI SAFETY

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SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

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•

An Operator’s Handbook is fastened to the operator cab of the Excavator. It’s brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

•

The AEM Safety Manual delivered with the machine gives general safety information.

•

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

•

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

•

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

Before Operation Carefully follow the operating and maintenance instructions in this manual.

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

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

The dealer explains the cap abilities and restrictions of the Bobcat Excavator and att achment 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 att achments.

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

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

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

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

•

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

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

•

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.

Call Before You Dig 1-888-258-0808 When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI EXC-0805

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SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS (CONT’D)

A Qualified Operator Must Do The Following:

Safe Operation Is The Operator’s Responsibility

Understand the Written Instructions, Rules and Regulations

Safety Alert Symbol

•

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

•

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

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

Carefully read the message that follows.

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

•

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

•

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

•

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

•

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

W-2001-1285

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

I-2019-0284

WARNING WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

Know the Work Conditions

W-2044-1285

•

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.

Safe Operation Needs A Qualified Operator

•

For an operator to be qualif ied, he or she must not use drugs or alcoholic drinks which imp air alertness or coordination while working. An operator who is t aking prescription drugs must get medical advice to determine if he or she can safely operate a machine.

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

•

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

The Bobcat Excavator and att achment 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-0805

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Have Training with Actual Operation

Manual for connecting the battery and for jump starting.

SAFETY INSTRUCTIONS (CONT’D) Fire Prevention •

The machines and some att achments 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 main tained, can be a source of arcs or sparks.

Use the procedure in the Operation & Maintenance Manual for cleaning the spar k arrestor muffler (if equipped).

Figure 1

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

•

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

•

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

•

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight.

Repair or replace any damaged part.

•

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

•

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

•

Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

•

Stop the engine and let it cool before adding fuel. No smoking!

•

•

Know where fire extinguis hers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].

Sl EXC-0805

Use the procedure in the Operation & Maintenance XV 19 of 86

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The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muf fler and the exhaust gases are still hot.

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.

6814961 6814970

6814965

6815915

6814960

6814959 6814969

6902282

6814968

6804233

6576048 Under Engine Cover

6814962

6814964 6533899(2) 6815993 (2)

6589129 (2)

B-19805

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On Control Console

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

6808185 Inside Canopy

6814976

6817138

Dealer Copy -- Not for Resale

6594897

6732148

6814967 7106627

6595014

6560573

6700388

6565990

6811054

Under Engine Cover

B-19797

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OPERATING INSTRUCTIONS BLADE CONTROL / TRACK EXPANSION LEVER . . . . . . . . . . OI-11 Expanding And Retracting The Tracks . . . . . . . . . . . . . . . . . OI-11 Raising And Lowering The Blade. . . . . . . . . . . . . . . . . . . . . . OI-11 BOOM SWING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 BUCKETS AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . OI-15 Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-15 Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-15

OPERATING INSTRUCTIONS

CONTROL LOCKOUT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Daily Inspection And Maintenance. . . . . . . . . . . . . . . . . . . . . OI-12

Dealer Copy -- Not for Resale

ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 HYDRAULIC CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Standard (STD) Control Pattern. . . . . . . . . . . . . . . . . . . . . . . . OI-8 INSTRUMENTS AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . OI-3 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 OPERATOR CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 TOPS Approved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4

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OPERATING INSTRUCTIONS (CONT’D) OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Avoiding Track Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Backfilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Boom Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Driving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 Lifting A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Operating In Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-20 Operating On Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Operating On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-19 PARKING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . OI-13 Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . OI-13

Dealer Copy -- Not for Resale

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-14 Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-14 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-14 STEERING LEVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-6 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . OI-6 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . OI-22 Fastening To Transport Vehicle . . . . . . . . . . . . . . . . . . . . . . . OI-23 Loading Onto Transport Vehicle. . . . . . . . . . . . . . . . . . . . . . . OI-22 UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . OI-6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-6

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INSTRUMENTS AND CONTROLS

Light Switch

Instrumentation

Figure OI-2

Figure OI-1 1

2

3 1

5

4

P-43162

P-43180

Move the switch up (Item 1) ON; down to turn OFF.

[Figure OI-2] to turn light

All the instrument s are located on the control console [Figure OI-1].

NOTE: Key switch must be ON for the light to come ON.

REF

DESCRIPTION

FUNCTION

Operator Controls

1 2

Glow Plug Indicator Battery Charge Warning Indicator Engine Oil Pressure Warning Indicator

ON when glow plugs are energized.

Comes ON when the battery is not being charged.

ON when engine oil pressure is low.

Stop engine immediately if light does not go OFF. Records the total operating hours of the machine.

Used to activate glow plugs, start and stop engine.

3

4

Hourmeter

5

Key Starter Switch

Figure OI-3 5

2

1

4

3

10

12

P-43163

8

9

11

P-43165

P-43167

OI-3 25 of 86

6

7

REF

DESCRIPTION

REF

DESCRIPTION

1 2 3 4 5 6

Left Hand Control Lever Right Hand Control Lever Left Steering Lever Right Steering Lever Horn Button Blade / Track Width Control Lever

7 8 9 10 11 12

Engine Speed Control Upperstructure Slew Lock Swing Pedal Auxiliary Hydraulic Control Track Expansion Selector Control Lockout Lever

316 Excavator Operation & Maintenance Manual

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P-43169

CONTROL LOCKOUT LEVERS

OPERATOR CANOPY

Operation

TOPS Approved

Figure OI-4

Figure OI-5

1

1

P-43175 P-43833

[Figure OI-4] The excavator has an operator canopy (TOPS) (Tip Over Protective Structure) (meets ISO 121 17) as st andard equipment [Figure OI-5].

When the control lockout is raised, the hydraulic control functions are locked and cannot be operated.

The canopy provides operator protection if the excavator tips over. The seat belt must be worn for T OPS protection.

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Lower the control lockout lever (Item 1) before operating the machine.

ENGINE SPEED CONTROL

BOOM SWING PEDAL

Operation

Operation

Figure OI-6

Figure OI-7

1 1 2

P-43165

[Figure OI-6]

The Boom Swing Pedal is located at the right side of the control console [Figure OI-7].

Move the lever up to incr ease engine RPM; move down to decrease RPM [Figure OI-6].

Push the toe of the pedal (Item 1) [Figure OI-7] to swing the boom to the right.

The Engine S peed Control (Item 1) controls the RPM of the engine.

Push the heel of the pedal (Item 2) [Figure OI-7] to swing the boom to the left.

When not using the swing pedal, the heel can be folded forward to prevent operation of the boom swing function.

In this position it can be used as a footrest.

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P-43164

UPPERSTRUCTURE SLEW LOCK

STEERING LEVERS

Operation

Forward And Reverse Travel

Figure OI-8

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

Figure OI-9 1

When the upperstructure slew lock is engaged (locked), the upperstructure of the excavator is locked to the track frame and will not swing. The upperstructure must be aligned straight forward (with the boom over the blade) OR 180° to the rear for the upperstructure slew lock to engage.

P-43163

Put the blade so that it is at the front of the machine (as you sit in the operator’s seat). Slowly move both steering levers (Item 1) [Figure OI-9] forward for forward travel; backward for reverse travel.

Raise the lever slightly (Item 1) [Figure OI-8], turn it to the left and lower the lock.

Raise the lever and turn to the right to disengage the upperstructure slew lock [Figure OI-8].

WARNING •

IMPORTANT Before slewing the upperstructure, make sure the slew lock is disengaged.

•

I-2051-0905

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

Move the steering levers slowly. Abrupt lever motion will cause the machine to jerk.

W-2510-1205

WARNING AVOID INJURY The upperstructure slew lock lever must be engaged when transporting the machine.

W-2197-0904

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P-43167

STEERING LEVERS (CONT’D) Turning

A

B

C

D

E

F

Dealer Copy -- Not for Resale

Figure OI-10

Right Turn Push the left steering lever forward (Item A) [Figure OI10] to turn right while traveling forward.

Pull the left steering lever backward (Item C) [Figure OI10] to turn right while traveling backward.

Counter-Rotation Right Turn Push the lef t steering leve r forward and pull the right steering lever backward (Item E) [Figure OI-10].

Left Turn Push the right steering lever forward (Item B) [Figure OI10] to turn left while traveling forward.

Pull the right steering lever backward (Item D) OI-10] to turn left while traveling backward.

[Figure

Counter-Rotation Left Turn Push the right steering leve r forward and pull the lef t steering lever backward (Item F) [Figure OI-10].

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HYDRAULIC CONTROLS

Right Control Lever

Standard (STD) Control Pattern

Figure OI-12

The work equipment (backhoe and upperstructure swing) is operated by using the right and left control levers.

Left Control Lever Figure OI-11 P-43163

B-21926

The right lever is used to operate the arm and bucket [Figure OI-12].

1. Arm Out. B-21925

2. Arm Out and Bucket Dump.

The left lever is used to operate the boom and to swing the upperstructure [Figure OI-11].

3. Bucket Dump.

4. Arm In and Bucket Dump.

1. Boom Lower.

5. Arm In.

2. Boom Lower and Swing Right.

6. Arm In and Bucket Curl.

3. Upperstructure Slew Right.

7. Bucket Curl.

4. Boom Raise and Swing Right.

8. Arm Out and Bucket Curl.

5. Boom Raise.

6. Boom Raise and Swing Left.

WARNING

7. Upperstructure Slew Left.

8. Boom Lower and Swing Left.

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

• Lower the blade to the ground.

• Stop the engine & remove the key.

W-2196-0595

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P-43163

HYDRAULIC CONTROLS (CONT’D)

Right Control Lever

ISO Control Pattern

Figure OI-14

NOTE: The Bobcat Excavator comes configured from the factory with Standard (STD) Controls (See Standard (STD) Control Pattern on Page OI-8.)

See your Bobcat dealer for the procedure on how to change to ISO controls.

The work equipment (back hoe & upper structure swing) is operated by using the left and right control levers.

P-43163

Left Control Lever Figure OI-13

B-21924

The right lever is used to operate the boom and bucket [Figure OI-14].

1. Boom Lower.

2. Boom Lower and Bucket Dump.

3. Bucket Dump.

B-21923

4. Boom Raise and Bucket Dump.

The left lever is used to operate the arm and to swing the upperstructure [Figure OI-13].

5. Boom Raise.

6. Boom Raise and Bucket Curl.

1. Arm Out. 7. Bucket Curl.

2. Arm Out and Swing Right.

8. Boom Lower and Bucket Curl.

3. Swing Right.

4. Arm In and Swing Right.

WARNING

5. Arm In. 6. Arm In and Swing Left.

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

• Lower the blade to the ground.

• Stop the engine & remove the key.

7. Swing Left.

8. Arm Out and Swing Left.

W-2196-0595

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P-43163

HYDRAULIC CONTROLS (CONT’D)

Figure OI-16

Auxiliary Hydraulics Figure OI-15 2

1 1 P-43167

Press the Auxiliary Hydraulics Pedal (Item 2) [Figure OI16] to provide hydraulic pressure to the top hydraulic line (Item 1) [Figure OI-15]. Release the pedal to stop hydraulic flow.

Excavators have auxiliary hydraulic lines (Item 1) [Figure OI-15] located on the boom.

Quick couplers are available for use with hydraulically controlled attachments.

When you are not using the auxiliary hydraulics, engage the locking pin so that you can use the pedal as a footrest.

Only the top auxiliary line is pressurized. The bottom line is for return oil flow.

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

Be careful when connecting and disconnecting quick couplers.

HORN Operation Figure OI-17

W-2220-0396

1

P-43163

Press the button (Item 1) [Figure OI-17] at the end of the right hand hydraulic control lever to sound the horn.

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Pull the locking pin out (Item 1) [Figure OI-16] to allow the pedal to pivot.

P-43174

Figure OI-20

BLADE CONTROL / TRACK EXPANSION LEVER Raising And Lowering The Blade Figure OI-18

1 2 3 P-43312

P-43167

P-43164

To prevent wear and damage to the track, always lift the excavator before expanding or retracting the track frame.

Pull the lever backward (Item 2) [Figure OI-18] to raise the blade.

I-2193-0599

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

With the boom and arm posi tioned over the blade, lower the blade until the tracks are raised 1 to 2 in. (25 to 50 mm) off the ground [Figure OI-20].

Expanding And Retracting The Tracks

Rotate the upper structure 180°.

Figure OI-19

Lower the boom and arm to raise the rear of the excavator until the track is 1 to 2 in. (25 to 50 mm) off the ground [Figure OI-20].

Press and hold the T rack Expansion Pedal (Item 3) [Figure OI-18] with your left foot. Push the Blade Control / Track Expansion Lever forward (Item 1) [Figure OI-18] to expand the tracks; pull backward (Item 2) [Figure OI18] to retract the tracks. Release the T rack Expansion Pedal.

NOTE: Always operate the machine with the tracks expanded all the way or retracted all the way.

P-43172

Raise the boom and arm to lower the rear of the excavator to the ground.

P-43171

Raise the blade all the way.

The excavator can be operated with the track frame in the retracted or expanded position [Figure OI-19].

Turn the upperstructure 180°.

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IMPORTANT

Push the lever forward (Item 1) [Figure OI-18] to lower the blade.

DAILY INSPECTION

6814967A

Daily Inspection And Maintenance

WARNING

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [Figure OI-21] is a guide for correct maintenance of t he Bobcat Excavator . It is located on the engine cover and also in the MACHINE SIGN TRANSLATION section. (See SER VICE SCHEDULE (6814967) on Page MST-3.)

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

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

Check the following items before each day of operation: • • • • • • • • • • • •

Operator Canopy (TOPS) and mounting hardware Seat belt and mounting hardware Damaged decals, replace as needed Check function of the control lockout levers Air cleaner system Engine coolant level and for coolant leaks Clean engine area of any flammable material Hydraulic fluid level and system for leaks Grease all pivot points Track tension Engine cover latch Repair broken and loose parts

W-2003-0903

Fluids such as engine oil, hy draulic fluid, coolants, etc., must be recycled or disposed of in an environment ally safe manner. Some regulations require that cert ain spills and leaks on the ground must be cleaned in a specific manner. See local, st ate, and federal regulations for correct disposal.

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Figure OI-21

Figure OI-23

PRE-STARTING PROCEDURE Before Starting The Engine

1

Figure OI-22

2 2 1

P-43834

Release the seat lever (Item 1) [Figure OI-23] to adjust the seat forward or backward for comfortable operation.

P-43835

NOTE: The control lockout levers must be in the down position for the hydraulic control levers to operate.

The Operation & Main tenance Manual and other manuals can be kept in a cont ainer (Item 2) [Figure OI22] provided behind the operator’s seat.

NOTE: Make sure the engine cover is latched.

Use the canopy, the tracks and safety treads to enter.

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Fasten the seat belt and lower the control lockout levers (Item 2) [Figure OI-23].

Read and underst and the Op eration & Maintenance Manual and the Operator ’s Handbook (Item 1) [Figure OI-22] before operating.

STARTING THE ENGINE Procedure

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.

WARNING •

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

Never wear loose clothing when working near machine.

I-2034-0700

Cold Temperature Starting If the temperature is below freezing, preform the following to make starting the engine easier.

W-2135-1188

Put all controls in neutral position.

•

Figure OI-24 GLOW START PLUG

GLOW RUN PLUG OFF

GLOW PLUG

• • •

Turn the key to GLOW PLUG position again [Figure OI-24], then to START position [Figure OI-24], then release.

Use the correct type and viscosity engine oil for the anticipated starting temperature. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-6.)

Make sure the battery is fully charged.

Install an engine heater.

P-43180

Put the Engine S peed Control at the 1/2 speed position [Figure OI-24].

Turn the key counterclockwise to GLOW PLUG position [Figure OI-24] and hold until the indicator light goes of f (about 6 seconds).

Turn the key to ST ART position [Figure OI-24] and release the key when the engine st arts. It will return to RUN position [Figure OI-24].

Stop the engine if the warning indicators do not go OFF .

Check the cause before starting the engine again.

Turn the switch OFF [Figure OI-24] to stop the engine.

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•

BUCKETS AND ATTACHMENTS

Removing

Installing

Park the excavator on flat level ground and put the bucket on the ground.

Remove the fasteners and pivot pins (Items 1, 3 & 4) [Figure OI-25]. Keep the pivot pins clean.

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.

WARNING 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.

W-2140-0189

Figure OI-25

W-2052-0500

1

Dealer Copy -- Not for Resale

2 3 4

P-43316

Install the link (Item 2) [Figure OI-25] into the bucket, align the hole, inst all the pivot pin and washer (Item 3) [Figure OI-25].

Install the arm into the bucket, align the hole, inst all the pivot pin (Item 1) [Figure OI-25].

Install the fasteners (Item 4) [Figure OI-25]. Add grease to the pivot pins before operation.

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OPERATING PROCEDURE

Lifting A Load

Operating On Public Roads

Do not exceed the rated lif t capacity. (See W ARNING (6817138) on Page MST-6.)

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

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

Check with utility comp anies for underground electrical, water, gas lines, etc. Work slowly in ares of underground utilities.

Wrap the chain assembly around the bucket mounting plate.

Figure OI-26

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

Run the engine at idle sp eed to warm the engine and hydraulic system before operating the excavator.

B-21927

IMPORTANT

Make sure the load is ev enly weighted and centered on the lifting chain, and is secured to prevent the load from shifting [Figure OI-26].

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

I-2015-0284

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

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W-2374-0500

OPERATING PROCEDURE (CONT’D) Excavating

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

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

W-2119-0788

Figure OI-28 WRONG

W-2116-0903

Lower the blade to provide stability.

Expand the tracks for increased excavating performance.

1

2

TS-2061

TS-2064

3

TS-2062

Do not dig under the excavator [Figure OI-28].

TS-2063

4

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

Do not move the excavator wh ile the bucket is in the ground.

B-21922

1. Extend the arm, lower the boom and open the bucket [Figure OI-27].

2. Retract the arm while lowering the boom and curling the bucket) [Figure OI-27].

3. Raise the boom, retract th e arm and curl the bucket [Figure OI-27]. Rotate the upper structure.

NOTE: Do not allow the bucket to contact the ground when swinging the upper structure.

4. Extend the arm and uncurl the bucket to dump the material into a pile or truck [Figure OI-27].

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Figure OI-27

OPERATING PROCEDURE (CONT’D)

Driving The Excavator

Boom Offset

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

Figure OI-29 1

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

2

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

B-15767

4

B-15763

B-15762

1. Swing the upper structure, offset the boom to the left (Item 1), center (Item 2), and right (Item 3)[Figure OI29] to dig a square hole the width of the machine without repositioning the excavator.

B-15765

2. The boom offset allows the operator to dig close to buildings and other structures (Item 4)[Figure OI-29].

If one or both tracks have become stuck in sof t or wet ground, raise one track at a time by turning the upperstructure and pushing the bucket against the ground [Figure OI-31].

Backfilling Figure OI-30

Put planks under the tracks and drive to dry ground.

Figure OI-32

B-15766

Use the blade to backfill the trench or hole af excavating [Figure OI-30].

ter B-15764

The bucket can also be used to pull the excavator. Raise the blade, extend the arm an d lower the boom. Operate the boom and arm in a digging manner [Figure OI-32] to pull the excavator forward.

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3

Figure OI-31

B-15761

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.

•

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

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

Always fasten seat belt.

W-2498-0304

Figure OI-34

W-2497-0304

Traveling On Side Slopes

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

Traveling Up Slopes

Figure OI-33

12 in.

(304 mm) Maximum 15° Maximum

15° Maximum MC-1865D

When traveling up slopes or on side slopes that are 15 degrees or less, position th e machine as shown and run the engine slow [Figure OI-34].

25° Maximum TS-2068

Always expand the tracks when working on slopes or rough coditions.

When going down grades t hat exceed 15 degrees, put the machine in the position shown and run the engine slowly [Figure OI-33].

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

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

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

Damage to the blade or cylinder can result.

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Traveling Down Or Backing Up Slopes

OPERATING PROCEDURE (CONT’D)

Operating In Water

Operating On Slopes (Cont’d)

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

Figure OI-35 Recommended Position For Working On A Slope

Figure OI-36

When operating on a slope, level the work area before beginning [Figure OI-35].

P-43181

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

Do not operate or immerse the excavator in water higher than the bottom of the swing circle [Figure OI-36].

Do not work on slopes which are over 15 degrees.

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

Use a slow work cycle.

Avoid working with the tracks across the slope. This will reduce stability and increase the tendency for the machine to slide. Position the Excavator with the blade downhill and lowered.

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.

Avoid swinging or extendi ng 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.

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

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MC-1865C

OPERATING PROCEDURE (CONT’D)

PARKING THE EXCAVATOR

Avoiding Track Damage

Procedure

Figure OI-37

Figure OI-38 WRONG

B-21595

B-21596

WRONG

WRONG

B-21597

B-21598

P-43833

on a sharp edge or stepped

Stop the machine on level ground. Lower the work equipment and the blade to the ground [Figure OI-38].

•

Do not travel or turn grade.

•

The illustration [Figure OI-37] shows operating conditions to avoid to prevent damage to the rubber tracks.

•

Do not turn sharply on a surface with a high-friction factor such as concrete or asphalt.

•

Keep oil off the track. Clean any oil spills.

•

Do not operate on a beach or in an area which can cause excessive corrosion.

•

If the machine is not used for a long period of time, keep it indoors to prevent direct exposure to sunlight, rain, snow, etc.

Dealer Copy -- Not for Resale

WRONG

Figure OI-39

P-43349

Move the speed control lever fully down [Figure OI-39] and run the engine at idle speed for about 5 minutes to allow it to cool.

Stop the engine.

Raise the control lockout levers.

Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel. Exit machine.

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LIFTING THE EXCAVATOR Procedure Fully extend the cylinders of the bucket, arm and boom.

Raise the blade all the way.

Turn the upper structure so that the boom is at the opposite end as the blade.

Put all the controls in neutral and engage the upperstructure slew lock (See UPPERSTRUCTURE SLEW LOCK on Page OI-6.)

WARNING

• • •

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. Engage the swing locking lever.

Never lift with operator on machine.

Dealer Copy -- Not for Resale

•

W-2202-0595

Figure OI-40

1

2

P-43182

P-43183

Fasten the chains to the ends of the blade (Item 1) [Figure OI-40] and up to a lif ting fixture above the canopy. The lifting fixture must extend over the sides of the canopy to prevent the chains from hitting the TOPS. Install a 1 inch (25 mm) bolt (Grade 5) through the holes at the top of the boom (Item 2) [Figure OI-40]. Install nut.

Fasten a chain from the bolt to the lift fixture.

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TRANSPORTING THE EXCAVATOR

Fastening To Transport Vehicle

Loading Onto Transport Vehicle

Figure OI-42

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

1

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

Align the ramps with the center of the transport vehicle.

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

Use metal loading ramps with a slip resistant surface.

2 P-43578

P-43550

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

Fasten chains to the front corners of the blade (Item 1) and to the tie down loop at the rear of the track frame (Item 2) [Figure OI-42].

Determine the direction of the track movement before moving the machine (bla de forward). Engage the upperstructure slew lock (See UPPERSTRUCTURE SLEW LOCK on Page OI-6.)

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

WARNING

Figure OI-41

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W-2058-0494

P-43739

Move the machine forward onto the transport vehicle [Figure OI-41].

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

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

Stop the engine and remove the key.

Put blocks under the front and rear of the track shoes.

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

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PREVENTIVE MAINTENANCE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Dust Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Replacing The Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 BLADE EXTENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-22 Installing And Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-22 CONTROL LOCKOUT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . PM-17

PREVENTIVE MAINTENANCE

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . PM-11 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-12 Dealer Copy -- Not for Resale

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Fuse Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Removing And Installing The Battery. . . . . . . . . . . . . . . . . . PM-15 Service The Electrical System And Battery . . . . . . . . . . . . . PM-13 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . PM-14 ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Closing the Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Opening the Engine Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . PM-10 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . PM-9 Removing Water From The Fuel System. . . . . . . . . . . . . . . . PM-8 Replacing The Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8

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PREVENTIVE MAINTENANCE (CONT’D) HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . PM-16 Replacing The Hydraulic Filter. . . . . . . . . . . . . . . . . . . . . . . PM-16 LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . PM-20 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-3 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . PM-18

Dealer Copy -- Not for Resale

TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-19 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-19

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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-2003-0903 instructions can cause injury or death.

CORRECT

CORRECT

CORRECT

B-10731a

B-15797

B-15798

Bobcat without

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-15799

B-15800

B-15801

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-19806

B-19807 B-16102

B-6589 B-16102

Never service the Hydraulic Excavator instructions.

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

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

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

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

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

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

Use eye protection approved for type of welding.

Keep side access covers closed except for service.

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 Operat ion & Maintenance Manual ca n 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.

MSW26-0805

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Dealer Copy -- Not for Resale

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

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SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat product.

WARNING

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

W-2003-0199

SERVICE SCHEDULE Engine Cooling System Engine Oil Hydraulic Fluid Track Tension Indicators and Lights Operator Canopy Safety Signs and Safety Treads Pivot Points Control Lockout Levers General Inspection Seat Belt Fuel Filter Engine Air Filter and Air System Swing Pinion / Circle Hydraulic Fluid, Hoses and Tubelines Radiator Fins Battery Spark Arrestor Muffler Alternator / Fan Belt Engine Air Filter and Air System Engine Oil and Filter Hydraulic Reservoir Fuel Tank Hydraulic / Hydrostatic Filter Fuel Filter Engine Coolant Hydraulic Suction Filter Final Drive Cases Hydraulic Oil Hydraulic Suction Filter

SERVICE REQUIRED

8-10

Clean debris from oil cooler and radiator. Check coolant level cold, add premixed coolant as needed.

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

Check level and add as needed.

Check and adjust as needed.

Check for correct operation of all indicators and lights.

Check the condition of the canopy and mounting hardware.

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

Lubricate with multi-purpose lithium based grease.

Check for correct operation.

Check for leaks, loose bolts and nuts. Make corrections as needed.

Check the condition of seat belt.

Remove the trapped water.

Check and empty dust cup as needed. Check for leaks and damaged components. Do not use compressed air to clean elements.

Grease the swing pinion and swing circle.

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

Check and clean with low air or water pressure as needed.

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

Empty Spark Chamber.

Check for damage and correct tension. Adjust or replace as needed.

Check and empty dust cup. Replace filter as needed. Check for leaks and damaged components. Do not use compressed air to clean elements.

Replace oil and filter. Use CD or better grade oil and Bobcat filter.

Drain sediment and water.

Drain sediment and water.

Replace the filter element.

Replace filter element.

Flush the cooling system. Replace the coolant.

Clean the filter.

Check oil level and add as needed.

Replace the fluid.

Replace the filter.

50

•

•

100 250 500 1000 2000

Dealer Copy -- Not for Resale

ITEM

HOURS

^ ^ ^ ^ ^ ^

^ On new machine first service must occur at this interval.

• Or every 12 months.

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ENGINE COVER

ALTERNATOR BELT

Opening the Engine Cover

Adjusting The Alternator Belt

The engine cover must be op ened to provide access for machine maintenance.

Replace the belt if it has stretched or there are cracks in the belt. Replace the pulley if the belt contacts the bottom of the groove in the pulley.

Figure PM-1 Stop the engine.

Figure PM-2

1

3

2 1 P-43553

Use the key to release the latch (Item 1) [Figure PM-1] and raise the engine cover (Item 2) [Figure PM-1] all the way up until it is supported in the open position.

P-39951

Closing the Engine Cover

Open the engine cover.

Hold the engine cover open and release the support (Item 3) [Figure PM-1]. Lower the engine cover and engage the latch.

Loosen the mounting and adjustment bolt [Figure PM-2].

s (Item 1)

Move the alternator away from the engine to tighten the belt.

The tension is correct when there is 1/2 in. (13 mm) belt movement at the center of the belt span with 13 lb. (58 N) of force.

Tighten the mounting and adjustment bolt [Figure PM-2].

s (Item 1)

Close the engine cover.

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P-43179

AIR CLEANER

Replacing The Filter

Dust Cup

Remove and clean the dust cup. (See Dust Cup on Page PM- 7.)

For the correct service interval (See SER SCHEDULE on Page PM- 5.)

VICE

Figure PM-4

Figure PM-3

2

P-39945

1 1

P-59193

Remove the fastener (Item 1) and filter element (Item 2) [Figure PM-4].

Release the fasteners and re move the dust cup (Item 1) [Figure PM-3].

Inspect and clean the air cl eaner hose and housing (Do not use compressed air to clean). Make sure all connections are tight.

Separate the pieces of the dust cup (Inset) [Figure PM3] and thoroughly clean.

Install new filter element and fastener. Install the dust cup and engage the fasteners.

Reassemble and install the dust cup.

Install the coolant recovery tank on the mounting bracket.

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P-59194

FUEL SYSTEM Fuel Specifications

WARNING

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

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

The following is a suggested blending guideline which should prevent gelling problems during freezing temperatures.

TEMP. F° (C°)

NO. 2

W-2063-0887

NO. 1

WARNING

+15° (9°)

100%

0%

Down to -20° (-29°)

50%

50%

Below -20° (-29°)

0%

100%

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

See your fuel supplier for local recommendations.

W-2103-1285

Filling The Fuel Tank

Open the engine cover. (See ENGINE COVER on Page PM- 6.)

Figure PM-5

Figure PM-6

Dealer Copy -- Not for Resale

Open the engine cover. (See ENGINE COVER on Page PM- 6.)

1

2 1 P-59196

P-59195

Remove the fuel cap (Item 1) [Figure PM-5] at the right side of the engine compartment.

Remove the water trap (Item 1) [Figure PM-6]. Empty the water, clean and inst all the cont ainer. Hand tighten the nut.

Use a clean, approved safety cont ainer to add fuel. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING!

Replacing The Fuel Filter Remove the filter cont ainer (Item 2) Remove and discard the element.

Install and tighten the fuel fill cap. Close the engine cover.

[Figure PM-6].

Clean the filter cont ainer and the area around the filter head. Install a new fuel f ilter element and hand tighten the nut.

Removing Water From The Fuel System For the service interval w hen to remove water from or replace the fuel filter (See SER VICE SCHEDULE on Page PM- 5.)

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FUEL SYSTEM (CONT’D)

Figure PM-8

Draining The Fuel Tank For the correct service interval (See SER SCHEDULE on Page PM- 5.)

VICE 1

Turn the upperstructure 90° counterclockwise to align the drain between the tracks.

Figure PM-7

1 P-59197

Open the engine cover.

Open the valve (Item 1) [Figure PM-8].

Turn the key to the START position and run the starter for 3 to 6 seconds.

P-43548

NOTE: If the engine starts, turn the key off immediately.

Remove the drain plug (Item 1) [Figure PM-7] from the bottom of the fuel t ank and let the fuel drain into a container.

Open the engine cover again and close the valve (Item 1) [Figure PM-8].

Dispose of the fuel in an environmentally safe manner.

Close the engine cover.

Removing Air From The Fuel System Turn the key to ST ART and release the key when the engine starts.

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

IMPORTANT

WARNING

Do not engage the starter for longer than 30 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

I-2209-0301

Repeat the procedure as needed until the engine starts.

W-2072-0496

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Close the engine cover.

Figure PM-10

ENGINE LUBRICATION SYSTEM Checking Engine Oil Check the engine oil every day before starting the engine for the work shift.

Open the engine cover. (See ENGINE COVER on Page PM- 6.)

Figure PM-9

1 2 P-43546

Remove the drain plug (Item 1) the oil into a container.

[Figure PM-10]. Drain

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

1

Dealer Copy -- Not for Resale

Figure PM-11 P-59197

Remove the dipstick (Item 1) . Keep the oil level between the marks on the dipstick [Figure PM-9]

1

Use a good quality motor oil that meet s the correct API Service Classification. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-6.)

Replacing Oil And Filter For the correct service interval (See SER SCHEDULE on Page PM- 5.)

VICE P-39951

Run the engine until it is at operating temperature. S top the engine.

Remove the oil filter element (Item 1) and clean the oil filter housing.

Open the engine cover. (See ENGINE COVER on Page PM- 6.)

[Figure PM-11]

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

Install and tighten the oil drain plug.

Remove the fill cap (Item 2) [Figure PM-11] and put 3.4 qts (3,2 L) of oil into the engine. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-6.)

Install the fill cap.

Start the engine and let run for several minutes.

Stop the engine and check for leaks at the oil filter. Check the oil level. Add oil as needed if it is not at the top mark on the dipstick.

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COOLING SYSTEM

Figure PM-12

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

Cleaning The Cooling System

1

Open the engine cover (See ENGINE COVER on Page PM- 6.)

Use low air pressure or low water pressure to clean the radiator and oil cooler.

Checking Coolant Level P-59198

WARNING

The coolant level must be between the marks (Item 1) [Figure PM-12] on the coolant recovery tank.

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

You can be seriously burned.

W-2070-1203

IMPORTANT

WARNING

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

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.

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

W-2019-1285

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

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

I-2124-0497

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

Premix the coolant at 50% water and 50% ethylene glycol to provide a -34°F (-37°C) freeze protection.

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If the coolant level is low , add premixed coolant to the coolant recovery tank.

Remove the lower radiator hose (Item 2) [Figure PM-14] to remove coolant from the radiator.

COOLING SYSTEM (CONT’D) Replacing The Coolant For the correct service interval (See SER SCHEDULE on Page PM- 5.)

After the coolant is removed, close drain valve and install the radiator hose..

VICE

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

WARNING

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

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

You can be seriously burned.

Add premixed coolant to the radiator until full and to the correct level in recovery tank.

W-2070-1203

Premix the coolant at 50% water and 50% ethylene glycol to provide a -34°F (-37°C) freeze protection.

Figure PM-13

1

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

Install the radiator cap and tighten.

Close the engine cover.

P-39947

When the engine is cool, loosen and remove the radiator cap (Item 1) [Figure PM-13].

Figure PM-14

2

1

P-43545

Put a hose on the drain valve on the lef t side of the engine block (Item 1) [Figure PM-14]. Open the valve and drain the coolant into a container.

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Check the condition of ethylene glycol in your cooling system.

The battery is located under the engine cover at the right side of the machine (Item 1) [Figure PM-16].

ELECTRICAL SYSTEM Description

Figure PM-17

The excavator has a 12 volt, negative ground electrical system.

Figure PM-15

1 2 3 4

P-9589

P-9590

Fuses The electrical system is protected by four fuses located on the lef t side of the control console [Figure PM-15].

The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found and corrected before starting the engine again.

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.

Loosen the thumb screw and remove the fuse cover.

If electrolyte level is lower than 1/2 inch above the plates, add distilled water only.

Fuse Function Refer to [Figure PM-15] for following reference numbers.

REF.

FUNCTION

AMP

1

Lights

10

2

Hourmeter And Function Indicator Lights

10

3

Horn

10

4

Regulator

10

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

Service The Electrical System And Battery

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.

Figure PM-16

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

W-2065-1296

1 P-59199

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The battery cables must be clean and tight [Figure PM17]. Remove acid or corrosion from the battery and cables using a sodium bicarbonate and water solution.

After installing, cover the battery terminals and cable ends with battery saver grease to prevent corrosion.

P-43168

ELECTRICAL SYSTEM (CONT’D)

Stand on the ground at the right side of the machine.

Using A Booster Battery (Jump Starting)

Start the engine. After the engine has started, remove the negative (-) cable from the excavator frame first, then disconnect the remaining cables.

IMPORTANT IMPORTANT

If jump starting the excavator from a second machine:

Damage to the alternator can occur if: • Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.)

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

When jump starting the excavator from a battery installed in a second machine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

I-2060-0195

art the

I-2023-1285

Engage the upperstructure slew lock. BE sure the key switch is OFF before conn ecting cables. The booster battery must be 12 volt.

WARNING

Raise the engine cover. (See ENGINE COVER on Page PM- 6.)

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

Figure PM-18 4

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

Battery gas can explode and cause serious injury.

2

W-2066-0705

P-43673

1 3

WARNING P-31860

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

Connect one end of the first cable to the positive (+) terminal of the booster battery (Item 1) [Figure PM-18].

Connect the other end of the same cable to the positive (+) terminal (Item 2) [Figure PM-18] of the excavator battery.

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.

Connect the end of the second cable to the negative (-) terminal of the booster battery (Item 3) [Figure PM-18].

Connect the other end of the same cable to the frame of the excavator (away from the battery) (Item 4) [Figure PM-18].

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

W-2065-1296

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If it is necessary to use a booster battery to st engine, BE CAREFUL!

ELECTRICAL SYSTEM (CONT’D)

HYDRAULIC SYSTEM

Removing And Installing The Battery

Checking And Adding Fluid

Raise the engine cover. (See ENGINE COVER on Page PM- 6.)

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.

Figure PM-19

Raise the engine cover.

3

1

Figure PM-20 4 2 2

1 Disconnect the negative cable (Item 1) [Figure PM-19] from the battery.

P-59200

Remove the positive cable (Item 2) [Figure PM-19].

Check the fluid level in the sight gauge (Item 1) [Figure PM-20]. The level must be at the center of the sight gauge.

Remove the nut s (Item 3) [Figure PM-19] from the battery clamp and remove the clamp (Item 4) [Figure PM-19].

Remove the fill cap (Item 2) [Figure PM-20] and add fluid as needed.

Remove the battery.

Install the battery in the re verse order and connect the negative cable last to help prevent sparks.

Install the fill cap and lower the engine cover.

WARNING

WARNING

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

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

W-2103-1285

In case of acid contact, wash immediately with water.

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

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

W-2065-1296

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P-59199

Figure PM-22

HYDRAULIC SYSTEM (CONT’D) Replacing The Hydraulic Filter For the correct service interval (See SER SCHEDULE on Page PM- 5.)

VICE

Raise the engine cover.

1

Figure PM-21

1 P-43548

2

3

Drain the fluid into a container. Recycle or dispose of the used fluid in an environmentally safe manner.

P-59200

Clean the filter.

Remove the filter element (Item 1) [Figure PM-21].

Install the drain / filter cover (Item 1) [Figure PM-22].

Clean the filter housing wh ere the filter gasket makes contact.

Add fluid to reservoir (Item 2) [Figure PM-21] until it is at the center of the sight gauge (Item 3) [Figure PM-21].

For type and cap acity (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-6.)

Put clean hydraulic fluid on the gasket. Inst all the new filter element and hand tighten only.

Start the engine and run the excavator through the hydraulic functions. Stop the engine. Check the fluid level at the sight gauge and add fluid as needed. Check the filter area for leaks.

Start the engine and run the excavator through the hydraulic functions. Stop the engine. Check the fluid level at the sight gauge and add fluid as needed.

Replacing Hydraulic Fluid For the correct service interval (See SER SCHEDULE on Page PM- 5.)

VICE

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

Remove and replace the hydraulic filter.

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Remove the fill cap (Item 2) [Figure PM-21] then remove the drain / filter cover (Item 1) [Figure PM-22] from the bottom of the reservoir.

CONTROL LOCKOUT LEVERS Inspection And Maintenance When the control lockout leve rs are raised, the hydraulic control levers must not function.

Sit in the oper ator’s seat, fasten the seat belt and st art the engine.

Figure PM-23

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1

P-43617

Raise the control lockout levers (Item 1) [Figure PM-23].

Try to move the left and right hydraulic control levers. The levers must be firmly locked in neutral position and there should not be any hydraulic function for the boom, arm, bucket and swing.

Service the system if these controls do not deactivate when the control lockout is raised.

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SPARK ARRESTOR MUFFLER For the correct service interval (See SER SCHEDULE on Page PM- 5.)

WARNING

VICE

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.

Do not operate the excavato r with a defective exhaust system.

Stop the engine and raise the engine cover.

W-2050-1285

Figure PM-24

WARNING

1

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

Failure to obey can cause serious injury.

WARNING

P-43554

Remove the plug (Item 1) bottom of the muffler.

[Figure PM-24] from the

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.

Lower the engine cover , enter the excavator and fasten the seat belt.

W-2068-1285

Have a second person with safety goggles, hold an object over the outlet of the muffler.

WARNING

Start the engine and run for about 10 seconds. The carbon deposits will be forced out of the muf fler through the cleanout hole.

Stop the engine, raise the engine cover and inst plug.

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

all the

Failure to do so can cause injury or death.

W-2203-0595

Close the engine cover.

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W-2011-1285

TRACK TENSION

Figure PM-26

NOTE: The wear of undercarriage parts vary with working conditions and types of soil conditions. Maintain the correct track tension by inspecting regularly. See SERVICE SCHEDULE on Page PM- 5 for the correct service interval.

3/8-5/8 in.

10-15 mm

Adjusting

Frame

Roller

Figure PM-25

P-43718

Measure the rubber track sag at the middle track roller [Figure PM-26]. Do not get your fingers into pinch points between the track and the tr ack roller. Use material of appropriate size to check the gap between the cont act edge of the roller and top edge of the track guide [Figure PM-26].

1

Figure PM-27 P-43716

Turn the uppercarriage to one side. Lower the boom until it raises one track off the ground about 2 inches (50 mm).

Put blocks under the track frame (Item 1) [Figure PM-25] and raise the boom until the weight of the machine is on the blocks.

Turn the uppercarriage p arallel with the tracks. S top the engine.

P-43551

WARNING

Remove the two bolts and cover.

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

Loosen the lock nut an d turn the other nut [Figure PM27] until adjustment is correct. Tighten the lock nut.

W-2142-0903

Repeat procedure for the other track.

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FINAL DRIVE CASE

LUBRICATING THE EXCAVATOR

Checking And Adding Oil

Lubrication Locations

Figure PM-28

Lubricate the excavator as specified for the best performance of the machine. (See SER SCHEDULE on Page PM- 5.)

VICE

Record the operating hours each time you lubricate the machine.

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

1

Figure PM-29 1 P-43552

Remove both plugs and add o il to the top hole until oil comes out of the lower hole.

2

Use sealing t ape (EXAMPLE: T eflon Tape) on the threads and install both plugs.

P-39937

Repeat for other side of machine.

Replacing Oil

Ref. Description (Number of Fittings)

Rotate the tracks so that one of the plugs is at the bottom, then remove both plugs.

1. Blade Cylinder - Rod End (1) 2. Blade Cylinder - Base End (1)

Add oil. (See Checking And Adding Oil 20.)

on Page PMFigure PM-30 4

3 P-39953

P-39954

P-39957

3. Boom Swing Cylinder - Rod End (1) 4. Boom Swing Cylinder - Base End (1) PM-20 66 of 86

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Put the machine on a level surface with the plugs positioned as shown (Item 1) [Figure PM-28].

Figure PM-33

LUBRICATING THE EXCAVATOR (CONT’D) Lubrication Locations (Cont’d) Figure PM-31

9 8

5

P-39936

8. Arm Cylinder - Base End (1) P-43616

9. Arm Cylinder - Rod End (1)

5. Boom Swing Pivot (2) Figure PM-32

10 6

11 10

P-39934

10. Bucket Link Pivot (1) (Also lubricates rod end of bucket cylinder.)

11. Bucket Pivots (2)

7 P-39938

6. Boom Cylinder - Rod End (1) 7. Boom Cylinder - Base End (1)

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Figure PM-34

LUBRICATING THE EXCAVATOR (CONT’D)

BLADE EXTENSION

Lubrication Locations (Cont’d)

Installing And Removing

Figure PM-35

Figure PM-37

2

1 13 P-43315

P-43578

12. Swing Circle Pinion (1)

Put a block (Item 1) [Figure PM-37] under the blade.

13. Swing Circle Bearing (1)

Fully lower the blade to the block and stop the engine.

Figure PM-36

Remove the extensions from the back side of the blade (Item 2) [Figure PM-37].

Figure PM-38 14

P-43719

14. Track Expansion Tube, as required (4)

P-43579

NOTE: Spread lubriplate gearshield extra heavy grease evenly on wear surfaces on both sides of machine as required.

Use the same bolts to install the extensions on the ends of the blade [Figure PM-38].

When not using the extensions, always store them on the back side of the blade [Figure PM-38].

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12

MACHINE SIGN TRANSLATIONS IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8 SERVICE SCHEDULE (6814967). . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6804233) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8 WARNING (6804233) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8 WARNING (6576048) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8 WARNING (6817138) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 WARNING (6808185) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-5 WARNING (6814970) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8

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WARNING (6814976) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7

MACHINE SIGN TRANSLATIONS

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SERVICE SCHEDULE (6814967)

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SERVICE SCHEDULE (CONT’D) (6814967)

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WARNING (6808185)

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WARNING (6817138)

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WARNING (6814976)

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WARNING (6814970)

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WARNING (6804233)

IMPORTANT (6560573) WARNING (6576048)

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SPECIFICATIONS EXCAVATOR SPECIFICATIONS (316) . . . . . . . . . . . . . . . . . . . . SPEC-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . SPEC-6 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6

SPECIFICATIONS

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PUBLICATIONS AND TRAINING RESORCES . . . . . . . . . . . . . SPEC-7

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EXCAVATOR SPECIFICATIONS (316) Machine Dimensions All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

35.9” (913)

29.5” (750)

82.7” (2100)

14.8” (375) 7.1” (180)

38.2” (970)

5.8” 11.8” (147) (300) 27.6” (700) 35.4” (900)

7.8” (200) 60.6” (1538)

34.0” (863)

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• •

B-21830

50.7” (1289)

111.6” (2835) 79.2” (2011)

86.5” (2198) 79.1” (2010

36.4” (924)

35.1” (891)

44.9” (1140)

36.8” (934)

60.0” (1550)

54.0” (1372) 80.1” (2035) 111.8” (2840)

108.5” (2755)

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EXCAVATOR SPECIFICATIONS (316) (CONT’D) Performance Operating Weight

1676 lb. (760 kg)

Travel Speed

1.2 mph (2.0 km/hr.)

Engine Make/Model

Kubota D722

Fuel/Cooling

Diesel/Liquid

Horsepower, Maximum

9.9 HP (7,4 kW)

Maximum Governed RPM

2250-2350 RPM

Torque, Maximum

28.9 lbf.-ft. (39,2 N•m) @ 1800 RPM

Number of Cylinders

3

Displacement

44 cu. in. (0.72 L)

Bore/Stroke

2.70 in. / 2.80 in. (67 mm / 68 mm)

Lubrication

Pressure System with Filter

Crankcase Ventilation Air Cleaner

Open Dry replaceable paper cartridge with safety element Diesel-Compression

Engine Coolant

Ethylene Glycol / Water Mixture

Starting Aid

Glow Plugs

Controls Steering

Two hand levers

Hydraulics

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

Auxiliary Hydraulics Engine

Left foot pedal Hand lever; key-type starter switch and shutdown

Brakes Travel Service & Parking Swing Service Holding

Hydraulic Lock in Motor Circuit Hydraulic Lock on Motor Pin Lock

Drive System Final Drive Type of Reduction

Each track is independently driven by axial Piston Motor Two stage planetary gear reduction

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Ignition

EXCAVATOR SPECIFICATIONS (316) (CONT’D) Hydraulic System Two Hydraulic Pumps

Engine Driven Gear Type

Pump Capacity Machine Hydraulics Auxiliary

2.70 GPM (10,2 L/min.)

5.39 GPM (20,4 L/min.)

System Relief at Quick Couplers

2347 PSI (165 bar)

Filter (Hydraulic)

Full flow replaceable, 3-micron synthetic media element

Electrical Alternator

Belt driven, 12.5 amps, open

Battery

12 volts, cold cranking amps @ 0°F (-18°C)

Starter

12 volts, gear type, 1.34 HP (1,0 kW)

Instrumentation

Gauges: Hourmeter Warning lights: Glow Plugs, System Voltage, Engine Oil Pressure,

See FUEL, COOLANT AND LUBRICANTS on Page SPEC-6

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Capacities

FUEL, COOLANT AND LUBRICANTS Chart

Engine Oil

TYPE OF FLUID

RECOMMENDED FLUIDS

CAPACITY 3.2 qt. (3,1 L)

Use SAE Viscosity Number as Listed With API Classification CD or Better

Fuel

Diesel Fuel

Temp. F° +15° (9°) Down to -20° (-29°) Below -20° (-29°)

No. 2 100% 50% 0%

2.38 Gal. (9 L) No.1 0% 50% 100%

Coolant

Ethylene Glycol

Add premixed coolant; 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low. This mixture will provide freeze protection to -34°F (-37°C).

1 Gal. (3,8 L)

Hydraulic

Bobcat Fluid

6903117 - (2.5 Gal.) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

3.4 Gal. (13 L)

Drive Motors (each side)

Gear Lube

SAE-90W GL-4

7.4 oz. (0,39 L)

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RESERVOIR

PUBLICATIONS AND TRAINING RESORCES OPERATOR’S HANDBOOK

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

6902282

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

OPERATION & MAINTENANCE MANUAL

- gives basic operation instructions and safety warnings.

6902283

EXCAVATOR OPERATOR TRAINING COURSE

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

- Introduces operator to step-by-step basics of excavator operation. Also available in S panish P/N 6900125.

SERVICE MANUAL 6902285

OPERATOR SAFETY VIDEO 6724750 - Provides basic safety instructions.

- complete maintenance instructions for your Bobcat Excavator.

EXCAVATOR SERVICE SAFETY TRAINING COURSE

SAFETY MANUAL 6901951

6900916 6724793 - Introduces Service Technicians to step-by-step basics of proper and safe excavator maintenance and servicing procedures

- provide basic safety procedures and warnings for your Bobcat Excavator.

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WARRANTY Bobcat Excavators

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company’s option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement. Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors. The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, and other high-wear items.

This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6570375 (3-04)

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Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Excavator will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) tracks for twelve (12) months on a prorated basis based on the remaining depth of the track at the time any defect is discovered, and (iii) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

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