PDF DOWNLOAD Bobcat X225 Excavator Operation & Maintenance Manual (SN 508312001 & Above)

X 225 Excavator

Operation & Maintenance Manual (S/N 508312001 & Above)

6720537 (9–90) Revised (9–98)

Printed in U.S.A.

© Melroe Company 1998

OPERATOR SAFETY WARNINGS Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2003–1089

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–10731

MC–1862A

MC–1859A

MC–1865A

Never operate without instructions.

Read machine signs and Operation & Maintenance Manual.

Do not grasp control handles when entering canopy or cab.

Be sure controls are in neutral before starting.

Sound horn and check behind machine before starting.

Never operate without approved canopy or cab.

Never modify equipment.

Avoid steep areas or banks that could break away.

WRONG

WRONG

CORRECT

CORRECT

15° Maximum MC–1867

MC–1868

MC–1865B

15° Maximum MC–1878C

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

Operate on flat, level ground.

Keep bystanders out of maximum reach area.

Do not travel or turn with bucket extended.

Never carry riders.

Never exceed a 15° slope to the side.

Never travel up a slope that exceeds 15°.

CORRECT

CORRECT

CORRECT

SAFETY EQUIPMENT

Never use attachments not approved by Melroe Company.

1. Seat Belt 2. Swing Lock 3. ROPS/TOPS Canopy or Cab 4. Machine Safety Signs 5. Safety Tread 6. Grab Handles

25° Maximum MC–1878B

MC–1859A

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

To leave Excavator, lower the attachement.

Stop the engine.

Fasten seat belt securely.

Operate controls only from operator’s seat.

OSW20–0498

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

CALIFORNIA PROPOSITION 65 WARNING

SAFETY

OPERATING INSTRUCTIONS

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

PREVENTIVE MAINTENANCE REFERENCE INFORMATION Write the correct information for YOUR Bobcat Hydraulic Excavator in the spaces below. Always use these numbers when referring to your Hydraulic Excavator.

SPECIFICATIONS

Bobcat Hydraulic Excavator Serial Number . . . . . . . . . . . . . . .

Engine Serial Number . . . . . . . .

NOTES:

YOUR BOBCAT EXCAVATOR DEALER: ADDRESS: PHONE: Melroe Company P.O. Box 128 Gwinner, ND 58040–0128 Melroe Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

Melroe Company is ISO 9001 certified ISO 9001 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Melroe Company products.

British Standards Institute (BSI) is the Certifier Registrar Melroe chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Melroe manufacturing plants and the Melroe corporate offices (Gwinner, Bismarck & Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance.

Continued certification is subject to periodic audits.

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

What does ISO 9001 mean to Bobcat Customers? It means that Melroe Company produces your Bobcat loader (excavator or Spra–Coupe) and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS 3974896

ENGINE OIL FILTER

6653968 6667352

FUEL FILTER (S/N 508312001–508312647) FUEL FILTER (S/N 508312648–508312999)

6646494

AIR CLEANER

3974310

RADIATOR CAP

6653336

HYDRAULIC FILTER

6662222

BATTERY

6658230

ETHELENE GLYCOL ANTI–FREEZE

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

FOREWORD FOREWORD This manual gives the owner/operator necessary operating, and preventive maintenance instructions for the Bobcat Hydraulic Excavator.

Read this manual completely and know the Bobcat Hydraulic Excavator before operating and servicing it. All references to left or right on the excavator are given in relation to the operator’s left or right hand while in the operator’s seat.

For further information, see your Bobcat Hydraulic Excavator dealer. Parts Manuals, Service Manuals and extra Operation & Maintenance Manuals are available. The Compact Excavator Operator Training Course is also available.

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . vi

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

A

Always use the complete serial number of the machine when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number is on the front of the machine frame, to the right of the boom.

N–10469

B

ENGINE SERIAL NUMBER The engine serial number is located by the fuel injection pump on the engine block [B].

N–10408

C

DELIVERY REPORT The Delivery Report items must be explained to the owner/operator by the dealer. The dealer is to fill out the form and the owner/operator signs the form to indicate his understanding [C]. Once the delivery report is signed and returned to the factory, the machine warranty begins.

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR IDENTIFICATION * ROPS/FOPS CANOPY

ARM CYLINDER

ENGINE COVER

ARM

SWING FRAME BLADE TRACK FRAME CONTROL LEVERS

TRACK BOOM

OPERATOR SEAT

BUCKET CYLINDER

BOOM CYLINDER BUCKET LINK

• BUCKET

BLADE CYLINDER

* ROPS, FOPS – Roller–Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and SAE J1043. The bobcat Excavator is base–equipped with a standard canopy as shown.

• Factory option bucket vi

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix, x FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii, xiii

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SAFETY

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SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Bobcat Hydraulic Excavator is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards which are common for off highway, rough terrain applications but not unique for use of Bobcat Hydraulic Excavator. The excavator has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the excavator must be used with adequate ventilation. The excavator must not be used in an area with explosive dusts or gases or so that the engine exhaust can contact flammable material. Some excavators maybe equipped with a spark arrestor muffler which is required for operation in certain areas.

The dealer recommends the capabilities of the excavator and attachments for each application. The dealer demonstrates the safe operation of the excavator according to the manufacturer’s instructional materials which are also available to all operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the Bobcat Hydraulic Excavator. The user must check with the dealer or Melroe Company literature or load diagram to identify safe loads.

The following publications provide information on the safe use and maintenance of the excavator and attachments: • The Delivery Report is used to check whether complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the Bobcat Hydraulic Excavator gives operating information as well as routine maintenance information. It is a part of the machine and must stay with the machine when it is sold.

Replacement Operation & Maintenance Manuals can be purchased from your dealer.

• Every Bobcat Hydraulic Excavator has machine signs (or decals) which instruct on the safe care and operation. The signs and their location are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Hydraulic Excavator dealer.

• The Bobcat Hydraulic Excavator has a plastic Operator’s Handbook fastened to the operator cab. 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 CIMA safety manual contains information for safe operation and maintenance.

• The Service Manual and Parts Manual are optional manuals available from your Bobcat Hydraulic Excavator dealer for use by mechanics to do shop–type service and repair.

• The Bobcat Compact Excavator Operator Training Course is available through your local dealer. This course is intended to provide rules and practices of correct operation of the Hydraulic Excavator.

• The Bobcat Hydraulic Excavator Safety Video is available from your Bobcat Dealer.

The dealer and owner/operator review the recommended uses of the excavator and attachments when excavator is delivered. If the owner/operator will be using the excavator for a different application than was originally demonstrated by the dealer, ask the dealer for recommendations on the new use.

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

SI22–0398

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

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

Operator must have instructions before operating Bobcat loader or excavator and approved attachment.

Untrained operators can cause injury or death.

W–2253–0996 B–10731

The Excavator must be in good operating condition before use. Check all of the items on the Service Schedule under the 8–10 hour column or as shown in this manual.

For your safety, warnings are on the machine and in the Operation & Maintenance manual. Failure to obey warnings can cause injury or death.

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

W–2044–1285

I–2019–0284

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS • The written instructions from Melroe Company include the Delivery Report, Operation & Maintenance Manual, Operator Handbook, and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements.

Regulations may apply to local driving requirements or use of Slow Moving Vehicle emblem. Regulations may identify a hazard such as a utility line.

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demonstration and verbal instruction. This training is given by your excavator dealer before the excavator is delivered.

• The new operator should start in an area without bystanders and use all the controls until he can operate safely under all conditions of the work area.

• The Compact Excavator Operator Training Course is available in English and Spanish. The course provides information for safe and efficient operation. See your dealer for availability.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated lift capacity of the excavator. For example, you should not use the excavator for lifting heavy objects.

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

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

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing excavator. Safety glasses,

hearing protection or an excavator special application kit are required for some work. See your dealer about Melroe Safety equipment.

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

SI23–0598 x

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FIRE PREVENTION The excavator has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. These conditions make it important to avoid applications where explosive dust or gases can be ignited by arcs, sparks or heat.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The excavator must be cleaned as often as necessary to avoid this accumulation. This flammable debris in the engine compartment can be a fire hazard when the machine is parked with a hot engine.

If equipped the spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. This spark arrestor muffler does not change the need to avoid use of the excavator in an atmosphere with explosive dust or gases or where the exhaust can contact flammable material.

• Do not use the Hydraulic Excavator where explosive dust or gases can be ignited by arcs, sparks, hot components or exhaust gases.

• The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent overheating. Remove all flammable material.

• 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. Tighten or replace any parts that show leakage. Always clean fluid spills.

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can explode and injure bystanders.

• Always clean the excavator before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

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

• Use the procedure in Operation & Maintenance Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for servicing the spark arrestor muffler (if equipped) every 100 hours of operation.

• Know where fire extinguishers and first aid kits are located and how to use them. A fire extinguisher is available from your Bobcat Dealer.

SI24–0398

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

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. Replacement machine signs are available from your Bobcat Excavator dealer.

6537587 (ISO) 6587139 6643358

6533901

6537456 (STD)

6534217

6587247 6587124

6533927

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

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

6533902 (ISO) 6643356 6586696

6643355

6537457 (STD)

6565990

6534739

6561379

6537595 6539148 Cab Models 6539149 Canopy Models

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225(S/N508312001&Above)ExcavatorOperation&MaintenanceManual#6720537–ContentsSection

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

OPERATING INSTRUCTIONS AUXILIARY OPERATION PEDAL LOCK/FOOTREST . . . . . . . . . . . . . . . . . . 10 BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BOOM SWING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CONTROL CONSOLE LEVER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OPERATING INSTRUCTIONS

CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation Of Left Control Lever (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation Of Right Control Lever (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation Of Left Control Lever (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation Of Right Control Lever (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Breaking In A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 General Operation Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operating In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Operating On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PARKING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STARTING/STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normal Starting Procedure (With Engine Warm) . . . . . . . . . . . . . . . . . . . . . . 11 STEERING LEVERS/FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Making A Counter–Rotation Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SWING LOCKING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TRANSPORTING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . 16

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GETTING ON AND OFF THE MACHINE

A

Use the grab handles, the tracks and the safety tread to get on and off the machine [A].

PI–10411

Fasten the seat belt snugly. Adjust the seat belt so that the buckle is centered between the hips [B].

B

PI–07353

Lower the left control console before starting the engine.

(See Page 15) [C].

C

Lift up on the lever (Item 1) [C] to release and raise the control console.

1

PI–10412

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SEAT

A

The operator seat can be adjusted as follows: Use the lever (Item 1) [A] to slide the seat back or forward for easy reach of the machine controls.

NOTE: For ease of access to the seat adjusting lever, have the left hand console in the raised position.

1

PI–10414

The handle (Item 1) [B] has three adjustments for operator weight. Rotate the handle to change the adjustment.

B

1

Turn the knob (Item 2) [B] to angle the back of the seat for operator comfort.

2

PI–10413

CONTROL CONSOLE LEVER LOCK

C

The control lock (Item 1) [C] disconnects the hydraulics from the joystick control levers when the left control console is in the raised position. (The joystick control levers will not operate with the console raised).

1

NOTE: The travel levers, blade lever, boom swing pedal and the attachment operation pedal functions are NOT affected by the control lock.

PI–10417

Lower the left control console to engage the joystick control levers.

D

PI–10418

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

INSTRUMENT PANEL

A 8

The instrument panel has the following instruments [A]:

1 2

1. PREHEAT INDICATOR – When turning the key switch to the HEAT position, the light comes ON, showing the glow plugs are heating.

7

3

2. ENGINE TEMPERATURE – Overheat indicator.

STOP the engine when lit.

6

4

3. LOW FUEL INDICATOR – Lights when fuel level is below 1.5 gals. (5 L).

5

4. FUEL GAUGE – Shows the amount of fuel in the tank.

5. HOURMETER – Records total operating hours.

N–10415

B

6. CHARGING GAUGE – Shows battery charge rate.

A

7. ENGINE TEMPERATURE GAUGE – Shows engine coolant temperature. Buzzer sounds when temperature reaches 230°F (110°C).

B

D C

8. ENGINE OIL LAMP – When the engine oil pressure is low, the light comes ON and audible alarm sounds. STOP the engine.

NOTE: To check oil pressure and water temperature lights, turn the key to the on position. Bulbs should light for ten seconds. Allow five seconds cooling time and try again.

PI–10416

C

LIGHT SWITCH The key switch has the following functions [B]: A. Light switch is OFF. B. PRE–HEAT position, hold switch in this position for the appropriate amount of time, as shown in [C], for starting in cold weather conditions.

C. START the engine.

D. ON (run) psition, once the engine is running release the key and this positon is obtained automatically.

6589058

NOTE: Always turn key switch to OFF position after the engine is stopped or battery will discharge.

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS

A

The work equipment is operated by using the left and right control levers (joysticks) [A] & [B].

Operation Of Left Control Lever (ISO) Arm and Swing (Decal P/N 6589741) The left lever is used to operate the arm and swing the upperstructure [A]: 1.

2.

3.

4.

Arm Out Arm Out and Swing Right Swing Right Arm In and Swing Right

5.

6.

7.

8.

Arm In Arm In and Swing Left Swing Left Arm Out and Swing Left

PI–10420

Before swinging the upperstructure, make sure the swing lock is disengaged.

I–2051–0189

PI–08226

Operation Of Right Control Lever (ISO)

B

Boom and Bucket (Decal P/N 6589740) The right lever is used to operate the boom and bucket [B]: 1.

2.

3.

4.

Boom Lower Boom Lower and Bucket Dump Bucket Dump Boom Raise and Bucket Dump

5.

6.

7.

8.

Boom Raise Boom Raise and Bucket Curl Bucket Curl Boom Lower and Bucket Curl

PI–10419

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 PI–08227

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS (Cont’d)

A

The work equipment is operated by using the right and left control levers (joysticks) [A] & [B].

Operation Of Left Control Lever (STANDARD) Boom and Swing (Decal P/N 6589842) The left lever is used to operate the boom and swing the upperstructure [A]: 1.

2.

3.

4.

Boom Lower Boom Lower and Swing Right Swing Right Boom Raise and Swing Right

5.

6.

7.

8.

Boom Raise Boom Raise and Swing Left Swing Left Boom Lower and Swing Left

PI–10420

Before swinging the upperstructure, make sure the swing lock is disengaged.

I–2051–0189

PI–02864

Operation Of Right Control Lever (STANDARD)

B

Arm and Bucket (Decal P/N 6589843) The right lever is used to operate the arm and bucket [B]: 1.

2.

3.

4.

Arm out Arm Out and Bucket Dump Bucket Dump Arm In and Bucket Dump

5.

6.

7.

8.

Arm In Arm In and Bucket Curl Bucket Curl Arm Out and Bucket Curl

PI–10419

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 PI–02863

–7–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SPEED CONTROL LEVER

A

The speed control lever is used to control the engine speed [A]:

3

2

1

1. ENGINE STOP – Pull the lever all the way backward and hold until engine stops.

2. LOW IDLE POSITION – Lever is spring loaded to return from stop position to idle position.

3. HIGH IDLE POSITION – Push the lever fully forward from low idle position for full engine RPM. PI–10421

HORN BUTTON

B

The horn button (Item 1) [B] is located in the right control lever grip.

1

N–10415

SWING LOCKING LEVER When the swing lock pin (Item 1) [C] is engaged (locked postion), the upper works of the excavator is locked to the track frame and will not pivot.

C

Lift the swing lock pin (Item 1) [D] to disengage swing frame from the track frame, put the pin in the unlocked position.

1

PI–10422

AVOID INJURY

D

The swing lock lever must be engaged when transporting the machine.

W–2197–0595

1 Engage the swing lock pin only after the upper works is parallel with the track frame.

I–2052–0297

N–10423

–8–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

STEERING LEVERS/FOOT PEDALS

A

Forward And Reverse Travel

FORWARD

Slowly push or pull the right (Item 1) [A] and left (Item 2) [A] steering levers/foot pedals for forward or reverse travel.

1 NEUTRAL

2

REVERSE

AVOID INJURY OR DEATH PI–10424

• Check the blade location before traveling.

When the blade is to the rear, operate the steering levers/foot pedals in the opposite direction to when the blade is in the front.

• Move the steering levers/foot pedals slowly.

Abrupt lever motion will cause the machine to jerk.

B

Right Pivot Turn (Forward)

Left Pivot Turn (Forward)

W–2235–0396

Turning Operate the steering levers/foot pedals in the following manner to change the direction of a stationary machine (with blade forward): LEFT TURN – Push the right steering lever/foot pedal forward to turn to the left in the forward direction [B]. Pull it back to make the machine turn left in the reverse direction [C].

B–10979

RIGHT TURN – Push the left steering lever/foot pedal forward to turn to the right in the forward direction [B]. Pull it back to make the machine turn to the right in the reverse direction [C].

C

Right Pivot Turn (Reverse)

Left Pivot Turn (Reverse)

Changing direction of a moving machine, the left and right steering levers/foot pedals are pushed or pulled in the same direction.

B–10979

Making A Counter–Rotation Turn

D

To counter–rotate the machine to the left, pull the left steering lever/foot pedal back and push the right steering lever/foot pedal forward [D].

To counter–rotate the machine to the right, push left steering lever/foot pedal forward and pull the right steering lever/foot pedal back [D].

Counter–Rotation Turn (Right) –9–

Counter–Rotation Turn (Left) B–10979

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

BOOM SWING PEDAL

1

A

Raise the pedal lock/footrest (Item 1) [A] to operate the boom swing pedal.

3

Push the pedal (Item 2) [A] on the right side to swing the boom to the right and push the pedal on the left side to swing the boom to the left.

2

NOTE: The purpose of the boom swing pedal is to offset the boom with respect to the upperstructure.

AUXILIARY OPERATION PEDAL LOCK/FOOTREST

4

Raise the pedal lock/footrest (Item 3) [A] to operate the attachment operation pedal.

PI–10426

The pedal (Item 4) [A] controls optional equipment when mounted on the arm.

B

The excavator is equipped with 2–way flow auxiliary lines.

Push the pedal (Item 4) [A] to activate the hydraulic function. The right side of the pedal is hydraulic pressure/flow to the female coupler and the left is hydraulic pressure/flow to the male coupler [A] and [C].

To change to one–way flow (return to tank with low back pressure) move the center hose (Item 1) [B] to the fitting (Item 2) [B] and cap the center fitting. The pedal will now supply fluid when pushed to the right side only.

2 1

Install the center hose (Item 1) [B] onto the fitting (Item 2) [B] when using the hydraulic breaker.

The female coupler (Item 1) [C] is pressure, the male coupler (Item 2) [C] is return when pedal is pushed to the right.

PI–10427

C

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

1 2 PI–10452

W–2003–0797

D

BLADE CONTROL LEVER The lever (Item 1) [D] is used to raise and lower the blade: Position A – Pushed Forward – Lowers the blade.

Position B – Neutral – Blade is stopped and held in position.

1

Position C – Pulled Back – Raises the blade.

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

A

B

C N–10476

–10–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

DAILY INSPECTION

A

Check the following items before starting each day of operation: • Operator Canopy or Cab (ROPS) and mounting hardware.

• Seat belt and its mounting hardware.

• Damaged decals, replace as needed.

• Air cleaner and intake hoses.

• Engine coolant level and for coolant leaks.

• Engine oil level and for engine leaks.

• Clean engine area of any flammable material.

• Hydraulic fluid level and system for leaks.

• Grease all pivot points.

• Cylinder and attachment pivot points.

• Track tension.

• Repair broken and loose parts.

PI–10426

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

1

2

W–2144–0189 PI–10421

STARTING/STOPPING THE ENGINE Normal Starting Procedure (With Engine Warm)

C

Fasten the seat belt.

Lower the left control console to the locked position.

Put all control levers in the neutral position [A].

Pull the engine speed control lever to the low idle position (Item 2) [B].

Move the key to HEAT position (if required), the light will come on. Hold the key in the heat position for 5 to 10 seconds [C].

Turn the key to the START position [D].

6589058

When the engine is started, release the key and it will return to the run (ON) position.

D

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

PREHEAT

OFF ON

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

I–2034–0284

CD–02824

–11–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

2

W–2050–1285

1

PI–10421

• Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

B

W–2051–1086

Cold Temperature Starting Condition Use the following procedure to make starting easier: Replace the engine oil with correct type and viscosity for the anticipated starting temperature. (See Oil Specifications Page 47.)

Make sure the battery is fully charged.

6589058

Install a tank heater on the engine.

C

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

W–2071–1285

Push the engine speed control lever fully forward (Position 2) [A].

Turn the key to HEAT position, the light will come on [B].

Preheat the engine for 30 seconds maximum.

PI–02824

Turn the key to START position and start the engine [C].

Release the key, and it will return to the run ON position.

When the engine speed increases, move the engine speed control lever immediately to low idle (Position 1) [A].

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

I–2034–0284

–12–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

When operating in water or crossing streams, first check the soil conditions, depth and flow of water. Never operate in water higher than the bottom of the swing circle.

OPERATING PROCEDURE Breaking In A New Machine When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or Directional Signals may be required.

NOTE: Be careful when removing the machine from water. The engine may become filled with water and damage could result.

A new machine requires careful operation during the first 100 hours to break in various parts.

Do not operate the machine when visibility is poor (fog, mist or smoke).

If a machine is subjected to hard use during the initial operation, the performance and service life will be reduced.

Do the following when operating a new machine:

If it is necessary to operate the control levers when moving the machine near a cliff, road shoulders, or sloping ground, stop the machine travel before operating any work equipment levers.

•

After starting, let the engine idle for 5 minutes so the engine and components can warm up.

Do not dig under the machine.

•

Avoid operation with heavy loads or at high speeds.

•

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

Avoid sudden starting or stopping or abrupt motions.

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

General Operation Suggestions

Do not move the machine with the bucket in the ground or trench.

Know where the first aid kit and fire extinguisher are and know how to use them. Also know how to contact emergency assistance.

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

When operating on uneven ground or in places where there are obstacles, do the following:

•

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

•

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

To brake the machine when going down a slope, put the steering levers in NEUTRAL position. This will engage the hydrostatic braking.

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

When working in wet or soft ground, put planking on the ground to prevent the machine from getting stuck. If the machine is stuck in soft soil, use the following procedure to move the machine to firm ground:

NOTE: The left hand control console must be in the locked down position, with the engine stopped, to activate the accumulator pressure to lower the boom/bucket (attachments) to the ground.

1. If one track or both tracks are stuck in soft soil, push the bucket down against the ground to raise the track (or tracks, one side at a time) off the ground.

Start the engine and resume the operation.

2. Place timber (planks) under the track(s) and drive the machine to firm ground.

3. It may help to put the bucket into the ground in front and move the arm as if you were digging to help move the machine.

–13–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Operating On Slopes

TRAVELING DOWN OR BACKING UP SLOPES

AVOID INJURY OR DEATH • Do not travel across or up slopes which are

over 15 degrees to the side, or to the back of machine or 25 degrees to the front. Keep boom centered while traveling.

• Keep attachments as low as possible when traveling on slopes or in rough conditions.

MC–01878B

W–2199–0595

B

TRAVELING ON SIDE SLOPES

TRAVELING UP SLOPES

15 °Maximum

15° Maximum

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

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

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

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

MC–01878C

Stop the machine travel before moving the upper equipment controls. Never allow the blade to strike a solid object. Damage to the blade or hydraulic cylinder can result.

C

RECOMMENDED POSITION FOR WORKING ON A SLOPE

When working on a slope, it is recommended to level the work area [C].

If this is not possible, the following procedures should be used: Do not work on slopes which are over 15 degrees.

Slow down the work cycle.

Avoid working with the tracks across the slope as this reduces stability and increases the tendency for the machine to slide. Position the excavator with the blade down hill and lowered.

MC–01865C

Avoid swinging or extending the bucket farther than necessary in a down hill direction. When you must swing the bucket down hill, keep the dipper 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.

–14–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

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

Do not operate or immerse the Excavator in water higher than the bottom of the swing circle [A].

Water Level

Properly grease the Excavator when it has been operated or immersed in water for a period of time.

MC–01857

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.

B

PARKING THE HYDRAULIC EXCAVATOR STOP

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

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

Push the speed control lever fully to the rear and hold in this position until the engine comes to a complete stop [B].

PI–10421

Turn the key switch to the OFF position [C].

C

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

PREHEAT

OFF ON

START

CD–02824

–15–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

TRANSPORTING THE HYDRAULIC EXCAVATOR

A

Make sure the parking brakes on the transport vehicle are engaged and wheels are blocked.

Align the ramps with the center of the transport vehicle.

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

Use metal loading ramps and slip resistant surface.

Make sure the ramps are the correct length and width, and can support the weight of the machine.

The rear of the trailer must be properly blocked or supported when loading or unloader the excavator

P–02831

Determine the direction of the track movement before moving the machine (blade forward). Engage the swing lock pin to lock the upperstructure.

B

Move the machine forward onto the transport vehicle [A].

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

After loading the machine, position the arm and bucket as shown [B].

Lower the boom.

Stop the engine and remove the key.

Use the following procedure to fasten the Excavator to the transport vehicle:

P–02832

C

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

Fasten holddown chains to the front corners of the blade and to the tie down loop at the rear of the track frame to prevent it from moving when going up or down slopes, or during sudden stops [C] & [D].

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

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.

P–02278

D 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–02833

–16–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

LIFTING THE EXCAVATOR

A

Fully extend the cylinders of the bucket, arm & boom.

Put the work equipment control levers in neutral and engage the swing locking lever.

2 Hooks

AVOID INJURY OR DEATH

• Use a lifting fixture with sufficient capacity

MC–01857

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.

B

W–2202–0595

Secure the lifting fixture sling to the two lifting holes at the left and right side at the rear of the upperstructure and the lift eye on the boom [A] & [B].

Install a spreader bar above the cab to prevent lifting fixture from rubbing on ROPS or the rear engine cover.

P–08384

–17–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

BUCKET

A

225(S/N508312001&Above)ExcavatorOperation&MaintenanceManual#6720537–OperatingInstructionsSection

Removal

1 2

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.

P–02573

W–2140–0189

Select a flat level surface. Put the bucket on the ground.

Remove the quick pin from the pivot pins (Items 1 & 2) [A].

Remove the pivot pins and keep them clean. Do not damage the dust seals in the arm and the link.

Installation Install the arm into the bucket and align the hole [A].

Install the pivot pin (Item 1) [A].

Attach the link to the other hole and install the pivot pin (Item 2) [A].

Install the quick pins. Add grease to the pivot pins before operation.

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285

–18–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removal And Installation Of The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Service The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PREVENTIVE MAINTENANCE

FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 In–Line Fuel Filter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Replacement Of Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . 35 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SWING MOTOR REAR REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Steel Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

–19–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

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

W–2003–0797 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B–10731

B–14148

B–14142

Bobcat without

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

Never service the Hydraulic Excavator instructions.

B–14147

B–14141

B–14145

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Vent exhaust to outside when engine must be run for service.

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

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

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

WRONG

WRONG

WRONG

B–14146

B–14143

B–6589

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

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 contacts, hot parts and exhaust.

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

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

Lead–acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

–20–

MSW20–0498

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Hydraulic Excavator.

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

W–2003–0797

ITEM Engine Air Cleaner

Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Points Fuel Tank/Fuel Filer Swing Circle Swing Pinion Engine Oil & Filter Alternator Belt Final Drive Case Hydraulic Filter Fuel Filters Battery Cooling System Alternator & Starter Cooling System Hydraulic Tank Final Drive Case

SERVICE REQUIRED

8–10

Empty the dust cup. Replace the filter element only when the red ring shows in the indicator window. Check for leaks and damaged components.

Check the oil level and add oil as needed.

Check coolant level in recovery tank.

Check for correct operation.

Check the fastening bolts, nuts, & condition of cab.

Check the condition & that fasteners are tight.

Check for damaged signs (decals) replace as needed.

Check & adjust tension.

Check fluid level.

Lubricate 23 grease fittings.

Drain water and sediment from fuel tank/fuel filter.

Lubricate two grease fittings.

Lubricate one grease fitting.

Replace oil & filter element.

Check & adjust tension.

Check fluid level & add oil as needed.

Replace filter element.

Replace filter elements.

Check & clean cable ends & check electrolyte level.

Clean the radiator fins.

Check the condition.

Drain, flush & add new coolant to the cooling system.

Change the fluid & filter, clean fill neck strainer.

Change the oil.

50

100

250

500 1000

*

* Or Every 12 Months

–21–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ENGINE COVER

A

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

W–2012–0497

Keep the engine cover closed when operating the machine.

N–10429

W–2141–0189

B

Open the engine cover to service the engine. Pull on the latch and lift the engine cover up until it is fully raised [A].

1

AIR CLEANER SERVICE See the SERVICE SCHEDULE Page 21 for the correct service interval.

Replace the filter element when the red ring shows in the window of the condition indicator (Item 1) [B].

NOTE: Push the button on the condition indicator, start the engine and run the engine at high idle. If the red ring does not show, do not replace the filter element.

PI–08174

Service the air cleaner as follows:

C

Loosen the clamp on the dust cup [C].

N–08175

Remove the dust cup [D].

D

N–08176

–22–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

Remove the rubber cup to clean the dust cup [A].

N–10430

Remove the wing nut (Item 1) [B].

B

1

N–08178

Remove the filter element [C].

C

Check the air cleaner housing for damage.

Wipe the canister and the seal surface clean with a clean cloth. Do Not use compressed air.

Install a new filter element. Install and tighten the wing nut.

Install the dust cup so the arrow points up.

Check that all the air cleaner hose clamps are tight.

Push the button on the condition indicator so the red ring does not show.

N–08179

–23–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM

A

Fuel Specifications Use Number 2 diesel fuel in the engine. During very cold temperature, Number 1 fuel can be used.

1 Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

N–10415

W–2063–0887

B

Fuel System Service

1

The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the key switch is ON. Use the key to unlock the fuel fill cap (Item 1) [B].

Turn the fill cap to remove it.

N–10431

NOTE: The fuel fill strainer can be removed for cleaning [C]. Make sure it is installed before adding fuel to the tank.

C

Use a clean, approved safety container to add fuel to the tank.

Add fuel only in an area that has a free movement of air and no open flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel fill cap.

N–10432

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

–24–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel System Service (Cont’d) To remove the water and sediment from the fuel tank, remove the drain plug (Item 1) [A] on the bottom of the tank.

1

N–10433

Fuel Filters (S/N 12001–12647)

B

See the SERVICE SCHEDULE Page 21 for the correct service interval.

Turn the valve to the OFF position [B].

Loosen retaining ring and remove the final fuel filter (Item 1) [B].

1

Replace the filter element and hand tighten retainer ring only.

PI–10434

Turn the valve to the ON position [C].

C

PI–10435

Remove the in–line fuel filter (Item 1) [D] and replace it with a new element. (In–line fuel filter is on early models only.)

D

Removing Air From The Fuel System (S/N 12001–12647)

2 1

Turn the key switch to the ON position (do not start the engine). The fuel system has an electrical fuel pump (Item 2) [D]. After several minutes the fuel pump will remove the air from the fuel system.

Turn the key switch to the OFF position.

PI–10436

–25–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filters (S/N 12548 & Above) See the Service Schedule Page 21 for the correct service interval for water drainage.

1

To remove the water from the fuel filter element, open the drain valve (Item 1) [A] at the bottom of the fuel filter element.

When fuel, free of water emerges from the drain valve, close the drain valve.

2

See the Service Schedule Page 21 for the correct service interval for fuel filter element replacement.

CD–13228

Remove the hose (Item 1) [B] from the filter housing and plug the hose, or firmly squeeze the hose, to eliminate the fuel from siphoning out of the tank when the element is removed.

B

Remove the fuel filter element (Item 2) [A]. Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the new fuel filter element, and hand tighten.

1

CD–13229

In–line Fuel Filter (If equipped)

C

Remove the in–line fuel filter (Item 1) [C] and replace it with a new fuel filter. (In–line fuel filters used on early models only.)

2

1

PI–10436

Removing Air From The Fuel System (S/N 12538 & Above)

D

Loosen the filter bleed screw (Item 1) [D]. Let the fuel gravity feed from the fuel tank until it emerges from the breather vent, free of air bubbles. Close the bleed screw.

Turn the key switch to the ON position (do not start the engine). Leave the key in the ON position for serval minutes. This will remove air from the fuel system.

PI–13180

–26–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

A

Check the engine oil every day.

Stop the engine. Open the engine cover.

Remove the dipstick [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CE. (See Fuel, Coolant and Lubricants Chart, Page 52.)

N–10437

B

Engine Oil And Filter Replacement See the SERVICE SCHEDULE Page 21 for the correct service interval.

Use the following procedure to change the oil and filter: Run the engine until it is at operating temperature.

Turn the upperstructure so the engine oil can drain between the tracks. Stop the engine.

1

Remove the drain plug (Item 1) [B]. Drain the oil into a container.

N–10473

C

Remove the oil filter (Item 1) [C], using a filter wrench.

Clean the filter housing surface. Put clean grease on the filter gasket. Install the new filter and hand tighten only.

Install and tighten the oil drain plug.

1

N–10438

Remove the oil fill cap (Item 1) [D]. Put 6.3 qts. (6,0 L) of oil into the engine. (See Fuel, Coolant and Lubricants Chart & Capacity, Page 52.)

D

Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter and the drain plug.

Check the oil level and add oil as needed to bring it to the top mark on the dipstick.

N–10439

–27–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

COOLING SYSTEM

A

Coolant Level

1 When the engine is cool, the coolant level in the recovery tank (Item 1) [A] must be half full.

If the coolant level is low, add premixed coolant (50% water and 50% ethylene glycol) to the recovery tank.

Coolant Replacement

N–10440

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

B

W–2070–1285

1

Turn the upperstructure so there is access to the engine and radiator from between the tracks. Stop the engine.

Loosen and remove the radiator cap (Item 1) [B].

Open the radiator drain valve (Item 1) [C] at bottom of radiator.

Drain all the coolant from the system NOTE: Also remove all coolant from the coolant recovery tank (Item 1) [A].

N–10441

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

C

Premix coolant in a separate container.

Premix the coolant; 50% water and 50% ethylene glycol.

Fill the radiator with the premixed coolant until it is full.

Add coolant to the recovery tank until it is half full.

Run the engine at idle speed for about 5 – 10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).

1

Stop the engine. Check the coolant level and add as needed to bring it up to the radiator filler neck. Install the radiator cap and tighten.

B–13026

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ALTERNATOR/FAN BELT ADJUSTMENT

A

To adjust the belt tension, use the following procedure: STOP the engine. Open the engine cover.

The belt should deflect about 1/2 inch (13 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 13 lbs. (58 N) pressure [A].

N–10442

B

If the tension is not correct:

1

Loosen the alternator mounting bolt.

Loosen the adjustment bolt (Item 1) [B].

Move the alternator until the belt tension is correct.

Tighten the adjustment bolt and alternator mounting bolt.

Replace the belt if it has stretched or there are cracks in the belt. Check the pulley grooves, make sure the belt is not in contact with the bottom of the grooves in the pulleys.

CD–10443

–29–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

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

1

Fuses The fuses are located in the lower part of the right hand control console [A].

Loosen the two knobs (Item 1) [A] and remove the access plate.

1

1. FUSE – 15 Amp [B].

2. FUSE – 20 Amp [B].

3. FUSE – 10 Amp [B].

4. FUSE – 10 Amp [B].

N–10444

Replace the fuses with the same type and capacity.

NOTE: Before replacing any fuse, find and fix the problem that caused the fuse to blow. Make sure the key switch is in the OFF position before replacing the fuse.

B

1 2

Service The Electrical System

3

The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery saver grease [C].

Check for broken or loose connections.

4

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

N–10445

With factory equipped battery, no maintenance is needed as this is a maintenance free battery.

C

If the machine has a Melroe parts replacement battery installed, check the electrolyte level in the battery.

If it is lower than 1/2 inch (13 mm) above the plates, add distilled water only.

N–10446

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

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

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

W–2065–1296

–30–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting)

(+) If jump starting the excavator from a second machine:

(–)

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

1

2

N–10446

I–2060–0195

If it is necessary to use an extra battery to start the engine.

BE CAREFUL! Make sure the swing locking lever is in the engaged position.

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

The key switch must be in the OFF position.

The booster battery must be 12 volt.

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.

Open the engine cover.

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal (Item 1) [A] of the machine battery.

Battery gas can explode and cause serious injury.

W–2066–1296

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the same cable to the frame (Item 2) [A].

NOTE: Also see Cold Temperature Condition Page 12.

Starting

Start the engine. After the engine is running, remove the cable (Item 2) [A] connected to the frame first.

Disconnect the cable from the machine battery (Item 1) [A].

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the excavator. (Remove both cables from the battery.)

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

I–2023–1285

–31–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removal And Installation Of The Battery Open the engine cover.

Disconnect the negative (–) cable (Item 1) [A] first.

(+)

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

2

3

Remove the two wing nuts and remove the holddown clamp (Item 3) [A].

(–)

Remove the battery from the compartment.

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

1 N–10446

Install the battery. Install the holddown clamp and tighten the wing nuts.

Connect the battery cables. Connect the negative (–) cable (Item 1) [A] last to prevent sparks at the terminal.

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

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

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

W–2065–1296

–32–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM

A

Checking And Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure:

1

Put the machine on a flat level surface.

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

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [A] located on the side of the hydraulic reservoir.

N–10449

B

If the fluid level is not correct, remove oil fill cap [B].

N–10447

Check the condition of the fill strainer [C]. The screen must be installed in fill neck when adding oil.

C

Add the correct fluid to the reservoir until it is visible in the sight gauge. (See Fuel, Coolant and Lubricants Chart, Page 47.)

Install the reservoir cap.

N–10448

Replacement Of The Hydraulic Filter See the SERVICE SCHEDULE Page 21 for the correct service interval.

D

Open the engine cover.

Use a filter wrench and remove the filter element (Item 1) [D].

Clean the housing where the filter gasket makes contact.

1

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

Start the engine. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level at the reservoir and add as needed. Check around the filter for leaks.

N–10450

–33–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM (Cont’d)

A

Hydraulic Reservoir See the SERVICE SCHEDULE Page 21 for the correct service interval.

Move the upperstructure so there is clearance for the reservoir drain between the tracks.

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

Remove the hydraulic filter. (See Page 33.)

Remove the drain plug from the bottom of the reservoir [A].

N–10451

Drain the fluid into a container.

B

Install the drain plug.

Install a new hydraulic filter. (See Page 33.)

Add approximately 10.5 gals. (40 L) for S/N 12001–12045 or 9.5 gals (36 L) for S/N 12046 & Above of fluid to the reservoir. (See Coolant and Lubricants Chart, Page 47.)

1 1

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

1

PI–10453

Always clean up spilled fuel or oil, Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

Diagnostic Couplers The diagnostic couplers are located on each hydraulic pump (Item 1) [B].

The couplers can be used to check circuit pressures.

(Refer to the Service Manual.)

–34–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

A

Lubricate the Hydraulic Excavator as specified in the SERVICE SCHEDULE Page 21 for the best performance of the machine.

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

Ref.

3

2

Description (# of Fittings)

2

1

1. Blade Cylinder Rod End, every 8–10 hours (1) [A].

2. Blade Pivots, every 8–10 hours (2) [A].

N–10454

3. Blade Cylinder Base End, every 8–10 hours (1) [A].

B

4. Boom Swing Bracket Pivot, every 8–10 hours (2) [B].

5

5. Boom Base Pivot, every 8–10 hours (1) [B].

4

6. Boom Cylinder Base End, every 8–10 hours (1) [B].

6 4 N–10455

7. Boom Swing Cylinder Rod End, every 8–10 hours (1) [C].

C

8. Swing Circle Pinion, every 50 hours (1) [C].

Install four pumps of grease from a grease gun into the grease fitting. Rotate the upperstructure 180° and install four more pumps of grease into the grease fitting.

8

7 N–10456

9. Boom Cylinder Rod End, every 8–10 hours (1) [D].

D

10. Arm Cylinder Base End, every 8–10 hours (1) [D].

10

9

N–10457

–35–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A

11

Ref. Description (# of Fittings) 11. Arm Cylinder Rod End , every 8–10 hours (1) [A].

12. Arm Base Pivot, every 8–10 hours (1) [A].

13

12

13. Bucket Cylinder Base End, every 8–10 hours (1) [A].

N–10458

14. Bucket Cylinder Rod End, every 8–10 hours (1) [B].

B

15. Bucket Link Pivots, every 8–10 hours (2) [B].

15

16. Bucket Pivots, every 8–10 hours (4) [B].

16 14

N–10459

17. Swing Circle Ball Bearings, every 50 hours (2) [C].

C

NOTE: Do not over–grease the swing circle or damage to the seals could result. Install four to five pumps of grease from a grease gun into each of the two grease fittings. Rotate the upper structure 90° and install four to five pumps of grease into each of the two grease fittings.

17

N–10474

18. Boom Swing Cylinder Base End, every 8–10 hours (1) [D].

D

(Under the right side of the upperstructure)

18

N–10475

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SWING MOTOR GEAR REDUCTION

A

See SERVICE SCHEDULE Page 21 for the correct service interval.

Remove the seat and cover over the swing motor. (See Service Manual for the correct procedure.)

Remove the plug (Item 1) [A] and check the oil level.

If the level is not to the bottom edge of the plug, add oil as needed. (See Fuel, Coolant and Lubricant Chart Page 47.)

1

FINAL DRIVE CASE

CD–10656

Checking Oil Level

B

Put the machine on a flat level surface with the plugs positioned as shown in figure [B].

Remove the top plug (Item 1) [B]. The oil level should be at the bottom edge of the plug hole.

1

Add gear lube 90W through the hole if the oil level is below the hole. (See Fuel, Coolant and Lubricant Chart, Page 47.)

Install and tighten the plug.

Repeat the procedure for the other side.

2

Draining Final Drive Case

N–10460

See the SERVICE SCHEDULE Page 21 for the correct service interval.

Put the machine on flat level surface with the plugs positioned as shown in figure [B].

Remove the bottom plug (Item 2) [B] and top plug (Item 1) [B].

After all the gear lube is removed, install and tighten the bottom plug (Item 2) [B].

Add .55 quarts (0,5 L) of gear lube 90W to the top plug hole (or until gear lube level is at the bottom edge of the plug hole). Install the plug.

Repeat the procedure for the other side.

–37–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

TRACK TENSION

A

NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. See SERVICE SCHEDULE Page 21 for the correct service interval.

Adjustment Raise the machine using the boom and arm [A] Raise the blade and install jackstands under the blade and swing frame [A] and [B]. Lower the boom until all machine weight rest on the jackstands.

N–10461

Stop the engine.

B

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

W–2142–0189 N–10477

Rubber Tracks

C

Measure the rubber track sag at the middle track roller [C]. Do Not get fingers into pinch points between the track and the track roller. Use a bolt or a dowel of the appropriate size to check the gap between the contact edge of the roller and the top edge of the track guide lug [C] and [D].

Rubber Track Gap . . . . . . . . . . . . . . . . 9/16 inch (15mm)

P–02837

D

Track Frame Track 9/16” (15 mm)

Roller

Track B–14067

–38–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

TRACK TENSION (Cont’d)

A

Steel Tracks

Steel Track

Measure the steel track sag at the center of the track, between the lower edge of the track frame and the top surface of the track [A].

4.25’’–4.75’’ (108–120 mm)

Steel Track Sag . . 4.25 – 4.75 inches (108–120 mm ).

Center of Track

PI–13227

To adjust the track tension, do the following:

B

Loosen the two bolts (Item 1) [B] from the cover. Pivot the cover downward.

1

1

NOTE: Some models do not have this cover.

P–02610

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

C

1 P–02608

Loosen the bleed fitting (Item 1) [D] to release tension from the track.

D

NOTE: Do not loosen the grease fitting (Item 2) [D].

Repeat the procedure for the other side.

2 NOTE: Right hand side track frame grease fitting and bleed fitting are shown in photo [D]. For left hand side track frame, the grease fitting (Item 2) [D] will be on the bottom and bleed screw (Item 1) [D] will be on the top.

1 P–02609

–39–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

225(S/N508912001&Above)ExcavatorOperation&MaintenanceManual#6720537–PreventiveMaintenanceSection

–40–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

SPECIFICATIONS ADDITIONAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 BUCKET SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 FUEL, COOLANT AND LUBRICANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . 47 HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 43 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

–41–

SPECIFICATIONS

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

–42–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

S

HYDRAULIC EXCAVATOR SPECIFICATIONS

S

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.

15.4 (381) 80.4 (2042)

23.45 (595)

MC–01404

163.8 (4160) 118.7 (3021)

93.5 (2377) 53.43 (1357) 22.74 (577)

14.6 (370.9) 12.60 (320)

53.1 (1350)

43.3 (1100) 55.9 (1420)

54.3 (1372)

.98 (25)

70.89 (1800)

MC–01402

C D G

Inches (mm)

E

H F

B

I

A B C D E F G

J

A

MC–01403

H I J

–43–

Max. digging depth Max.vertical wall depth Max. digging reach Max. digging reach at ground level Max. digging height Max. dumping height Max. work equipment radius W/boom at max. height & arm retracted Max. height of Min. swing radius Max. lift above ground (blade) Max. drop below ground blade

97.31(2471.6) 62.74(1593.5) 171 (4344.2) 165.8(4213.7) 148 (3761) 101.27 (2577.2) 80.8 (2054.5) 115.6 (2936) 13.6 (345.9) 9.5 (241)

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) Lifting Capacity With Blade Off Ground (Model 225 with Canopy)

Lifting Capacity With Blade Off Ground (Model 225 with Cab)

–44–

225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) 225 OPERATIONS & PERFORMANCE Operating Weight (W/Canopy) . . . . . . . .

(W/Cab) . . . . . . . . . . .

Travel Speed . . . . . . . . . . . . . . . . . . . . . . .

Controls: Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . .

Function . . . . . . . . . . . . . . . . . . . . . . . . .

5440 lbs. (2468 kg) 5771 lbs. (2618 kg) 1.35 MPH (2,2 km/hr.)

Two hand lvers Two joystick levers control boom, bucket, arm and swing.

One lever controls blade.

Left foot pedal controls auxiliary hydraulic.

Right foot pedal controls boom swing.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Maximum Torque . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM – Full Load .

No Load . .

Low Idle Speed . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication System . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota D–1402–B Diesel 23.1 HP (17 kW) @ 2500 RPM 85.1 cu. in. (1395 cu. cm.)

62.9 ft.lbs. (85 Nm) @ 1800 RPM 2500 RPM 2600 RPM 1000 RPM Three 3.35/3.23 (85/82) Liquid Pressure Cartridge Type – Full Flow 12 Volt, (1.4 kW) Reduction Drive 12 Volt, 50 Amp. 12 Volt, 400 Cold Crank Amps. at 0°F (–18°C) 75 min. reserve capacity at 25 Amps.

HYDRAULIC SYSTEM Pump Numbers . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting (at control valve) Control Valves . . . . . . . . . . . . . . . . . . . . . .

Three Triple Section Gear Pumps 3x7.14 ga./min. (27,03 L/min) 2350 PSI (16201 kPa) 6 Spool, Parallel Type, Open Center 3 Spool, Parallel Type, Open Center Two Axial Piston 1.05 cu. in. (17,2 cc. rev.)

Orbit Motor 4.9 cu.in./rev. (80,6 cc.rev) 2350 PSI (16201 kPa) 363 PSI (2500 kPa)

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting . . . . . . . . . . . . . . . .

Joystick Control Setting . . . . . . . . . . . . . .

Port Relief (Arm) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief (Boom) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief (Bucket) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING SYSTEM Swing Drive . . . . . . . . . . . . . . . . . . . . . . . .

Swing Circle . . . . . . . . . . . . . . . . . . . . . . .

Swing Speed . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Left) . . . . . . . . . . . . . . . . . .

(Right) . . . . . . . . . . . . . . . . . .

2950 PSI (20345 kPa) 2950 PSI (20345 kPa) 2950 PSI (20345 kPa) 3400 PSI (23448 kPa) None 3400 PSI (23448 kPa) Orbit Motor to a 4.26:1 Planetary Drive Single Row Shear Type Ball Bearings W/Internal Gears Built Into Swing Circle 9.5 RPM 38.78 degrees 77.5 degrees

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HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) HYDRAULIC CYLINDERS Boom (Cushion–Boom Up) . . . . . . . . . . .

Arm (Cushion–Retract & Extend) . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Cushion–Left & Right) . . .

Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore 2.75 (70) 2.75 (70) 2.75 (70)) 2.38 (60) 2.75 (70)

Rod Dia. 1.50 (38) 1.50 (38) 1.50 (38) 1.38 (35) 1.50 (38)

Stroke 21.6 (590) 19.7 (500) 15.7 (400) 15.7 (400) 4.92 (125)

DRIVE SYSTEM Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Type of Reduction . . . . . . . . . . . . . . . . . . .

Maximum Drawbar Pull . . . . . . . . . . . . . .

Gradeability . . . . . . . . . . . . . . . . . . . . . . . .

Each Track is driven by a Hydraulic Axial Piston Motor 53:1 Two Stage Planetary 5000 lbs. (2668 kg.)

30 degrees

BRAKES Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Lock in Motor Hydraulic Lock on Motor & Pin Lock

UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crawler–Tractor Design Undercarriage. Sealed Track Rollers W/Reinforced Box–Section Grease Type Track Adjusters W/Shock Absorbing Recoil Springs

TRACK Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Shoes . . . . . . . . . . . . . . . . . . .

Number of Track Rollers . . . . . . . . . . . . .

Ground Pressure . . . . . . . . . . . . . . . . . . . .

Rubber (Standard) 11.8 (300) 37 3 4 PSI (0,28 kPa)

Steel (Optional) 12.6 (320) Single Assembly 3 4.16 PSI (0,29 kPa)

CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Engine Oil & Filter . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir(12001–12045) . . . .

(12046 & Above) . . .

Final Drive Case (Each) . . . . . . . . . . . . . .

9 Gals. (34 L) 6.3 Qts. (6,0 L) 6.3 Qts. (6,0 L) 10.5 Gals. (40 L) 9.5 Gals. (36 L) 0.55 Qts. (0,5 L)

MISCELLANEOUS Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2683 lbs. (1218 kg) 3863 lbs. (1754 kg)

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

FUEL, COOLANT AND LUBRICANTS Use the following chart for correct selection of Fuel, Coolant and Lubricants.

AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID

Engine oil pan

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

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100 C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38

CAPACITY Refill 6.3 qts.

(6,0 L)

SAE 10W–30 SAE 15W–40 SAE 5W–30 SAE 30 SAE 20W/20 SAE 10W

Fuel Tank

Diesel Fuel

9 gals (34,0 L)

No. 1 No. 2

Cooling System

Coolant Mixture

Hydraulic Tank

Bobcat Fluid 6563328*

S/N 12001–12045 10.5 gals. (40L) S/N 12046 & Abv. 9.5 gals. (36L)

Swing Motor Gear Reduction

SAE 30

0.32 gals.

(0,3 L)

Final Drive Case (each)

90W Gear

0.55 qts.

(0,5 L)

50/50 Water & Anti–Freeze

.

6.3 qts.

(6,0 L)

* If Bobcat fluid (P/N 6563328) is not available, use Engine Oil SAE 10W–30/10W–40, Class SE. ENGINE OIL SPECIFICATIONS Description When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the SERVICE SCHEDULE Page 21.

Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%.

Fuel Sulphur Content

Change Interval Of Engine & Oil Filter

0.5 to 1.0% Above 1.0%

1/2 of Regular Interval 1/4 of Regular Interval

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

BUCKET SPECIFICATIONS

MC–1411

Bucket Size

Caacity SAE Heaped

Shipping Weight

12 in. (300 mm) 16 in. (400 mm) 20 in. (500 mm) 24 in. (600 mm)

1.02 cu. ft. (0,029 cu. m.)

1.61 cu. ft. (0,046 cu. m.)

2.36 cu. ft. (0,067 cu. m.)

2.88 cu. ft. (0,082 cu. m.)

106.9 lbs. (48,5 kg) 123.0 lbs. (55,8 kg) 135.7 lbs. (61,6 kg) 157.8 lbs. (68,9 kg)

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225(S/N508312001&Above)ExcavatorOperation&MaintenanceManual#6720537–SpecificationsSection

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

COMPACT EXCAVATOR OPERATOR TRAINING COURSE 6722950–English 6900125–Spanish

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

SAFETY VIDEO 6724750

OPERATION & MAINTENANCE MANUAL 6720537 –complete instruction on the correct operation and the routine maintenance of the BOBCAT Compact Excavator.

–provides basic safety instructions.

Safety Manual

CONSTRUCTION INDUSTRY MANUFACTURERS ASSOCIATION

SERVICE MANUAL 6720874 –complete maintenance and overhaul instructions for your BOBCAT Compact Excavator.

SAFETY MANUAL 6570354

CIMA

–provides basic safety procedures and warnings for your BOBCAT Compact Excavator.

PARTS MICROFICHE

–Up–to–date PARTS information is also available. See your BOBCAT dealer.

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225 (S/N 508312001 & Above) Excavator Operation & Maintenance Manual

WARRANTY EXCAVATOR The Melroe Company warrants to its authorized dealer and authorized excavator dealers of Melroe Equipment, Ltd., who in turn, warrants to the original buyer (owner) that each Bobcat Excavator will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

During the warranty period, the authorized selling Melroe Excavator dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe Excavator product which fails because of defects in material and workmanship. The owner shall provide the authorized excavator dealer with prompt written notice of the defect and allow reasonable time for replacement or repair.

Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized excavator dealer for warranty work are the responsibility of the owner.

Warranty does not cover replacement of scheduled service items such as oil, filters, turn–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe attachment according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570375 (1–87) Revised (3–96)

Printed in U.S.A.