PDF DOWNLOAD Bobcat X231 Excavator Operation & Maintenance Manual (SN 508912001 & Above)

X 231 Excavator

Operation & Maintenance Manual (S/N 508912001 & Above)

6720943 (6–93) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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:

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

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231 (S/N 508912001 & 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 serivcing 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 also available.

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

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SERIAL NUMBER LOCATIONS

A

Always use the 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 left of the boom [A].

N–09233

B

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

N–11917

D

DELIVERY REPORT All 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].

v

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR IDENTIFICATION BOOM BUCKET CYLINDER

BUCKET LINK

OPERATOR SEAT

BOOM CYLINDER CONTROL LEVERS

BLADE CYLINDER

BUCKET

OPERATOR CAB ARM CYLINDER

ENGINE COVER

ARM

BLADE

TRACK FRAME

TRACK

N–11918 N–11919

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix, x FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MACHINE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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231 (S/N 508912001 & 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

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

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

6643358 6537456 (U.S.)

6537587 (I.S.O.)

6537476

6536127

6643361

6577754 6643354

N–11918

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

MACHINE SIGNS TRANSLATIONS (DECALS) (Cont’d)

6537457 (U.S.)

6537588 (I.S.O.)

6565990

6561379

*6643356

6643355

*6577754 CAB MODELS 6586563 CANOPY MODELS 6586564

6534739 6537595

* Decal Located In Engine Compartment xiii

N–11919

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231(S/N508912001&Above)ExcavatorOperation&MaintenanceManual#6720943–ContentsSection

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OPERATING INSTRUCTIONS AUXILIARY OPERATION PEDAL AND LOCK/FOOTREST . . . . . . . . . . . . . 10 BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BOOM SWING PEDAL LOCK/FOOT REST . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CONTROL LEVER (JOYSTICK) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LIFTING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 OPERATOR CAB FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Breaking In A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General Operation Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operating In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PARKING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Normal Starting Procedure (W/Engine Warm) . . . . . . . . . . . . . . . . . . . . . . . . 12 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 . . . . . . . . . . . . . . . . . . . . 17 TWO SPEED FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

GETTING ON AND OFF THE MACHINE

A

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

PI–11920

B

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

PI–09238

C

Lower the control console before starting the engine [C].

(See Page 12.)

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

1 PI–11921

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

SEAT

A

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

1

Select the seat height position number of the knob (Item 4) [A].

2

Turn the weight adjustment handle (Item 2) [A] until the number in the window (Item 3) [A] matches the number on the bottom of the knob (Item 4) [A].

3

NOTE: Turn the handle (Item 2) [A] clockwise (as viewed in the photo) to increase weight adjustment, counterclockwise to decrease weight adjustment.

4

P–02900

B

Turn the knob (Item 1) [B] to angle the back of the seat for operator comfort.

1

PI–11923

C

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

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

1

PI–11925

Lower the control console to engage the joystick control levers [D].

D

PI–11926

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

INSTRUMENT PANEL The instrument panel has the following instruments [C]:

A

1

8

2

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

3

7

2. ENGINE TEMPERATURE LAMP – Overheat indicator, when the engine coolant temperature exceeds the allowable temperature range, the light comes ON, STOP the engine.

4 6 5

3. LOW FUEL INDICATOR LAMP – When fuel level is low, the light comes ON. Add fuel.

N–11924

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

B

5. HOURMETER – Records total operating hours.

6. CHARGING GAUGE – Shows battery charge rate.

1

7. ENGINE TEMPERATURE GAUGE – Shows engine coolant temperature.

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

FUSES The fuses are located in the right hand control console, below the seat [B].

N–11950

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

C

1. 15 AMP. FUSE – This fuse supplies power to the accessories, ie: cab, horn [C].

1 2

2. 20 AMP. FUSE – This fuse supplies power to the ignition switch [C].

3

3. 10 AMP. FUSE – This fuse supplies power to the dash panel and hourmeter [C].

4

4. 10 AMP. FUSE – This fuse supplies power to the fuel shutoff solenoid [C].

KEY SWITCH

N–11951

The key switch has the following functions [D]:

D

A. Key switch is OFF and engine is shut off.

B. PRE–HEAT position, hold switch in this position to activate the glow plugs for starting in cold weather conditions.

B

C. START the engine.

A

D C

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

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

PI–10416

See Pages 12 and 13 for the starting procedure.

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS

A

The work equipment is operated by using the left and right control levers (joystick) [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 to swing the upperstructure [A]: 1.

2.

3.

4.

5.

6.

7.

8.

P–02944

Arm out.

Arm out and swing right.

Swing right.

Arm in and swing right.

Arm in.

Arm in and swing left.

Swing left.

Arm out and swing left.

Before swinging the upper works, 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.

5.

6.

7.

8.

Boom lower.

Boom lower and bucket dump.

Bucket dump.

Boom raise and bucket dump.

Boom raise.

Boom raise and bucket curl.

Bucket curl.

Boom lower and bucket curl.

P–02915

Before leaving the machine: • Lower the attachments to the ground.

• Stop the engine & remove the key.

W–2167–0195

PI–08227

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS (Cont’d)

A

The work equipment is operated by using the right and left control levers (joystick) [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.

5.

6.

7.

8.

P–02944

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

Before swinging the upper works, 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.

5.

6.

7.

8.

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

P–02915

Before leaving the machine:

• Lower the attachments to the ground.

• Stop the engine & remove the key.

W–2167–0195

PI–02863

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

SWING LOCKING LEVER

A

When the swing locking lever (Item 1) [A] is engaged (locked position), the upperstructure of the excavator is locked to the track frame and will not swing.

LOCKED 1

PI–11930

B

Lift the swing lock lever (Item 1) [B] to disengage the upperstructure from the track frame, pivot the lever to the right to put the pin in the unlocked position.

UNLOCKED

1

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

W–2197–0595 PI–11931

C 1 Never engage the swing control lever when the swing lock pin is engaged. Engage the swing lock pin aly after the upper works is parallel with the track frame.

I–2052–0189

HORN BUTTON The horn button (Item 1) [C] is located in the right control lever (joystick) grip.

P–02930

SPEED CONTROL LEVER

D

The speed control lever is used to control the engine speed [D].

1. LOW IDLE POSITION – Pull the lever backward (position 1) for low idle, (Approximately 1000 RPM).

2. HIGH IDLE POSITION – Push the lever fully forward (position 2) for full engine RPM, (Approximately 2500 RPM).

2

1 P–02923

–8–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

STEERING LEVERS/FOOT PEDALS

A

Forward And Reverse Travel

2

1

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

AVOID INJURY OR DEATH N–11932

• 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

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

BOOM SWING PEDAL

A

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

3

1

4

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

AUXILIARY FOOTREST

OPERATION

PEDAL

AND

2

LOCK/

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

PI–11932

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

B

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

Push pedal (Item 4) [A] to activate hydraulic function.

Right side of pedal is hydraulic pressure/flow to the female coupler and left is hydraulic pressure/flow to the male coupler.

1–WAY FLOW

2–WAY FLOW

1

AVOID INJURY OR DEATH Before moving the auxiliary flow control knob: • Lower the blade to the ground.

• Lower the bucket to the ground.

• Stop the engine.

PI–11934

2

C

W–2198–0595

The flow control knob (Item 1) [B] is located in front of the excavator frame by the boom swing cylinder.

To change to 1–way flow for hydraulic breaker operation (for reduced back pressure to tank) pull the knob (Item 1) [B]. The pedal will now supply fluid when pushed to right side only.

During two way flow operations, the female coupler (Item 1) [C] is pressure when the pedal is pushed to the right and the male coupler (Item 2) [C] is pressure when the pedal is pushed to the left.

1 PI–11976

BLADE CONTROL LEVER

D

The lever (Item 1) [D] is used to raise and lower the blade.

Position A – Push Forward – Lowers the blade.

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

Position C – Pull Back – Raises the blade.

NOTE: Keep the blade lowered when digging.

1 A

B

C

PI–11933

–10–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

TWO–SPEED FOOT PEDAL

A

Slow Speed: When pedal (Item 1) [A] is in the up position (Normal).

SLOW

Fast Speed: When pedal is pushed down [A].

FAST PI–11935

–11–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

DAILY INSPECTION

A

Check the following items before each days operation: *Operator Canopy or Cab (ROPS) and mounting hardware. *Seat belt and 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–11932

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

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

B 1

2

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.

PI–11933

W–2144–0189

C

STARTING THE ENGINE Normal Starting Procedure (W/Engine Warm)

OFF PREHEAT

Fasten the seat belt.

PREHEAT

ON

Lower the control console to the locked postion.

OFF ON

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

START

Pull the fuel control lever back to low idle (position 1) [B].

START

Move the key to PREHEAT position, the light will come on. Hold the key in the heat position for 5 seconds maximum.

PI–02824

Turn the key to the START position [C].

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

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

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

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

Do not 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

W–2050–1285

–12–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

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

1

W–2050–1285

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust

P–11936

gas. Keep flammable material away.

B

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

OFF PREHEAT

Cold Temperature Starting Condition

PREHEAT

ON

OFF ON

Use the following procedure to make starting easier: START

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Oil Specifications, Page 49.)

START

Make sure the battery is fully charged.

PI–02824

Install a tank heater on the engine.

Follow the steps under Normal Starting Procedure and repeat the steps below until engine starts:

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.

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

W–2071–1285

I–2034–0284

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

Turn the key to PREHEAT position, the light will come on [B]. Preheat the engine for 15 seconds maximum.

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 speed control lever immediately to the idling position (1) [A].

–13–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURE Breaking In A New Machine

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

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

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

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.

• Avoid sudden starting or stopping or abrupt motions.

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

General Operation Suggestions

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

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

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

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

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.

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

• Avoid traveling over objects (such as rocks, trees,

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

stumps, etc.).

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:

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

Start the engine and resume the operation.

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.

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.

–14–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

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–2198–0595

• When going down a slope, control the speed with the

B

steering levers and the speed control lever.

TRAVELING ON SIDE SLOPES

TRAVELING UP SLOPES

15° Maximum

15 °Maximum

• 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

MC–01878C

C

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

W–2199–0595

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.

Operating In Water

Water Level

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.

MC–01857

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

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

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.

–15–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

PARKING THE HYDRAULIC EXCAVATOR

A

Stop the machine on level ground. Lower the attachments to the ground.

LOW IDLE POSITION

Push the speed control lever fully to the rear (low idel position) [A].

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

PI–11936

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

B

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

HEAT

OFF ON

START

PI–02824

–16–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

TRANSPORTING THE HYDRAULIC EXCAVATOR

A

• Make sure the parking brakes on the transport vehicle are engaged and tracks 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.

• Determine the direction of the track movement before

moving the machine (blade forward). Engage the swing lock pin to lock the upperstructure.

P–02831

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

B

• 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: 1. Put blocks under the front and rear of the track shoes.

P–02832

C

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

3. Use chain binders to tighten the chains and then safely 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

–17–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

LIFTING THE HYDRAULIC 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.

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

• Maintain center of gravity and balance when lifting.

• Do not swing boom or upperstructure.

Engage the swing locking lever.

• Never lift with operator on machine.

MC–01561

W–2202–0595

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

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

–18–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

BUCKET

A

Removal

1

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.

2 P–03016

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

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

NOTE: Install shims (Item 1) [B] as needed to eliminate any gap between the bucket and the arm and the links.

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

–19–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

231(S/N508912001&Above)ExcavatorOperation&MaintenanceManual#6720943–OperatingInstructionsSection

–20–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Electric Solenoid (Engine Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal And Installation Of The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ROPS Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Service The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PREVENTIVE MAINTENANCE

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 In–Line Fuel Filter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replacement Of Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . 38 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

–21–

231 (S/N 508912001 & 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.

–22–

MSW20–0498

231 (S/N 508912001 & 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.

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 Filter Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Cooling System Hydraulic Tank Final Drive Case

SERVICE REQUIRED

8–10

50

100

250

500 1000

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

Check the oil level & 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 & clean.

Check fluid level.

Lubricate 24 grease fittings.

Drain water & sediment from fuel tank/fuel filter. Check fill neck strainer.

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 element.

Check & clean cable ends & check electrolyte level.

Replace the filter element.

Clean the radiator fins.

Check the condition.

Check & adjust valve clearance Drain, flush & add new coolant to the cooling system.

Change the fluid, clean fill neck strainer.

Change the oil.

After the first 50 hours of machine operation do the following: • Replace the hydraulic fluid filter.

• Check the condition of fan belt.

After the first 250 hours of machine operation do the following procedures: • Change oil in final drive case.

G Check and adjust engine valve clearance.

–23–

231 (S/N 508912001 & 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–2012–0290

Keep the engine cover closed when operating the machine.

N–11937

W–2141–0189

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

B

AIR CLEANER SERVICE See the Service Schedule Page 23 for the correct service interval.

Replace the filter element when the red ring shows in the window of the condition indicator.

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

N–08175

Service the air cleaner as follows:

C

Loosen the clamp on the dust cup and remove the dust cup [B].

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

N–10430

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

D

1

N–08178

–24–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

Remove the filter element [A}.

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.

N–08179

Push the button (Item 1) [B] on the condition indicator so the red ring does not show.

B 1

N–09362

–25–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM

A

Use Number 2 diesel fuel in the engine. During very cold temperatures, Number 1 fuel can be used. (See Fuel, Coolant and Lubricants Chart, Page 49.)

1 Stop and cool the engine before adding fuel.

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

W–2063–0887

N–11924

Fuel System Service

B

The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the engine is running.

Use the key to unlock the fuel fill cap [B].

Turn the fill cap to remove it.

N–11938

Remove and inspect the fill neck screen [C].

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 flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel fill cap.

N–11939

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.

D

W–2103–1285

To remove water and sediment from the fuel tank, remove the plug (Item 1) [D] from the bottom of the fuel tank.

Drain fuel and sediment into a container and dispose of properly.

1 N–10433

–26–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filters See the Service Schedule Page 23 for the correct service interval.

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

Drain the water into a container. When fuel free of water emerges from the drain valve, close the drain valve.

1

See the Service Schedule Page 23 for the correct service interval for fuel filter element replacement.

CD–13231

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 1

Remove the fuel filter element (Item 2) [B]. 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.

3 2 CD–13230

In–Line Fuel Filter (If Equipped)

C

Remove the in–line fuel fulter (Item 1) [C] and replace it with a new fuel filter.

(In–line fuel fitlers on early models only.)

1

CD–13232

Removing Air From The Fuel System

D

Loosen the filter bleed screw (Item 3) [B] on the filter housing.

Pump the priming ball (Item 1) [D] until fuel, free of air bubbles emerges from the bleed screw. Tighten the bleed screw (Item 3) [B].

1

PI–11963

–27–

231 (S/N 508912001 & 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].

N–11943

B

Keep the oil level between the marks on the dipstick [B].

Use a good quality motor oil that meets API Service Classification of CE. (See Fuel, Coolant and Lubricants Chart, Page 49.)

N–11944

Engine Oil And Filter Replacement

C

See the Service Schedule Page 23 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 drain plug is located between the tracks. Stop the engine.

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

1 CD–09266

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

D

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

Install and tighten the oil drain plug.

1

N–11945

–28–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Engine Oil And Filter Replacement (Cont’d) Remove the oil fill cap [D]. Put 9.0 qts. (8,5 L) of oil into the engine (See Fuel, Coolant and Lubricants Chart & Capacity, Page 49.)

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.

COOLING SYSTEM Coolant Level

N–11946

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

B

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

Coolant Replacement

1

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

N–11947

W–2070–1285

C

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 [C].

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

PI–09363

Drain all the coolant from the system.

D

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

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

Premix 50% water and 50% ethylene glycol in a separate container. Fill the radiator with the pre–mixed coolant until it is full. Add coolant to the recovery tank until it is half full.

1

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).

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.

N–11948

–29–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ALTERNATOR 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–11949

If the tension is not correct:

B

Loosen the alternator mounting bolt.

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

Move the alternator until the belt tension is correct.

Tighten the adjustment bolt and mounting bolt.

1

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

–30–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

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

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

Loosen the two knobs (Item 6) [B] and remove the access plate.

1. FUSE – 15 AMP: This fuse supplies power to the accessories, ie: cab, horn, heater [B].

N–11950

2. FUSE – 20 AMP: This fuse supplies power to the ignition switch [B].

B

3. FUSE – 10 AMP: This fuse supplies power to the dash panel and hourmeter [B].

1

4. FUSE – 15 AMP: This fuse supplies power to the fuel shutoff solenoid [B].

6

2 Replace the fuse with the same type and capacity.

3

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.

4 N–11951

5. FUSE – 10 AMP: This fuse supplies power to the cab wipers, cab lights and dome light (if equipped) [C].

C

5

N–11952

–31–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Service The Electrical System Open the engine cover [A].

N–11937

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 [B].

B

Check for broken or loose connections.

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.

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

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

N–11954

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

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 for several minutes and get medical attention in case of eye contact.

W–2065–1286

–32–

231 (S/N 508912001 & 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:

2

1

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.

N–11953

I–2060–0195

If it is necessary to use a booster 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 rear 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.

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].

W–2066–1296

NOTE: See Cold Temperature Starting Condition, Page 13.

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 loader (Remove both cables from the battery).

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

I–2023–1285

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removal And Installation Of The Battery

1

Open the engine cover.

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

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

2

N–11954

Remove the two wing nuts and remove the hold down clamp (Item 1) [B].

B

1

PI–11955

C

Remove the battery from the compartment [C].

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

Install the battery. Install the hold down clamp and tighten the wing nuts.

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

N–11956

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 for several minutes and get medical attention in case of eye contact.

W–2065–1286

–34–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Electric Solenoid (Engine Stop) The electric solenoid (Item 1) [A] shuts off fuel supply and stops the engine when the key is turned to the OFF position.

1

PI–11977

B

ROPS Electrical [B].

1. WORK LIGHT SWITCH – turn for lights on or off.

3

1

2. 2–SPEED WIPER SWITCH – turn to first position for slow, second position for hight speed.

2

3. FUSE – 15 Amp for wiper motor.

4. DOME LIGHT SWITCH – Push button turns interior light on or off.

4

PI–11957

Heater Control

C

The rotary switch (Item 1) [C] controls the heater fan motor; OFF–LOW–HIGH speed.

Temperature control (Item 2) [C] control heat range.

1 2

P–00768

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM

A

Check And Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure: Put the machine on a flat level surface.

1

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–11959

B

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

N–11960

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 in the sight gauge. (See Fuel, Coolant and Lubricants Chart, Page 49.)

Install the reservoir cap.

Replacement Of The Hydraulic Filter N–11961

See the Service Schedule Page 23 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.

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

1

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

–36–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM (Cont’d)

A

Hydraulic Reservoir See the Service Schedule Page 23 for the correct service interval.

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

1

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

Remove and replace the hydraulic filter (See Page 36.)

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

N–11962

Drain the fluid into a container.

B

Install the drain plug.

Add approximately 12 gals. (45.4 L) of fluid to the reservoir. (See Fuel, Coolant and Lubricants Chart, Page 49.)

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

1

Remove the plate (Item 1) [B] to remove oil and any debris from the raditor/cooler area.

N–11964

C

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

1

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

The couplers can be used to check circuit pressures.

(Refer to the Service Manual.)

N–11965

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

A

Lubricate the Hydraulic Excavator as specified in the Service Schedule Page 23 for the best performance of the machine.

1

Record the operating hours each time you lubricate the Hydraulic Excavator.

2

2

Always use a good quality lithium based multipurpose grease when lubricating the machine.

3

Apply the lubricant until extra grease shows.

Ref.

Description (# of Fittings)

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

N–10454

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

B

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

4 5

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

9

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

7

6

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

8

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

5

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

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.

N–11966

C

11

9. Swing Shaft, every 8–10 hours (1) [B].

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

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

10

N–11967

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

D

13. Arm Base Pivot, every 8–10 hours (1) [D].

12

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

13 14

N–11968

–38–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d) Ref.

A

Description (# of Fittings)

16 15

15. Bucket Cylinder end, every 8–10 hours (1) [A].

17

16. Bucket Link Pivots, every 8–10 hours (2) [A].

17. Bucket Pivots, every 8–10 hours (3) [A].

N–11969

18. Swing Circle Ball Bearings, every 50 hours (2) [B].

B

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.

18

N–09289

19. Boom Swing Cylinder Base End, every 8–10 hours (1) [C]. (Under the right side of upperstructure)

C

19 N–11970

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A

Checking Oil Level Put the machine on a flat level surface with the plugs positioned as shown in figure [A].

1

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

2

Add gear lube 90W through the hole if the oil level is below the hole. (See Fuel, Coolant and Lubricant Chart, Page 49.)

Install and tighten the plug.

N–11971

Repeat the procedure for the other side.

Draining Final Drive Case See the Service Schedule Page 23 for the correct service interval.

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

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

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

Add 0.55 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 and tighten the plug.

Repeat the procedure for the other side.

–40–

231 (S/N 508912001 & 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 23 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 track frame [B]. Lower the boom until all machine weight rest on the jackstands.

N–11972

Stop the engine.

B

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

W–2142–0189

N–10677

Rubber Tracks

C

Measure the rubber track sag at either 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] & [D].

Rubber Track

2.25’’–2.75’’ (57–69 mm)

Rubber Track Gap . . . . . 2.25–2.75 inches (57–69 mm) Steel Track Cap . . . . . 4.25–4.75 inches (108–120 mm)

Center of Track

D

CD–13226

Steel Track

4.25’’–4.75’’ (108–120 mm)

Center of Track

CD–13227

–41–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

TRACK TENSION (Cont’d)

A

231(S/N508912001&Above)ExcavatorOperation&MaintenanceManual#6720943–PreventiveMaintenanceSection

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

1

PI–11973

Loosen the fitting (Item 1) [B] 1 to 1–1/2 turns to release tension from the track [B].

B

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

2

1

PI–11974

C

Repeat the procedure for the other side.

Lower the cover (Item 1) [C] to clean debris from the track housing.

1

PI–11975

–42–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

SPECIFICATIONS BUCKET SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FUEL, COOLANT AND LUBRICANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . 49 HYDRAULIC EXCAVATOR SPECIFICATIONS Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cylinder Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Operation & Perfrmance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

–43–

SPECIFICATIONS

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

–44–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS • All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE standards. Specifications are

Machine Dimensions

subject to change without notice.

16.8 (426) 27.9 (710)

MC–1581

190.2 (4831) 137.6 (3495)

53.8 (1368)

94 (2388)

21.9 (558)

.98 (25)

60.8 (1545) 61.3 (1557)

14.8 (377)

78.2 (1987) 12.6 (320)

MC–1583

MC–1582

60.7 (1542)

C D G

E H F

I

J

Max. digging depth

B

Max. vertical wall depth

82.5 (2097)

C

Max. digging reach

195.4 (4963)

D

Max. digging reach at ground level

190.5 (4840)

E

Max. digging height

182 (4725)

F

Max. dumping height

126 (3200)

G

Max. work equip, radius (w/ boom at max. height & arm retracted)

82 (2088)

H

Max. height of Min. swing radius

140 (3561)

I

Max. lift above ground (blade)

14 (357)

J

Max. drop below ground (blade)

11 (280)

B A

MC–1580

A

With 32.2 (820) Arm 120 (3050)

–45–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) Lifting Capacity With Blade Off Ground (Model 231 with Canopy)

Lifting Capacity With Blade Off Ground (Model 231 with Cab)

–46–

231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) 231 OPERATIONS & PERFORMANCE Operating Weight W/Cab & Standard Bucket W/Rubber Tracks . . . . . . . . . . . . . . . . .

W/Steel Tracks . . . . . . . . . . . . . . . . . . .

Operating Weight W/Canopy & Standard Bucket W/Rubber Tracks . . . . . . . . . . . . . . . . .

W/Steel Tracks . . . . . . . . . . . . . . . . . . .

Travel Speed Low Range . . . . . . . . . . . . . . . . . . . . . . .

High Range . . . . . . . . . . . . . . . . . . . . . .

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

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

7465 lbs. (3385 kg) 7623 lbs. (3457 kg) 7134 lbs. (3235 kg) 7292 lbs. (3307 kg) 1.24 MPH (2,0 km/hr.)

2.30 MPH (3,7 km/hr.)

Two hand or optional foot levers control speed and direction Foot lever controls 2 speed drive motors Right and Left joysticks control boom, bucket, arm and swing Left foot pedal controls auxiliary hydraulic.

Right foot pedal controls boom swing.

Separate hand lever controls blade.

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 V–1902 Diesel 34 HP (25.4 kW) @ 2500 RPM 116 cu. in. (1902 cu. cm.)

82.5 ft.lbs. (111.8 Nm) @ 1800 RPM 2500 RPM 2600 RPM 1000 RPM Four 3.35/3.23 (85/82) Liquid Pressure System with Filter Cartridge Type – Full Flow 12 Volt, (1.4 kW) 12 Volt, 50 Amp. 12 Volt, 400 Cold Crank Amps.

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

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

Capacity (Implement) . . . . . . . . . . . . . . . .

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

Control Valves . . . . . . . . . . . . . . . . . . . . . .

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

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

Three Triple Section Gear Pumps (3) 9.1 GPM (34,5 L/min.)

2500 PSI (17235 kPa) Three Spool & Six Spool Two Axial Piston Orbit Piston

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

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

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

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

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

Axial Piston Motor Planetary Drive Single Row Shear Type Ball Bearings W/Internal Gears Built Into Swing Circle 9.5 RPM 50 degrees 90 degrees

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

231

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

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

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

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

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

Bore 3.25 (83) 3.00 (76) 3.25 (83) 3.00 (76) 3.50 (89)

Rod Dia. 1.75 (44) 1.75 (44) 2.00 (50) 1.50 (38) 1.75 (44)

Stroke 25.31 (643) 23.62 (600) 19.69 (500) 20.67 (400) 4.92 (125)

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

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

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

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

Each Track is driven by an Axial Piston Motor 2 Stage Planetary Gear Reduction 7100 lbs. (3550 kg.)

30 degrees

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

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

Hydraulic Lock in Motor Hydraulic Lock on Motor & Pin Lock

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

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

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

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

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

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

Crawler–Tractor Design Undercarriage. Sealed Track Rollers W/Box–Section Track Roller Frame Grease Type Track Adjusters W/Shock Absorbing Recoil Springs Rubber (Standard) 12.6 (320) 41 4 each side 4.63 PSI (32 kPa)

Steel (Optional) 12.6 (320) 41 4 each side 4.7 PSI (32,6 kPa)

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

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

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

Hydraulic Reservoir . . . . . . . . . . . . . . . . . .

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

12 Gals. (45,4 L) 9.0 Qts. (8,5 L) 6.3 Qts. (6 L) 12 Gals. (45,4 L) 0.55 Qts. (0,5 L)

MISCELLANEOUS Arm Digging Force . . . . . . . . . . . . . . . . . .

Bucket Digging Force . . . . . . . . . . . . . . . .

Maximum Loading Height . . . . . . . . . . . .

3600 lbs. (1633 kg) 5170 lbs. (2350 kg) 115 (2925)

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

FUEL, COOLANT AND LUBRICANTS Use this 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 CC, CD or CE

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 9.0 qts.

(8,5 L)

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

Fuel Tank

Diesel Fuel

12 gals (45,4 L)

No. 1 No. 2

Cooling System

50/50 Water & Anti–Freeze

Hydraulic Tank

6563328*

50/50 Water & Anti–Freeze

12.12 gals (46 L)

Swing Motor Gear Reduction Final Drive Case (each)

6.3 qts.

(60 L)

0.63 qts.

(0,6 L) 90W Gear

0.55 qts.

(0,5 L)

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

(See Page 23.)

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%

1/2 of Regular Interval

Above 1.0%

1/4 of Regular Interval

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231 (S/N 508912001 & Above) Excavator Operation & Maintenance Manual

231(S/N508912001&Above)ExcavatorOperation&MaintenanceManual#6720943–SpecificationsSection

BUCKET SPECIFICATIONS

Bucket Size

Capacity SAE Heaped

Shipped Weight

12 in. (305 mm) 16 in. (406 mm) 20 in. (509 mm) 24 in. (609 mm) 30 in. (762 mm)

1.59 cu. ft. (0,043 cu. m.)

2.12 cu. ft. (0,060 cu. m.)

2.81 cu. ft. (0,080 cu. m.)

3.62 cu. ft. (0,103 cu. m.)

4.60 cu. ft. (0,130 cu. m.)

126.6 lbs. (57,5 kg) 144.0 lbs. (65,4 kg) 160.0 lbs. (73,0 kg) 175.6 lbs. (79,7 kg) 215.9 lbs. (98,0 kg)

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231 (S/N 508912001 & 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.