Operation and Maintenance Manual

Transcription

1 EN 444 Excavator Operation and Maintenance Manual S/N & Above Bobcat Europe EN (09-06) Printed in Europe

2 OPERATOR SAFETY WARNINGS WARNING The operator must have instructions before running the machine. Untrained operators can cause injury or death. Never operate without instructions. Read machine signs and operation & Maintenance Manual. This symbol with a warning statement, means: Warning, be alert! your safety is involved! Carefully read the message that follows. Wrong 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. Correct Never operate without approved canopy or cab. Avoid steep areas or banks that could break away. Never modify equipment. Correct Correct 5 max 5 max Never exceed a 5 slope to the side. Wrong Use caution to avoid tipping do not swing heavy load over side of track. Operate on flat, level ground. Never use attachments not approved by Bobcat Company. Wrong Keep bystanders out of maximum reach area. Wrong Never travel up a slope that exceeds 5. Correct 5 max Never exceed 5 when going down or backing up a slope. Do not travel or turn with bucket extended. Never carry riders. Correct Correct SAFETY EQUIPMENT. Seat Belt. Swing Lock 3. Machine Safety Signs 4. Safety Tread 5. Grab Handles To leave the excavator, lower the attachment. Stop the engine. Fasten seat belt securely. Operate controls only from operator s seat.

3 CONTENTS CONTENTS CONTENTS...i FOREWORD... iii SAFETY INSTRUCTIONS... OPERATING INSTRUCTIONS...5 PREVENTIVE MAINTENANCE...43 SPECIFICATIONS...79 REFERENCE INFORMATION Write the correct information for YOUR excavator in the spaces below. Always use these numbers when referring to your Bobcat excavator. Bobcat excavator serial number Engine serial number Notes Your Bobcat excavator dealer Address Phone Bobcat Europe J. Huysmanslaan 59 B-65 LOT Belgium EN (09-06) i

4 CONTENTS ii EN (09-06)

5 FOREWORD FOREWORD IMPORTANT This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat excavator. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR Bobcat excavator. If you have any questions, see your Bobcat dealer. Read this manual completely and know the Bobcat 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. Bobcat Company is ISO 900:000 certified... iv Items needed for regular maintenance... iv Serial number locations...v Bobcat excavator serial number...v Engine Serial Number...v Delivery report...v Bobcat excavator identification... vi Excavator vi Features and accessories... vii Standard items... vii Options and accessories... vii EN (09-06) iii

6 FOREWORD Bobcat Company is ISO 900:000 certified ISO 900:000 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Bobcat products. British Standards Institute (BSI) is the Certified Registrar Bobcat chose to assess the Company s compliance with the ISO 900:000 set of standards. The BSI registration certifies that the two Bobcat manufacturing plants and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 900:000. Only certified assessors, such as BSI, can grant registrations. ISO 900:000 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. Items needed for regular maintenance Description Code Engine oil filter Fuel filter Fuel pre-filter Primary air filter Secondary air filter Hydraulic oil filter (return filter) Hydraulic ventilation filter Cab ventilation filter Fan / fuel pump belt Alternator belt Air conditioning belt Cab ventilation dust filter Engine oil Hydraulic oil Grease for lubricating points SAE 5W40 CE/SG (9 L) Multi purpose, lithium-soap based grease (KK-30 / DIN 585) iv EN (09-06)

7 FOREWORD Serial number locations Bobcat excavator serial number Engine Serial Number Always use the serial number of the excavator when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. The engine serial number is located on the engine in the location shown in [Figure ]. Figure The excavator serial number plate [Figure ] is located on the frame of the machine in the location shown. Figure S0805 Delivery report S0803 The Delivery Report items must be explained to the owner/ operator by the dealer. The dealer is to fill in the form and the owner/operator signs the form to indicate his understanding [Figure 3]. Excavator Serial Number The Excavator serial number plate () is located on the frame of the machine in the location shown [Figure ]. Figure 3 XXXX XXXXX Module. - Production Sequence (Series) Module. - Model/Engine Combination.The four digit Model/Engine Combination Module number identifies the model number and engine combination..the five digit Production Sequence Number identifies the order which the loader is produced. B EN (09-06) v

8 FOREWORD Bobcat excavator identification Excavator 444 Figure 4 Ref & Description Arm cylinder Boom 3 Boom cilinders 4 Operator handbooks 5 Operator seat with seat belt 6 Grab handle 7 Return to tank coupler 8 Auxiliary couplers (on both sides) 9 Arm 0 Blade cilinders Bucket Right side cover 3 Rear cover 4 Upperstructure 5 Blade 6 Undercarriage / Track frame 7 Tracks 8 Bucket cilinder "! % # $ & '! " # % $ S0 vi EN (09-06)

9 FOREWORD Features and accessories Standard items Options and accessories Model 444 Bobcat excavators are equipped with the following standard items: Below is a list of some equipment available from your Bobcat excavator dealer as dealer and/or factory installed accessories and factory installed options. 500 mm dozer bladel See your Bobcat dealer for other available options, accessories and attachments. 500 mm rubber or steel tracks Adjustable suspension seat Auxiliary hydraulics Options Boom anti-drop valve Control console locks 500 or 800 mm steel tracks Cupholder Air conditioning 000 mm dipperstick Air-cushioned operator's seat Enclosed cab* with heater Articulated boom Electrical disconnect Dipperstick Horn Dipperstick hose rupture safety valve Hydraulic joystick controls Dozer blade float position Seat belt Keyless ignition Two-speed travel Independent diesel heating Working lights Electric refuelling pump Warranty: months, 000 hours Bucket rod with crane hook Secondary auxiliary hydraulic circuit * Tip Over Protective Structure (TOPS) - Meets requirements of ISO/DIS 7 Travel motion alarm MS08 quick-change attachment mounting system Special paint Yellow rotating beacon Attachments These and other attachments are approved for use on this model Bobcat excavator. Do not use unapproved attachments. Attachments not manufactured by Bobcat may not be approved. The versatile Bobcat excavator quickly turns into a multijob machine with a variety of attachments. See your Bobcat dealer for more details on these and other attachments and field accessories. Ejector bucket Grading bucket Ripping tooth Rotating clamshell bucket Tilt bucket Trenching bucket EN (09-06) vii

10 FOREWORD viii EN (09-06)

11 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS Table of contents Safety instructions...3 Safe operation is the operator s responsibility...3 Before operating the Bobcat excavator...3 Safe operation needs a qualified operator...4 A qualified operator must do the following...4 Fire prevention EN (09-06)

12 SAFETY INSTRUCTIONS EN (09-06)

13 SAFETY INSTRUCTIONS Safety instructions Safe operation is the operator s responsibility Before operating the Bobcat excavator Carefully follow the operating and maintenance instructions in this manual. WARNING The Bobcat excavator is highly manoeuvrable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat excavator usage. This symbol with a warning statement means: Warning, be alert! Your safety is involved! Carefully read the message that follows. The Bobcat excavator has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness, so use the excavator with adequate ventilation. The excavator has a spark arrester exhaust system or silencer which is required for operation in certain areas. WARNING Operator must have instruction before operating the machine. Untrained operators may cause injury or death. The dealer explains the capabilities and restrictions of the Bobcat excavator and attachments for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for a rated lift capacity and secure fastening to the Bobcat excavator. The user must check with the dealer or Bobcat literature to determine safe loads of materials of specified densities for the excavatorattachment combination. IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. WARNING The following publications and training materials provide information on the safe use and maintenance of the Bobcat excavator and attachments: Warnings on the machine and in the manuals are for your safety. Failure to obey warnings may cause injury or death. The Delivery report is used to assure that complete instructions have been given to the new owner and that the Bobcat excavator and attachment are in safe operating condition. The Bobcat excavator and attachment must be in good operating condition before use. The Operation & Maintenance Manual delivered with the Bobcat excavator or attachment gives operating information as well as routine maintenance and service procedures. It is a part of the machine and is stored in a container provided inside the cab of the excavator. Replacement Operation & Maintenance Manuals may be ordered from your Bobcat dealer. Check all the items on the Bobcat SERVICING Schedule Sticker under the 8-0 hour column or as shown in the Operation & Maintenance Manual. Machine signs (decals) instruct on the safe operation and care of your Bobcat excavator or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer. An Operator s handbook is fastened to the cab of the excavator. Its 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 dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he should ask the dealer for recommendations on the new use. Sl EN (09-06) 3

14 SAFETY INSTRUCTIONS Safe operation needs a qualified operator Fire prevention For an operator to be qualified, he/she must not use drugs or alcoholic drinks which impair his/her alertness or coordination while working. An operator who is taking prescription drugs should seek medical advice to determine if he/she can safely operate a machine. The machines and some attachments have components which are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. A qualified operator must do the following Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can be a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard. Understand the written instructions, rules and regulations The written instructions from Bobcat company include the Delivery report, Operation & Maintenance Manual, Operator s handbook and machine signs (decals). The spark arrester exhaust system (if fitted) is designed to control the emission of hot particles from the engine and exhaust system, but the silencer and the exhaust gases are still hot. Check the rules and regulations at your location. The rules may include employer s work safety requirements. Regulations may apply to local driving requirements or use of a Slow Moving Vehicle (SMV) emblem. Regulations may identify a hazard such as a utility line. Do not use the machine where exhaust, arcs, sparks or hot components may contact flammable material, explosive dust or gases. Have training with actual operation The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating. Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered. Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part. The new operator must start in an area without bystanders and use all the controls until he can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating. Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use petrol or diesel fuel for cleaning parts. Use commercial nonflammable solvents. Know the work conditions Know the weight of the materials being handled. Avoid exceeding the Rated Lifting Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material. Do not use ether or starting fluids on any engine which has glow plugs. These starting aids may cause an explosion and injure you or bystanders. Always clean the machine, disconnect the battery, and disconnect the wiring from the electronic controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas may be produced. 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. Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or special applications kit are required for some work. See your dealer about Bobcat Safety equipment. Stop the engine and let it cool before refuelling. No smoking! Use the procedure in the Operation & Maintenance Manual for connecting the battery and for starting with jump leads. Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer EN (09-06)

15 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Table of contents Pictograms...7 Controls and instrumentation...8 Left control lever...8 Left console...9 Right control lever...0 Right console... Steering levers / foot pedals... Blade control lever...4 Boom swing pedal...4 Operator cab...5 Description...5 Entering And Exiting The Excavator...5 Raising and lowering the left console...5 Emergency exits...6 Front window ventilation...9 Top window...9 Wiper/washer fluid reservoir...0 Heating, air conditioning (option) and ventilation...0 Changing work attachments... General... Procedure for changing work attachments... Clamshell grab bucket... Attaching the rock breaker...4 Auxiliary hydraulic flow adjustment...5 Relieving hydraulic pressure...6 Daily inspection...6 Pre-starting procedure...8 Starting the engine...3 Key switch...3 Cold temperature starting procedure EN (09-06) 5

16 OPERATING INSTRUCTIONS Operating procedure Rated Operating Capacity Operating on public roads Lifting a load Excavating Boom offset Backfilling Driving the excavator Operating on slopes Operating in water Parking the excavator Recovery and transport of the machine... 4 Recovery of the machine... 4 Lifting the machine... 4 Transport of the machine EN (09-06)

17 OPERATING INSTRUCTIONS Pictograms The following table explains the meaning of the pictograms which may be attached to your machine: Battery charge indicator Travel speed, fast Pre-heating Travel speed, slow Engine oil pressure Dozer blade float position Coolant temperature Hydraulic rock breaker Air filter Changeover ISO SAE control Lashing points Fuel Fuel level Suspension points for loading by crane Fan Heater / Ventilation First-aid kit Windshield wash/ wipe system Fire extinguisher Horn R Travel motion alarm Danger of crushing Hydraulic oil Danger of injury Hydraulic oil level Hydraulic oil filter clogging indicator Observe notes in Operating Instructions Operational status Grease gun Lubricating point Operating hours Working floodlights Rotating beacon Overload warning device EN (09-06) 7

18 OPERATING INSTRUCTIONS Controls and instrumentation Left control lever Figure 5 Figure 7 S0808 S Reference Description Left control lever (Joystick) See below for left lever function. Upperstructure slew brake button When slewing the upperstructure while working on a slope, push and hold the slew brake button until the slew circuit is engaged. Release the button when the upperstructure starts to slew. This will prevent the upperstructure from drifting when the slew circuit is first engaged The work equipment (boom, arm, bucket, and upperstructure slew) is operated by using the left and right control levers (joysticks). Function The left lever is used to operate the arm and to slew the upperstructure Functions [Figure 7]:. Arm out. Arm out and slew right Push and hold the switch to provide hydraulic flow to the quick couplers. Release the switch to stop hydraulic flow. The switches (3 & 4) are used for hydraulic Note: This switch is inoperable when powered attachments the hydraulic breaker operation switch is activated. (such as a clamshell bucket). Push and hold the switch to reverse the direction of flow to the quick couplers. Release the switch to stop hydraulic flow. Arm Rest 3. Slew right 4. Arm in and slew right 5. Arm in 6. Arm in and slew left 7. Slew left 8. Arm out and slew left (Adjustable) Figure 6 S0809 Reference Description Holding Brake Push Button Function Holding brake for uppercarriage slewing motion EN (09-06)

19 OPERATING INSTRUCTIONS Left console Figure 8 Close 4 Open 3 S080 Reference Description Function Changeover ISO / SAE- control Switch (Optional) Battery Disconnect Switch 4 Fresh Air/Recirculation Open the aspirating holes for fresh Lever air. Close the aspiration holes to recirculate the cab air EN (09-06) Turn the key /4 turn counterclockwise and remove the key to disconnect the battery from the electrical system. Install the key and turn /4 turn clockwise to connect the battery to the electrical system. 9

20 OPERATING INSTRUCTIONS Right control lever Figure 9 Figure 3 4 S08 S0855 The right lever is used to operate the boom and bucket. Reference Description Function Functions [Figure ]:. Boom lower Right Control Lever (Joystick) See below for right lever function. Horn Press the button on the control lever to sound the horn. Momentary Hydraulic Switch Additional control circuit - Grab/rock breaker 3&4. Boom lower and bucket dump 3. Bucket dump 4. Boom raise and bucket dump 5. Boom raise Figure 0 6. Boom raise and bucket curl 7. Bucket curl 8. Boom lower and bucket curl WARNING AVOID INJURY OR DEATH Before leaving the machine: Lower the work equipment to the ground. Lower the blade to the ground. Stop the engine & remove the key. S083 Reference Description Function Switch Arm Rest (Adjustable) - Future Use EN (09-06)

21 OPERATING INSTRUCTIONS Right console Figure Figure S08 Reference Description S084 Reference Description Function Function Heater/AC Fan Switch Three speed fan motor control. Wiper/Washer Switch Starts and stops the wiper motor. Press and hold the bottom of the switch to activate the washer. Shows the amount of fuel in the tank. 3 - Hourmeter Displays the total operating hours on the Excavator. Rotating Beacon (If equipped) 4 Light Switch 5 Battery Charge Indicator Light will illuminate when the voltage is out of range. Press the switch to turn on the cab/ boom work light. 5 6 Glow Plugs/Manifold Heater Light will illuminate when the glow plugs/manifold heater is energized. Two Speed Travel Control Switch Engages and disengages high range travel speed. (The switch will be illuminated in high range.) 7 Engine Oil Pressure Indicator Light will illuminate when the engine oil pressure is low. 6 Auxiliary Hydraulic Mode Switch 8 Air Filter Indicator Light will illuminate when the air flow becomes restricted. Press this switch when using the hydraulic breaker. (The switch will be illuminated.) 7 Float Switch 9 Hydraulic Oil Filter Clogging Indicator Light will illuminate when the hydraulic oil filter is becoming clogged. Press this switch to put the blade in the float position. (The switch will be illuminated.) 8 0 Hydraulic Oil Level Indicator Light will illuminate when the hydraulic oil level in the tank is low. Overload Warning Switch Start/Run Switch Starts and stops the Excavator engine. Press this switch to engage the overload warning alarm. (The switch will be illuminated.) The warning alarm will sound when the boom/arm/ bucket functions are being overloaded. 9 Motion Alarm (If equipped) - 0 Air Conditioning Switch (If equipped) Turns on and off the air conditioning (optional). Boom Load Indicator Shows load on boom cylinder circuit when lifting. Engine Temperature Gauge Shows the engine coolant temperature. 3 Fuel Gauge EN (09-06)

22 OPERATING INSTRUCTIONS Steering levers / foot pedals Figure 4 Forward and reverse travel Note: The following procedures describe forward, reverse, left & right as seated in the operator's seat. Figure 6 S085 Reference Description Function Engine Speed Control Controls the RPM of the engine. Lever (throttle) Push the lever forward for low speed. Pull the lever back to increase engine speed. Temperature Control Lever S0845 Push the lever forward to increase the cab temperatures; backward to decrease temperature. Reference Description Function Steering levers Put the blade so that it is at the front of the machine (as you sit in the operator's seat). Slowly move both steering levers* forward for forward travel; backward for reverse travel.* Foot pedals Steering can also be controlled with foot pedals Figure 5 WARNING AVOID INJURY OR DEATH Check the blade location before travelling. When the blade is to the rear, operate the steering levers/foot pedals in the opposite direction to when the blade is in the front. Move the steering levers/foot pedals slowly. Abrupt lever motion will cause the machine to jerk. S088 Reference Description Function Auxiliary Power Outlet EN (09-06)

23 OPERATING INSTRUCTIONS Turning Left turn Right Turn Figure 7 Figure 0 S0849 S0846 Push the left steering lever forward to turn right [Figure 7] while travelling forward. Push the right steering lever forward to turn left while travelling forward [Figure 0]. Figure 8 Figure S0850 S0847 Pull the left steering lever backward to turn right [Figure 8] while travelling backward. Pull the right steering lever backward to turn left while travelling backward [Figure ]. Counter-Rotation Right Turn Counter-Rotation Left Turn Figure 9 Figure S0848 S085 Push the left steering lever forward and pull the right steering lever backward [Figure 9] EN (09-06) Push the right steering lever forward and pull the left steering lever backward [Figure ]. 3

24 OPERATING INSTRUCTIONS Boom swing pedal Blade control lever Figure 3 Reference Description Function Pedal [Figure 3] Push the left side of the pedal to swing the boom to the left. Push the right side of the pedal to swing the boom to the right. Figure 5 S0877 Reference Description Function Lever Push the lever forward to lower the blade. Pull the lever backward to raise the blade. S0879 Note: Keep the blade lowered when digging to help stabilize the Excavator. Note: The purpose of the boom swing pedal is to offset the boom with respect to the upperstructure for digging close to a structure [Figure 5]. Figure 4 S0867 Reference Description Switch Function Push the switch to put the blade in the float position (the switch will be illuminated) EN (09-06)

25 OPERATING INSTRUCTIONS Operator cab Raising and lowering the left console Description Figure 7 WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat. Changes to the cab may cause loss of operator protection from rollover and falling objects, and result in injury or death. Entering And Exiting The Excavator Figure 6 S080 Raise the console before exiting the cab. Pull up on the handle [Figure 7]. The lift spring will assist in raising the console. Lower the console before operating the Excavator. Push down on the handle until the console is in the down position. Note: When the console is raised, the hydraulic and traction systems are locked and will not operate. S00 Use the grab handles and track to enter and exit the Excavator [Figure 6] EN (09-06) 5

26 OPERATING INSTRUCTIONS Emergency exits The left door, right side window and front window provide emergency exits. Cab door The start key can be used to lock the cab door. Right side window Push the door all the way open until the latch engages to hold the door in the open position. Figure 8 Figure 30 S08 S084 Reference Description Window latch Function Press it together and slide the window to the rear of the Excavator. Reference Description Latch Function Pull down to release the door. Figure 9 S003 Exit through the window [Figure 9] EN (09-06)

27 OPERATING INSTRUCTIONS Front window Opening The Front Window (emergency exit) Figure 3 Note: The right hand latch is shown. The procedure is the same for both latches. Figure 33 Unlock Lock S085 Figure 3 S087 Reference Description Latches Function Turn the two latches to the unlocked position. Figure 34 S086 Reference Description The front window Function The front window is equipped with a wiper and moveable sunvisor. S088 Use both window grab handles to pull the top of the window in [Figure 34]. Continue moving the window in and up over the operator's head EN (09-06) 7

28 OPERATING INSTRUCTIONS Figure 35 Figure 37 Unlock Unlock Lock Lock S089 Reference Description The front window S083 Function Reference Description The front window is equipped with a wiper and moveable sunvisor. Latches Function Rotate the two latches to the locked position. Closing The Front Window (emergency exit) Figure 36 Lock Unlock S0830 Reference Description Latches Function Rotate the two latches to the unlocked position. Use both window grab handles to pull the window down EN (09-06)

29 OPERATING INSTRUCTIONS Front window ventilation Top window The front window may be opened approximately 8 mm. Sun shade Figure 38 The top window is equipped with a retractable sun shade. Figure 39 S083 S0833 Reference Description Locks Function Figure 40 Pull back on the window until the locks engage the slots in the window hinge. S0834 Reference Description EN (09-06) 9 Function Handle To extend the shade, pull the handle towards the rear of the Excavator. Right bracket Engage the ends of the shade in the left and right brackets. Hold the handle and allow the shade to slowly retract to the stored position.

30 OPERATING INSTRUCTIONS Wiper/washer fluid reservoir Vents Figure 43 Figure 4 S0838 S0835 Reference Description Reservoir Figure 44 Function The reservoir is located behind the operators seat on the left side of the Excavator. Use an antifreeze washer solution in freezing temperatures. Heating, air conditioning (option) and ventilation Cab fresh air vent The cab fresh air vent is located behind the operators seat. Figure 4 S0839 Figure 45 Open Close S0837 S0840 Reference Description Lever Function Move the lever to the right to close the vent. Move the lever to the left to open the vent. Reference Description 0 Heat and air conditioning vents Function There are four heat and air conditioning vents. Turn the vents to direct air as desired EN (09-06)

31 OPERATING INSTRUCTIONS Changing work attachments Procedure for changing work attachments General Various working attachments are available to achieve maximum utilization of the machine for a variety of applications. IMPORTANT In the case of a hydraulically controlled attachment, first of all the hydraulic connection must be disconnected (after relieving pressure). The machine is equipped with a quick-attach system to shorten the time it would take to install attachments. When mounting a clamshell grab, rotatable ditch-cleaning bucket or a hydraulic rock breaker, an additional control circuit is required. Additionally, an open return (return line directly to tank) may be required when operating the hydraulic rock breaker. For replacement, the work attachment must be lowered to the ground and positioned so that it cannot tilt. Figure 46 WARNING When the attachments have been removed, they must be secured against tilting and overturning to avoid possible injuries to persons. IMPORTANT The system must be relieved of pressure before hydraulic connections are disconnected. S005 The quick-mount hitch is then opened with the control rod until the locking bolts are completely retracted. Check the function of the quick-mount hitch lock and grease the bolts if necessary. Attach another work attachment and close the quickmount hitch until the locking bolts are completely extended and the lock is in place. The control rod must be kept in the drivers s cab EN (09-06)

32 OPERATING INSTRUCTIONS Clamshell grab bucket Attaching the clamshell grab bucket Retract the bucket cylinder piston rod completely. Figure 47 Turn the diverter valves clockwise on both sides (position 3 on [Figure 48]) to direct hydraulic flow to the auxiliary quick couplers for clamshell open/close functions bucket. WARNING Whilst assembling and using a clamshell grab with the quick-attach system, the bucket cylinder piston rod must be fully retracted. S084 IMPORTANT When the grab is operated, the change-over switch must be in position Rock breaker OFF (see [Figure 5]) Remove any dirt or debris from the surface of both the male and female couplers. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced. Remove the protective caps Ensure that the indicator lamp in the switch is OFF. Attach the clamshell grab and close the quick mount hitch. Figure 48 Connect the swivel motor to the couplings (position on [Figure 48]). Thread the couplers from the attachment to the couplers on the Excavator. Tighten the couplers until fully seated. LEFT SIDE Connect the open / close function to the couplings (position on [Figure 48]).Thread the couplers from the attachment to the couplers on the Excavator. Tighten the couplers until fully seated. 4 Thread the protective caps together. 3 Note: When the grab has been dismantled, re-open the diverter valves (position 3 on [Figure 48]) and Install the protective caps on the quick couplers. bucket cylinder additional control circuit WARNING AVOID BURNS RIGHT SIDE Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers. 3 additional control circuit bucket cylinder S EN (09-06)

33 OPERATING INSTRUCTIONS Operating the clamshell grab bucket Figure 5 WARNING Keep all bystanders 6 m away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death. Figure 49 S0953 Move the right joystick to the right () [Figure 49] to open the clamshell [Figure 5]. Figure 5 S0865 Figure 50 S0865 Figure 53 S095 Move the right joystick to the left () [Figure 49] to close the clamshell [Figure 50]. S0955 Push and hold the switch () [Figure 5] to rotate the bucket in the counter clockwise direction [Figure 53]. Push and hold the switch () [Figure 5] to rotate the bucket in the clockwise direction [Figure 53] EN (09-06) 3

34 OPERATING INSTRUCTIONS Attaching the rock breaker The hydraulic rock breaker is mechanically attached in the same manner as a bucket attachment. WARNING Before mounting an unapproved rock beater, it is essential to consult your dealer. The hydraulic pressure supply for the rock breaker is connected to the lines of the additional control circuit (position on [Figure 48]) by a hose coupling. IMPORTANT OPTION: The hydraulic pressure supply for rock breakers of foreign brand is connected to a line of the additional control circuit and the return via the open return line connection. The mounting and operating instructions of the hydraulic rock breaker manufacturer must be observed. Figure 55 The hydraulic circuit of the rock breaker must be secured according to the instructions of the hydraulic rock breaker manufacturer. Standard protection: 435 psi/ 300 BAR Figure 54 S084 LEFT SIDE Set the change-over switch (see figure [Figure 55]) to Rock breaker operation. 4 3 bucket cylinder additional control circuit RIGHT SIDE 3 additional control circuit bucket cylinder S EN (09-06)

35 OPERATING INSTRUCTIONS Auxiliary hydraulic flow adjustment The auxiliary hydraulic flow can be increased or decreased. Figure 58 Figure 56 S0875 S0873 Reference Description Reference Description Floormat Control valve Function The auxiliary hydraulic flow control valve is located under the cab floor. Function Figure 59 Pull up on and remove the floormat. Figure 57 S0876 S0874 Reference Description Reference Description Battery compartment cover Function Remove the battery compartment cover. Nut Function Loosen the nut and turn the adjustment screw in to increase auxiliary hydraulic flow. Tighten the nut after the flow adjustment has been made. Note: Maximum Flow 00 LPM Minimum Flow 0 LPM EN (09-06) 5

36 OPERATING INSTRUCTIONS Relieving hydraulic pressure Daily inspection Stop the engine and turn the key to the RUN position. Check the following items before each day of operation: Figure 60 Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The Service Schedule is a guide for correct maintenance of the Bobcat Excavator. It is located inside the rear door of the Excavator and also in the MACHINE SIGN TRANSLATION SECTION. Operator Cab and mounting hardware. Seat belt and mounting hardware. Damaged decals, replace as needed. Check control console lockout. Air cleaner and intake hoses. Engine oil level and for engine leaks. Hydraulic fluid level and system for leaks. S0864 Grease all pivot points. Cylinder and attachment pivot points. Track tension. Reference Description Function hydraulic breaker switch Repair broken and loose parts. Press the hydraulic breaker switch OFF. The light is not illuminated. WARNING Figure 6 Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. Fluids such as engine oil, hydraulic fluid, coolants, etc.must be disposed of in an environmentally safe manner.some regulations require that the certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal. S0865 Reference Description Switches Function Press the switches () on the right control lever several times to relieve the hydraulic pressure. Turn the key to the OFF position EN (09-06)

37 OPERATING INSTRUCTIONS Figure 6 SERVICE SCHEDULE EVERY 8-0 HOURS (50 hrs) Check engine coolant level. Check engine oil level. Check hydraulic fluid level. Check and adjust track tension. Check indicator lights for correct operation. Check canopy or *cab condition and mounting hardware. Check seat belt condition and mounting hardware. Check for damaged signs (decals) - Replace as needed. Grease all machinery pivot points. (See illustrations) Drain water and sediment from fuel tank and fuel filter. (qty 3) Check control console lockout for proper operation. Check for leaks and or tightness of pipes, hoses, control unit, hydraulic pumps, cylinders, etc. (50 hrs) (qty ) (qty ) 4 EVERY 50 HOURS 3 Grease swing pinion, swing circle and door hinges. Check battery, cables and electrolyte level. 7 EVERY 00 HOURS 6 Check and adjust belt(s) if required. 5 (qty ) EVERY 50 HOURS Check oil level in both final drive cases. Clean radiator, oil cooler, *A/C condenser and clean / replace cab ventilation filter. EVERY 500 HOURS (50 hrs) Replace hydraulic filter. Check alternator and starter connections. Replace diesel fuel filter and prefilter. Check air intake. Replace engine oil and filter. EVERY 000 HOURS OR EVERY 6 MONTHS Check and adjust engine valve clearance. Replace oil in both final drive cases. Drain and flush cooling system - Replace coolant. Replace hydraulic fluid and filter(s) - Clean reservoir. IMPORTANT THIS MACHINE IS FACTORY EQUIPPED U.S.D.A. FORESTRY SERVICE APPROVED ARRESTOR EXHAUST SYSTEM. FILTER CHART WITH A SPARK THE SPARK ARRESTOR MUFFLER, IF EQUIPPED, MUST BE CLEANED TO KEEP IT IN WORKING CONDITION. THE SPARK ARRESTOR MUFFLER MUST BE SERVICED BY DUMPING THE SPARK CHAMBER EVERY 00 HOURS OF OPERATION. ON SOME MODELS, THE TURBOCHARGER FUNCTIONS AS THE SPARK ARRESTOR AND MUST OPERATE CORRECTLY FOR PROPER SPARK ARRESTOR FUNCTION. * Service only when machine is equipped with this item. Service at first 50 hours, then as scheduled. Service at first 00 hours, then as scheduled. IF THIS MACHINE IS OPERATED ON FLAMMABLE FOREST, BRUSH OR GRASS COVERED LAND, IT MUST BE EQUIPPED WITH A SPARK ARRESTOR ATTACHED TO THE EXHAUST SYSTEM AND MAINTAINED IN WORKING ORDER. FAILURE TO DO SO WILL BE IN VIOLATION OF CALIFORNIA STATE LAW, SECTION 444. PRC. REFER TO LOCAL LAWS AND REGULATIONS FOR SPARK ARRESTOR REQUIREMENTS. SEE THE OPERATION AND MAINTENANCE MANUAL FOR MORE INSTRUCTIONS.. PRIMARY AIR FILTER SECONDARY AIR FILTER ENGINE OIL FILTER FUEL FILTER FUEL PRE FILTER HYDRAULIC VENTILATION FILTER HYDRAULIC INSERT FILTER CAB VENTILATION FILTER See illustrations above for filter locations. See Operation & Maintenance Manual for more information and instructions EN (09-06) 7 8 G EN

38 OPERATING INSTRUCTIONS Pre-starting procedure Figure 63 Figure S0836 Reference Description Operator's Handbook Function Reference Description Read and understand the Operation & Maintenance Manual and the Operator's Handbook before operating. Figure 64 S088 Function Lever Pull up on the lever to adjust the seat forward or backward. Lever Pull up on the to adjust the bottom of the seat forward or backward. 3 Lever Pull up on the lever to adjust the incline of the seat bottom. 4 Knob 5 Window Turn the adjustment knob until the operators weight is shown in the window. The seat is adjustable from 50 Kg to 30 Kg. Figure 66 S00 Use the grab handles and the tracks to enter the Excavator [Figure 5]. S0883 Reference Description 8 Lever Function Pull up on the lever to change the incline of the seat back EN (09-06)

39 OPERATING INSTRUCTIONS Figure 67 Figure 69 S0884 Reference Description Knob S0886 Function Reference Description Turn the adjustment knob to adjust the lumbar support in the seat back. Wheel Function Rotate the adjustment wheel to raise or lower the armrests. Figure 68 Figure 70 S0885 Reference Description Arm rest S0887 Function Reference Description Raise the arm rest. Note: The right armrest is shown. The procedure is the same for the left arm rest EN (09-06) 9 Mirror Function Adjust the mirror for a clear view to the rear of the Excavator from the operator s seat.

40 OPERATING INSTRUCTIONS Figure 7 S0888 Reference Description Seat belt Function Fasten the seat belt. Figure 7 S0889 Lower the control console [Figure 7]. Note: There is a control lock switch in the left console which deactivates the hydraulic control levers (joysticks) and the traction drive system when the control console is in the raised position. The console must be in the down position for the hydraulic control levers (joysticks) and traction system to operate. Note: If the control lock switch does not deactivate the control levers and the traction system when console is raised, see your Bobcat dealer for service EN (09-06)

41 OPERATING INSTRUCTIONS Starting the engine Key switch Perform the Pre-starting procedure on page 8. Figure 75 Stop WARNING Run/Preheat AVOID INJURY OR DEATH Start Fasten seat belt, start and operate only from the operator seat. Never wear loose clothing when working near machine. S089 Figure 73 Reference Description Function Key Turn the key () [Figure 75] to the RUN/PREHEAT position. Figure 76 S0845 Reference Description Levers Function Put the control levers in the neutral position. S0893 Figure 74 Reference Description Low Speed Function Glow plug light The glow plug light will be illuminated, showing the glow plugs are on. Wait for the light to go off. When the glow plug light goes out, turn the key to the start position and release the key when the engine starts.the key will return to the run position. Stop the engine if the warning lights and alarm do not go off. Check for the cause before starting the engine again. High Speed Turn the key switch OFF to stop the engine. S0867 IMPORTANT Reference Description Engine speed control EN (09-06) Function Do not engage the starter for longer than 5 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again. Move the engine speed control fully forward to the low speed position. 3

42 OPERATING INSTRUCTIONS Cold temperature starting procedure Figure 78 If the temperature is below freezing, perform the following to make starting the engine easier: Replace the engine oil with the correct type and viscosity or the anticipated starting temperature. ( Fluid Specifications on page 9.) Make sure the battery if fully charged. Note: If the battery is discharged (but not frozen) a booster battery can be used to jump start the Excavator. ( Using A Booster Battery (Jump Starting) on page 60.) S0893 Install an engine heater. Figure 77 Reference Description Low Speed Function Glow plug/manifold heat light The glow plug/manifold heat light will be illuminated showing the glow plugs are on. Wait for the light to go off. When the light goes out, turn the key to the start position and release the key when the engine starts. The key will return to the run position. When the engine speed increases, move the speed control lever to the low speed position until the engine warms up. Turn the key switch off to stop the engine. High Speed S0867 Reference Description IMPORTANT Function Speed control lever Move the speed control lever back to the high speed position. Key Turn the key to the RUN / PREHEAT position. Do not engage the starter for longer than 5 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again. IMPORTANT Machines warmed up with moderate engine speed and light load have longer life. IMPORTANT Do not use ether with glow plug (preheat) systems. Explosion can result which can cause in jury or death, or severe engine damage EN (09-06)

43 OPERATING INSTRUCTIONS Operating procedure Rated Operating Capacity The capacity of the excavator changes as the boom/arm is raised or extended. The Rated Operating Capacity table below (see also Rated Operating Capacity on page 86) shows the capacity of the machine at different load positions. Figure 79 EXCAVATOR MODEL 444 WARNING BOOM LENGTH ARM LENGTH RUBBER TRACKS CIRCUIT PRESSURES WORKING 360 bar HOLDING 380 bar OVERLOAD CAN TIP THE EXCAVATOR AND CAUSE INJURY OR DEATH 3750 mm 000 mm 500 mm Do not lift or hold any load that exceeds these ratings at their specified load radii and height. Total rated load is shown. The weight of all lifting devices must be deducted to determine the net load that can be lifted. Lift Point Height Where applicable, specifications conform to ISO Standards. Specifications are subject to change without notice. Lift Point is bucket hinge point with standard bucket attached and bucket cylinder fully extended. Lift Radius LIFT POINT HEIGHT RATED LIFT CAPACITY OVER BLADE, BLADE DOWN - kg RATED LIFT CAPACITY OVER BLADE, BLADE UP - kg RATED LIFT CAPACITY OVER SIDE, BLADE UP - kg LIFT RADIUS - mm LIFT RADIUS - mm LIFT RADIUS - mm mm Ground G EN Operating on public roads When operating on a public road or highway, always follow local regulations. For example: A slow moving vehicle (SMV) sign, or direction signals may be required. Check with utility companies for underground electrical, water, gas lines, etc. Work slowly in areas of underground utilities EN (09-06) 33

44 OPERATING INSTRUCTIONS Lifting a load WARNING WARNING AVOID INJURY OR DEATH AVOID INJURY OR DEATH DO NOT exceed rated operating capacity. Excessive load can cause tipping or loss of control. Check area to be dug for overhead or underground lines such as electrical, gas, oil, water, etc. CALL and consult local utilities before digging. Extreme caution must be used in areas where lines are present. Extend the bucket cylinder completely and lower the boom to the ground. Stop the engine. Wrap the chain assembly around the bucket mounting plate. Figure 80 WARNING AVOID INJURY OR DEATH Keep all bystanders 6 m away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death. S0896 Make sure the load is evenly weighted and centered on the lifting chain, and is secured to prevent the load from shifting [Figure 80]. Lift and position the load. When the load is in position and tension is removed from the lift chain (secondary lift system), remove the secondary lift system EN (09-06)

45 OPERATING INSTRUCTIONS Excavating Note: Do not allow the bucket teeth to contact the ground when swinging the upperstructure. Lower the blade to provide stability. Figure 8 Figure 84 MS855 S0900 Extend the arm, lower the boom and open the bucket [Figure 8]. Extend the arm and uncurl the bucket to dump the material into a pile or truck [Figure 84]. Figure 8 IMPORTANT Avoid operating hydraulics over relief pressure. Failure to do so will overheat hydraulic components. Figure 85 WRONG MS856 Retract the arm, while lowering boom and curling the bucket [Figure 8]. Figure 83 MS-857 Do not dig under the Excavator [Figure 85]. Do not use the bucket as a breaker or pile driver. It is better to excavate hard or rocky ground after breaking it with other equipment. This will reduce damage to the Excavator. Do not move the Excavator while the bucket is in the ground. Dig only by moving the boom and arm toward the Excavator. MS854 Do not back dig (digging by moving the boom and arm away from the Excavator). Damage to the attachments may occur. Raise the boom, retract the arm and curl the bucket [Figure 83]. Rotate the upperstructure EN (09-06) 35

46 OPERATING INSTRUCTIONS Boom offset Figure 89 Figure 86 S090 S0905 Figure 87 The boom offset allows the operator to dig close to buildings and other structures [Figure 89]. S0903 Figure 88 S0904 Swing the upperstructure, offset the boom to the right [Figure 86], centre [Figure 87], and left [Figure 88] to dig a square hole the width of the machine without repositioning the Excavator EN (09-06)

47 OPERATING INSTRUCTIONS Driving the excavator Backfilling When operating on uneven ground, operate as slow as possible and avoid sudden changes in direction. Figure 90 Avoid travelling over objects such as rocks, trees, stumps, etc. When working on wet or soft ground, put planks on the ground to provide a solid base to travel on and prevent the Excavator from getting stuck. Figure 9 S0906 Use the blade to backfill the trench or hole after excavating [Figure 90]. S0907 If one or both tracks have become stuck in soft or wet ground, raise one track at a time by turning the upperstructure and pushing the bucket against the ground [Figure 9]. Put planks under the tracks () [Figure 9] and drive the Excavator to dry ground. Figure 9 S0908 The bucket may also be used to pull the Excavator. Raise the blade, extend the arm and lower the boom. Operate the boom and arm in a digging manner [Figure 9] EN (09-06) 37

48 OPERATING INSTRUCTIONS Operating on slopes WARNING WARNING AVOID INJURY OR DEATH AVOID INJURY OR DEATH Do not travel across or up slopes that are over 5 degrees. Avoid steep areas or banks that could break away. Do not travel down or back up slopes that exceed 5 degrees. Keep boom centred and attachments as low as possible when travelling on slopes or in rough conditions. Look in the direction of travel. Look in the direction of travel. Always fasten seat belt. When going down a slope, control the speed with the steering levers and the speed control lever. Figure 94 Figure 93 Travelling on side slopes Travelling down or backing up slopes 304 mm Maximum 5 max 5 max S090 S0909 When going down grades that exceed 5 degrees, put the machine in the position shown, and run the engine slowly [Figure 93]. Figure 95 Travelling up slopes Operate as slow as possible and avoid sudden changes in lever direction. Avoid travelling over objects such as rocks, trees, stumps, etc. Stop the machine before moving the upper equipment controls. Never allow the blade to strike a solid object. Damage to the blade or hydraulic cylinder can result. 5 max S09 When travelling up slopes or on side slopes that are 5 degrees or less, position the machine as shown and run the engine slow [Figure 94] & [Figure 95] EN (09-06)

49 OPERATING INSTRUCTIONS Figure 96 Figure 97 Recommended position for working on a slope S09 S0845 When operating on a slope, level a work area [Figure 96] before beginning. Reference Description If this is not possible, the following procedures should be used: Do not work on slopes which are over 5 degrees. Use a slow work cycle. Avoid working with the tracks across the slope. This will reduce stability and increase the tendency for the machine to slide.position the Excavator with the blade downhill and lowered. Avoid swinging or extending the bucket more than necessary in a down hill direction. When you must swing the bucket downhill, keep the arm low and skid the bucket downhill. To brake the machine when going down a slope, move the steering levers to the 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 to the ground. Note: If the engine stops, the boom/bucket (attachments) can be lowered to the ground using hydraulic pressure which is stored in the accumulator. The console must be in the down position, and the key switch in the ON position. Use the control lever to lower the boom. When working with the bucket on the uphill side, keep the bucket as close to the ground as possible. Dump the soil far enough away from the trench or hole to prevent the possibility of a cave in EN (09-06) Steering levers Function Start the engine and resume operation. 39

50 OPERATING INSTRUCTIONS Operating in water Parking the excavator Mud and water should be removed from the machine before parking. In freezing temperatures, park the machine on boards or concrete to prevent the track or undercarriage from freezing to the ground and preventing machine movement. 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. Figure 99 Figure 98 S0867 Water Level Reference Description S07 Do not operate or immerse the Excavator in water higher than the bottom of the swing circle [Figure 98]. Function Speed control lever Move the speed control lever fully forward to the low engine speed position. Key switch Turn the key switch to STOP. Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel. Raise the control console and exit the machine. Grease the Excavator when it has been operated or immersed in water for a period of time. Greasing forces the water out of the lubrication areas. Water must be removed from the cylinder rods. If water freezes to the cylinder rod, the cylinder seals can be damaged when the rod is retracted EN (09-06)

51 OPERATING INSTRUCTIONS Recovery and transport of the machine Switch off the engine. Recovery of the machine Dismount from the excavator and close the doors. In order to recover the machine, the following tow fixing points are present: Attach the excavator to the 3-point hoisting appliance at the points illustrated ([Figure 0]) in the correct manner. Figure 00 Figure 0 S07 S08 Reference Description Lugs on chassis (crawler frame, rear) Towing hitch on chassis (crawler frame, front) 3 Towing lug - rear centre of chassis Reference Description Blade Fasten chains to the ends of the blade and up to a lifting fixture above the cab. The lifting fixture must extend over the sides of the cab to prevent the chains from hitting the cab. Towing eye Fasten a chain to the towing eye and up to a lifting fixture. Lifting the machine WARNING Function AVOID INJURY OR DEATH Use a lifting fixture with sufficient capacity for the weight of the Excavator plus any added attachments. Maintain centre of gravity and balance when lifting. Do not swing boom or upperstructure. Never lift with operator on machine. To load the excavator onto a flat bed trailer, etc., the following activities must be carried out: Empty and fold in the bucket. Position the work equipment straight ahead. Slew the uppercarriage in such a way that the work equipment is in straight ahead position, as opposed to the dozer blade. Completely raise the boom. Retract the dipperstick EN (09-06) 4

52 OPERATING INSTRUCTIONS Transport of the machine When transporting the machine, observe the rules, motor vehicle laws and vehicle limit ordinances. Use a transport and towing vehicle of adequate length and capacity. Figure 0 Secure the parking brakes and block the wheels of the transport vehicle. Align the ramps with the centre of the transport vehicle. Secure the ramps to the truck bed and be sure ramp angle does not exceed 5 degrees. Use metal loading ramps with a slip resistant surface. Use ramps that are the correct length and width, and can support the weight of the machine. The rear of the trailer must be blocked or supported when loading or unloading the Excavator to prevent the front of the transport vehicle from raising. Determine the direction of the track movement before moving the machine (blade forward). During transport on a flat bed trailer, by rail, etc., the machine must be properly lashed at the marked points and secured with chocks. To do so, lower the dozer blade and rest the work equipment on the ground. S096 Put blocks at the front and rear of the tracks. WARNING Be aware of the total transport height! Risk of accident when driving in tunnels, under bridges, etc.! EN (09-06)

53 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE Table of contents Maintenance safety...45 Servicing schedule...46 Chart...46 Rear cover...47 Opening and closing the rear cover...47 Right side cover...47 Opening And Closing The Right Side Cover...47 Air cleaner...48 Daily check...48 Replacing the filters...48 Fresh Air Filter...49 Fuel system...50 Fuel specifications...50 Filling the fuel tank...50 Removing Water From The Pre-Filter...5 Pre-Filter Removal...5 Pre-Filter Installation...5 Fuel Filter Removal And Installation...5 Draining The Fuel Tank...53 Engine lubrication system...54 Checking engine oil...54 Oil Chart...54 Replacing Oil And Filter...54 Cooling system...56 Cleaning The Cooling System...56 Replacing The Coolant...57 Electrical system...58 Description...58 Fuse And Relay Location...59 Using A Booster Battery (Jump Starting)...60 Removing And Installing The Battery...6 Alternator belt...63 Adjusting Belt Tension EN (09-06) 43

54 PREVENTIVE MAINTENANCE Fan / Fuel pump belt Adjusting Belt Tension Air conditioning compressor belt Adjusting Belt Tension Hydraulic system Checking And Adding Hydraulic Oil Replacing The Hydraulic Oil Hydraulic Filter Removal Hydraulic Filter Installation Diagnostic Couplers Track tension Rubber Track Clearance Steel Track Clearance Adjustment Travel motor... 7 Checking Oil Level... 7 Draining The Travel Motor... 7 Lubrication of the hydraulic excavator Lubrication of attachments Swing Bucket Lubrication Clamshell Bucket Lubrication EN (09-06)

55 PREVENTIVE MAINTENANCE Maintenance safety WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. Correct Correct Correct Never service the Bobcat Compact Excavator without instructions. Use the correct procedure to lift and support the excavator. Cleaning and maintenance are required daily. Wrong Wrong Wrong Have good ventilation when welding or grinding painted parts. Vent exhaust to outside when engine must be run for service. Always lower the bucket and blade to the ground before doing any maintenance. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning. Wrong Wrong Wrong Stop, cool and clean engine of flammable materials before checking fluids. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Lead-acid batteries produce flammable and explosive gases. 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. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protections approved for type of welding. Never fill fuel tank with engine running, while smoking, or when near open flame. Keep rear door closed except for service. Close and latch door before operating the excavator. Never modify equipment or add attachments not approved by Bobcat Company. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Maintenance procedures which are given in the Operation & Maintenance manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training course is available from your Bobcat dealer EN (09-06) 45

56 PREVENTIVE MAINTENANCE Servicing schedule Chart WARNING Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The servicing schedule is a guide for correct maintenance of the Bobcat excavator. Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (stickers) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions may cause injury or death. SERVICING SCHEDULE ITEM HOURS SERVICE REQUIRED Engine Coolant Check coolant level. Add premixed coolant as needed. Engine Oil Check the engine oil level and add as needed. Hydraulic Fluid, Hoses and Tubelines and Reservoir Breather Cap Check the hydraulic fluid level and add as needed. Check for damage and leaks. Repair or replace as needed. Tracks Tension Check and adjust track tension as needed. Indicators and Lights Check for correct operation of all indicators and lights. Operator Canopy/Cab Check cab/canopy condition and hardware. Seat Belt Check condition. Check mounting fixings. Safety Signs and Safety Treads Check for damaged signs (stickers) and safety treads. Replace any signs or safety treads that are damaged or worn. Pivot Points Grease all machinery pivot points. Fuel Tank & Filter Drain water and sediment from fuel tank and fuel filter. Control Console Check control console lockout for proper operation. Swing Circle & Pinion Grease swing circle and swing pinion. Door Hinges Grease door hinges. Battery Check battery, cables, connections and electrolyte level. Add distilled water as needed Belts Check and adjust bolts. Travel Motor Check lubricant level in both travel motors. Hydraulic Oil Cooler, *Engine Oil Cooler, *Radiator, A/C Condenser and Cab Ventilation Filter Clean radiator/oil cooler fins. Clean A/C condenser. Clean/replace cab filter. (**) Hydraulic Filter Replace the filter. (**) Engine Oil & Filter Replace engine oil and filter. (**) Air Filter Intake Check/clean air filter intake Alternator & Starter Check alternator and starter connections (***) (*) Fuel Filters Replace diesel fuel pre-filter and filter. Engine Valves Check and adjust engine valve clearance. Travel Motors Replace oil in both travel motors. Engine Cooling System Drain and flush cooling system. Replace coolant. (Watercooled engines only.) Hydraulic System Replace hydraulic fluid and filter. Clean reservoir. (**) (*) Also at first 50 hours (**) Also at first 00 Hours (***) Or every 6 months EN (09-06)

57 PREVENTIVE MAINTENANCE Rear cover Right side cover Opening and closing the rear cover Opening And Closing The Right Side Cover Figure 04 WARNING AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual. WARNING Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander. S0963 Figure 03. Push the latch () and raise the right side cover.. Lower the right side cover and push down firmly to close the rear cover. Note: The start key can be used to lock the right side cover. S096. Push the latch () and raise the rear cover.. Lower the rear cover and push down firmly to close the rear cover. Note: The start key can be used to lock the rear cover EN (09-06) 47

58 PREVENTIVE MAINTENANCE Air cleaner Daily check Replacing the filters See ( Servicing schedule on page 46 for the correct service interval.) Outer filter. Unlatch the air filter cover latches () [Figure 06]. Figure Remove the air filter cover () [Figure 06]. Figure 07 S08 S0965 Reference Description Function Air filter condition indicator 4. Remove the outer filter (). If the air filter condition indicator is illuminated, the outer filter element needs to be replaced. Replace the inner filter every third time the outer filter is replaced. 5. Check the housing for damage. 6. Clean the housing and seal surface. Do not use compressed air. Figure Install the outer filter. 8. Install the cover. 3 S0964. Open the right side cover to inspect the air intake () for damage or restrictions EN (09-06)

59 PREVENTIVE MAINTENANCE Fresh Air Filter Inner Filter Figure 09 Replace the inner filter every third time the outer filter has been replaced. Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated. Remove the air cleaner cover and outer filter.. Pry up on the ends of the air filter ().. Pull the air filter () out of the housing. 3. Discard the inner air filter after it has been removed. 4. Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris. Figure 08 S0970 Position the Excavator as shown [Figure 09]. Figure 0 S Install the new inner filter (). Install the, outer filter and air cleaner cover. S097. Remove the eleven bolts and washers of the cover plate () [Figure 0]. Installation: Tighten the bolts to 4-6 Nm torque.. Remove the cover (). Figure S Remove the four bolts (). 4. Remove the filter () EN (09-06) 49

60 PREVENTIVE MAINTENANCE Fuel system Fuel specifications Filling the fuel tank Use only clean, high quality diesel fuel, Grade No. or Grade No... Open the rear cover and remove the fuel fill cap Note: The fuel fill cap can be locked. Use the fuel fillcap key to lock and unlock the cap. The following is a suggested blending guideline which should prevent fuel gelling problems during freezing temperature. Temp. ( C) No. -9 C 5+(5 ) 00% 0% Down to -9 C (-0 C) 50% 50% Below -9 C (-0 C) 0% 00% Figure No. Note: See your fuel supplier for local recommendations. WARNING Stop and cool the engine before refuelling. NO SMOKING! Failure to obey warnings may cause an explosion or fire. S0973 Figure 3 WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which may result in injury or death. S0974. Check the condition of the fill strainer screen (). Clean or replace as necessary. 3. Use a clean, approved safety container to add fuel. Refuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! 4. Install and tighten the fuel fill cap. 5. Close the tailgate. Note: See Servicing schedule on page 46 for the correct service interval when to remove water from or replace the fuel filter EN (09-06)

61 PREVENTIVE MAINTENANCE Removing Water From The Pre-Filter WARNING. Open the tailgate. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Donot use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.. Loosen the drain () at the bottom of the filter to drain water from the filter. Figure 4 Figure 6 S0975 WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. S0976. Unscrew the filter housing (). Pre-Filter Removal Figure 7 Note: See Service Schedule for the service interval when to replace the fuel pre-filter. (See Servicing schedule on page 46.) Clean the area around the fuel pre-filter housing. Figure 5 S Remove the filter () from the filter housing. S0975. Loosen the drain () at the bottom of the filter housing and drain the fuel out of the housing EN (09-06) 5

62 PREVENTIVE MAINTENANCE Pre-Filter Installation Fuel Filter Removal And Installation. Clean the filter housing in clean solvent and dry with compressed air. Note: See Service Schedule for the service interval when to replace the fuel filter. (See Servicing schedule on page 46.). Check the condition of the O-ring () [Figure 8] and replace if required. Figure 0 Figure 8 S098 S0978. Remove the filter (). 3. Install the filter in the housing [Figure 8].. Put clean oil on the seal of the new filter. Figure 9 3. Install the filter and hand tighten. S Close the drain () on the bottom of the filter housing EN (09-06)

63 PREVENTIVE MAINTENANCE Draining The Fuel Tank Figure 3 Figure S0984 S0986 Position the Excavator as shown [Figure ].. Open the drain () and drain the fuel into a container. Figure WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. S0985. Remove the cap () from the drain EN (09-06) 53

64 PREVENTIVE MAINTENANCE Engine lubrication system Checking engine oil Replacing Oil And Filter. Check the engine oil after every 8-0 hours of operation and before starting the engine for the work shift. Note: See Service Schedule for the service interval for replacing the engine oil and filter. (See Servicing schedule on page 46.) Figure 4 Figure 6 S0987 S0989. Open the right side cover and remove the dipstick (). Rotate the upperstructure so the right side is positioned between the tracks [Figure 6]. Run the engine until it is at operating temperature. Stop the engine. 3. Keep the oil level between the marks on the dipstick. Open the right side cover. Oil Chart Figure 7 Figure 5 S0990. Remove the cap (). S0988 Use a good quality motor oil that meets the correct API Service Classification. See oil chart [Figure 5] EN (09-06)

65 PREVENTIVE MAINTENANCE. Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter. Check the oil level on the dipstick (3). Figure 8 3. Add oil as needed if it is not at the top mark on the dipstick. S099. Install the drain hose () on the oil pan.. Tighten the hose until oil starts to drain from the oil pan. 3. Drain the oil in a container. 4. Recycle or dispose of used oil in an environmentally safe manner. Figure 9 3 S Remove the oil filter () and clean the filter housing surface. 6. Use a genuine Bobcat replacement oil filter. 7. Put clean engine oil on the filter gasket. Install the filter and hand tighten. 8. Remove the drain hose and install the cap on the oil pan after the oil has been completely drained. 9. Remove the fill cap (). 0. Put oil in the engine. (See Fluid Specifications on p. 9). Install the fill cap EN (09-06) 55

66 PREVENTIVE MAINTENANCE Cooling system Cleaning The Cooling System Figure 3 Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the right side cover. Use air pressure or water pressure to clean the radiator/oil cooler. Be careful not to damage the fins when cleaning. Checking Coolant Level WARNING Do not remove radiator cap when the engine is hot. You can be seriously burned. S0993 Open the right side cover.. The surge tank () must be half full when the engine is cold. Figure 30 IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. S099 WARNING. Check the coolant level in the surge tank (). Wear safety glasses to prevent eye injury when any of the following conditions exist: When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used EN (09-06)

67 PREVENTIVE MAINTENANCE Replacing The Coolant Note: See Service Schedule for the correct service interval to replace the coolant. (See Servicing schedule on page 46.) Figure 34 Figure 3 View from top S Remove the lower radiator hose (). 4. Drain the coolant from the engine. S After the coolant is removed, install the plug () and lower radiator hose ().. When the engine is cool, loosen and remove the radiatorcap (). 6. Recycle or dispose of the used coolant in an environmentally safe manner. Figure Mix the coolant in a separate container. Note: The Excavator is factory filled with ethylene glycol coolant. 8. Add premixed coolant, 50% water and 50% ethylene glycol to the reservoir if the coolant level is low. 9. 3,8 L of ethylene glycol mixed with 3,8 L of water is the correct mixture of coolant to provide a -37 C (-34 F) freeze protection. 0. Use a refractometer to check the condition of ethylene glycol in your cooling system. S0994. Fill the radiator with the premixed coolant. Install the radiator cap.. Remove the plug () from the back side of the engine block.. Run the engine until it is at operating temperature. 3. Stop the engine. Note: The plug is located next to the alternator mount bracket. 4. Check the coolant level (COLD) in the surge tank when cool. Drain the coolant from the engine EN (09-06) 5. Add coolant to the tank as needed. 57

68 PREVENTIVE MAINTENANCE Electrical system Description WARNING The Excavator has a volt, negative ground electricalsystem. The electrical system is protected by fuses located in the right console and beside the battery [Figure 35] & [Figure 36]. The fuses will protect the electrical system when there is an electrical overload.the reason for the overload must be found before starting the engine again. 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 5 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. The battery cables must be clean and tight. Check the electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution. Put Battery Saver P/N or grease on the batteryterminals and cable ends to prevent corrosion. Figure 35 S0997. To check or replace the fuses in the right console, remove the three screws ().. Remove the cover (). Figure 36 S EN (09-06)

69 PREVENTIVE MAINTENANCE Fuse And Relay Location Figure 37 Reference Description Amperage Interior light, radio 5 Auxiliary power outle 0 3 Front lights 5 4 Rear work lights Horn 6 Heater fan motor 5 7 Wiper/Washer 0 8 Control module signal input 5 9 Optional work lights and heating K Front work lights relay K Rear work light relay K3 Air Conditioner relay Always replace fuses with the same type and capacity. S0998 Figure 39 Figure 38 S0870 S0999. To check or replace fuses beside the battery, pull up on and remove the floor mat (). The location and sizes are shown below and [Figure 37] & [Figure 38]. Figure 40 S0874. Remove the battery compartment cover () EN (09-06) 59

70 PREVENTIVE MAINTENANCE Using A Booster Battery (Jump Starting) Figure 4 If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator's seat and one person to connect and disconnect the battery cables. Be sure the key switch is OFF. The booster battery must be volt. Figure 4 S000. Remove the cover () for access to the fuses. Reference Description (FA) Main fuse 30 (FB) Pre-Heat 60 3 (KO) Pre-Heat relay Amperage S0870 Always replace fuses with the same type and capacity.. Pull up on and remove the floor mat (). Figure 43 S Remove the battery compartment cover (). WARNING 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 5 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention EN (09-06)

71 PREVENTIVE MAINTENANCE Note: See Cold temperature starting procedure on page 3. WARNING Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 6 C (60 F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury. 3. Start the engine. After the engine has started, remove the ground (-) cable first (). 4. Disconnect the cable from the Excavator battery (). WARNING 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. Figure 44 WARNING 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. S006. Connect one end of the first cable to the positive (+) terminal of the booster battery. Connect the other end ofthe same cable to the positive (+) terminal () of the Excavator battery.. Connect the end of the second cable to the negative (-) terminal of the booster battery. Connect the other end ofthe same cable to the Excavator frame () (away from the battery) EN (09-06) 6

72 PREVENTIVE MAINTENANCE Removing And Installing The Battery Figure 47 WARNING 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 5 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Getprompt medical attention. S Remove the nuts () and remove the hold down clamp (). Figure Remove the battery. 7. Always clean the terminals and the cable ends, even when installing a new battery. 8. Install the battery. Install the hold down clamp and tighten the bolts. 9. Connect the battery cables. Connect the negative (-) cable () last to prevent sparks. S0870. Pull up on and remove the floormat (). Figure 46 S0874. Remove the battery compartment cover (). 3. Disconnect the negative (-) cable () first. 4. Disconnect the positive (+) cable () EN (09-06)

73 PREVENTIVE MAINTENANCE Alternator belt Fan / Fuel pump belt Adjusting Belt Tension Adjusting Belt Tension Check the alternator belt deflection at the mid span of the belt between the crankshaft pulley and alternator pulley. Figure 49 Apply approximately 45 mm force to the belt. The belt should deflect 0 mm. Figure 48 S098. Check the fan/fuel pump belt deflection mid span of the belt between the crankshaft pulley and the fuel pump pulley ().. Apply approximately 45 N of force to the belt. The belt should deflect 0 mm. Figure 50 S. Loosen the three alternator bolts () [Figure 48] and rotate the alternator until the belt is correctly tensioned.. Tighten the bolts. S 3. Loosen the two bolts () on the fuel pump mount. Rotate the fuel pump until the belt is correctly tensioned. 4. Tighten the bolts EN (09-06) 63

74 PREVENTIVE MAINTENANCE Air conditioning compressor belt Hydraulic system Adjusting Belt Tension Checking And Adding Hydraulic Oil Figure 5 Figure 53 S00 S0. Check the air conditioning compressor belt deflection mid span of the belt between the crankshaft pulley and the compressor pulley ().. Check the hydraulic fluid level, it must be visible in the sight gauge (). Figure 54. Apply approximately 45 mm force to the belt. The belt should deflect 0 mm. Figure 5 S03. Clean the surface around the reservoir (breather) cap and remove the cap from the reservoir (). S0 3. Add the correct oil to the reservoir until it is visible in the sight gauge. (See Fluid Specifications on p. 9.) 3. Loosen the bolts () and rotate the compressor until the belt is correctly tensioned. 4. Check the breather cap and clean as necessary. Replace the cap if damaged. 4. Tighten the bolts. 5. Install the reservoir cap. 6. Close the rear cover EN (09-06)

75 PREVENTIVE MAINTENANCE Replacing The Hydraulic Oil See Service Schedule for the correct service interval. (See Servicing schedule on page 46.) 5. Remove the drain hose and install the cap on the hydraulic reservoir. Retract the arm and bucket cylinders, lower the bucket tothe ground. Stop the engine. 6. Add fluid to the reservoir. (See Fluid Specifications on p. 9.) Open the rear cover. 7. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed. Figure 55 WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. WARNING Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. S04. Remove the cap () from the hydraulic reservoir drain. Figure 56 S05. Install the drain hose () on the hydraulic reservoir. Tighten the hose until oil starts to drain from the reservoir. 3. Drain the fluid into a container. 4. Recycle or dispose of the fluid in an environmentally safe manner EN (09-06) 65

76 PREVENTIVE MAINTENANCE Hydraulic Filter Removal Hydraulic Filter Installation See Service Schedule for the correct service interval. (See Servicing schedule on page 46.) Clean the filter bowl in clean solvent and dry with compressed air. Figure 60 Open the rear cover. Figure 57 S09 S06. Inspect the O-rings () on the outside and inside bottom of the filter bowl. Replace the O-rings if damaged.. Remove the filter cover () and spring. Figure 58 Figure 6 S07 S08. Remove the filter and filter bowl (). Figure 59. Install a new filter () in the filter bowl. S08 3. Remove the filter () from the filter bowl EN (09-06)

77 PREVENTIVE MAINTENANCE Diagnostic Couplers Figure 6 Open the rear cover and right side cover. Figure 65 S07 3. Install the filter and filter bowl (). S09 Figure 63 Figure 66 S00 S Inspect the O-ring (). Replace if damaged. Figure 67 Figure 64 S03 S06. The four diagnostic couplers () [Figure 65], [Figure 66] & [Figure 67] are located on the hydraulic circuitry. 5. Install the spring and cover (). The couplers can be used to check circuit pressures. (Refer to the Service Manual.) EN (09-06) 67

78 PREVENTIVE MAINTENANCE Track tension Rubber Track Clearance Figure 69 Note: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. See Servicing schedule on page 46 for the correct service interval. Note: On new Excavators or on Excavators with new rubber tracks installed, check and adjust as needed the rubber track clearance two to three times on the first day of operation. S035 WARNING Figure 70 AVOID INJURY Keep fingers and hands out of pinch points whenchecking the track tension. Track Frame Raise one side of the machine (approximately fourinches) using the boom and arm. 0 mm Figure 68 Track Roller Track S Measure the track sag at the fourth roller (= middle of the track). Do not get fingers in pinch points between the track and track roller. Use a bolt or dowel of the appropriate size to check the gap between the contact edge of the roller and the top edge of the track guide lug [Figure 70]. 4. Rubber track clearance 0 mm. S034. Raise the blade fully and install jackstands () [Figure 68] & [Figure 69] under the blade and track frame. Lower the boom until all machine weight is on the jackstands. Steel Track Clearance Note: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. See Servicing schedule on page 46 for the correct service interval.. Stop the engine. Note: On new Excavators or on Excavators with new steel tracks installed, check and adjust as needed the steel track clearance two to three times on the first day of operation EN (09-06)

79 PREVENTIVE MAINTENANCE Adjustment WARNING Figure 7 AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension. Figure 7 0 mm S036. Loosen the top bolt ().. Remove the bottom bolt and washer (). 3. Pivot the cover out of the way. Figure 73 S038. Park the Excavator on a flat and level surface.. Put a straight edge () on the top of the track surface between the rear sprocket and the top idler wheel. Measure between the top of the track and the bottom of the straight edge. S Remove the grease fitting adapter () from the end of a grease gun. 3. Steel track clearance 0 mm. Figure 74 S Install the track tensioning adapter () on the end of a grease gun EN (09-06) 69

80 PREVENTIVE MAINTENANCE Figure 78 Figure 75 S04 S To release track tension, loosen the tensioner (). Do not remove the tensioner. 6. Install the adapter () on the track tensioner. Figure 76 Note: Do not remove the tensioner () [Figure 78] unless pressure is released. After track tension has been released, remove all grease from the tensioner area. Repeat the procedure for the other track. S04 Figure 77 S Add grease to the track tensioner until the track tension indicator () is flush with the cylinder edge () [Figure 76] & [Figure 77] EN (09-06)

81 PREVENTIVE MAINTENANCE Track shoes (steel track) Damaged track shoes have to be replaced immediately. Replacement Figure 79 3 S Remove the four hexagon bolts () [Figure 79]. Take the square () [Figure 79]. Remove the track shoe (3) [Figure 79]. Mount the new track shoe. Note: Observe the mounting position! Fasten the track shoe using new bolts and nuts. Tightening torque: 370 +/- 0 Nm EN (09-06) 7

82 PREVENTIVE MAINTENANCE Travel motor Draining The Travel Motor Checking Oil Level Figure 80 Figure 8 S045 S046. Put the machine on a level surface with the plugs positioned as shown ( & ).. Put the machine on a level surface with the plugs positioned as shown ( & ).. Remove the plug (). The oil level should beat the bottom edge of the plug hole.. Remove both plugs ( & ) and drain into a container. Recycle or dispose of the fluid in an environmentally safe manner. 3. Remove the plug () and add gear lube through the hole if the oil level is below the hole (). (See Fluid Specifications on p. 9.) 3. After all the gear lube is removed, rotate the track motor to the position shown. 4. Install both plugs. 4. Add gear lube to the plug hole () until the gear lube level is at the bottom edge of the plug hole (). Install and tighten the plugs. 5. Repeat the procedure for the other side. 5. Repeat the procedure for the other side EN (09-06)

83 PREVENTIVE MAINTENANCE Lubrication of the hydraulic excavator Lubricate the Hydraulic Excavator. See Service Schedule for the best performance of the machine. (See Servicing schedule on page 46.) Always use a good quality lithium based multipurpose grease when lubricating the machine. Apply the lubricant until extra grease shows. WARNING Replace damaged grease nipples immediately and check if grease passes through! Overview of lubricating points Figure / /5 /4 3/ EN (09-06) 73

84 PREVENTIVE MAINTENANCE Lubricate the following locations on the Hydraulic Excavator EVERY 8-0 HOURS: Figure 85 Figure S047 S049 Ref. Description (# of Fittings) 7. Boom pivot (). Figure 86. Right blade cylinder rod end ().. Right blade cylinder base end (). 3. Right side blade pivot (). 8 Figure S Boom swing pivot (). Figure 87 S Left blade cylinder rod end (). 5. Left blade cylinder base end () Left side blade pivot (). S05 9. Boom cylinder rod end () EN (09-06)

85 PREVENTIVE MAINTENANCE Figure 88 Figure S053 S Boom cylinder base end (). 5. Lower bucket link pivot (). Figure 9. Arm cylinder base end (). Figure S Bucket cylinder rod end (). S054. Arm cylinder rod end (). 7. Bucket link pivot (). Figure Bucket cylinder base end (). Figure S058 S Bucket link pivot (). 4. Arm pivot () EN (09-06) 9. Bucket pivot (). 75

86 PREVENTIVE MAINTENANCE Lubricate the following locations on the Hydraulic Excavator EVERY 50 HOURS: Figure 96 Figure S05 0. Boom swing cylinder base end ().. Boom swing cylinder rod end (). 4 Figure 95 S Door hinges (). 3 S059. Lubrication of the swing toothing (). 3. Lubrication of the swing bearing () EN (09-06)

87 PREVENTIVE MAINTENANCE Lubrication of attachments Swing Bucket Lubrication Clamshell Bucket Lubrication Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows. Overview Figure 99 Lubricate the following locations EVERY 8-0 HOURS: N Figure 97 N N N "N S4 Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows. S06. Bucket pivot (). Lubricate the following locations EVERY 8-0 HOURS:. Cylinder base end (). Figure 00 Figure 98 3 S063 S06. Bucket pivot points (4). 3. Cylinder rod end () EN (09-06) 77

88 PREVENTIVE MAINTENANCE Figure 0 S064 Figure 0 S065. Cylinder link pivots (5) [Figure 0] & [Figure 0] EN (09-06)