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a GC ®

Service Manual
E10 Compact Excavator

S/N A33P11001 & Above

Dealer Copy -- Not for Resale

&J
B6986788-EN (03-09) Revised (05-11) {3} Printed i n Belgium © Bobcat Company 2011

1 of 591
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MAINTENANCE SAFETY

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Training is necessary before operating or servicing machine. Read and .p
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.c

understand the Operation and Maintenance Manual, Operator's Handbook and

s i g n s (stickers) o n machine. Follow warnings a n d instructions i n t h e manuals
when making repairs, adjustments o r servicing. Check for correct function after
adjustments, repairs o r service. Untrained operators a n d failure t o follow
instructions can cause injury o r death. W-2003-0807

0) Safety A l e r t Symbol: T h i s symbol w i t h a w a r n i n g statement, means: “Warning, b e alert! Your safety i s

i n v o l v e d ! ” Carefully read t h e message that follows.

CORRECT CORRECT
Py

— — ERT AA
P-90216 4a RIO75 RIO72
ANever service t h e Bobcat Compact se the correct procedure to i
Excavator without instructions. and support the excavator.
WRONG WRONG WRONG

Dealer Copy -- Not for Resale

RIO76
Have good ventilation when
elding o r grinding painted parts.
Wear dust mask when grinding
painted parts. Toxic dust and gas
can be produced.
RIO73
A \ vent exhaust to outside when
engine must b e run for service.
Exhaust system must b e tightly
sealed. Exhaust fumes can Kill
without warming.
RIOTT
A \ Aways lower the bucket and
blade t o the ground before doing
any maintenance.
A Never modify equipment or add
attachments not approved b y
Bobcat Company.

WRONG WRONG

an RIO74
Stop, cool and clean engine o f
flammable materials before
checking fluids.
Never service or adjust machine
with the engine running unless
instructed to d o s o i n t h e
manual.
Avoid contact with leakin
hydraulic fluid o r diesel fue
under pressure. I t can penetrate
the skin o r eyes.
Never fill fuel tank with engine
running, while smoking, or
near open flame.
A Keep body, jewellery and clothin
away from moving parts, electrica
contact, hot parts and exhaust.
Wear eye protection t o guard from
battery acid, compressed springs,
fluids under pressure and flying
debris when engines are running
o r tools are used. Use eye
protections approved for type o f
welding.
Keep tailgate closed except for
service. Close a n d latch tailgate
when before operating the excavator.
B-19798
A ) Lead-acid batteries produce
flammable and explosive gases.
Keep arcs, sparks, flames a n d
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin o n contact.
A 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 i n the Cperation and Maintenance Manual can be performed by the owner/
operator without any specific technical raining. Maintenance rocedures which are not in the Operation and
aintenance Manual must be performed ONL BY QUALIFIE BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.

MSW33-0409

o f 691
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CONTENTS
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FOREWORD. . . ee eee ii

SAFETY INSTRUCTIONS . ee eee eee eae \

FIRE PREVENTION ©... ee eee eee vi

SERIAL NUMBER LOCATIONS . eee ein ix

DELIVERY REPORT . «Le eee X

BOBCAT EXCAVATOR IDENTIFICATION. ©. oie eae Xi

SAFETY AND MAINTENANCE. . . eee eens10-01

HYDRAULIC SYSTEM ee eae 20-01

UNDERCARRIAGE. . . eee eee 30-01

UPPERSTRUCTURE AND SWING SECTION. _ . . . i a a n 40-01

Dealer Copy -- Not for Resale

iii

ELECTRICAL SYSTEM AND ANALYSIS . ieee 50-01

ENGINE SERVICE .. ee eee 60-01

SPECIFICATIONS. | © eee SPEC-01

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FOREWORD
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This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must b e made after the excavator has had service or repair:
1 . Check that the fold-down 9. Check for correct function o f
TOPS is in good condition indicator lamps.

et
and is not modified.

2 . Check that fold-down TOPS 10. Check hydraulic fluid level,

mounting hardware is engine oil level and fuel J 0)
tightened and i s Bobcat supply. = “\§
approved.
-z—
3. The seat belt must b e 11. Inspect for fuel, oil or
correctly installed, functional hydraulic fluid leaks. fF
W—E
and in good condition. é

Dealer Copy -- Not for Resale

é
4. Machine signs (decals) must 12. Lubricate the excavator.
b e legible and in the correct
location.

5. Travel levers, control levers — 13. Check the condition of the

and foot pedals must return to battery and cables. gn

neutral. Check that the pedal | : )

locks are in working order. a
6. Check for correct function of 14. Inspect the air cleaner for :

the work lights. damage or leaks. Check the (4:41

condition of the element. ATs
/ /1: RN
7. Attachment locking pins must 15. Check the electrical charging
function correctly and b e in system.
good condition. &

8. Safety treads must b e in good 16. Check tracks for wear and
condition. tension. Use only approved
tracks.

FW EXC UC-0508 SM

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17. Inspect for loose o r broken 2 0 . Check the control console
parts or connections. interlocks for correct function.

J
18. Check for any field 2 1 . Check function o r condition o f
modification not completed. all equipped options and &e &
accessories (examples: oF
boom light, motion alarm, &
etc).
19. Operate the machine and 2 2 . Recommend t o t h e owner
check all functions. that all necessary corrections
b e made before the machine
is returned to service.

Dealer Copy -- Not for Resale

FW EXC UC-0508 SM

8 of 591 iv E 1 0 Service Manual

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SAFETY INSTRUCTIONS The following publications provide information on the safe
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use and maintenance of the Bobcat machine and c
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A Safety Alert Symbol

T h i s s y m b o l w i t h a w a r n i n g statement m e a n s :
“Warning, b e alert! Your safety i s involved!”
Carefully read t h e message t h a t follows.
T h e Delivery Report i s used to assure that complete
instructions have been given to the n e w owner and
that the machine i s i n safe operating condition.
The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information a s well a s routine maintenance a n d

EK A WARNING
Instructions are necessary before operating o r
servicing m a c h i n e . Read a n d understand t h e
Operation & Maintenance M a n u a l , Operator's
H a n d b o o k a n d s i g n s (decals} o n m a c h i n e . Follow
wamings and instructions i n the manuals when
making repairs, adjustments o r servicing. C h e c k for
correct function after adjustments, repairs o r
service. Untrained operators a n d failure t o follow
instructions can cause injury o r death.
W-2003-0807
= {IX Fy
T h i s n o t i c e identifies procedures w h i c h must b e
followed t o avoid damage t o the m a c h i n e .
1-2019-0284
BJA A
T h e s i g n a l word D A N G E R o n t h e m a c h i n e a n d i n t h e
manuals indicates a hazardous s i t u a t i o n which, i f n o t
avoided, will result i n death o r s e r i o u s injury.
D-1002-1107
service procedures. I t i s a part o f the machine a n d can
be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Machine signs (decals) instruct on the safe operation
and care o f your Bobcat machine o r attachment. T h e
signs and their locations are shown i n the Operation
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
An Operator's Handbook fastened to the operator
cab. It's brief instructions are convenient to the
operator. The handbook i s available from your dealer 3
i n a n English edition or one of many other languages. @
See your Bobcat dealer for more information on gy
translated versions. =
Ke)
The A E M Safety Manual delivered with the machine k e
gives general safety information. )
|
>
The Service Manual and Parts Manual are available a
from your dealer for use b y mechanics to d o shop- CO
type service and repair work. Fr
©
[+73
The Compact Excavator Operator Training Course i s
available through your local dealer o r at
www.training.bobcat.com o r www.bobcat.com.
This course i s intended to provide rules a n d practices
o f correct operation of the Bobcat excavator. T h e
course i s available i n English a n d Spanish versions.
Service Safety Training Courses are available from
your Bobcat dealer o r a t www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

AA WARNING T h e Bobcat compact excavator Safety Video i s

available from your Bobcat dealer o r a t
The s i g n a l word WARNING o n t h e m a c h i n e a n d i n t h e www.training.bobcat.com o r www.bohcat.com.
m a n u a l s indicates a potentially hazardous situation
which, i f n o t avoided, c o u l d result i n death o r s e r i o u s
injury.
W-2044-1107

SI EXC EMEA-0409 SM

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INSTRUCTIONS {CONTD) FIRE PREVENTION to
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The dealer and owner / operator review the
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recommended uses of the product when delivered. If the

owner / operator will b e using the machine for a different
application(s) h e o r she must ask the dealer for
recommendations o n the new use.

Maintenance

The machine a n d some attachments have components

that are at high temperatures under normal operating
conditions. The primary source of high temperatures i s
the engine and exhaust system. The electrical system, if
damaged o r incorrectly maintained, can b e a source o f
arcs o r sparks.

Flammable debris (leaves, straw, etc.) must b e removed

Cutting o r drilling concrete containing sand o r rock regularly. I f flammable debris i s allowed to accumulate, it
containing quartz may result i n exposure to silica dust. can cause a fire hazard. Clean often to avoid this
Use a respirator, water spray or other means to control accumulation. Flammable debris i n the engine
dust. compartment i s a potential fire hazard.

The operator's area, engine compartment and engine

Dealer Copy -- Not for Resale

cooling system must b e inspected every day and cleaned
i f necessary to prevent fire hazards a n d overheating.

All fuels, most lubricants and some coolants mixtures are

flammable. Flammable fluids that are leaking o r spilled
onto hot surfaces o r onto electrical components can
cause a fire.

Operation

D o not use the machine where exhaust, arcs, sparks o r

hot components can contact flammable material,
explosive dust o r gases.

Electrical

B®
Check all electrical wiring and connections for damage.
Keep the battery terminals clean a n d tight. Repair o r
replace any damaged part or wires that are loose o r
frayed.

Battery gas can explode and cause serious injury. Use

the procedure i n the Operation & Maintenance Manual
for connecting the battery and for jump starting. D o not
jump start o r charge a frozen o r damaged battery. Keep
any open flames o r sparks away from batteries. D o not
smoke i n battery charging area.

S| EXC EMEA-0409 S M

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FIRE PREVENTION {CONT'D} Welding A n d Grinding to
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Always clean the machine a n d attachment, disconnect d f- x

the battery, and disconnect the wiring from the Bobcat

Check hydraulic tubes, hoses and fittings for damage
and leakage. Never use open flame o r bare skin to check
for leaks. Hydraulic tubes and hoses must b e properly
routed a n d have adequate support a n d secure clamps.
Tighten o r replace a n y parts that show leakage.
Always clean fluid spills. D o not use gasoline o r diesel
fuel for cleaning parts. Use commercial nonflammable
solvents.
Fueling
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 o r welding painted
parts. Wear dust mask when grinding painted parts.
Toxic dust o r gas can b e produced.
Dust generated from repairing nonmetallic parts such a s
hoods, fenders o r covers can b e flammable o r explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Stop the engine a n d let i t cool before adding fuel. N o

smoking! D o not refuel a machine near open flames o r

Not for Resale

sparks. Fill the fuel tank outdoors.

Starting

D o not use ether o r starting fluids o n any engine that has

glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you o r bystanders. located and how to use them. Inspect the fire

Dealer Copy
extinguisher a n d service the fire extinguisher regularly.
Use the procedure i n the Operation & Maintenance Obey the recommendations o n the instructions plate.
Manual for connecting the battery and for jump starting.

Spark Arrester Exhaust System

The spark arrester exhaust system i s designed to control

the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.

Check the spark arrester exhaust system regularly to

make sure i t i s maintained a n d working properly. Use the
procedure i n the Operation & Maintenance Manual for
cleaning the spark arrester muffler (if equipped).

S I EXC EMEA-0409 SM

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SERIAL NUMBER LOCATIONS E n g i n e Serial Number
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requesting service information o r when ordering parts.

Excavator Serial Number

Figure 1

| |

A $8326

The engine serial number plate (litem 1 ) [Figure 2 ] i s

located o n top o f the engine.
S7626
Figure 3

The excavator serial number plate (Item 1 ) [ F i g u r e 1 ] is

located o n the front left hand corner of the frame.

Explanation o f Excavator Serial Number:

XXXX XXXXX
| Medule 2 . - Production Sequence

=i
(Series)

Module 1. - Model / Engine

Combination

1 . The four-digit M o d e l/ Engine Combination Module

number identifies the model number and engine 57955
combination.

2 . The five-digit Production Sequence Number identifies The engine serial number (Item 1 ) [Figure 3] i s engraved
the order i n which the excavator i s produced. o n the engine just below the fuel injection pump.

13 of 591 E 1 0 Service Manual

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Figure 4
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DELIVERY REPORT

B-16315

The Delivery Report items must b e explained to the

owner / operator b y the dealer. The dealer i s to complete
the form and the owner/operator signs the form t o
indicate his understanding [Figure 4].

Dealer Copy -- Not for Resale

14 of 591 E 1 0 Service Manual

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BOBCAT EXCAVATOR IDENTIFICATION
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HYDRAULIC
CONTROL LEVERS
(JOYSTICKS)
[ 1 ] FOLD-DOWN TOPSa

OPERATION &
MAINTENANCE
MANUAL
: /

TAILGATE — a
a,
TIE DOWN /
A

Dealer Copy -- Not for Resale

TRACK ——___ J LIFT POINTS

TIE DOWN
Pad TRACK FRAME

OPERATOR'S SEAT
WITH SEAT BELT

ARM
CYLINDER | irr POINT
AUXILIARY HYDRAULIC >
QUICK COUPLERS {IF OPERATOR'S
EQUIPPED) — HANDBOOK

BUCKET | gr BOOM
CYLINDER T T u! / CYLINDER
BOOM -

ARM )

2 2

BUCKET LINK — ~~
_ UPPERSTRUCTURE
[2] BUCKET BLADE
CYLINDER S8ds7

[ 1 ] T O P S (Tip Over Protective Structure) a s standard equipment. The T O P S meets I S O 12117.

[2] Several different buckets and other attachments are available from your Bobcat excavator dealer.

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AIR CLEANER . . eee 10-60-1
Daily Check . . . . . . eee 10-60-1
Replacing The Filters. . . . . LL... eee. 10-60-1

ALTERNATOR BELT . . . . eee eee 10-140-1

Adjusting The Alternator Belt... . ....... li... 10-140-1

CONTROL CONSOLE LOCKOUTS . . . ieee. 10-160-1

Inspection And Maintenance . . . . . . . . . LLL... 10-160-1

COOLING SYSTEM . . eee ee e a 10-70-1

Checking The Coolant Level . . . . . . . . . eee. 10-701
Cleaning The Cooling System . . . . . . . i iiiia.. 10-70-1
Replacing The Coolant . . . . . . . . . . . iii 10-70-2

ENGINE LUBRICATION SYSTEM . . . . . eee eee 10-90-1

Checking Engine Oil... eee 10-90-1
Removing And Replacing Qil And Filter. . . ........._ ......................... 10-90-1

Dealer Copy -- Not for Resale

EXCAVATOR STORAGEAND RETURNTOSERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Return to Service... .. eee 10-170-1
LS Co] = To =
J 10-170-1

FOLD-DOWN TOPS ©... ee eee eee ee eee eee 10-30-1

Lowering The Fold-Down TOPS . . ei. 10-30-1
Raising The Fold-Down TOPS... ee .. 10-30-2
TOPS Position . . . 10-30-1

FUEL SYSTEM... eee eee e e e eee e a e 10-80-1

Draining The Fuel Tank . . . . 10-80-3
Filling T h e Fuel Tank . . . . . . ieee 10-80-1
Fuel Specifications. . . . . . . . . ea 10-80-1
Removing Air From The Fuel System . . . . LL... 10-80-3
Removing Water From The Fuel Filter. . . . . . . ..._._ _ _.... ..... . ... ........ 10-80-2
Replacing The Fuel Filter. . . 10-80-2

HYDRAULIC SYSTEM ee ieee 10-100-1

Checking And Adding Hydraulic Oil . _ . _ _ a... 10-100-1
Diagnostic Connectors. . . . 10-100-1
Replacing Hydraulic Oil . . ee 10-100-2
Replacing The Hydraulic Filter. . . . . . . . . . . . . . . . . . .... . .. . ............. 10-100-2

LIFTING AND BLOCKING THE EXCAVATOR . . . . . . i... 10-10-1

Procedure . . . . . . . . eee 10-10-1
Continued O n Next Page

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LIFTING THE EXCAVATOR . . . . . eee ee eee eee e a e 10-121

LUBRICATION OF THE HYDRAULIC EXCAVATOR. . . . . . . . . . . . . . . ......... 10-1101

MOTION ALARM. . 10-190-1

Adjusting Switch Position. . . . . ee ee eee 10-190-2
Description. . aaa 10-190-1
Inspecting. . . . . . . . eee 10-190-1

SEAT BELT . . aa 10-1501

Inspection And Maintenance . . . . . . . . . . . . . . Li 10-150-1

SERVICE SCHEDULE . . . eee atte eens 10-50-1

0 = 10-50-1

SPARK ARRESTER MUFFLER . . . . . . . . . . ieee 10-1301

Cleaning Procedure . . . . . . . . . . eee eee 10-130-1

Dealer Copy -- Not for Resale

STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . 10-180-1

TAILGATE . «eee eee 10-40-1

Opening And Closing The Tailgate . . . ...._ _....... .... oo... ....... 10-40-1

TRANSPORTING THE EXCAVATOR . ieee 10-201

Fastening To Transport Vehicle . . . . . . . . . . . oo. 10-20-2
Loading Onto Transport Vehicle. . . . . . Lo. 10-20-1

TRAVEL MOTOR. . eee eee 10-1201

Checking Oil Level . . a 10-1201
Draining The Travel Motor . . . . . . . . iia 10-1201

UPPERSTRUCTURE SLEW LOCK . . . . . iii. 10-111

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LIFTING AND BLOCKING THE EXCAVATOR F i g u r e 10-10-3
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Always park the machine on a level surface.

Figure 10-10-1

58758

The machine must b e blocked u p a s shown i n [Figure

10-10-3].

Stop the engine.

S8452
A WARNING
P u t jackstands u n d e r t h e b l a d e a n d rear c o r n e r s o f

Dealer Copy -- Not for Resale

Raise one side of the machine (approximately 100 m m t h e u n d e r c a r r i a g e before w o r k i n g u n d e r t h e machine.
[4 in]) using the boom and arm a s shown i n [Figure 1 0 - Failure t o b l o c k u p t h e m a c h i n e m a y a l l o w it t o m o v e
10-1]. o r fall a n d result i n injury o r death.
W-2218-1185

Figure 10-10-2

AVOID INJURY OR DEATH

D o n o t loosen t h e grease fitting more than o n e

— complete rotation. A l s o , b e careful not t o loosen a n y
S756 | og 58757 part other than t h e grease fitting. If t h e grease fitting
o r a n y part is loosened t o o much, it c a n fly off u n d e r
h i g h pressure. If the grease does n o t ooze smoothly,
Raise the blade fully and install wooden blocks (Item 1 )
try moving t h e machine back a n d forth for a short
[Figure 10-10-2] or jackstands under the blade a n d the
distance.
track frame. Lower the machine until all machine weight
W-2143-0189
i s o n the wooden blocks or jackstands.

Rotate the upperstructure 180 degrees and repeat

procedure for other side.

19 of 591 10-101 E 1 0 Service Manual

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or
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!
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O

O
N

N
Y

Y
U

U
UPPERSTRUCTURE SLEW LOCK F i g u r e 10-11-2
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Figure 10-111 d f- x
chang

57629

57628
— Move the lever (Item 1 ) [ F i g u r e 10-11-2] u p a n d to the
left to disengage the upperstructure from the track frame.
Move the lever (ltem 1 ) [ F i g u r e 1 0 - 1 1 1 ] to t h e right and Fit the lever properly t o fully disengage the Slew Lock.
down t o engage the Upperstructure Slew Lock. Fit the
lever properly to fully engage the Slew Lock. When the
Slew Lock i s engaged (locked), the upperstructure of the

Dealer Copy -- Not for Resale

excavator is locked to the track frame and will not rotate.

NOTE: The upperstructure m u s t b e i n t h e straight

forward o r straight backward position for t h e AVOID INJURY
upperstructure t o lock.
T h e upperstructure slew l o c k lever must b e engaged
w h e n transporting the machine.
W-2197-0904

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or

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!

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O

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N

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Y

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U

U
LIFTING THE EXCAVATOR Figure 1 0 - 1 2 1
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Fully extend the cylinders of the bucket and arm. Fully d f- x
chang

retract the boorn cylinder.

Raise the blade all the way.

Turn the upperstructure s o that the boom i s a t the

opposite end a s the blade.

Put all the controls i n neutral and engage the

upperstructure slew lock. (See UPPERSTRUCTURE
S L E W L O C K o n Page 10-11-1.)

AVOID INJURY OR DEATH
* U s e a lifting fixture w i t h sufficient capacity for
t h e w e i g h t o f t h e excavator p l u s a n y added
attachments.
+ Maintain center o f gravity a n d balance w h e n
{
= a
Fasten the chains to the ends of the blade (item 1 )
[Figure 10-12-1] and u p to a lifting fixture above the
canopy.
Fasten a chain i n the hook of the boom (Item 2 ) [Figure
10-12-1] and u p to the lifting fixture.

Dealer Copy -- Not for Resale

lifting. .
» Do not swing boom or upperstructure. Engage Figure 10-12-2
t h e upperstructure slew lock.
+ Never lift with operator o n m a c h i n e .
W-2202-0607

58818

The maximum angle between the front and rear chains

must not exceed 4 5 ° [Figure 10-12-2].

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or

or
!

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W
O

O
N

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Y

Y
U

U
TRANSPORTING THE EXCAVATOR Figure 10-201
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Loading Onto Transport Vehicle d f- x
chang

When transporting the machine, observe the rules, motor

vehicle laws and vehicle limit ordinances. Use a
transportation and towing vehicle of adequate length and
capacity.

Secure the hand brakes and block the wheels of the

transport vehicle.

Align the ramps with the center of the transport vehicle.

Secure the ramps t o the truck (or trailer) bed and b e sure
ramp angle does not exceed 1 5 degrees.

Use metal loading ramps with a slip resistant surface that

are the correct length and width, and can support the
weight of the machine.
The rear o f the trailer must b e blocked o r supported when
loading o r unloading the excavator to prevent the front of
the transport from raising.
Move the machine forward onto the transport vehicle
[Figure 10-20-1].
D o not change direction of the machine while it i s o n the
ramps.

Dealer Copy -- Not for Resale

Determine the direction of the track movement before Lower the boom, arm, bucket and blade to the transport
moving the machine (blade forward). Engage the vehicle.
upperstructure slew lock. (See UPPERSTRUCTURE
SLEW LOCK on Page 10-11-1.) Stop the engine and remove the key.

P u t blocks under the front a n d rear o f the tracks shoes.

26 of 591 10-201 E 1 0 Service Manual

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or

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O O
N N
Y Y
U U
TRANSPORTING
k
to
B
THE EXCAVATOR (CONT'D) Figure 10-204 to
B

lic lick
ww

ww
om

om
C 1 JJ 3 C
w w
.p e .c .p e.
c
Fastening T o Transport Vehicle
d f- x
chang
d f- x
chang

Figure 10-20-2

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

Figure 10-20-5
Fasten chains t o the front corners o f the blade (item 1 )
{Figure 10-20-2].
F \

Dealer Copy -- Not for Resale

1 1
F i g u r e 10-20-3

J .

When o n the transport vehicle, loop the chains through

the holes i n the mounting frame.
- [sea ]

Loop the chain (Item 1 } [Figure 10-20-5] around the

Fasten chains to both sides of the track frame (Item 1 ) bucket link.
{Figure 10-20-3] or the tie down loop at the rear of the
undercarriage (Item 1 ) [Figure 10-20-4].

AVOID SERIOUS INJURY OR DEATH

Adequately designed ramps o f sufficient strength are

needed t o support the w e i g h t o f t h e machine w h e n
loading onto a transport vehicle. W o o d ramps c a n
break a n d cause personal injury.
W-2058-0807

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or

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W

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O

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N

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Y

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U

U
FOLD-DOWN TOPS Figure 10-30-2
B

B
to

to
k

k
lic

lic
ww

ww
om

om
—— —
C

C
w c w c
.p e. .p e.
d f- x
chang TOPS Position d f- x
chang

AVOID INJURY O R DEATH

Use t h e T i p Over Protective Structure (TOPS). TOPS
ONT
changes not approved b y Bobcat Company c a n
cause l o s s o f operator protection a n d result i n injury
o r death. The TOPS must b e i n t h e r a i s e d p o s i t i o n
with t h e seat b e l t fastened. There i s n o tip-over
protection when t h e T O P S i s i n t h e lowered position.
W-2742-0608 [ S8755

The excavator can b e temporarily used with the TOPS
lowered for access through height restricted openings.
D o not fasten seat belt when the TOPS i s i n the D O W N
position.
Remove the retainer clip (Item 1), washer (tem 2 ) and
pin (item 3 ) [Figure 10-30-2] o n both sides o f the fold-
down TOPS (Item 2 ) [Figure 10-301].
Figure 10-30-3
BR

Dealer Copy -- Not for Resale

Stop the engine, exit the machine and put the TOPS i n
the U P a n d LOCKED position after passing through
height restricted opening.
=y (>
Lowering The Fold-Down T O P S

pd Bikey
Figure 1 0 - 3 0 1
f
i 1

58437

Lower the canopy (ltem 1) [Figure 10-30-3].

58440

The excavator i s equipped with a Tip-Over Protective

Structure (TOPS) (Item 1 ) [Figure 10-30-1].

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O O
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Y Y
U U
FOLD-DOWN
k
to
B
TOPS (CONT'D) F i g u r e 10-30-6 to
B
ck
lic — li
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Lowering T h e Fold-Down T O P S (Cont'd)
d f- x
chang
d f- x
chang

Figure 10-30-4

Tan LO

S8437

Raise the canopy (Item 1 ) [ F i g u r e 10-30-68].

“S8754
— ——
Figure 10-30-7

Reinstall the pin (Item 1 ) [ F i g u r e 10-30-4] into the T O P S

hole.

Dealer Copy -- Not for Resale

oN.
Keep the retainer clip (Item 2 ) and washer (ltem 3 ) within
the pin (ltem 1 ) [ F i g u r e 10-30-4].

R a i s i n g T h e Fold-Down TOPS

To raise the Fold-Down TOPS, follow the same procedure

i n reverse.

Figure 10-30-5

[ S8755

fig Install the pin (tem 1 ) [Figure 10-30-7] into the TOPS
hole.

Install the washer (tem 2 ) and retainer clip (Item 3 )

[Figure 10-30-7].
(2

“5a754
a —]
AVOID INJURY OR DEATH
U s e t h e T i p Over Protective S t r u c t u r e (TOPS). TOPS
Remove the retainer clip (Item 1 ) and washer (item 2 )
changes not approved b y Bobcat Company c a n
you placed within the pin (item 3 ) [Figure 10-30-5] during
cause loss o f operator protection a n d r e s u l t i n injury
the lowering step.
o r death. T h e TOPS m u s t b e i n t h e raised position
with t h e seat belt fastened. There i s n o tip-over
Remove the pin (item 3) [Figure 10-30-5] from the TOPS
protection w h e n the TOPS i s i n t h e lowered position.
hole.
W-2742-0608

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or

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W
O

O
N

N
Y

Y
U

U
TAILGATE Figure 10-40-2
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang O p e n i n g A n d C l o s i n g T h e Tailgate d f- x
chang

AVOID INJURY OR DEATH

Never service o r adjust t h e m a c h i n e w h e n t h e engine

i s r u n n i n g u n l e s s instructed t o d o s o i n t h e manual.
W-2012-0497

$8950

Raise the tailgate (item 1 ) until t h e rod (Item 2 ) [Figure

10-40-2] i s i n the engaged position.
Keep t h e rear door closed w h e n operating t h e
To close the tailgate, lift u p slightly o n the tailgate (Item 1 )
machine. Failure t o d o s o c o u l d seriously i n j u r e a
until the rod (litem 2) [Figure 10-40-2] can b e moved to
bystander.
W-2020-1285 the disengaged position. Slowly lower the tailgate until it
i s completely lowered and i n the latched position.

Dealer Copy -- Not for Resale

Figure 10-40-1 NOTE: The tailgate can b e locked using the Start key.

~<a HH

0
$7632

Release the latch (Item 1 ) [ F i g u r e 10-40-1] a n d pull the

tailgate open.

Close the tailgate before operating the excavator.

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W

W
O

O
N

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Y

Y
U

U
SERVICE S C H E D U L E
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w Chart w

A WARNING
c c
.p
d f- x e. .p
d f- x e.
chang chang

Maintenance work must b e done at regular intervals.

Failure to d o s o will result i n excessive wear and early
failures. The service schedule i s a guide for correct AVOID INJURY OR DEATH
maintenance of the Bobcat excavator.
Instructions are necessary before operating o r
servicing m a c h i n e . Read a n d understand the
Operation & Maintenance Manual, Operator's
Handbook a n d s i g n s (decals) o n m a c h i n e . Follow
warnings a n d instructions i n the manuals w h e n
m a k i n g repairs, adjustments o r servicing. Check for
correct function after adjustments, repairs o r
service. Untrained operators a n d failure t o follow
instructions c a n cause injury o r death.
W-2003-0807

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED [3]
8-10 100 | 250 | 500| 1000
Engine Coolant Check coolant level. A d d premixed coolant a s needed.
Engine Oil Check the engine oil level and add a s needed.
Hydraulic Fluid, Hoses a n d Check the hydraulic fluid level a n d add a s needed. Check for damage a n d

Dealer Copy -- Not for Resale

Tubelines
Engine A s Filter and Air System
Tracks
Indicator A n d Lights
Control Console Lockout
Fold-Down T O P S
Seat Belt
Safety Signs and Safety Treads
Pivot Points
Swing Circle a n d Pinion
Fuel Tank and Filter
Battery
Alternator/ Fan Belt
Spark Arrester Muffler
Fue! Filter
‘travel Motor
Engine Gil and Filter
Radiator and O i l Cooler (if
equipped)
Hydraulic Fitter and Reservoir
Breather
Alternator and Starter
Engine Valves
“Travel Motor
Hydraulic System
Engine Cooling System
leaks. Repair or replace as needed.
Check condition indicator a n d empty dust cup a s needed. Check air system
for leaks.
Check a n d adjust track tension a s needed.
Check for comect operation o f the indicator and lights.
Check for comect operation. Repair or replace as needed.
Check condition. Check mounting hardware.
Check condition. Check mounting hardware.
Check for damaged signs (decals) and safety treads. Replace any signs o r
safety treads that are damaged o r worn.
Grease all machinery pivot points.
Grease two fittings.
Drain water and sediment from fuel tank and fuel hiter.
Check battery, cables, connections and electrolyie level. Add distilled water
as needed.
Check condition o f belt a n d adjust a s needed. [11
Clean t h e spark chamber.
Replace fuel filter.
Check lubricant level in both travel motors.
Replace oil and filter. Use C D o r better grade oil and Bobcat filter [11
Clean debris from the radiator fins.
Replace the hydraulic filter and reservoir breather. 2
Check the alternator a n d starter connections. 2]
Check a n d adjust the engine vaive clearance.
Repiace lubricant i n both travel motors. [2]
Replace the hydraulic fluid and filters. Clean the reservon. 12
Drain a n d flush the cooling system. Replace premixed coolant. Every 2 years

[1] Service at the first 50 hours, then as scheduled.

[2] Service at the first 100 hours, then as scheduled.
[3] O r every year.

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Y

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U

U
AIR CLEANER F i g u r e 10-60-3
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang (See “SERVICE SCHEDULE" o n page 10-50-1.) for the d f- x
chang

correct service interval.

Daily Check

F i g u r e 10-60-1

S764

Pull the outer filter (Item 1} [Figure 10-60-3] from the air
cleaner housing.

Check the housing for damage.

S§7576
—— Clean the housing and the seal surface. D O N O T use
compressed air.

Dealer Copy -- Not for Resale

Check the condition indicator (Item 1 ) [ F i g u r e 10-60-1]. if
the red ring shows in the condition indicator, the filter Install a n e w outer filter.
needs to b e replaced.
Install the dust cup (Item 2 ) [Figure 10-60-2] and turn it
R e p l a c i n g T h e Filters clockwise about 45° turn.

F i g u r e 10-60-2 Push the locking tab i n (Item 1) [Figure 10-60-2].

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

57633

Oufer Filter

Pull out the locking tab (item 1 ) [ F i g u r e 10-60-2].

Turn the dust c u p (item 2 ) [Figure 10-60-2]

counterclockwise about 45° turn.

Remove and clean the dust cup.

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or

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O O
N N
Y Y
U U
AIR
k
to
B
CLEANER (CONT'D) to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Replacing The Filters (Cont'd)
d f- x
chang
d f- x
chang

inner Filter

Only replace the inner filter under the following

conditions:

» Replace the inner filter every third t i m e the outer filter

i s replaced.

= After the outer filter has been replaced, press the

button o n the top of the condition indicator (item 1 )
[ F i g u r e 10-60-1] and start the engine. R u n at full rpm,
then reduce engine speed a n d stop the engine. If the
red ring shows i n the condition indicator, replace the
inner filter.

Figure 10-60-4

Dealer Copy -- Not for Resale

57635

Pull out the locking tab (Item 1 ) and remove the dust cup
(item 2 ) [ F i g u r e 10-60-2], the outer filter (Item 1 ) [Figure
10-60-3] and the inner filter (item 1 ) [Figure 10-60-4].

N O T E : Make s u r e a l l s e a l i n g surfaces are free o f dirt

and debris.

Install the new inner filter.

Install the outer filter and the dust cup.

Press the button o n the condition indicator t o reset the

condition indicator (item 1) [Figure 10-60-1] (the red ring
will not show anymore).

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or

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!

!
W

W
O

O
N

N
Y

Y
U

U
COOLING SYSTEM Checking T h e Coolant Level
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Check the cooling system every day to prevent over- Open the tailgate. d f- x
chang

heating, loss of performance o r engine damage.

F i g u r e 10-70-1
Cleaning The C o o l i n g System

Remove the upper right hand side cover. (See Upper

Right Hand Side Cover Removal And Installation on
Page 40-210-1.)

Use air pressure or water pressure to clean the radiator

and oil cooler.

S7633
AVOID BURNS

D o n o t remove radiator c a p w h e n t h e e n g i n e i s hot. The coolant level must b e between FULL (A) a n d L O W
Y o u can b e seriously burned. (B) i n the recovery tank (Item 1 ) [Figure 10-70-1].
W-2070-1203

ealer Copy -- Not for Resale

if the coolant level is low, add premixed coolant to the
recovery tank (item 1 ) [ F i g u r e 10-70-1].

AVOID INJURY OR DEATH

» [ » fy

Wear safety g l a s s e s t o prevent eye injury when a n y

o f t h e following conditions exist: AVOID ENGINE DAMAGE
* W h e n fluids are u n d e r pressure.
* F l y i n g debris o r l o o s e material i s present. Always u s e the correct ratio o f water t o antifreeze.
* Engine is running.
* Tools are b e i n g used. T o o m u c h antifreeze reduces cooling system QO
W-2019-0907 efficiency a n d m a y cause serious premature e n g i n e
damage.

Too little antifreeze reduces the additives which

protect t h e internal e n g i n e components; reduces the
b o i l i n g point a n d freeze protection o f t h e system.

Always a d d a premixed solution. Adding full strength

concentrated coolant can cause serious premature
e n g i n e damage.
12124-0497

36 of 591 10-701 E 1 0 Service Manual

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F- t F- t
PD

PD
or

or
! !
W W
O O
N N
Y Y
U U
COOLING
k
to
B
SYSTEM {CONT'D} F i g u r e 10-70-3 to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Replacing The Coolant
d f- x
chang
d f- x
chang

(See SERVICE SCHEDULE o n Page 10-50-1.) for

correct service intervals.

Stop the engine.

a
Open the tailgate.

58300

AVOID BURNS
O p e n the drain plug (Item 1 } [ F i g u r e 10-70-3] o n the
D o not remove radiator c a p when t h e e n g i n e i s hot. engine block and drain the coolant into a container.
You can b e seriously burned.
W-2070-1203
After all the coolant i s removed, close the drain plug.

Figure 10-70-2 F i g u r e 10-70-4

Dealer Copy -- Not for Resale

S671 57639
—_—

When the engine i s cool, remove the radiator cap (litem 1 ) Slide the hose clamp (tem 1 ) [Figure 10-70-4] away
[Figure 10-70-2]. from the end o f the hose a n d remove the hose from the
recovery tank.

Remove the bolts (tem 2 ) [Figure 10-70-4] from the

recovery tank.

Remove the recovery tank and empty its contents i n a

container.

Recycle or dispose of the used coolant in an

environmentally safe manner.

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F- t F- t
PD

PD
or

or
! !
W W
O O
N N
Y Y
U U
k
to
B
COOLING SYSTEM (CONT'D) to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
d f- x
chang Replacing T h e Coolant (Cont'd) d f- x
chang

Mix the coolant i n a separate container.

NOTE: The c o o l i n g system i s factory filled with

propylene glycol ( p u r p l e color). D O N O T m i x
propylene glycol with ethylene glycol.

Follow the following steps when using concentrated

coolant instead of a ready-to-use premix:

» mix the coolant i n a separate container: 4 , 3 L (one

gallon and one pint) of propylene glycolmixed with 3.8
L. {one gallon) o f water i s the correctmixture of coolant
to provide a -37°C (-34°F) freezeprotection.

» Add premixed coolant, 4 7 % water and 5 3 % propylene

glycol to the coolant tank until the coolant level
reaches the M I N marker o n the tank (Item 1 ) [Figure
10-70-4].

Dealer Copy -- Not for Resale

» [ » Fy

AVOID ENGINE DAMAGE

Always u s e t h e correct ratio o f water t o antifreeze.

T o o m u c h antifreeze reduces c o o l i n g system

efficiency and m a y cause serious premature e n g i n e
damage.

T o o little antifreeze reduces t h e additives w h i c h

protect t h e internal e n g i n e components; reduces the
b o i l i n g p o i n t a n d freeze protection o f t h e system.

Always a d d a premixed s o l u t i o n . A d d i n g f u l l strength

concentrated coolant c a n cause serious premature
engine damage.
1-2124-0497

Use a refractometer to check the condition of propylene

glycol i n your cooling system.

A d d premixed coolant until the level i s correct.

Run the engine until it i s at operating temperature. Stop

the engine. Check the coolant level and add a s needed.
Install the radiator cap and tighten.

Add coolant to the recovery tank a s needed.

37 of 591 10-70-3 E 1 0 Service Manual

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PD
or

or
! !
W W
O O
N N
Y Y
U U
to
B
FUEL SYSTEM to
B

lick lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
d f- x
chang Fuel Specifications d f- x
chang

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

Grade No. 1 .
AVOID INJURY OR DEATH
The following i s a suggested blending guideline which
should prevent fuel gelling problems during freezing Stop a n d cool the e n g i n e before a d d i n g fuel. N O
temperature. S M O K I N G ! Failure t o obey warnings c a n cause a n
explosion o r fire.
W-2063-0807
Temp. C° (°F) NO. 2 NO. 1
-9 (15) 100% 0%
Down to -29 (-20) 50% 50%
Below -29 (-20) 0% 100% A \ WARNING
AVOID INJURY OR DEATH
A t a minimum, L o w Sulfur (500 p p m sulfur) Diesel Fuel
must b e used i n this machine.
The following fuels m a y also b e used i n this machine: Always clean u p spilled fuel o r c i l . Keep heat, flames,
sparks o r lighted tobacco away from fuel a n d oil.
+ Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel. Failure t o u s e care around combustibles c a n cause
explosion o r fire.
» Biodiesel Blend Fuel - Must contain n o more than five W-2103-0508

Dealer Copy -- Not for Resale

percent biodiesel mixed with low sulfur o r ultra low
sulfur petroleum based diesel. This is commonly
marketed a s B S blended diesel fuel. Removing Water From T h e Fuel Filter

Filling T h e F u e l Tank Open the tailgate.

Figure 1 0 - 8 0 1 F i g u r e 10-80-2

[Sr

Mt Prey

57638 $7639

Remove the fuel fill c a p (Hem 1 } [ F i g u r e 10-80-1] o n the Loosen the drain (Item 1 ) [Figure 10-80-2] at the bottom
left side o f the excavator.
o f the filter to drain water from the filter.
Use a clean, approved safety container to add fuel. A d d
fuel only in an area that has a free movement of air and
n o flames or sparks. N O SMOKING!

Install and tighten the fuel fill cap.

{See “SERVICE SCHEDULE" on page 10-50-1.) for the

service interval when to remove water from o r replace the
fuel filter.

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or

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N N
Y Y
U U
FUEL
k
to
B
SYSTEM {CONT'D) Removing Air From T h e Fuel System to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Replacing The Fuel Filter
d f- x
chang After replacing the fuel filter o r when the fuel tank has run d f- x
chang

out of fuel, air must b e removed from the fuel system

Remove the filter (tem 2 ) [Figure 10-80-2]. before starting the engine.

Clean the area around the filter housing. Put clean oil o n F i g u r e 10-80-4
the seal of the new filter. Install the fuel filter and tighten
by hand.

Remove the air from the fuel system. (See “Removing Air
From The Fuel System” o n page 10-80-3.) oman

Draining The F u e l Tank

(See “SERVICE SCHEDULE" o n page 10-50-1.) for the

correct service interval.

Open the tailgate.

Figure 10-80-3

S8301
—

Dealer Copy -- Not for Resale

O p e n the fuel filter vent (Item 1 ) [ F i g u r e 10-80-4].

Operate the hand pump (priming bulb) (Item 2 ) [Figure

10-80-4] until the fuel flows from the vent with no air
bubbles.

Close the vent (Item 1 ) [Figure 10-80-4] on the fuel filter

housing.

Start the engine and let it run at low idle. It m a y b e

necessary to open the vent at the fuel injection pump
S8300
— {tem 3 ) [Figure 10-80-4] briefly until the engine runs
smoothly.
Remove the fuel line clamp (Item 1 ) [ F i g u r e 10-80-3].

Remove the fuel line (Item 2 ) [Figure 10-80-3] from the

engine.

Drain the fuel into a container. D o this b y operating the

hand p u m p (priming bulb) (Item 3) [Figure 10-80-3] until
the fuel flows from the fuel line.
Reuse, recycle or dispose o f fuel i n a n environmentally
safe manner.
AVOID INJURY OR DEATH
Diesel fuel o r hydraulic fluid u n d e r pressure c a n
penetrate s k i n o r eyes, causing serious injury o r
death. F l u i d leaks u n d e r pressure m a y not b e visible.
Use a piece o f cardboard o r w o o d t o find leaks. D o
n o t use your bare hand. Wear safety goggles. If fluid
enters s k i n o r eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

4 0of 591 10-80-2 E 1 0 Service Manual

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or

or
!

!
W

W
O

O
N

N
Y

Y
U

U
ENGINE LUBRICATION SYSTEM Removing A n d Replacing O i l A n d Filter
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Checking E n g i n e Qil (See SERVICE SCHEDULE on Page 10-50-1.) ford f- xthe
chang

service interval for replacing the engine oil and filter.

Check the engine oil every day before starting the engine
for the work shift. R u n the engine until it i s at operating temperature. Stop
the engine.
Figure 10-90-1
—
F i g u r e 10-90-3
TN

, re - =~ o t anil
A 27 See

$8302
ee]
$7642

Resale
Open the tailgate a n d remove the dipstick (ltem 1 )
[Figure 10-90-1]. Remove the drain plug (Item 1 ) [ F i g u r e 10-90-3] from the QQ
bottom o f the engine. Drain the used oil into a container -
Keep the oil level between the marks o n the dipstick. and recycle o r dispose o f used oil i n a n environmentally L
safe manner.

Dealer Copy -- Not

Figure 10-90-2
Install and tighten the oil drain plug.
ENGINE OIL
RECOMMENDED SAE VISCOSITY NUMBER
[od (LUBRICATION QILS FOR DIESEL ENGINE CRANKCASE) Installation: Tighten the oil drain plug t o 32,4 - 37,3 N m
—40 3 4 9 gd 18 13 =F 1 a4 410 415 429 427 432 438 idd od (24 - 2 8 ft-Ib) torque.
1 1 1 1 1]
SAE 40W or 20W-50
gg Bo
S A E 10W-30
™t Co
SAE 15W—40
_-
- SEW

* SAE5W-30

|< SAE 20W-20

S Y N T H E T IOIL
selLTT
SAE 10W

C Use recommendationfrom Synthetic O10Mfr.

NN T N I I I
—40 3 -20 -10 0 +30 +20 430 40 +50 480 4F0 480 400 4100 + 1 0 +120

F TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CE, CD, CF4, C G 4 , 8 Q )
* Can be used ONLY when available with appropriate diesel rating.
B-16320

Use a good quality motor oil that meets the correct API
Service Classification [Figure 10-90-2].

41 of 591 10-901 E 1 0 Service Manual

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or

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O O
N N
Y Y
U U
ENGINE
k
to
B
LUBRICATION SYSTEM {CONT'D} F i g u r e 10-90-5 to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Replacing O i l A n d Filter (Cont'd)
d f- x
chang
d f- x
chang

Figure 10-90-4
—

Cg

Remove the fill cap (Item 1 ) [ F i g u r e 10-90-5].

58302
— Put i n 3 , 8 L (4.0 qt) o f oil into the engine.

Remove the oil filter (Item 1 } [ F i g u r e 10-90-4] with a filter Use a good quality motor oil that meets the comrect API
wrench a n d clean the filter housing surface. Service Classification [Figure 10-90-2].

Dealer Copy -- Not for Resale

Use a genuine Bobcat filter. Install the fill cap.

Put clean oil o n the filter gasket. Start the engine and let it run for several minutes.

Install the filter and tighten b y hand. Stop the engine. Check for leaks at the oil filter. Check
the oil level.

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

dipstick.

4 2of 591 1090-2 E 1 0 Service Manual

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or

or
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W W
O O
N N
Y Y
U U
to
B
HYDRAULIC SYSTEM to
B

lick lick
ww

ww
om

om
C C
w w
.c

A WARNING
c
.p e .p e.
d f- x
chang Checking A n d A d d i n g Hydraulic Qil d f- x
chang

Put the machine o n a level surface.

Retract the arm and bucket cylinders, put the bucket o n
the ground and raise the blade. Stop the engine.
Figure 10-100-1
AVOID INJURY OR DEATH
Always clean u p spilled fuel o r o i l . Keep heat, flames,
sparks o r lighted tobacco away from fuel a n d oil.
Failure t o u s e care around combustibles c a n cause
explosion o r fire.
W-2103-0508

Diagnostic Connectors

F i g u r e 10-100-3

Dealer Copy -- Not for Resale

S7956

Thy

The fluid must b e a t the center of the sight gauge (item 1 )

[Figure 10-100-1].
58560
F i g u r e 10-100-2
2\Y

The two diagnostic connectors (litem 1 ) [Figure 10-100-

A

3 ] are located o n the hydraulic manifold block.

The connectors can b e used b y your Bobcat dealer to

check circuit pressures.

56717

Open the tailgate.

Remove the oil fill cap (item 1 ) [Figure 10-100-2].

A d d the correct fluid to the reservoir until i t i s at the

center o f the sight gauge (item 1 ) [ F i g u r e 10-100-1].
{See “Fluid Specifications” o n page SPEC-10-8.) Install
the cap. Close the tailgate.

4 3of 591 10-100-1 E 1 0 Service Manual

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PD
or

or
! !
W W
O O
N N
Y Y
U U
HYDRAULIC
k
to
B
SYSTEM (CONT'D) Replacing Hydraulic Oil to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
Replacing The Hydraulic Filter
d f- x
chang (See “SERVICE SCHEDULE” o n page 10-50-1.) for the d f- x
chang

correct service interval.

{See “SERVICE SCHEDULE" o n page 10-50-1.) for the
correct service interval. Retract the arm and bucket cylinders, lower the bucket to
the ground. Stop the engine.
Open the tailgate.
Remove and replace the hydraulic filter.
Figure 10-100-4
Figure 10-100-6

~\

ai
Ce

Dealer Copy -- Not for Resale

| S6771
$8301

Remove the filter (Item 1 ) [ F i g u r e 10-100-4]. Remove the ail fill cap (Item 1 ) [Figure 10-100-6).

Clean the housing where the filter gasket makes contact.

Put clean hydraulic fluid on the gasket. Install the new

filter and tighten b y h a n d only.

Figure 10-100-5

57956
— eu |

Start the engine. Run the excavator through the hydraulic

functions. Stop the engine. Check the fluid level at the
sight gauge (item 1 ) [Figure 10-100-5] and add a s
needed. Check the filter area for leaks.

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or

or
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W W
O O
N N
Y Y
U U
k
to
B
HYDRAULIC SYSTEM (CONT'D) to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
d f- x
chang R e p l a c i n g Hydraulic Q i l (Contd) d f- x
chang

Figure 10-100-7

S6773

Remove the lower right hand side cover. (See “Lower

Right Hand Side Cover Removal A n d installation” o n
page 40-210-3.)

Dealer Copy -- Not for Resale

Remove the plug (ltem 1 ) [Figure 10-100-7] and drain
the hydraulic oil into a container.

After all the hydraulic oil has been removed, put the plug
back onto the fitting.

=?) I Fy

F l u i d s u c h a s e n g i n e oil, h y d r a u l i c f i u i d , coolants,
grease, etc. m u s t b e d i s p o s e d o f i n a n
environmentally safe manner. S o m e regulations
require that certain spills a n d leaks o n t h e g r o u n d
must b e cleaned i n a specific manner. See local, state
a n d federal regulations for t h e correct disposal.
1-2067-0499

=? { ) IX fy

If t h e f l u i d i s b e i n g d r a i n e d b e c a u s e o f a system
failure, remove a n d c l e a n all hydraulic lines.
1-2045-0788

A d d fluid to the reservoir until i t i s a t the center of the

sight gauge (item 1 ) [Figure 10-100-5]. (See “Fluid
Specifications” o n page SPEC-10-9.) Run the excavator
through the hydraulic functions. Stop the engine. Check
the fluid level and add a s needed.

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or

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!

!
W

W
O

O
N

N
Y

Y
U

U
LUBRICATION OF THE HYDRAULIC EXCAVATOR Figure 10-110-3
B

B
to

to
k

k
lic

lic
ww

ww
om

om
C

C
w c w c
.p e. .p e.
d f- x
chang Lubricate the hydraulic excavator a s specified i n the 5
-—
d f- x
chang

service schedule. (See “SERVICE SCHEDULE" o n : “es ap hd ~ A -

page 10-50-1.) for the best performance of the machine.

Record the operating hours each time you lubricate the

hydraulic excavator.

Always use a good quality lithium based multipurpose

grease when lubricating the excavator. Apply the
fubricant until extra grease shows.

Figure 10-110-1

57642

3. Blade Cylinder, R o d End, every 8 - 1 0 hours (item 1 )

[Figure 10-110-3].

F i g u r e 10-110-4

Dealer Copy -- Not for Resale

57643

Ref Description ( # o f Fittings}

1. Blade Cylinder, Base End, every 8 - 1 0 hours (tem 1 )

[ F i g u r e 10-110-1].

F i g u r e 10-110-2 57644

4. Boom Swing Cylinder, R o d End, every 8 - 1 0 hours

(item 1 ) [Figure 10-110-4].

S7658
——

2. Blade Pivots, every 8 - 1 0 hours (Item 1 ) [Figure 1 0 -

110-2], both sides.

4 7of 591 10-1101 E 1 0 Service Manual

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F- t F- t
PD

PD
or

or
! !
W W
O O
N N
Y Y
U U
LUBRICATION
k
to
B
OF THE HYDRAULIC EXCAVATOR Figure 10-110-7 to
B

lic ck
C (CONT'D)
li
ww

ww
om

om
C
w w
.p e .c .p e.
c
d f- x d f- x
chang chang
Figure 10-110-5
<
»

57646
—d

my $6784 8. Boom, Base Pivot, every 8 - 1 0 hours (litem 1 ) [Figure

10-110-7].
5. Boom Swing Cylinder, Base End, every 8 - 1 0 hours F i g u r e 10-110-8
(Item 1) [Figure 10-110-5].

Dealer Copy -- Not for Resale

Figure 10-110-6
C/ a.

57647

S7653 9. Boom Cylinder, Base End, every 8 - 1 0 hours (item 1 )

[Figure 10-110-8].

6. Boom Cylinder, Rod E n d (ltem1) [Figure 10-110-6]. 10. A r m Cylinder, Base End, every 8 - 1 0 hours (litem 2 )
[Figure 10-110-8].
7. Boom Swing Pivot, every 8 - 1 0 hours (tem 2 )
[Figure 10-110-6].

48 of 591 10-110-2 E 1 0 Service Manual

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or

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!

!
W

W
O

O
N

N
Y

Y
U

U
LUBRICATION OF THE HYDRAULIC EXCAVATOR Figure 10-110-11
B

B
to

to
k

k
{CONT'D}
lic

lic
ww

ww
om

om
C

C
w c w c
.p
d f- x e. .p
d f- x e.
chang chang
Figure 10-110-8
B

rl
$7648 13. Bucket Cylinder, Base end, every 8 - 1 0 hours (ltem
1) [Figure 10-110-11].
11. Arm Cylinder, Rod End, every 8 - 10 hours (item 1) F i g u r e 10-110-12
[ F i g u r e 10-110-9).

Dealer Copy -- Not for Resale

F i g u r e 10-110-10

57651

$7649 14. Bucket Cylinder, R o d end, every 8 - 1 0 hours (Item 1 )

[Figure 10-110-12].
12. Arm Pivot, every 8 - 1 0 hours (Item 1 ) [ F i g u r e 10-110- 15. Bucket Link, Bucket Cylinder Pivot, every 8 - 1 0 hours
10]. {litem 2 ) [Figure 10-110-12].

4 9of 591 10-110-3 E 1 0 Service Manual

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PD

PD
or

or
! !
W W
O O
N N
Y Y
U U
LUBRICATION
k
to
B
OF THE HYDRAULIC EXCAVATOR Figure 10-110-15 to
B

lic ck
C (CONT'D)
li
ww

ww
om

om
C
w w
.p e .c .p e.
c
d f- x d f- x
chang chang
Figure 10-110-13

57655
1 ||

_ 87662 20. Track Expansion Tube, as required (litem 1) [Figure

16. Bucket Link Pivot, every 8 - 1 0 hours (Item 1 ) [Figure
10-110-13].
17. Bucket Pivots, every 8 - 10 hours (Item 2) [Figure 10-
10-110-15] (both sides).
NOTE: Spread lubriplate gear shield extra heavy
grease evenly o n wear surfaces o n both sides
o f excavator as required.

Dealer Copy -- Not for Resale

110-13].

F i g u r e 10-110-14

$7654
——

18. Swing Circle Bearing, every 5 0 hours (litem 1 ) [ F i g u r e

10-110-14].

19. Swing Circle Pinion, every 5 0 hours (item 2 ) [Figure

10-110-14]. P u m p 4 - 5 times with a grease gun.
Rotate the upperstructure 90° and repeat three more
times.

NOTE: D o not over-grease t h e swing circle; damage

t o the seal could result.

50 of 591 10-1104 E10 Service Manual

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W W
O O
N N
Y Y
U U
k
to
B
TRAVEL MOTOR Draining T h e Travel Motor to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
d f- x
chang Checking Qil Level chang
(See “SERVICE SCHEDULE" o n page 10-50-1.) for the d f- x

correct service interval.

Figure 10-120-1
Put the machine o n a level surface with the plugs
positioned a s shown (Items 1 a n d 2 ) [Figure 10-120-1].

Remove the bottom plug (item 2 ) a n d top plug (Item 1 )

[Figure 10-120-1] and drain into a container. Recycle o r
dispose o f the used lubricant i n a n environmentally safe
manner.

After all the gear lube i s removed, install the bottom plug
(item 2 ) [Figure 10-120-1].

Add gear lube to the top plug hole (item 1 ) [Figure 1 0 -

120-1] until the gear lube level i s at the bottom edge o f
the plug hole. (See “Fluid Capacities” o n page SPEC-10-
8.) (See “Fluid Specifications” o n page SPEC-10-9.).
55240
Install and tighten the top plug.

Put the machine o n a level surface with the plugs Repeat the procedure for the other side.
positioned a s shown (Items 1 and 2) [Figure 10-120-1].

Dealer Copy -- Not for Resale

Remove the top plug (item 1 ) [Figure 10-120-1]. The oil
level should b e a t the bottom edge of the plug hole.

A d d gear lube through the plug hole if the oil level i s

below the hole. (See “Fluid Capacities” o n page SPEC-
10-8.) (See “Fluid Specifications” o n page SPEC-10-9.).
Install and tighten the top plug.

Repeat the procedure for the other side.

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W W
O O
N N
Y Y
U U
to
B
SPARK ARRESTER MUFFLER Start the engine and run for about 1 0 seconds while to a
B

lick lic
k
second person, wearing safety glasses, holds a piece of c
ww

ww
om

om
C C
w c w
.p e. .p
d f- x a n g e
.
d f- x
chang C l e a n i n g Procedure wood over the outlet of the muffler (the carbon deposits ch

will b e forced out o f the muffler cleanout hole).

(See “SERVICE SCHEDULE" o n page 10-50-1.) for the
correct service interval. Stop the engine. Install a n d tighten the plug.

Do not operate the excavator with a defective exhaust Re-install the cover.
system.

Stop the engine.

Figure 1 0 - 1 3 0 1

AVOID INJURY OR DEATH

W h e n a n e n g i n e i s r u n n i n g i n a n enclosed area, fresh
a i r must b e added t o avoid concentration o f exhaust
fumes. If the e n g i n e i s stationary, vent the exhaust
outside. Exhaust fumes c o n t a i n odorless, invisible
gases w h i c h c a n kill without warming.
W-2050-0807

Dealer Copy -- Not for Resale

57554
A \ WARNING
Stop e n g i n e a n d allow t h e muffler t o c o o l before
Remove t h e bolts (item 1 } [ F i g u r e 10-130-1] from the c l e a n i n g t h e s p a r k chamber. Wear safety g o g g l e s .
cover. Failure t o obey c a n cause serious injury.
W-2011-1285

Remove the cover.

Figure 10-130-2

Never u s e m a c h i n e i n a t m o s p h e r e w i t h e x p l o s i v e
d u s t o r gases o r where exhaust can contact
flammable material. Failure t o obey warnings c a n
cause injury o r death.
W-2068-1285

57636
W h e n t h e e n g i n e i s r u n n i n g d u r i n g service, t h e
steering levers must b e i n neutral.
Remove the plug (item 1 ) [ F i g u r e 10-130-2] from the
bottom of the muifler. Failure t o d o s o c a n cause injury o r death.
W-2203-0595

5 3of 591 10-130-1 E 1 0 Service Manual

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PD

PD
or

or
! !
W W
O O
N N
Y Y
U U
k
to
B
ALTERNATOR BELT Remove the cover. to
B

lic lick
ww

ww
om

om
C C
w w
.p e .c .p e.
c
d f- x
chang Adjusting T h e Alternator Belt F i g u r e 10-140-3 d f- x
chang

Replace the belt if it has stretched o r there are cracks i n

the belt. Replace the pulley if the belt makes contact with
the bottom of the groove i n the pulley.

The tools listed will b e needed to d o the following

procedure:

P/N 7001906 - Bowed Key Wrench 11x13

NIE
Stop the engine.

Figure 10-140-1

le
———-
3) Dw EN 58243

Loosen the upper alternator bolt (Item 1 ) [Figure 10-140-

3].

Dealer Copy -- Not for Resale

Po : S674

Remove the two bolts (item 1) and remove the fan guard
(Item 2 ) [ F i g u r e 10-140-1].

Remove the fill cap (item 3 ) [Figure 10-140-1] from the

hydraulic reservoir.

Figure 10-140-2

S7554
——

Remove the four bolts (Item 1 ) [ F i g u r e 10-140-2].

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or

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W W
O O
N N
Y Y
U U
ALTERNATOR
k
to
B
BELT (CONT'D) F i g u r e 10-140-5 to
B

lic lick
ww

ww
om

om
C C
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Adjusting T h e Alternator Belt (Cont'd)
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Figure 10-140-4

ly,

58247

If a belt tension tool i s available, move the alternator

: 58243
— ——
Loosen the lower alternator mounting and adjustment
bolt {item 1) [Figure 10-140-4].
toward the front o f the machine (ltem 2 ) [Figure 10-140-
4] until the belt (Item 1 ) [ F i g u r e 10-140-5] has (New belt
= (New belt = 249 - 267 N [56 - 60 Ibf] or Used belt = 214
- 231 N [48 - 52 Ibf]) tension.

Dealer Copy -- Not for Resale

If a belt tension tool is not available, move the alternator
toward the front of the machine (litem 2) [Figure 10-140-
4] until the belt (item 1 ) [Figure 10-140-5] has 1 3 m m
(0.50 in) movement at the middle of the belt span with 5 8
N (13 Ibf) of force.

Tighten the mounting and adjustment bolts.

Install the cover, fill cap and fan guard.

56 of 591 10-140-2 E 1 0 Service Manual

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SEAT BELT Figure 10-150-1 to
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Failure t o properly i n s p e c t a n d m a i n t a i n t h e s e a t belt

can c a u s e lack o f o p e r a t o r restraint r e s u l t i n g i n
serious injury o r death.
W2466-0703

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly o r more

often if the machine i s exposed to severe environmental
conditions o r applications.

The seat belt system should b e repaired o r replaced i f it

shows cuts, fraying, extreme o r unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,

Dealer Copy -- Not for Resale

dusty / dirty conditions, abrasion to the seat belt webbing,
o r damage to the buckle, latch plate, retractor (if
equipped), o r hardware.

B-22283

The items below are referenced i n [Figure 10-150-1].

1. Check the seat belt webbing. If the system i s

equipped with a retractor, pull the webbing completely
out and inspect the full length of the webbing. Look for
cuts, wear, fraying, dirt and stiffness.

2. Check the buckle a n d latch for correct operation.

Make sure latch plate i s not excessively worn,
deformed o r buckle i s not damaged o r casing broken.

3 . Check the retractor web storage device (if equipped)

b y extending the seat belt webbing t o determine if it
looks correct and that i t spools out and retracts the
webbing correctly.

4. Check webbing i n areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color o f the webbing i n these areas i s extremely faded
and / o r the webbing i s packed with dirt, the webbing
strength can have deteriorated.

S e e your Bobcat dealer for approved seat belt system

replacement parts for your machine.

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CONTROL CONSOLE LOCKOUTS Figure 10-160-2
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Figure 10-160-1

$8438

Raise the left console (Item 1 ) [Figure 10-160-2). T h e

green light (Item 1 ) [Figure 10-160-1] o n the instrument
58951 panel will g o off.

Move the joystick control levers. There should b e n o

When a console i s raised, the hydraulic control levers
movement of the boom, arm, slew o r bucket.
(joysticks) and traction system must not function.

Dealer Copy -- Not for Resale

Move the steering control levers. There should b e n o
Sit i n the operator's seat, fasten the seat belt a n d start
movement of the excavator tracks.
the engine.
F i g u r e 10-160-3
The joystick control levers and traction system must b e
deactivated when either console i s raised.

Service the system if these controls d o not deactivate

when a control console is raised. (See your Bobcat®
dealer for service.)

58439

Raise t h e right console (item 1 ) [ F i g u r e 10-160-3]. T h e

green light (item 1 ) [Figure 10-160-1] o n the instrument
panel will g o off.

Move the joystick control levers. There should b e n o

movement of the boom, arm, slew o r bucket.

Move the steering control levers. There should b e n o

movement of the excavator tracks.

5 9of 591 10-160-1 E 1 0 Service Manual

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