1GENERALINFORMATION
SERVICEMANUAL
TABLEOFCONTENTS
2ENGINE
3FUELSYSTEM
4ELECTRICALSYSTEM
5UNDERCARRIAGE
6DRIVETRAIN
7UNDERCARRIAGEHYDRAULICS
*ConsulttheEngineServiceManual
8UPPERSTRUCTUREHYDRAULICS
9UPPERSTRUCTURE
WARNING:Thissymbolisusedinthismanualtoindicateimportantsafetymessages.Wheneveryousee thissymbol,carefullyreadthemessagethatfollows,asthereisariskofseriousinjury.
GENERALINFORMATION
Cleanning
Cleanallmetalpartsexceptbearings,inasuitable cleaningsolventorbysteamcleaning.Donotuse causticsodaforsteamcleaning.Aftercleaning,dry andputoilonallparts.Cleanoilpassageswith compressedair.Cleanbearingsinasuitablecleaning solvent,drythebearingscompletelyandputoilon thebearings.
Inspection
Checkallpartswhenthepartsaredisassembled. Replaceallpartsthathavewearordamage.Small scoringorgroovescanberemovedwithahoneor crocuscloth.Completeavisualinspectionfor indicationsofwear,pittingandthereplacementof partsnecessarytopreventearlyfailures.
Bearings
Checkbearingsforeasyaction.Ifbearingshavea loosefitorroughactionreplacethebearing.Wash bearingswithasuitablecleaningsolventandpermit toairdry.DONOTDRYBEARINGSWITH COMPRESSEDAIR.
Needlebearings
Beforeyoupressneedlebearingsinaborealways removeanymetalprotrusionsintheboreoredgeof thebore.Beforeyoupressbearingsintopositionput petroleumjellyontheinsideandoutsidediameterof thebearings.
Gears
Checkallgearsforwearanddamage.Replacegears thathavewearordamage.
Oilseals,O-ringsandgaskets
Alwaysinstallnewoilseals,O-ringsandgaskets.Put petroleumjellyonsealsandO-rings.
Shafts
Checkallshaftsthathavewearordamage.Check thebearingandoilsealsurfacesoftheshaftsfor damage.
Serviceparts
AlwaysinstallgenuineCaseserviceparts.When orderingrefertothePartsCatalogforthecorrectpart numberofthegenuineCasereplacementitems. FailuresduetotheuseofotherthangenuineCase replacementpartsarenotcoveredbywarranty.
Lubrication
Onlyusetheoilsandlubricantsspecifiedinthe Operator’sorServiceManuals.Failuresduetothe useofnon-specifiedoilsandlubricantsarenot coveredbywarranty.
SAFETY
ThissymbolmeansATTENTION!BECOMEALERT!YOUR SAFETYISINVOLVED.Themessagethatfollowsthe symbolcontainsimportantinformationaboutsafety.Carefully readthemessage.Makesureyoufullyunderstandthe causesofpossibleinjuryordeath.
TopreventinjuryalwaysfollowtheWarning,Caution andDangernotesinthissectionandthroughoutthe manual.
Putthewarningtagshownbelowonthekeyforthe keyswitchwhenservicingorrepairingthemachine. Onewarningtagissuppliedwitheachmachine. AdditionaltagsPartNumber331-4614areavailable fromyourservicepartssupplier
WARNING:Readtheoperator’smanualto familiarizeyourselfwiththecorrectcontrol functions.
WARNING:Operatethemachineand equipmentcontrolsfromtheseatposition only.Anyothermethodcouldresultin seriousinjury.
WARNING:Thisisaonemanmachine,no ridersallowed.
WARNING:Beforestartingengine,study Operator’sManualsafetymessages.Read allsafetysignsonmachine.Cleartheareaof otherpersons.Learnandpracticesafeuse ofcontrolsbeforeoperating. Itisyourresponsibilitytounderstandand followmanufacturersinstructionson machineoperation,serviceandtoobserve pertinentlawsandregulations.Operator’s andServiceManualsmaybeobtainedfrom yourCasedealer.
WARNING:Ifyouwearclothingthatistoo looseordonotusethecorrectsafety equipmentforyourjob,youcanbeinjured. Alwayswearclothingthatwillnotcatchon objects.Extrasafetyequipmentthatcanbe requiredincludeshardhat,safetyshoes,ear protection,eyeorfaceprotection,heavy glovesandreflectorclothing.
WARNING:Whenworkingintheareaofthe fanbeltwiththeenginerunning,avoidloose clothingifpossible,anduseextremecaution.
WARNING:Whendoingchecksandtests ontheequipmenthydraulics,followthe proceduresastheyarewritten.DONOT changetheprocedure.
WARNING:Whenputtingthehydraulic cylindersonthismachinethroughthe necessarycyclestocheckoperationorto removeairfromacircuit,makesureall peopleareoutoftheway.
WARNING:Useinsulatedglovesormittens whenworkingwithhotparts.
WARNING:Lowerallattachmentstothe groundorusestandstosafelysupportthe attachmentsbeforeyoudoanymaintenance orservice.
WARNING:Pinsizedandsmallerstreams ofhydraulicoilunderpressurecanpenetrate theskinandresultinseriousinfection.If hydraulicoilunderpressuredoespenetrate theskin,seekmedicaltreatment immediately.Maintainallhosesandtubesin goodcondition.Makesureallconnections aretight.Makeareplacementofanytubeor hosethatisdamagedorthoughttobe damaged.DONOTuseyourhandtocheck forleaks,useapieceofcardboardorwood.
WARNING:Whenremovinghardenedpins suchasapivotpin,orahardenedshaft,use asofthead(brassorbronze)hammeroruse adrivermadefrombrassorbronzeanda steelheadhammer.
WARNING:Whenusingahammerto removeandinstallpivotpinsorseparate partsusingcompressedairorusinga grinder,weareyeprotectionthatcompletely enclosestheeyes(approvedgogglesor otherapprovedeyeprotectors).
WARNING:Usesuitablefloor(service) jacksorchainhoisttoraisewheelsortracks offthefloor.Alwaysblockmachineinplace withsuitablesafetystands.
WARNING:Whenservicingorrepairingthe machine,keeptheshopfloorandoperator’s compartmentandstepsfreeofoil,water, grease,tools,etc.Useanoilabsorbing materialand/orshopclothsasrequired.Use safepracticesatalltimes.
WARNING:Somecomponentsofthis machineareveryheavy.Usesuitablelifting equipmentoradditionalhelpasinstructedin thisServiceManual.
WARNING:Engineexhaustfumescan causedeath.Ifitisnecessarytostartthe engineinaclosedplace,removetheexhaust fumesfromtheareawithanexhaustpipe extension.Openthedoorsandgetoutside airintothearea.
WARNING:Whenthebatteryelectrolyteis frozen,thebatterycanexplodeif(1),youtry tochargethebattery,or(2),youtrytojump startandruntheengine.Topreventthe batteryelectrolytefromfreezing,trytokeep thebatteryatfullcharge.Ifyoudonotfollow theseinstructions,youorothersinthearea canbeinjured.
Tighteningofcapscrews,nuts
Tightenalternatelysothattighteningtorquecanbeappliedevenly.Thenumbersinthefigurebelowindicatethe orderoftightening.
CapscrewswhichhavehadLoctiteused(whiteresidueremainsafterremoval)shouldbecleanedwithloghtoilor suitablecleaningsolventanddried.Apply2-3dropsofLoctitetothethreadportionofthecapscrewandthen tighten.
Torquetable
Tightencapscrewsandnutsaccordingtothetablebelowiftherearenootherspecialinstructions.
CapScrewNameSize(Size)M6M8M10M12M14M16M18M20
CapScrew Spanner
Socket HeadCap Screw Spanner [mm]5681012141417 [in.]0.200.240.320.390.470.550.550.67
