Case Cx27b Excavator Operators Manual - PDF DOWNLOAD

CX27B EXCAVATORS OPERATOR’S MANUAL

Part Number: 87458477

CNH AMERICA LLC TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ●

DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

●

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

●

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ●

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

Reads and understands the Manual(s) pertaining to the machine.

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow CNH America LLC instructions on machine operation and maintenance.

WARNING_01_NA

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2004 CNH America LLC All Rights Reserved Case and IH are registered trademarks of CNH America LLC

Bur 87458477NA Issued October, 2004

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CHAPTER 2 SAFETY, AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-3 2-3 2-3 2-4 2-4 2-9

CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Access Covers and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Operator’s Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Run-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Bringing the Machine Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Operating the Machine in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operating the Machine in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Operating the Machine on Sloping Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Moving A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Lowering the Attachment in the Event of a Machine Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Operating the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lubrication and Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Grease Fittings and Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Travel Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Checking the Condition of Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Track Rollers and idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Replacing a Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Fan and alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Inspecting and Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Fire Extinguisher (Not Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Plastic and Resin Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Welding on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Metric Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Connecting A Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-3 7-3 7-3 7-4 7-6 7-7

CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Overall Dimensions - ROPS Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Overall Dimensions - Cab Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-3 8-3 8-3 8-4 8-5 8-6

CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER CX COMPACT HYDRAULIC CRAWLER EXCAVATOR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. See Official documents. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the machine.

The standard attachments and tools of this machine are designed to carry out all kinds of earthmoving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is designed to carry out this kind of work. For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine's technical specifications and with prevailing safety requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial conformity with safety requirements.

The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your Dealer.

Before permitting a new operator on this machine, make sure: That the operator has received the necessary training on how to operate the machine correctly and safely.

That the operator has read and understood the instructions given in this manual.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is always complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your Dealer.

Your Dealer is at your disposal for any further information. He will also provide any after-sales service you may require, and genuine Case spare parts, your guarantee of quality and match.

The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat when the cab is over the idler wheels.

The illustration shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the upper structure.

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RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE 1

6

6

4

3

5

5

The CX compact excavator is a fully hydraulic machine. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump delivers hydraulic fluid to the control valves.

The control valves distribute the hydraulic fluid to the various cylinders and motors concerned. A cooling system maintains the hydraulic fluid at normal operating temperature.

2 BC02N192

1.

2.

3.

4.

5.

6.

1-2

Figure 1

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE TRAVEL REDUCTION GEARS (TRAVEL MOTORS) IDLER WHEELS

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CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE When ordering par ts, obtaining infor mation or assistance, always supply your Dealer with the type and serial number of your machine or accessories.

Write the following in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤

BS04H224

Manufacturing Year

Figure 1

ENGINE

ENGINE ➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump ➤ Swing Reduction Gear ➤ Travel Reduction Gears BS04H243

➤

Figure 2

Travel Control Valve ➤ Attachment Control Valve ➤ Swing Control Valve

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CHAPTER 2 - SAFETY, AND DECALS

Chapter 2 SAFETY, AND DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll-Over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 2-4 2-4 2-5 2-5 2-5 2-6 2-7 2-7 2-8 2-8 2-8 2-8 2-8 2-9

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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NOTES

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CHAPTER 2 - SAFETY, AND DECALS

SAFETY RULES PERSONAL SAFETY

WARNING: This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

M171C

Most accidents involving machine operating and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety signs on the machine before you operate or service the machine. See your dealer if you have any questions.

If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW Prohibition symbols such as used, are RED.

and

STOP

if

SAFETY AREA The safety area is the space necessary for the machine to operate at the maximum range of the tool is a full 360 ° swing plus 6 feet (2 metres).

1

Figure 1

BC02N197

OPERATOR’S MANUAL STORAGE SPACE

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability, and load characteristics of this machine before you start to operate this machine.

2 BC02N198

Figure 2

1. WORKING AREA 2. SAFETY AREA

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

The safety information given in this manual does not replace safety codes, insurance needs, federal, state, or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

Additional safety messages are used in the text of the manual to show specific safety hazards.

IMPORTANT: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

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CHAPTER 2 - SAFETY, AND DECALS

UTILITY SAFETY Safety precaution MUST be followed when working near buried and overhead Utility Lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• • • •

Electrical Power Line Gas Line

Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

OPERATOR PRECAUTIONS

Water Line Communication Line - Telephone or Cable Television

• Telephone or Cable Television IMPORTANT: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

IMPORTANT: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

PERSONNEL

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of typed of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

RH99G001

Figure 3

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum . . . . . . . . . . . . . . . .Yellow Communication, Telephone, Television . .Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Sewer . . . . . . . . . . . . . . . . . . . . . . . Green/Brown 2-4

• Wear the seat belt to maximize the protection capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

• Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

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CHAPTER 2 - SAFETY, AND DECALS

• Remove all loose object stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

• Remove the starter key or disconnect switch when leaving the machine parked or unattended.

OPERATING PRECAUTIONS

MOUNTING AND DISMOUNTING PRECAUTIONS

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean. Face the access system when climbing up and down

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s station.

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

• Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

• Do not operate the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

• Before leaving the operator’s station, lower the equipment to the ground, shut off the engine and place the function cancellation lever into the locked or up position.

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• Check brakes, steering and other machine control devices in accordance with the manufacturers instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a do not operate tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a do not operate tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

• Understand the machine limitations and keep the machine under control.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

• When roading a machine, know and use the signaling devices required on the machine.

Provide and escort for roading where required.

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CHAPTER 2 - SAFETY, AND DECALS

• On machines with independently operated wheel

• Do not operate the machine if you do not feel well.

brakes, lock the brake pedals together when roading to provide equalized brake application.

This can be dangerous for you and for the people around you.

• Use the recommended transport devices when

• You must make a judgment if weather, road, or

roading the machine.

• Use the approved drawbar and / or attachment

earth conditions will permit safe operation on a hill, ramp, or rough ground.

point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Stay away from hazardous areas such as ditches,

• Before you operate at night, check that all lamps

• Be alert and always know the location of all

illuminate.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

overhangs, etc. Walk around the work area before you start and look for hazards. workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

• Before you service the machine, put a Do Not Operate tag on the key switch. The Do Not Operate tag is included with your new machine.

Addition tags, part number LC20T01001P1, are available from your Dealer.

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. See the decal on the machine. Page 2-13.

You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

• If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

2-6

Figure 4

BS04J124

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

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CHAPTER 2 - SAFETY, AND DECALS

• Securely block the machine or any component

• Tighten the fuel tank cap securely. Should the fuel

that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

cap be lost, replace it only with the original manufacturers approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

• Use extreme caution when removing radiator

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

BURN PREVENTION

• When absolutely necessary to tow the machine,

WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturers. recommendations.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alt: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling

M144B

• When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

or near fueling operations.

• Never remove the fuel cap or refuel gasoline

HAZARDOUS CHEMICAL PRECAUTIONS

engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• If you are exposed to or come in contact with

• To avoid spilling fuel maintain control of the fuel

• Material Safety Data Sheets (MSDS) provide

filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top. Allow room for expansion.

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

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hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous. information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

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CHAPTER 2 - SAFETY, AND DECALS

• Before you service your machine, check the MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Check with your local environmental or recycling center or your information.

dealer

for

correct

disposal Figure 6

BC02N200

1. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

TRANSPORTING PRECAUTIONS K n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n t necessary for transporting this machine on a road or highway.

ROLL-OVER PROTECTIVE STRUCTURE (IF EQUIPPED) D o N OT m o d i f y t h e R O P S i n a n y m a n n e r.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. Contact your dealer for the type and location of a fire extinguisher on this machine.

SEAT BELT PRECAUTIONS

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M437

SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or tool as low as possible while

1

moving the machine around the jobsite.

• Never smoke while refuelling.

• The dozer blade control is functional even with the function cancellation lever locked up. (Hydraulic controls neutralized)

• Always know the position of the upperstructure in relation to the travel reduction or final drive gears.

2 BC02N375

Figure 5

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

1. Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat.

2. Tighten the seat belt by pulling on the loose end on the right-hand seat belt.

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CHAPTER 2 - SAFETY, AND DECALS

SAFETY DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily.

CE-NA000

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible, with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part.

NOTE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals for the machine, consult your authorized dealer.

CE-NA000

BS04H227

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Figure 7 Issued 10-04

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CHAPTER 2 - SAFETY, AND DECALS

BS04H228

2-10

Figure 8 Issued 10-04

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CHAPTER 2 - SAFETY, AND DECALS

BS04H229

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Figure 9

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CHAPTER 2 - SAFETY, AND DECALS

Figure 10

YN20T01013P1

Figure 13

YN20T01220P1

1. PART NUMBER YN20T01013P1

4. PART NUMBER YN20T01220P1 LOCATED INSIDE CAB ON RIGHT-HAND SIDE LOCATED ON THE RADIATOR COVER

Figure 14

PE20T01013P1

Figure 11

PW20T01007P1

5. PART NUMBER PE20T01013P1

2. PART NUMBER PW20T01007P1

LOCATED ON RADIATOR COVER

LOCATED ON TOP OF HYDRAULIC TANK

Figure 15

YN20T01012P1

6. PART NUMBER YN20T01012P1 LOCATED ON THE ENGINE COVER

Figure 12

YN20T01016P1

3. PART NUMBER YN20T01016P1 LOCATED ON SEAT STAND

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Figure 16

PE20T01014P1

7. PART NUMBER PE20T01014P1 LOCATED ON RADIATOR COVER Figure 19

2423T6110

10. PART NUMBER 2432T6110 LOCATED ON THE CRAWLER FRAME

Figure 20

PE20T01012P1

Figure 17

YN20T01009P1

11. PART NUMBER PE20T01012P1

8. PART NUMBER YN20T01009P1 LOCATED ON BOTH SIDES OF THE ARM LOCATED ON THE ENGINE RADIATOR

Figure 21

PY20T01077P1

12. PART NUMBER PY20T01077P1 LOCATED ON SEAT STAND

Figure 18

YN20T01338P1

9. PART NUMBER YN20T01338P1 LOCATED ON THE BATTERY BOX COVER

PY20T01069P1

Figure 22

13. PART NUMBER PY20T01069P1 LOCATED ON THE BATTERY BOX COVER 87458477NA

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CHAPTER 2 - SAFETY, AND DECALS

Figure 26

PY20T01062P1

17. PART NUMBER PY20T01062P1 LOCATED ON SEAT STAND

Figure 23

YN20T01006P1

14. PART NUMBER YN20T01006P1 LOCATED ON SEAT STAND

Figure 27

PE20T01027P1

18. PART NUMBER PE20T01027P1 LOCATED ON ROPS CANOPY AND INSIDE CAB

Figure 24

PE20T01016P1

15. PART NUMBER PE20T01016P1

Figure 28

YN20T01416P1

19. PART NUMBER YN20T01416P1

LOCATED ON SEAT STAND

LOCATED INSIDE OF FRONT WINDOW

Figure 25

PY20T01073P1

16. PART NUMBER PY20T01073P1 LOCATED ON TOP OF SEAT STAND

Figure 29

PM20T01035P1

20. PART NUMBER PM20T01035P1 LOCATED ON FRONT WINDOW

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Figure 33

YN20T01214P1

24. PART NUMBER YN20T01214P1 LOCATED ON INSIDE OF SIDE COVER Figure 30

PV20T01008P1

21. PART NUMBER PV20T01008P1 LOCATED INSIDE CAB DOOR

YN20T01039P1

Figure 34

25. PART NUMBER YN20T01039P1 LOCATED ON INSIDE OF RIGHT WINDOW (CAB), ON THE CEILING (CANOPY)

Figure 31

2423P3379

22. PART NUMBER 2432P3379 LOCATED ON SEAT STAND

Figure 32

PW20T01090P1

23. PART NUMBER PW20T01090P1 LOCATED NEAR FUEL PORT

PE20T01028P1

Figure 35

26. PART NUMBER PE20T01028P1 LOCATED ON RIGHT SIDE OF WINDOW (CAB), ON CEILING (CANOPY)

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CHAPTER 2 - SAFETY, AND DECALS

NOTES

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS CAB (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Windshield (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Window (Right-Hand Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Washer Fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 3-3 3-3 3-4 3-4 3-4 3-4

STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 ACCESS COVERS AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OPERATOR’S SEAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Fastening and Unfastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB (IF EQUIPPED) CAB DOOR WARNING: When seated in the operator’s compartment, with the engine running, make sure that you do not to operate the left-hand control lever inadvertently when unlocking the door. To prevent an incident, place the left-hand control arm in the raised position.

See Function cancellation lever.

CE-NA000

WARNING: Be careful not to get your hand or anything caught in the door when closing it.

CE-NA000

WARNING: Do not leave the door ajar. Fix it in a latched position.

CE-NA000

BC02N327

Figure 2

4. Use the door handle (1) to open the door from the inside.

WINDSHIELD 1. Move the machine to level ground, set the safety lever to the lock position, and stop the engine.

Figure 1

BC02N326

1. DOOR CATCH 2. DOOR HANDLE AND DOOR LOCK

1. Use key to lock or unlock door from outside the machine.

2. Use the door handle (2) to open the door from the outside.

BC02N328

Figure 3

2. Push the lock levers (2) on the right-hand and left-hand side of the windshield to unlock the front windshield.

3. To lock the door in the open position, slide the door back until the door locks on the door catch (1) at the rear of the cab.

1 BC02N321

Figure 4

1. HANDLE 2. LEVER

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. Use the handles on the right-hand and left-hand side of the windshield to raise and slide the front windshield into the ceiling.

CAB LAMP

4. Make sure to use the lever (2) to lock the front windshield into position in the ceiling.

FRONT WINDSHIELD (LOWER)

Figure 7

BC02N325

The cab lamp has a two position switch. ON and OFF. WINDSHIELD WASHER FLUID RESERVOIR BC02N322

Figure 5

The lower front windshield may only be removed when the windshield is open.

1

1. See Front Windshield (Upper) and do steps 1 to 4 to open the windshield.

2. Lift up to remove the window from the frame.

3. Put the front windshield (lower) into the brackets (3) of the rear window frame for storage.

WINDOW (RIGHT-HAND SIDE)

2

3

Figure 8

BC02N324

1. CAP 2. RESERVOIR 3. MOTOR

BC02N323

Figure 6

1. Release the lock (4) and slide the movable glass into position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES WARNING: Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

CE-NA000

WARNING: To get in or out of the cab, it is imperative that the upper structure frame is in line with the undercarriage.

CE-NA000

WARNING: Clean the steps and access handles and remove all traces of grease, oil, mud, and (in winter) ice.

CE-NA000

WARNING: Never jump down from the machine. When leaving the machine or upper structure, always face the machine and use the steps and access handles.

CE-NA000

When getting down from or getting onto the machine, use the steps, the tracks, and the access handles.

Figure 9

BC02N444

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

Figure 10

BS04H230

1.

2.

3.

4.

5.

6.

7.

8.

9.

RIGHT-HAND CONTROL LEVER LEFT-HAND CONTROL LEVER FUNCTION CANCELLATION LEVER RIGHT-HAND TRAVEL LEVER LEFT-HAND TRAVEL LEVER BOOM SWING SWITCH NIBBLER AND BREAKER SWITCH HORN SWITCH TRAVEL SPEED SELECT SWITCH

10.

11.

12.

13.

14.

15.

16.

17.

18.

GUAGE CLUSTER WORKING LIGHT SWITCH THROTTLE LEVER KEY SWITCH DECELERATION SWITCH DOZER BLADE LEVER OERATOR SEAT WIPER SWITCH (CAB ONLY) HEATER SWITCH (CAB ONLY)

WARNING: Before starting the engine, make sure that you are fully aware of the location of and the function of each control.

Incorrect operation of the controls can cause serious injuries.

CE-NA000

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL

Figure 11

BS04H246

1.

2.

3.

4.

5.

6.

7.

8.

ENGINE COOLANT (WATER) TEMPERATURE INDICATOR FUEL LEVEL INDICATOR ENGINE OIL PRESSURE INDICATOR LAMP COOLANT TEMPERATURE INDICATOR LAMP BATTERY CHARGE/INDICATOR LAMP LOW FUEL WARNING LAMP AIR CLEANER CLOGGING LAMP HIGH (2ND) TRAVEL SPEED LAMP

1. ENGINE WATER (COOLANT) TEMPERATURE INDICATOR BS04H248

Figure 13

This indicates the level of fuel in the fuel reservoir.

The indicator functions when the key switch is in the ON position. Normally the needle will take time to move up to the correct fuel level after turning the key switch to the ON position.

F indicates a Full reservoir.

E indicates an Empty reservoir Figure 12

BS04H247

The indicator functions when the key switch is in the ON position.

This indicator is divided into three zones:

When the indicator needle moves closer to the E (Empty) zone, fuel needs to be added in the reservoir.

2. HOURMETER

2 - Red Zone: Hot 1- White Zone: Normal operating temperature 3 - Blue Zone: Cold IMPORTANT: If the needle is in the red zone, move the machine to a safe location, lower the attachment to the ground, slow engine to idle until water temperature returns to the white zone, normal operating temperature.

1. FUEL LEVEL INDICATOR BS04H259

Figure 14

The hourmeter indicates the total time the engine has run.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Even if the machine is not moving, the meter continues to count as long as the engine is running, regardless of the engine speed.

6. FUEL LEVEL INDICATOR LAMP

While the engine is running, the indicator flashes to show that the hourmeter is active.

Use the hourmeter as reference for maintenance.

Figure 18

BC02N337

3. ENGINE OIL PRESSURE INDICATOR LAMP

BC02N334

Figure 15

This indicator illuminates (Red) when the engine is running and the engine oil pressure is too low.

IMPORTANT: If the indicator illuminates during machine operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine, and remove the ignition key. Check the engine oil level.

This indicator illuminates when the fuel level in the reservoir is too low, fuel must be added as soon as possible.

IMPORTANT: Do not wait until the fuel tank is completely empty before refilling or it will be necessary to bleed the fuel circuit.

7. HIGH (2nd) TRAVEL SPEED LAMP

Figure 19

BC02N338

This lamp illuminates (Yellow) when the travel speed is switched to high (2nd.) speed.

4. BATTERY CHARGE /INDICATOR LAMP

The travel speed selector switch is located on the grip of the right travel lever.

The speed automatically returns to low (1st.) speed when the starter switch is set to OFF. BC02N335

Figure 16

8. AIR CLEANER CLOGGING LAMP

This indicator illuminates (Red) when the key switch is turned to the ON position. The indicator should not be illuminated after the engine is running.

IMPORTANT: If the indicator illuminates during machine operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine, and remove the ignition key. Check the alternator drive belt and the charging circuit.

5. COOLANT TEMPERATURE INDICATOR LAMP

BC02N336

Figure 20

BC02N339

This lamp illuminates (Red) if the air cleaner filter is clogged. If the lamp is illuminated, clean or replace the element for the air cleaner immediately.

Figure 17

This indicator lamp illuminates (Red) when the engine coolant temperature is high.

Bring the engine to idle mode and reduce the water or fluid temperature. Check and clean the radiator.

IMPORTANT: If the indicator illuminates during machine operation, bring the engine to idle and reduce the coolant temperature, after the coolant temperature is lowered, move the machine to a safe location, lower the attachment to the ground, shut down the engine, and remove the ignition key. Check the alternator drive belt and the cooling system.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

SWITCHES 2. TRAVEL SPEED SELECT SWITCH

Figure 23

BC02N354

Use this switch to select travel speed, HIGH (2nd speed) or LOW (1st speed). When the starter switch is turned to the OFF position, the travel speed is automatically set to LOW. Select the desired speed before starting travelling.

1.

2.

3.

4.

5.

6.

7.

8.

9.

1. LOW SPEED - 2.3km/h (1.4mph) Select this speed when travelling on rough or soft terrains, slopes, in narrow places, when powerful tractive force is required, or loading or unloading from a truck / trailer.

Figure 21

BS04H231

KEY SWITCH TRAVEL SPEED SELECT SWITCH HORN SWITCH DECELERATION SWITCH WORKING LAMP SWITCH HEATER SWITCH (IF EQUIPPED) WINDSHIELD WIPER AND WASHER SWITCH (CAB ONLY) SWING CONTROL SWITCH NIBBLER AND BREAKER SWITCH

Figure 24

BC02N349

1. HIGH SPEED - 4.3km/h (2.7mph) Set to HIGH when travelling on flat, hard ground.

1. KEY SWITCH Figure 25

BC02N350

WARNING: Move the machine in LOW speed when loading/unloading the machine on to a truck/trailer and when on a slope.

Sudden change of the machine travel speed can cause the machine to roll over.

CE-NA000

Figure 22

BC02N353

This switch is used to start or stop the engine.

3. HORN SWITCH

HEAT POSITION: When engine start-up is difficult in cold climate, turn the key to the HEAT position to activate the pre-heating. Hold the key in the HEAT position for approximately 15 seconds and then turn the key to the START position to start the engine.

Release the key after the engine starts.

OFF: In the OFF position, the electrical system is turned off and the engine is stopped.

ON: In the ON position, the machine's electrical circuit is energized. Keep the key in this position while the machine is in operation.

START: Turn the key to the START position to start the engine. Release the key after the engine starts, the key will automatically return to the ON position.

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BS04H232

Figure 26

IMPORTANT: Always sound the horn before operating the machine. Sound the horn before starting engine, traveling, rotating (swinging) or operating the attachments.

Depress this switch, provided on the top of right operating lever to sound the horn.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 7. WINDSHIELD WIPER AND WASHER SWITCH (CAB ONLY)

4. DECELERATION SWITCH

BS04H245

Figure 27

Press this switch during the engine operation to shift the engine to the low speed.

Press this switch again to release the deceleration function. Turning the starter switch from ON to OFF will automatically release the deceleration function.

5. WORKING LAMP SWITCH (Boom)

Figure 30

BS04H252

This is used for the windshield wiper and washer fluid.

This switch has four positions: WASH . . . . . . . . . . . . . . . . . . .Spraying washer fluid.

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop ON . . . . . . . . . . . . . . . . . . . . . . . . . Wiper operation WASH . Wiper operation and spraying washer fluid.

NOTE: If windshield washer is used continuously for 20 seconds or more, or if windshield washer is operated without fluid, the motor mounted on windshield washer tank may have trouble.

8. BOOM SWING SWITCH

BS04H249

Figure 28

This is used for the boom working lamp.

3

This switch has two positions: OFF position . . . . . . . . . . . . Lamp is not illuminated ON position. . . . . . . . . . . . . . . . . Lamp is illuminated 6. HEATER SWITCH (IF EQUIPPED)

Figure 31

BC02N355

Operate the control lever right and left keeping the switch on the grip of the left control lever pressed in (ON positions), and the boom swings right and left Switch . . . . . . . . . . . . . . . . Pressed In (ON position) Operate lever right . . . . . . . . . . . .Boom swings right Operate lever left . . . . . . . . . . . . . .Boom swings left BS04H250

Figure 29

This is used to warm up the cab interior.

This switch has three positions: OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop L . . . . . . . . . . . . . . . . . . . . . . .Low speed drive of fan H . . . . . . . . . . . . . . . . . . . . . High speed drive of fan

WARNING: The swing operation does not stop even if the switch is turned off during the swing operation. To switch from boom swing to upperstructure swing the left control lever must return to the neutral position.

NOTE: Engine coolant is utilized for the heater, accordingly the heater generate warm air only when coolant is hot.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 9. NIBBLER AND BREAKER SWITCHES

A

WARNING: To access or exit the operator’s compartment, the Function Cancellation Lever must be in the raised position. Never try to avoid this basic requirement.

B

WARNING: Always place the safety lock lever in the LOCKED (up) position before leaving the operator cab. Never leave the machine unattended with engine running or Function Cancellation Lever in the down position.

Figure 32

BC02N355

There are two specifications for the machine, one is single hydraulic circuit for breaker only, and the other is combined hydraulic circuits for both breaker and nibbler.

CE-NA000

WARNING: Even when the Function Cancellation Lever is set in the LOCKED (up) position, the functions for dozer are still activated.

The switches are provided on the grip of the left-hand control lever.

NIBBLER Press switch A . . . . . . . . . . . . . . . . . . . Close Nibble Press switch B . . . . . . . . . . . . . . . . . . . Open Nibble BREAKER Press and hold switch B . . . Breaker starts operating Release switch B . . . . . . . . Breaker stops operating

CONTROL LEVERS

CE-NA000

NOTE: When the Function Cancellation Lever is set to the LOCKED (up) position, each attachment and swing motor are locked simultaneously, except the dozer blade, even though each lever can be moved, because they are of a hydraulic lock system.

However, the travel levers are separately locked with their mechanical locking mechanism to lock the movement itself of the levers.

BC02N365

Figure 34

LOCKING HYDRAULIC SYSTEM Figure 33

BS04H233

1.

2.

3.

4.

5.

FUNCTION CANCELLATION LEVER RIGHT/LEFT - HAND CONTROL LEVERS RIGHT/LEFT - HAND TRAVEL LEVERS THROTTLE CONTROL LEVER DOZER CONTROL LEVER

When the Function Cancellation Lever is set in the LOCKED (UP) Position the hydraulic system is shut down, except the dozer blade functions.

1. FUNCTION CANCELLATION LEVER The Function Cancellation Lever is provided to prevent any unexpected operation due to involuntary movement of the operator’s control levers.

The shape of the Function Cancellation Lever was designed to prevent the operator from leaving the operator’s compartment without having raised the lever beforehand.

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BC02N364

Figure 35

UNLOCKING HYDRAULIC SYSTEM When the safety lever is set to the UNLOCKED (DOWN) Position all hydraulic functions are active.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS 2. LEFT-HAND CONTROL LEVER (SAE Pattern)

Boom Swing Function Switch

3. RIGHT-HAND CONTROL LEVER (SAE Pattern)

Figure 37

BC02N367

1. BOOM SWING/REMOTE CONTROL SWITCH 2. RIGHT-HAND SWING 3. LEFT-HAND SWING

Operate the control lever right and left keeping the switch on the grip of the left-hand control lever pressed, and the boom swings right and left 1. Switch . . . . . . . . . . . . . . . . . . . . . . Pressed (ON) 2. Operate lever right . . . . Right-hand boom swing 3. Operate lever left. . . . . . . .Left-hand boom swing

Figure 36

BC02N366

1.

2.

3.

4.

5.

6.

7.

8.

BOOM DOWN (RIGHT-HAND CONTROL LEVER) BOOM UP (RIGHT-HAND CONTROL LEVER) BUCKET IN (RIGHT-HAND CONTROL LEVER) BUCKET OUT (RIGHT-HAND CONTROL LEVER) ARM OUT (LEFT-HAND CONTROL LEVER) ARM IN (LEFT-HAND CONTROL LEVER) ROTATION LEFT (LEFT-HAND CONTROL LEVER) ROTATION RIGHT (LEFT-HAND CONTROL LEVER)

IMPORTANT: The swing operation does not stop even if the switch is turned off during the swing operation. To switch from boom swing to upperstructure swing the left control lever must return to the neutral position.

WARNING: Because the boom swing operating range is wide, carefully operate the attachment paying attention to the surrounding conditions.

CE-NA000

These two levers activate each operation shown in the illustration.

All functions can be activated simultaneously.

The operator's control levers return to the neutral position when released, and the operation of attachment is stopped.

Optional control pattern is standard and may be changed to suit the operator.

NOTE: The control pattern may be changed to the backhoe pattern by removing the floor plate and changing the control pattern valve.

WARNING: Confirm for safety around the working area. Also ensure that each lever operation is in accordance with the operating pattern indicated on the labels.

If labels do not match the operator's control pattern, replace them immediately to avoid accidents and/or injury.

CE-NA000

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 4. Left-Hand Travel Control Lever

6. THROTTLE LEVER

5. Right-Hand Travel Control Lever

Figure 39

BC02N369

The throttle control lever is located to the right side of the operator's seat, next to the ignition switch. It is used to control the engine speed.

A . . . . . . . . . . . . . . . . . . . . . . . . . . . LO (Low Idling) Push the lever fully forward to set the engine in low idle.

B . . . . . . . . . . . . . . . . . . . . . . . . . . . .HI (High Idling) Pull the lever fully backward to set the engine in high idle.

Figure 38

BC02N368

A. FORWARD B. REVERSE C. CENTER POSITION (NEUTRAL)

7. DOZER BLADE EQUIPPED)

CONTROL

LEVER

(IF

Travel control is done by using the Travel Control Levers. To travel in a straight line, both levers have to be simultaneously operated, either forward or backward. Change of direction is done either by o p e r a t i n g a s i n g l e l e v e r, o r b y o p e r a t i n g simultaneously one lever forward and the other backward, so that the machine pivots on the spot.

These controls have 2 basic operational functions: A . . . . . . .Push both levers forward to travel forward.

B . . . . . . . . Pull both levers back to travel in reverse.

C . . . . . . . . . . . . . . . . . . . . Neutral (Center position) Release levers in the center position to stop the travel function.

IMPORTANT: In the normal travel position, the operator's compartment is above the idler wheels and the travel motors are to the rear of the upperstructure. If the upperstructure is turned 180 degrees in relation to the undercarriage, to move the machine forward, the levers have to be pulled towards yourself (i.e. in reverse) and vice-versa.

WARNING: Use caution to avoid coming in contact with other machines while traveling.

Make sure to know the location of the travel motors before operating the travel function.

CE-NA000

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BC02N370

Figure 40

This lever is located to the right of the operator and next to the gauge cluster. It is used to control the dozer up or down functions.

A . . . . . . . . . . . .Dozer down (Push the lever forward) B . . . . . . . . . . . . . . . . . Dozer up (Pull the lever back) The operation of the dozer blade stops when the lever is released. The lever returns to the neutral position.

With the engine stopped, if the dozer blade is in the raised position, it is still possible to lower it using the control lever until it touches the ground.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING: Even though the Function Cancellation Lever is set at locked position, the dozer control lever is not locked.

CE-NA000

3. Position the cover in the open position with the strut.

IMPORTANT: Always make sure to use the open door strut to secure the engine covers whenever they are in the open position.

WARNING: Before operating the dozer blade, make sure that there is no one standing in its working area.

CE-NA000

ACCESS COVERS AND GUARDS

Figure 43

BS04H211

KEY LOCKS

LOCKING 1. Return the strut to the original position, and store it into the holder.

BS04H212

Figure 41

ACCESS PANELS AND DOORS

A locking mechanism is provided for the engine guards. Use the key to open and close engine access panels (guards).

2. Close the cover.

3. Insert the key and turn counterclockwise to lock the cover.

4. Remove the key.

WARNING: Always install the struts when the doors are open.

CE-NA000

WARNING: Before undertaking any travel, make sure the side doors are properly closed.

CE-NA000

WARNING: Never leave tools or other objects behind the side doors.

CE-NA000

BC02N372

Figure 42

NOTE: Make sure to completely insert the key for proper operation. Damage can occur to the key or locking mechanism.

OPENING 1. Insert the key.

2. After releasing the lock, remove the key and open the cover.

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OPERATOR’S SEAT ADJUSTMENT In order to operate the machine correctly and with maximum efficiency and comfort, adjust the seat to fit the operator.

BC02N376

Figure 46

3. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

Figure 44

BC02N374

1. Pull the seat adjustment lever to right side.

2. Move the seat forward or backward to desired position.

3. Release the lever to lock the seat in position.

SEAT BELT

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

FASTENING AND UNFASTENING

1

M437

2 Figure 45

BC02N375

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

1. Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat.

2. Tighten the seat belt by pulling on the loose end on the right-hand seat belt.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 RUN-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 After the First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 After the First 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 BRINGING THE MACHINE UP TO OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Bringing the Engine Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Bringing The Hydraulic Fluid Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 OPERATING THE MACHINE IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8 4-8 4-8 4-8 4-8 4-8

OPERATING THE MACHINE IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Forward, Reverse, and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Right-Hand Turn (Forward Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Left-Hand Turn (Forward Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Left-Hand Turn (Reverse Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Right-Hand Turn (Reverse Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Right-Hand Pivot Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Left-Hand Pivot Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On A Truck Or Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Procedures for the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10 4-10 4-10 4-12

OPERATING THE MACHINE IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 OPERATING THE MACHINE ON SLOPING GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 MOVING A DISABLED MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 LOWERING THE ATTACHMENT IN THE EVENT OF A MACHINE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 OPERATING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Excavating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation For Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Periodical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Up After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-16 4-16 4-16 4-16

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE WARNING: Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual.

CE-NA000

Before operating this machine, be sure to do the following: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr ican ts ar e suita ble for p reva iling conditions. See Chapters 4 and 5.

2. Carry out the daily maintenance operations.

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or replace as necessary. See Chapter 6.

4. See Run-in period if the machine is new or if the engine has been reconditioned.

5. Check the track assemblies.

6. Clean the steps and access handles. Grease, oil, mud or ice (in winter) on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

OPERATING THE MACHINE WARNING: Check all controls and safety devices in a safe, open area before starting work.

CE-NA000

When operating the machine, be sure to do the following: 1. When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See Star ting The Engine in this chapter.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 5.

3. If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the ser vicing inter vals should be reduced accordingly.

4. Take note of the locations of pipes/cables before starting work.

5. Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the safest distances: See the decal on this machine for safe working distances.

9. Secure the cab door in either fully closed or fully opened position.

6. When working on a public highway, use standard traffic signs and take into consideration the working range of the upperstructure and its attachments. Local regulations stipulate the number, type and location of reflector strips.

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

7. Never operate the working or travel controls unless you are properly seated in the operator's seat with the seat belt correctly fastened.

11. Check that no tools or other items have been left on the machine (be it on the undercarriage or the upperstructure) or in the operator's compartment.

8. Modify your driving to suit the type of work and working conditions. See Operating instructions in the Job Site Operation section.

8. Make sure that the engine hood and the side doors are properly closed and latched.

12. Make sure no one is on or under the machine.

The operator must be alone on the machine.

9. Do not allow anyone within the machine's operating radius. Stop all operations until everyone has moved away.

13. Make sure no one is standing in the machine working area.

10. Operate all controls gradually to ensure smooth machine operation.

14. Find out about current safety measures in use on the work site.

11. See Operating in water if the machine will be standing in water during use.

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over.

12. See Transporting The Machine in this chapter when driving the machine onto a trailer.

16. Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signaling equipment is fully operational.

14. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine.

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13. See Lifting Procedures for The Machine in this chapter when it is necessary to lift the machine.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 15. Never use the attachment for sweeping the ground to level out rubble or push objects (transversal stress on the attachment).

16. Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

17. Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete halt until visibility has improved.

18. In the event of an operation problem or failure, move the machine to a safe place, lower the attachment to the ground, shut down the engine and remove the starter switch key. Locate the problem, repor t it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

AFTER THE FIRST 500 HOURS Change the oil in the travel reduction gears. See Travel Reduction Gears in Chapter 5

STARTING THE ENGINE NOTE: If the machine has been out of use for some time, see Starting Up After Storage in this chapter.

NOTE: If you need to start the engine using a booster battery, see Connecting A Booster Battery in Chapter 7.

1. Take up position correctly in the operator's seat with the seat belt correctly fastened. See Operator's seat in Chapter 3.

19. Do not stop the engine without taking prevailing weather conditions into consideration. See Stopping the engine.

20. See Parking the machine when you have to park the machine.

21. Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See Load handling.

22. When travelling with the hydraulic breaker (optional), make sure it is not too close and not pointing in the direction of the cab.

RUN-IN PERIOD Your machine will last longer and will give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

Figure 1

BC02N365

2. Make sure that the control function cancellation lever is in the RAISED position.

3. Make sure all control levers are set in the NEUTRAL position.

During this period: Warm up the engine before using it under load.

Do not run the engine for a long period at idle speed.

Frequently check the instruments on the instrument panel.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: AFTER THE FIRST 50 HOURS

Figure 2

BC02N380

1. CONTROL LEVER

4. Move the throttle control lever (1) approximately 25 mm (1 inch) from the Low Idle position.

Change the engine oil and replace the engine oil filter. Replace the return filter. See Chapter 5.

Check all nuts and screws are tightened to the correct torque. See Hardware torque inspection in Chapter 6.

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CHAPTER 4 - OPERATING INSTRUCTIONS Release the ignition key immediately after the engine star ts.The key will return to the ON position when you release the key.

IMPORTANT: Do not increase the engine speed (high idling) with a cold engine.

IMPORTANT: When the engine is running, let it heat up until the low idle mode is steady.

IMPORTANT: When the engine is running, check the indicators and lamps on the instrument panel regularly.

Figure 3

BS04H255

Lamp Number

1.

2.

3.

4.

5.

6.

KEY POSITION OFF →HEAT Pre-Heating

OFF →ON Before Start

START →ON Just after Start

1

OFF

ILLUMINATED

OFF

2

OFF

ILLUMINATED

OFF

3

OFF

OFF

OFF

4

OFF

OFF

OFF

5

OFF

OFF

OFF

6

OFF

OFF

OFF

ENGINE OIL PRESSURE INDICATOR LAMP BATTERY CHARGE/INDICATOR LAMP COOLANT TEMPERATURE INDICATOR LAMP FUEL LEVEL INDICATOR LAMP HIGH (2ND) TRAVEL SPEED LAMP AIR CLEANER CLOGGING LAMP

5. Do not start the engine in this step. Use the starter key to check the warning and indicator lamps. See the chart above.

6. Sound the horn before starting the engine.

IMPORTANT: Do not hold the starter key in the START position for more than 15 seconds. If the engine does not start, return the key switch to the OFF position, wait 30 seconds, and then try again.

Figure 4

BC02N378

7. Turn the ignition key to the START position to start the engine and release after starting the engine.

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CHAPTER 4 - OPERATING INSTRUCTIONS

BRINGING THE MACHINE UP TO OPERATING TEMPERATURE After star ting the engine and before using the machine, wait till the temperature of the coolant reaches 20°C (68°F).

BRINGING THE ENGINE UP TO OPERATING TEMPERATURE

Figure 7

BC02N364

2. Set the Function Cancellation Lever in the UNLOCKED (down) position.

BC02N381

Figure 5

1. THROTTLE LEVER

Set the throttle lever (1) in the middle position, between the low idling and high idling, and operate the engine for approximately 5 to 10 minutes with no load.

When the coolant temperature increases, do the hydraulic fluid warm-up procedure.

BRINGING THE HYDRAULIC FLUID UP TO OPERATING TEMPERATURE IMPORTANT: The correct operating temperature range for hydraulic fluid is 50 to 80°C (122 to 176°F).

Avoid machine operation when the hydraulic fluid temperature is below 20°C (68°F). Failure to do so will reduce the life of the hydraulic components.

Figure 8

BC02N366

1.

2.

3.

4.

5.

6.

7.

8.

BOOM DOWN (RIGHT-HAND CONTROL LEVER) BOOM UP (RIGHT-HAND CONTROL LEVER) BUCKET IN (RIGHT-HAND CONTROL LEVER) BUCKET OUT (RIGHT-HAND CONTROL LEVER) ARM OUT (LEFT-HAND CONTROL LEVER) ARM IN (LEFT-HAND CONTROL LEVER) ROTATION LEFT (LEFT-HAND CONTROL LEVER) ROTATION RIGHT (LEFT-HAND CONTROL LEVER)

3. Operate the boom control lever to raise the boom all the way up.

BC02N381

Figure 6

1. THROTTLE LEVER

1. Set the throttle lever in the Middle Speed position.

4-6

4. Operate the bucket control lever to retract it or extend it completely against relief. Hold this position for approximately one minute, then release lever and wait for approximately another minute before repeating process.

Repeat this procedure at least 10 times or until the temperature of the hydraulic fluid is safe for smooth attachment operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS

ENGINE OPERATION

STOPPING THE ENGINE

When the engine has started and before beginning work, the following procedure must be observed: 1. Let the engine idle for approximately five minutes until it has warmed up.

BC02N365

Figure 10

1. Set the Function Cancellation Lever in the LOCKED (down) position.

Figure 9 A. LOW IDLE POSITION (THROTTLE CONTROL LEVER) B. HIGH IDLE POSITION (THROTTLE CONTROL LEVER)

BC02N369

2. Move the throttle control lever to the High Idle speed position.

Once nor mal operating temperature has been reached, check the following: 1. The exhaust smoke is normal.

2. There is no abnormal noise or vibration.

3. There are no oil, fuel or water leaks.

The engine should be r un at full speed when operating conditions permit.

The operating speed of the machine and of the attachment should be controlled by means of the control levers.

Check the indicators and lamps on the instrument panel regularly.

IMPORTANT: Stop the engine immediately if one of the following situations occurs: 1. Sudden increase or decrease in engine speed.

2. Abnormal noise.

3. Black smoke at the exhaust.

Figure 11 A. LOW IDLE POSITION (THROTTLE CONTROL LEVER) B. HIGH IDLE POSITION (THROTTLE CONTROL LEVER)

BC02N369

2. Move the throttle control lever to the Low Idle speed position and let the engine r un for approximately a minute.

IMPORTANT: Always let the engine run at Low Idle before stopping the engine except in emergency situations.

IMPORTANT: In cold weather, let the engine run for approximately five minutes at Low Idle speed.

3. Turn the starter switch key to the OFF position.

IMPORTANT: When the engine is to be shut down for a considerable length of time, see Parking the Machine.

4. Illumination of instrument panel warning lamps.

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN COLD WEATHER Follow the following recommendations: BATTERY

OPERATION 1. Take up position in the operator's seat and adjust it so that all the controls are readily accessible.

See Operator's seat in Section 3. Then fasten your safety belt.

It must be fully charged.

2. Make sure the cab door is firmly latched in open or closed position (If equipped).

FUEL

3. Start the engine, taking into consideration the prevailing weather conditions. See Starting the engine.

1. To prevent condensation forming and water getting into the fuel system, fill the fuel tank after each day's work and drain off any water before starting the next day's work.

2. To prevent crystals forming at -2°C (28°F), use fuel which is rated for the ambient temperature or add an appropriate antifreeze to the fuel. See Ingredients in the Lubrication/Filters/Fluids section.

4. Check and make sure all gauges and warning lamps are operating correctly.

5. Sound the horn.

WARNING: In the normal travel position, the operator's compartment is above the idler wheels and the travel reduction gears are to the rear of the upperstructure. If the upperstructure is turned 180 degrees in relation to the undercarriage, the controls are reversed.

ENGINE OIL It should be of the right viscosity for the ambient temperature. See Ingredients in the Lubrication/Filters/Fluids section.

CE-NA000

HYDRAULIC FLUID The viscosity must correspond to the ambient temperature conditions. See Ingredients in the Lubrication/Filters/Fluids section.

COOLANT SOLUTION It should be suitable for the ambient temperature and contain a minimum of 50% ethylene glycol solution.

See Ingredients in the Lubrication/Filters/Fluids section.

OPERATING THE MACHINE IN HOT WEATHER 1. Follow the recommendations made below: 2. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

3. Use the correct solution of ethylene glycol and water in the cooling system.

Figure 12

BC02N388

6. Lower the Function Cancellation Lever.

7. Raise the attachment and the dozer blade (if equipped).

IMPORTANT: Before any travel operation, raise the attachment and dozer blade (if equipped).

8. Try out all the controls in a safe, open area.

4. Test the radiator cap before hot weather starts.

Replace the cap as required.

5. Clean all dirt and debris from the radiator, cooler and engine area.

6. Check the condition of the fan drive belt.

7. Check the dust valve in the air cleaner frequently during extreme dust conditions.

8. Use lubricants of the correct viscosity. See Fluids and lubricants in the Lubrication, Filters, and Fluids Chapter.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 13

BC02N386

A. HIGH (2ND) TRAVEL SPEED LAMP

BC02N387

Figure 15

3. Stopping machine travel.

NOTE: Travel speed depends on the tilting angle of the control levers and the travel mode speed selected. See Travel Speed Select Switch in Section 3.

Slowly move the control levers to the neutral (center) position to stop the machine.

RIGHT-HAND TURN (FORWARD TRAVEL)

For fast travel speed, depress and release the Travel Speed Select Switch once before operating the Control Levers. The High Travel Speed Lamp indicator (A) will illuminate in the gauge cluster.

Start the machine travel by operating the control levers.

To return to SLOW travel speed, stop machine travel and depress and release the Travel Speed Select Switch once.

NOTE: The travel speed is always reset to LOW SPEED each time the key switch is turned to the OFF position.

BC02N384

MACHINE TRAVEL

Figure 16

4. Turning to the right (Forward Travel).

Push the left-hand control lever forward.

FORWARD, REVERSE, AND STOPPING

5. Gradual turn to the right moving forward.

Push the right-hand control lever forward and at the same time, push the left-hand control lever in the same direction, but slightly harder.

LEFT-HAND TURN (FORWARD TRAVEL)

Figure 14

BC02N383

1. Straight line Forward Travel.

Push the two control levers forward at the same time.

2. Straight line Reverse Travel.

Pull the two control levers back at the same time.

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Figure 17

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CHAPTER 4 - OPERATING INSTRUCTIONS RIGHT-HAND PIVOT TURN

6. Turning to the left (Forward Travel).

Push the right-hand control lever forward.

7. Gradual turn to the left moving forward.

Push the left-hand control lever forward and at the same time, push the right-hand control lever in the same direction, but slightly harder.

LEFT-HAND TURN (REVERSE TRAVEL)

Figure 20

BC02N392

12. Turning on the spot (Pivot Turn), to the right.

Push the left-hand control lever forward and at the same time pull the right-hand control lever to the rear.

LEFT-HAND PIVOT TURN BC02N391

Figure 18

8. Turning to the left (Reverse Travel).

Pull the right-hand control lever back.

9. Gradual turn to the left moving in reverse.

Pull the left-hand control lever to the rear and at the same time, pull the right-hand control lever in the same direction, but slightly harder.

RIGHT-HAND TURN (REVERSE TRAVEL)

Figure 21

BC02N385

13. Turning on the spot, to the left Pull the left-hand control lever to the rear and at the same time push the right-hand control lever forward.

Figure 22

TRANSPORTING THE MACHINE

BY RAIL BC02N390

Figure 19

10. Turning to the right (Reverse Travel).

Pull the left-hand control lever back.

11. Gradual turn to the right moving in reverse.

Pull the right-hand control lever to the rear and at the same time, pull the left-hand control lever in the same direction, but slightly harder.

S i n c e t ra n s p o r t by ra i l i s s u b j e c t t o s p e c i a l regulations, consult an approved organization.

ON A TRUCK OR TRAILER WARNING: This machine could slip and fall from a trailer or ramp and cause serious injury. Make sure the trailer and ramps are clean. The machine should be in line with the trailer before being loaded.

CE-NA000

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CHAPTER 4 - OPERATING INSTRUCTIONS NOTE: In the normal travel position, the operator has the travel reduction gears or final drives to the rear of the upperstructure. If the upperstructure is turned 180° from this position the travel lever functions are reversed.

8. Lower the attachment and the dozer blade (if equipped) to the floor of the truck or trailer.

Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the right safety equipment.

1. Place blocks in front and behind the trailer wheels.

2. Raise the dozer blade. (if equipped).

BC02N365

Figure 25 Figure 26

9. Shut down the engine, remove the starter switch key, raise the function cancellation lever.

10. Make sure that the control function cancellation lever is in the raised position (Locked).

Figure 23

BC02N401

11. Make sure all control levers are set in the NEUTRAL position.

12. Make sure that all doors, hoods and access panels are correctly locked.

Figure 24

BC02N393

3. Place the machine in line with the truck or trailer, with the travel reduction gears towards the rear of the machine.

BC02N394

4. Raise the attachment and bring it to about twenty centimeters above the ramp.

13. Use blocks and cables to fasten the machine and the attachment to the truck or trailer.

Figure 27

5. When moving from the ramps onto the truck or trailer bed, raise the boom slightly as soon as the attachment touches the truck or trailer to bring the machine level and then move forward until the machine is resting entirely on the truck or trailer.

6. When the machine is completely on the truck or trailer, raise the attachment slightly and swing the upperstructure to bring the attachment around to the access ramp side.

7. Place the machine completely in front of the truck or trailer.

87458477NA

Issued 10-04

Bur

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING PROCEDURES FOR THE MACHINE WARNING: Lifting the machine must be done very slowly.

CE-NA000

WARNING: Make sure that there is no one under or near the machine while it is being lifted.

CE-NA000

WARNING: Improper lifting method and/or roping manner might cause a movement or slip of the machine while it is lifted up, resulting serious injury or damages on the machine.

CE-NA000

Figure 28

BC02N398

A. OVERALL HEIGHT

B. OVERALL LENGTH

B

D C E

14. Measure the distance between the ground and the highest point of the machine. You must know t h e o ve r a l l h e i g h t . S e e M a c h i n e o ve r a l l dimensions in the Chapter 8 (Specifications).

1 A

2

Figure 29

BS04H237

A. B. C. D. E. 1.

2.

5 000 MM (197 IN) 2 800 MM (110 IN) 15 DEGREES 4 600 MM (181 IN) 16 DEGREES CONNECT 1 CABLE SHACKLE HERE CONNECT 2 CABLE SHACKLES HERE. 1 EACH SIDE OF BLADE APPROXIMATE WEIGHT WITH RUBBER SHOE: 2 660 KG (5 870 LBS).

APPROXIMATE WEIGHT WITH IRON SHOE: 2 790 KG (6 150 LBS).

IMPORTANT: The cables (wire ropes) to be used for lifting the machine should have sufficient capacity for the machine weight.

4-12

Issued 10-04

Bur

87458477NA

CHAPTER 4 - OPERATING INSTRUCTIONS IMPORTANT: Do not impose a load suddenly on the cables (wire ropes) and shackles.

4. Make sure all control levers are set in the NEUTRAL position.

IMPORTANT: When the lifting work is carried out in cooperation with other persons, make sure to check every situation while exchanging signals with each other.

5. Make sure that all doors, hoods, and access panels are correctly locked.

IMPORTANT: During the lifting work, keep all persons away from and around the lifting machine, especially under the machine.

7. Install shackles at the two positions (2) provided at each end of the dozer blade. Connect the cables (wire ropes) to the shackles.

6. Install a shackle to the boom (1). Connect the cable (wire rope) the shackle.

8. If any of the cables (wire ropes) contact the machine when the cables (wire ropes) are in position, use wood blocks and soft material to protect the machine from damage.

9. Slightly lift the machine to confirm the balance, then lift up the machine.

B

OPERATING THE MACHINE IN WATER

D

1. Make sure that the bottom of the stream, or water in which you will work, can support the weight of the machine.

C E 1 A

2. Only the undercarriage up to the upper roller can be below water level.

IMPORTANT: Never work in water if the water level is higher than the track upper roller.

IMPORTANT: Do not operate in a fast flowing stream.

2

3. Before using the machine in water, inject large quantities of fresh grease into the attachment linkages and the dozer blade (if equipped), also on the turntable and its gear teeth.

Figure 30

BS04H238

A. B. C. D. E. 1.

2.

5 000 MM (197 IN) 2 800 MM (110 IN). ONE CABLE 12 DEGREES 4 600 MM (181 IN). TWO CABLES, ONE EACH SIDE 16 DEGREES CONNECT 1 CABLE SHACKLE HERE CONNECT 2 CABLE SHACKLES HERE. 1 EACH SIDE OF BLADE APPROXIMATE WEIGHT WITH RUBBER SHOE: 2 520 KG (5 560 LBS).

APPROXIMATE WEIGHT WITH IRON SHOE: 2 650 KG (5 840 LBS).

NOTE: See Chapter 8 (Specifications) for additional weight information.

1. Put the machine and boom in the position shown.

2. Shut down the engine, remove the starter switch key, raise the function cancellation lever.

BC02N402

Figure 31

A. MAXIMUM WATER DEPTH 1.

2.

3.

4.

UPPER ROLLER SWING BEARING WATER SURFACE BOTTOM OF A RIVER

3. Make sure that the control function cancellation lever is in the raised position (Locked).

87458477NA

Issued 10-04

Bur

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS

PARKING THE MACHINE 1. Position the machine on flat, level ground, away from soft ground, excavations or poorly shored cavities.

2. Place the upperstructure in line with the undercarriage.

3. Place both travel levers into the NEUTRAL position.

OPERATING THE MACHINE ON SLOPING GROUND WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc. modify terrain conditions. It is up to you to decide if the machine can be used in perfect safety.

CE-NA000

4. Place the bucket or attachment on the ground.

During hillside operations, be extra careful.

5. Place the dozer blade on the ground.

Make sure that the low speed travel is selected.

6. Turn the engine throttle lever to low idle position and let the engine run for approximately five minutes.

7. Shut down the engine and remove the starter switch key.

8. Raise the function cancellation lever.

9. Lock the operator's compartment door, if equipped and make sure that the hoods, lower panels and side doors are properly fastened.

10. Check that the no part of the machine is encroaching on the highway. If this cannot be avoided, set up approved traffic signs.

WARNING: Never jump down from the machine. When leaving from the operator's compartment, or from the upperstructure, always face the machine and use the steps and access handles.

CE-NA000

4-14

When digging on a slope, avoid swinging the upperstructure towards the bottom of the slope with the backhoe bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

Always travel in the same direction as the slope, to prevent the machine from turning over.

MOVING A DISABLED MACHINE If the machine becomes unable to move contact your Dealer. Do not attempt to move the machine.

LOWERING THE ATTACHMENT IN THE EVENT OF A MACHINE FAILURE Contact your Dealer if the machine becomes disabled with the attachment up. Do not attempt to lower the attachment.

Issued 10-04

Bur

87458477NA

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE BUCKET FILLING Fill the bucket by manoeuvring the arm. Keep the bottom of the bucket parallel to the cut. The bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

EXCAVATING METHOD

Figure 32

BC02N436

1

2

3 Figure 33

BC02N437

1. CORRECT 2. INCORRECT. THE BUCKET WILL DIG IN AND CAUSE A STALL 3. INCORRECT. THE BUCKET IS PUSHED UPWARDS. THIS WILL ALSO INCREASE THE CYCLE TIME

87458477NA

Issued 10-04

Bur

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE PREPARATION FOR STORAGE

PERIODICAL CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering. Before storing the machine, carry out the following operations:

Every month, check:

1. Clean the machine.

2. Retract the arm cylinder rod as for as possible and lower the boom until the attachment is resting on the ground.

3. Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your Dealer.

NOTE: When the machine resumes service, the film will disappear.

4. Drain the fuel tank and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

5. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil and replace the engine oil filter.

6. When the engine is cold, clean the outer parts of the engine with diesel fuel.

7. Clean or replace the air filter element.

A. The electrolyte level in the batteries and the battery charge. Recharge the batteries if necessary.

B. The grease on the cylinder rods.

C. The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

D. The condition of all lines, connectors, and clamps (rust). Lubricate if necessary.

E. The condition of the paint. Apply a coat of anti-rust treatment where necessary.

STARTING UP AFTER STORAGE 1. Close the drain valves and fill cooling system.

2. Drain the fuel tank and fill with clean diesel fuel.

3. Drain the engine sump, fill with clean engine oil and check the oil level.

4. Change the fuel filter.

5. Install the batteries.

6. Lubricate the machine thoroughly.

7. Check the condition of the fan drive belt and replace it if necessary.

8. Check the hydraulic fluid level and add more fluid if necessary.

9. Check the travel reduction gears oil level and add more oil if necessary.

8. Drain the cooling system, leave the drain valves open and do not tighten the radiator cap.

10. Clean the cylinder rods.

9. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries in a cool, dry place, where temperature is always above freezing.

12. Remove the Do Not Operate tag and start the engine, following the starting up procedure.

10. Paint any areas where the paint is missing or damaged.

11. Plug the air filter inlet and the exhaust pipe.

12. Remove the starter switch key and place a Do Not Operate label on the right-hand control arm and then raise the function cancellation lever (safety bar in inward position).

13. Lock the hoods and the cab door.

11. Unplug the air filter inlet and the exhaust pipe.

13. Keep a careful watch on all systems display panel lamps and indicators.

WARNING: Check the machine for leaks or for any parts that are broken, defective, or missing.

CE-NA000

WARNING: Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly.

CE-NA000

WARNING: Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

CE-NA000

4-16

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Component Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4 5-4 5-5 5-5 5-5 5-5 5-5 5-5 5-6

DAILY INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 GREASE FITTINGS AND LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Position for Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication - As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication - 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication - 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication - 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10 5-10 5-10 5-11 5-12 5-12

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13 5-13 5-13 5-13

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Radiator Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Cooling System Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15 5-15 5-15 5-15 5-15 5-15 5-16 5-16 5-16 5-16

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining and Cleaning the Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18 5-18 5-18 5-18 5-19 5-20 5-21 5-21

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Issued 10-04

Bur

87458477NA

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 Checking Hydraulic System Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 Hydraulic Reservoir Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Checking Hydraulic Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 Hydraulic Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Cleaning Filter for Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Cleaning Inline Filter for Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Replacing the Reservoir Air Filter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 TRAVEL REDUCTION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 Draining and Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

5-2

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SERVICING INSTRUCTIONS GENERAL INFORMATION Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the arm retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with the engine stopped, and the key removed from the starter switch. It is preferable to wait for all circuits to cool down before starting work.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing and remember to use the necessary safety equipment.

WARNING: There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your Dealer.

CE-NA000

WARNING: If the attachment is raised or if the machine moves without an operator, serious injury can result. Before performing any maintenance, proceed as follows: 1. Park the machine on flat, level ground.

2. Lower the attachment until it is resting on the ground.

3. Lower the dozer blade (if equipped) until it rests on the ground.

4. Shut down the engine and remove the starter key switch.

5. Lock the tracks to prevent any machine movement.

IMPORTANT: If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere, etc.), the servicing intervals should be reduced accordingly.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT: Oil and fluid should not be thrown on the ground. They must be stored and removed by a company which is responsible for their recycling or their disposal.

SERVICE SPECIFICATIONS Intervals between overhauls are much more frequent for the following applications: construction of tunnels using a hydraulic breaker, scale stripping, foundry cleaning, operation under water etc. For special applications consult your Dealer.

HOURMETER The hourmeter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

Ser vicing inter vals are carefully calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly as defined in this manual.

CE-NA000

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

BS04H259

Figure 1

CE-NA000

When carrying out service work on the machine, place a Do Not Operate tag on the instrument panel.

Never climb down from the operator's compartment leaving the engine running.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your Dealer.

87458477NA

Issued 10-04

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5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS CAPACITIES AND SPECIFICATIONS ENGINE Type of oil .................................................................................................................................. Case Akcela No. 1 Capacity (with filter change) ........................................................................................................ 5.5 liters (1.5 gal) COOLING SYSTEM System capacity .......................................................................................................................... 3.8 liters (1.0 gal) FUEL SYSTEM Reservoir capacity........................................................................................................................ 28 liters (7.4 gal) HYDRAULIC SYSTEM Type of fluid .................................................................................................Case Akcela Hy-Tran Ultra (MS 1209) Total system capacity ................................................................................................................... 25 liters (6.6 gal) Reservoir capacity........................................................................................................................ 20 liters (5.3 gal) TRAVEL REDUCTION GEARS Type of oil .................................................................................................................................. 135H EP 85W-140 Capacity (per reduction gear)................................................................................................... 0.35 liters (0.37 qt.)

Upper rollers..................................................................................................................................... 45 cc (1.5 oz.)

Idlers ................................................................................................................................................ 45 cc (1.5 oz.)

SWING REDUCTION GEAR Automatic from the Hydraulic system Swing bearing grease .............................................................................................................................. 251H EP Swing gear grease ................................................................................................................................... 251H EP

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION

HYDRAULIC FLUID

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Case Akcela Hy-Tran Ultra hydraulic fluid is specially designed for high pressure applications and for the Case hydraulic system.

Contact your Dealer who will supply you with the suitable coolant solution.

GREASE

ANTI-FREEZE/ANTI-CORROSION Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

For areas where the ambient temperature is over -36째C (-33째F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36째C (-33째F), it is advisable to use a blend of 40% water and 60% anti-freeze.

FUEL

TRANSMISSION COMPONENT OIL Extreme pressure oil used for enclosed transmission components.

135H EP 85W-140

The type of grease to use depends on ambient temperature.

251H EP ENVIRONMENT Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Contact your local Dealer to obtain information on the correct method of disposing of these lubricants.

Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.

FUEL STORAGE Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ENGINE OIL

Figure 2

BC02N250

OIL VISCOSITY AND OIL RANGE

CASE Akcela No. 1 motor oil is the oil recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

I f C A S E A k c e l a N o. 1 M u l t i p e r fo r m a n c e o r Performance engine oil cannot be obtained, use only oil of the API/CG/CF category.

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on CASE lubricants.

Figure 4

AKCELA NO 1

RB97F100

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and ser vice cer tain of its components.

IMPORTANT: If the slightest defect is found, repair it immediately before using the machine or see your Dealer.

Undercarriage Check the pad hardware.

Check the condition of the tracks.

Check that the upper and lower rollers and the idler wheels are not leaking oil.

ATTACHMENT

GENERAL REMARKS

Check for oil leaks on the cylinders.

Check for water or oil leaks.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator's compartment, etc.).

Check for damage.

ENGINE C h e ck t h e o i l l eve l a n d c h a n g e t h e o i l i f necessary.

Check the coolant level.

Check for clogging or damage to the radiator.

Check the radiator fan belt tension.

Check the condition of all lines.

Check the condition of the bucket teeth.

AFTER STARTING THE ENGINE Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check for abnormal noise on the hydraulic components.

Check for water or oil leaks on the components.

Check the audible alarm devices, working lights and windshield wipers.

Check that all circuits (travel, swing and tool) are functioning correctly.

Check the air filter is clean and not restricted.

Check for water or oil leaks on the components.

Check the condition of all lines.

UPPER STRUCTURE Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check for electrical short-circuits.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE CHART

Daily or Every 8 Hours

Every 50 Hours

Every 250 Hours

5-8

Radiator core

2

5-16

Radiator cap

1

6-3

Track shoes

2

5-10

Control Levers

6-11

Machine inspection

1

6-12

Fire extinguisher

1

5-15 5-14 5-24 5-25 6-13 6-3 5-16 6-11 5-11 5-11 5-11 5-11 6-3 5-22 5-21 5-21 5-14 5-16 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-32 5-13 6-11

Coolant level Engine oil level Hydraulic system lines Hydraulic reservoir level Loose or missing hardware. Bolt and nut torque Rubber track pads Radiator Fan / Alternator belt Bucket cylinder rod pin Arm / Link pin Bucket link pin Arm / bucket link pin Track tension Drain fuel tank sediment Drain water separator Clean water separator Engine oil and filter change Radiator and oil cooler Dozer blade pivot pins Dozer cylinder rod pin Dozer cylinder pin Boom foot pin Boom cylinder bottom pin Boom cylinder top pin Arm cylinder bottom pin Arm cylinder top pin Boom/Arm pivot pin Bucket cylinder bottom pin Bucket cylinder top pin Swing cylinder foot pin Swing cylinder rod pin Swing tower Air filter element Turntable (Swing) bearing Fan / Generator belt tension

1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1

8 8 8 8 8 8 8 8

REPLACE

LUBRICATE

* * *

DRAIN

* * * * * *

CHANGE

CLEAN

5-16

CHECK

As Required (* )

SERVICE POINTS

NUMBER OF POINTS

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

* *

8

50 50 50 50 50 50 50 50 250

250

250 250 250 250 250 250 250 250 250 250 250 250 250 250 250 250

250 250

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Lubrication and Maintenance Chart

Every 500 Hours Every 1000 Hours

Every 2000 Hours

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5-26 5-21 5-32 5-16 5-24 5-28 5-30 5-31 5-24 5-33 5-13 6-8 6-8

Hydraulic tank return filter Fuel filter Air filter element Cooling system Hydraulic fluid condition Hydraulic Suction filter Solenoid valve filter Pilot Circuit Filter Hydraulic Fluid Travel reduction gear Turntable gear lubrication Track Rollers Idler wheel (Track removal required)

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1 1 1 1

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

NUMBER OF POINTS

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

500 500 1000 1000 1000

1 1 1

2000 2000 2000 2000

2 1 10 2

2000 2000 2000 2000

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GREASE FITTINGS AND LUBRICATION POINTS MACHINE POSITION FOR LUBRICATION

LUBRICATION - AS REQUIRED

Make sure to put the machine in the following position before doing any lubrication.

251H EP See Machine Position for Lubrication.

CONTROL LEVERS Lubricate the control levers when a control lever does not move smoothly or is difficult to operate.

1. See Machine Position for Lubrication.

1

2 2 1

BC02N240

Figure 5

1. BUCKET 2. DOZER BLADE

1. Place the machine on flat and level ground.

2. Fully retract the arm cylinder and bucket cylinder.

Lower the boom and put the bucket on the ground.

3. Lower the dozer blade to the ground.

Figure 7

BC02N303

1. CONTROL LEVER 2. BOOT

2. Carefully loosen and slide the rubber boot (2) up the control lever (1).

4. Stop the engine.

5. Operate the control levers from right to left and front to rear 8 to 10 times to release pressure in each circuit.

4 3 1

1 5

2

Figure 8

BC02N304

BC02N239

Figure 6

6. Pull the safety lock lever up into the locked position.

1.

2.

3.

4.

5.

LUBRICATE THESE LOCATIONS (SHADED AREAS) UNIVERSAL JOINT TOP OF UNIVERSAL JOINT SHOWS LOCATION OF LUBRICATION (SHADED AREAS) SOCKET BOLT

3. Apply grease to the 4 locations (1) and the top of the of the universal joint (2).

4. Carefully slide the rubber boot (2) down the control lever (1) and install the boot.

5. Check the socket bolts (5) for the pilot valve.

Tighten the socket bolts if required.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LUBRICATION - 50 HOURS BUCKET LINKAGE

1 3

2 4 Figure 9

BC02N301

1.

2.

3.

4.

Bucket cylinder rod pin . . . . . . . .

Arm/Link pin . . . . . . . . . . . . . . . .

Bucket link pin . . . . . . . . . . . . . . .

Arm/Bucket link pin . . . . . . . . . . .

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1 grease fitting 1 grease fitting 1 grease fitting 1 grease fitting

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BOOM AND ARM

LUBRICATION - 250 HOURS SWING TOWER

4

1

1

5

7

2 3

6

2 3 Figure 10

BC02N302

1. Swing cylinder pin . . . . . . . . . . . . 1 grease fitting 2. Swing cylinder rod pin . . . . . . . . . 1 grease fitting 3. Swing tower pivot pin . . . . . . . . . 2 grease fittings BLADE LINKAGE

1

BC02N300

2

Figure 12

BC02N301

1.

2.

3.

4.

5.

6.

7.

Boom foot pin . . . . . . . . . . . . . . .

Boom cylinder bottom pin . . . . . .

Boom cylinder top pin . . . . . . . . .

Arm cylinder bottom pin . . . . . . .

Arm cylinder top pin . . . . . . . . . .

Boom/Arm pivot pin. . . . . . . . . . .

Bucket cylinder bottom pin . . . . .

1 grease fitting 1 grease fitting 1 grease fitting 1 grease fitting 1 grease fitting 1 grease fitting 1 grease fitting

3

Figure 11

1. Blade pivot pins . . . . . . . . . . . . . 2 grease fittings One each side of blade frame 2. Blade cylinder rod pin . . . . . . . . . 1 grease fitting 3. Blade cylinder pin. . . . . . . . . . . . . 1 grease fitting NOTE: Extended use of the dozer blade may require greasing more frequently.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Lubricating the Turntable (Swing) Bearing

Figure 13

BC02N256

1. Apply grease at the grease fitting until the old grease is replaced.

2. Rotate the upper structure 90°. (4 times).

3. Repeat steps 1 and 2 until all four positions are lubricated.

IMPORTANT: If the grease is white because of moisture content or contamination, replace with new grease.

LUBRICATION - 2000 HOURS LUBRICATING THE TURNTABLE (SWING) GEAR Contact your dealer for procedures. Change the grease immediately if the machine has been immersed in water in order to protect the pinion and internal gears from damage.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE OIL SERVICE SPECIFICATIONS Engine oil level check ............................................................................................................................Every 8 hours Oil change .........................................................................................................................................Every 250 hours Oil filter replacement..........................................................................................................................Every 250 hours Oil type .......................................................................................................................................... Case Akcela No. 1 Oil capacity ...................................................................................................................................... 5.5 liters (1.5 gal) ENGINE OIL LEVEL 1. Park the machine on level ground. Shut down the engine and remove the starter switch key.

2. When the engine has been stopped for fifteen minutes, remove the dipstick (1), wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

3. If the level is between the marks L (Low) and H (High) of the dipstick, the level is correct.

4. If the oil level is at mark L (Low) or below, remove the filler cap (2) and add oil up to mark H (High) of the dipstick.

NOTE: The oil level should NOT be higher than the mark H (High, maximum on the dipstick).

ENGINE OIL AND FILTER CHANGE NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

1. Park the machine on level ground. Shut down the engine and remove the starter switch key.

2. Figure 14: Remove the oil filler cap (2).

1

3. Figure 15: Remove the access cover (2) under the drain plug.

2

4. Place a container under the engine oil drain plug.

Use a container that will hold approximately 6.0 liter (1.6 gal).

5. Remove the drain plug (1) and allow the engine oil to drain.

BS04H256

Figure 14

1. DIPSTICK (ENGINE OIL) 2. FILLER CAP (ENGINE OIL)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

BC02N232

Figure 17

8. Coat the seal of the new filter with a light film of engine oil.

9. Install the new filter. Turn the filter until the seal comes into contact with the filter head by hand.

Then tighten an additional 1/2 to 2/3 turn.

IMPORTANT: Do not use a filter wrench to tighten the filter. Excessive tightening can damage the filter and the seals.

Figure 15

BS04H262

1.

2.

3.

4.

DRAIN PLUG (ENGINE OIL) ACCESS COVER (ENGINE OIL) DIP STICK (ENGINE OIL) FILL CAP (ENGINE OIL)

10. Fill the engine with new engine oil. Install the filler cap.

11. Run the engine for a few minutes and check that there are no leaks. Stop the engine.

6. Install the drain plug.

12. Install the access cover below the engine oil drain plug.

13. Check the oil level and add additional oil if necessary.

IMPORTANT: Always wait approximately ten minutes to allow the oil to return to the reservoir before checking the oil level.

Figure 16

BS04H216

7. Use a wrench (1) to rotate the oil filter (2) counterclockwise to loosen the oil filter. Remove the oil filter (2).

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

COOLING SYSTEM SERVICE SPECIFICATIONS Coolant reservoir check..................................................................................................... Every 8 hours or each day Checking the condition of cooling system clamps and hoses ............................. Every 250 hours or every 6 months Draining the system (long duration)...................................................................... Every 1000 hours or every 2 years Draining the system (with anti-freeze) (spring and autumn).................................................................... Twice a year System capacity .............................................................................................................................. 3.8 liters (1.0 gal) RADIATOR CAP WARNING: Boiling coolant solution can spray out if the radiator cap is removed while WARNING: Do not remove the radiator cap the system is still hot. To remove the cap, when the engine is hot. The system is still allow the system to cool down, turn the cap to under pressure and you could be scalded. the first notch and wait until there is no more CE-NA000 pressure. Then remove the cap.

1. Slowly loosen the cap to release pressure.

CE-NA000

WARNING: Check and service the cooling system according to the instructions given in this manual.

CE-NA000

2. Check the cap for damages or adhesion of dust.

3. Clean or replace if necessary.

4. Securely tighten the cap.

COOLANT SOLUTION

COOLANT LEVEL

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage.

The machine must be on level ground. The coolant level must be checked when the engine and cooling system are cold.

Do not use non-approved anti-r ust additives.

Anti-rust additives and ethylene-glycol can mix and w o r k a g a i n s t e a c h o t h e r, t h e r e b y r e d u c i n g anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your Dealer for suitable coolant solution.

CLEANING RADIATOR CORES 1. Open the left side cover and the cover under the seat.

2. Check for clogging on the radiator fins with dust, mud and debris.

3. Remove the material with compressed air.

WARNING: To prevent injury, always wear eye protection when working with compressed air.

M459

The coolant reservoir in on the right-hand side of the engine compartment.

Coolant Reservoir Level 1. Open the engine cover to check the coolant level in the coolant reservoir. The level in the coolant reservoir must be between the Full and Low marks.

2. If the coolant level is low, check the level of coolant in the radiator. See Radiator Coolant Level.

Radiator Coolant Level 1. Remove the radiator cap.

2. If the coolant level is low, fill the radiator with coolant solution until radiator is full.

IMPORTANT: Use the correct coolant solution.

3. Install the radiator cap (B).

4. Fill the coolant reservoir to the Full mark.

IMPORTANT: Do not fill the coolant reservoir above the Full mark.

5. Install the coolant reservoir cap (A).

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4. Drain the coolant from the radiator and cooling system.

BS04H217

1.

2.

3.

4.

Figure 18

BS04H341

1.

2.

3.

4.

COOLANT RESERVOIR CAP RADIATOR CAP RADIATOR COOLANT RESERVOIR

Figure 19

RADIATOR CAP PLUG RADIATOR COOLANT RESERVOIR

5. Close the drain valve when the radiator is completely empty.

6. See Cleaning the Cooling System or Filling the Cooling System.

CHECKING COOLING SYSTEM HOSES AND CLAMPS 1. Check the cooling system for loose clamps or cracked and worn hoses.

2. Replace any damaged hoses and tighten any loose clamps.

NOTE: See Draining the Cooling System and Filling the Cooling System if replacement of a hose is required.

DRAINING THE COOLING SYSTEM

CLEANING THE COOLING SYSTEM 1. Fill the system with a mixture of clean water and cleaning solvent (Radiator cleaner).

2. Start the engine. Let the engine run in low idle position for approximately ten minutes to bring the engine temperature to approximately 80°C (176°F). Operate the engine for approximately 10 minutes.

3. Stop the engine and open the drain valve. Flush the radiator with clean water until the water draining is clean.

1. Remove the cover under the radiator and drain valve.

WARNING: Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CE-NA000

2. Remove the radiator cap.

3. Open the drain valve located on the drain hose.

NOTE: Have a container of a suitable capacity ready.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FILLING THE COOLING SYSTEM 1. Fill the radiator with coolant solution until overflowing and install the radiator cap.

2. Fill the coolant reservoir to the Full mark and install the cap.

IMPORTANT: Use the correct coolant solution.

3. Run the engine at idle speed for about five minutes. Add coolant solution if the level in the coolant reservoir drops.

IMPORTANT: Do not fill the coolant reservoir above the Full mark.

BS04H341

1.

2.

3.

4.

Figure 20

COOLANT RESERVOIR CAP RADIATOR CAP RADIATOR COOLANT RESERVOIR

4. Install the cover under the radiator and drain valve.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FUEL SYSTEM SERVICE SPECIFICATIONS Fuel tank capacity ............................................................................................................................ 28 liters (7.4 gal) Type of fuel ........................................................................................................................................................Diesel Air bleed from the fuel system .................................................................................................................. As required Draining water and sediment from the fuel tank ......................................................... Every 50 hours or every week Water Separator Drain and clean the separator ................................................................................. Every 50 hours or every week Fuel Filter Clean the fuel filter ....................................................................................Every 250 hours or every three months Fuel filter replacement...................................................................................Every 500 hours or every six months Replacing the fuel hoses ................................................ Every 2 years or every 4000 hours (whichever comes first) CHECKING FUEL LEVEL 1. Turn the starter switch key to the ON position to illuminate the monitor panel.

2. Check the fuel level on the fuel gauge.

Figure 21

BS04H257

1. IGNITION KEY 2. FUEL GAUGE

FILLING THE FUEL TANK

BS04H213

To access the tank cap, open the hood on the front right-hand side of the machine.

NOTE: In cold weather, use fuel corresponding to the ambient temperature. See Lubrication and fluids.

Fill the fuel tank after each working day to prevent the formation of condensation.

WARNING: Never refuel the machine when the engine is hot or running. Never smoke while refueling.

R139C

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Make sure to wipe all areas with a clean dry rag to remove any spilled fuel.

1.

2.

3.

4.

Figure 22

FILLER CAP STRAINER DRAIN PLUG FUEL TANK

1. Clean carefully around the filler cap.

2. Fill the tank.

IMPORTANT: Make sure that no water or dust enters the fuel tank. Never remove the strainer for when filling the fuel tank.

3. Install the filler cap.

IMPORTANT: Make sure that the filler cap is correctly locked.

4. Close and lock the hood.

SA022

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5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BLEEDING AIR FROM THE FUEL SYSTEM It is necessary to bleed the system when:

• The tank has been completely emptied.

• The fuel filter has been replaced.

• Parts of the fuel system have been removed for servicing or repair work.

• The machine has been in storage for a fairly long period.

1. Make sure that the fuel tank is full.

2. Make sure the handle for the Fuel Filter and Water Separator are in the OPEN position.

3. Use a screwdriver to loosen the screw in the air breather plug (3) on the Fuel Filter Assembly 2-3 turns. See figure 24.

4. Turn the key on and start cranking the engine until fuel coming out through the air breather plug hole does not contain air bubbles.

5. Tighten the screw in the air breather plug (3) when the fuel coming out of the hole does not contain air bubbles.

6. Completely wipe off any spilled fuel. Start the engine and check for possible leakage.

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Make sure to wipe all areas with a clean dry rag to remove any spilled fuel.

SA022

WARNING: Completely wipe off any spilled fuel after replacing a filter element or bleeding the system.

CE-NA000

BS04H236

1.

2.

3.

4.

5.

A. B. C. D.

Figure 23

FUEL FILTER WATER SEPARATOR AIR BREATHER PLUG FUEL SHUTOFF DRAIN PLUG IN OUT CLOSE OPEN

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DRAINING AND CLEANING THE WATER SEPARATOR

REPLACING THE FUEL FILTER

If the red ring (D) in the water separator sinks down to the bottom of the case (F), no water is mixed in.

When the ring (D) is floating, water is mixed in up to the level of the ring. Drain the mixed water in accordance with the following procedures.

WARNING: Do not attempt this procedure if the engine is hot. Allow time to cool all engine parts.

1. Place the function cancellation lever in the up or locked position and shut the engine off.

2. Push the water separator handle to the up or closed position.

3. Loosen the ring (G) to remove the case (F) and drain the water out.

If the water is contaminated and dir ty it will be necessary to clean the element with diesel fuel.

4. Install the element (B) and O-ring (E) into the water separator case (F).

5. Tighten the ring (G) being careful not to overtighten.

6. Push the handle downward to set at OPEN position.

7. Bleed air from the fuel system following the procedure on the previous page.

Figure 25

BS04H264

1. FUEL FILTER

1. Clean the area around the filter head.

2. Place a receptacle of a suitable capacity under the filter and remove the filter, using a filter wrench.

3. Apply a thin coat of oil to the filter o-ring.

4. Install the fuel filter.

5. Start the engine and operate at an idle for several minutes and check for leakage.

NOTE: Do not fill the new filter with fuel before installing.

A

IMPORTANT: Do not use a filter wrench to install the filter. Overtightening the filter can damage the seal and filter.

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Make sure to wipe all areas with a clean dry rag to remove any spilled fuel.

SA022

Figure 24

BC02N211

A. B. C. D. E. F. G.

HEAD FOR WATER SEPARATOR FILTER SPRING RED FLOAT RING O-RING CASE RING NUT

WARNING: Engine fuel is flammable and can cause a fire or an explosion.

Make sure to wipe all areas with a clean dry rag to remove any spilled fuel.

SA022

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DRAINING THE FUEL TANK Since the water is accumulated during the night, it is effective to drain it before starting up the engine in the morning.

1. Swing the upper structure of the machine so the drain valve (2) under the fuel tank comes midway between the crawler shoes of left and right.

2. Place an empty container under the drain valve to catch the fuel and sediments.

Figure 26

BS04H261

1. FUEL TANK

2. DRAIN PLUG

3. Slowly open the drain valve to drain any water and sediments into the container.

4. When clean fuel begins to flow, close the drain valve (2).

NOTE: Check for fuel leakage after closing the drain valve.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Release the pressure in the hydraulic system before doing any maintenance work on the hydraulic system (Hydraulic fluid change, filter changes, strainer cleaning, cylinder repair, etc.).

1

2

Figure 27

BC02N240

BS04H215

Figure 29

1. BUCKET 2. DOZER BLADE

1. RUBBER CAP (AIR BREATHER) 2. HYDRAULIC RESERVOIR

1. Place the machine on flat and level ground.

7. Open the cover for the hydraulic reservoir and use the support rod to hold the cover in position.

2. Fully retract the arm cylinder and bucket cylinder.

Lower the boom and put the bucket on the ground.

3. Lower the dozer blade to the ground.

8. Press the rubber cap (1) on top of the air breather 6-7 times to release any pressure in the hydraulic reservoir.

4. Stop the engine.

5. Operate the control levers from right to left and front to rear 8 to 10 times to release pressure in each circuit.

Figure 28

BC02N239

6. Pull the safety lock lever up into the locked position.

87458477NA

Issued 10-04

Bur

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Capacity of the hydraulic reservoir .................................................................................................. 20 liters (5.3 gal) Total system capacity ...................................................................................................................... 25 liters (6.6 gal) Hydraulic fluid type ................................................................................................... See Fluid and Lubricants Chart Torque Specifications Cap screws(4) for hydraulic reservoir air filter ......................................................23.5 ± 2 Nm (17.3 ± 1.5 lb-ft) Cap screws(4) for hydraulic return filter ...............................................................23.5 ± 2 Nm (17.3 ± 1.5 lb-ft) 10 hours Check the hydraulic reservoir fluid level ....................................................................... Every 8 hours or each day Check the hydraulic system lines .....................................................................................................Every 8 hours 500 hours Replace the return filter ................................................................................................................Every 500 hours (After the first 50 hours during the run-in period) 2000 hours Clean the filter for the pilot valve ................................................................................................Every 2000 hours Clean the inline filter for the solenoid valve ................................................................................Every 2000 hours Clean the suction strainer ..........................................................................................................Every 2000 hours Change the hydraulic fluid ..........................................................................................................Every 2000 hours 4000 hours Replace the hoses .................................................... Every 2 years or every 4000 hours (whichever comes first) NOTE: If the machine is new or if a major component has been overhauled or replaced in the hydraulic system, replace the return filter after 50 hours of operation. After that, replace these filters at the regular interval.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See Bleeding air from the hydraulic components.

IMPORTANT: If metal filings are discovered in the replaced filters, see your Dealer.

WARNING: Before carrying out any operation on the hydraulic filters or the hydraulic system, the pressure must be released from the system. Failure to observe this instruction can cause injury. See Releasing Pressure In The Hydraulic System.

CE-NA000

WARNING: Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C (104°F).

CE-NA000

5-24

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

CE-NA000

HYDRAULIC BREAKER When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during standard digging. Check the hydraulic fluid level more frequently. In addition, when replacing the filters, also check the condition of the hydraulic fluid.

CHECKING HYDRAULIC SYSTEM LINES Make sure there are no leaks from the hydraulic system hoses, tubes, plugs, connections, and fittings.

Make sure all nuts and screws are tightened. Correct any problems discovered.

IMPORTANT: Release the pressure in the hydraulic system before doing any maintenance work on the hydraulic system (Hydraulic fluid change, filter changes, strainer cleaning, cylinder repair, etc.).

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CHECKING HYDRAULIC FLUID LEVEL

HYDRAULIC RESERVOIR ACCESS

1. To access the hydraulic reservoir, see Hydraulic Reservoir Access and do steps 1 through 5.

1

2

Figure 30

BC02N240

1. BUCKET 2. DOZER BLADE

1. Place the machine on flat and level ground.

2. Fully retract the arm cylinder and bucket cylinder.

Lower the boom and put the bucket on the ground.

3. Lower the dozer blade to the ground.

4. Stop the engine.

Figure 33

BS04J029

Hydraulic Fluid Temperatures L Level (Before Operation)

10 to 30째C (50 to 86째F)

H Level (Normal Operation)

50 to 80째C (122 to 176째F)

2. Check the sight gauge on the side of the hydraulic reservoir.

A. See Hydraulic Fluid Temperature chart.

Figure 31

B. The fluid must be located between the H and L marks on the sight gauge.

5. Pull the safety lock lever up into the locked position.

C. If the fluid level is below the L mark, go to step 3 to add hydraulic fluid.

BC02N239

D. If the hydraulic fluid level is correct, go to step 10.

Figure 32

BS04H215

1. RUBBER CAP (AIR BREATHER) 2. HYDRAULIC RESERVOIR

6. Open the cover for the hydraulic reservoir and use the support rod to hold the cover in position.

87458477NA

Issued 10-04

Bur

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ADDING HYDRAULIC FLUID TO THE RESERVOIR

BS04H220

1.

2.

3.

4.

Figure 34

CAPSCREW LOCK WASHER COVER O-RING

3. Clean the area around the base of the cover (3).

4. Remove the 4 capscrews (1) and lock washers (2).

Figure 35

BS04H218

5. Remove the cover (3)

3. Remove the capscrews (1) and lock washers (2).

6. Add hydraulic fluid as required.

4. Remove the cover (3) and O-ring (7).

7. Check the sight gauge on the side of the hydraulic reservoir.

5. Remove the spring (4), valve (5) and return filter (6).

8. Check the O-ring (4) for the cover (3). Replace the O-ring (4) if damaged.

6. Install a new return filter.

9. Install the cover (3) with the 4 capscrews (1) and lock washers (2). Tighten the capscrews to a torque of 23.5 ± 2 Nm (17.3 ± 1.5 lb-ft).

8. Install the O-ring (7).

10. Close the cover for the hydraulic reservoir.

RETURN FILTER 1. Release all pressure in the hydraulic reservoir.

See Releasing Pressure In The Hydraulic Reservoir on page 5-23 and do steps 1 through 8.

7. Clean and install the spring (4) and valve (5).

IMPORTANT: Check the O-ring and replace the O-ring if damaged.

9. Install the cover (3) with the capscrews (1) and lock washers (2). Tighten the capscrews to a torque of 23.5 ± 2 Nm (17.3 ± 1.5 lb-ft).

10. Close the cover for the hydraulic reservoir.

2. Clean the top and sides of the return filter cover and the top of the hydraulic reservoir.

5-26

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 9. Press the rubber cap on top of the air breather 3-4 times to release any remaining pressure in the hydraulic reservoir.

HYDRAULIC FLUID CHANGE

Figure 36

BS04H219

1. DRAIN PLUG 2. CONTAINER FOR HYDRAULIC FLUID

BS04H269

1. Park the machine on flat and level ground.

2. Rotate the machine to put the drain plug for the hydraulic reservoir between the tracks.

3. Fully retract the arm cylinder and bucket cylinder.

Lower the boom and put the bucket on the ground.

1.

2.

3.

4.

5.

Figure 38

CAPSCREW LOCK WASHER COVER O-RING REMOVE HYDRAULIC OIL FROM THIS OPENING

10. Clean the area around the base of the cover (3).

11. Remove the 4 capscrews (1) and lock washers (2).

4. Lower the dozer blade to the ground.

5. Stop the engine.

6. Operate the control levers right to left and front to rear 8 to 10 times to release pressure in each circuit.

12. Remove the cover (3).

13. Use an oil suction pump to remove the hydraulic fluid (5) from the hydraulic reservoir. Use a container that will hold approximately 40 liters (10.6 gallons) Drain Plug 14. Remove the access cover for the drain plug under the hydraulic reservoir.

15. Put a container under the drain plug for the hydraulic reservoir. Use a container that will hold approximately 40 liters (10.6 gallons).

16. Remove the drain plug to remove the remaining hydraulic fluid from the reservoir.

Figure 37

BC02N239

7. Pull the safety lock lever up into the locked position.

8. Open the cover for the hydraulic reservoir and use the support rod to hold the cover in position.

87458477NA

Issued 10-04

Bur

IMPORTANT: Be careful when removing the drain plug. Hydraulic fluid will flow from the drain hole.

17. Install the drain plug for the hydraulic reservoir after the hydraulic reservoir is empty. Tighten the drain plug to a torque of 73.5 Âą 1.5 Nm (54.2 Âą 1.1 lb-ft).

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 18. Install the access cover for the drain plug under the hydraulic reservoir.

21. Clean the suction strainer with solvent and let the suction strainer dry completely.

Suction Strainer

22. Check the suction strainer for damage. Replace the suction strainer if any damage is found.

NOTE: Make sure the overall length of the new suction strainer and rod is 460 mm (18.1 in).

23. Install the O-ring (1).

Figure 39

BS04H221

1.

2.

3.

4.

5.

CAP SCREW LOCK WASHER CAP O-RING SUCTION STRAINER

Figure 41

BS04H221

19. Remove the suction strainer (5) from the hydraulic reservoir.

1.

2.

3.

4.

5.

CAP SCREW LOCK WASHER CAP O-RING SUCTION STRAINER

24. Install the Suction Strainer (5).

1 2

BC02N246

Figure 40

1. O-RING 2. 460 MM (18.1 INCHES)

20. Remove the O-ring (1). Check the O-ring for damage. Replace the O-ring if any damage is found.

5-28

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FILLING THE HYDRAULIC RESERVOIR

26. Inspect the O-ring (4) for the cover (3).

IMPORTANT: Replace the O-ring (4) if damaged.

27. Install the cover (3) with the 4 capscrews (1) and lock washers (2). Tighten the capscrews to a torque of 23.5 ± 2 Nm (17.3 ± 1.5 lb-ft).

28. Close the cover for the hydraulic reservoir.

29. Start the engine. Let the engine run for approximately 5 minutes.

30. Slowly actuate each cylinder several times.

31. Rotate the upper structure several times.

32. See Hydraulic Reservoir Access and put the machine in position to check the hydraulic fluid level.

33. See Checking Hydraulic Fluid Level.

Figure 42

BS04H270

25. Add hydraulic fluid as required. Check the sight gauge on the side of the hydraulic reservoir for the fluid level. The hydraulic reservoir holds approximately 20 liters (5.3 gallons).

Figure 43

BS04H220

1.

2.

3.

4.

CAP SCREW LOCK WASHER CAP O-RING

87458477NA

Issued 10-04

Bur

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CLEANING LINE FILTER OF PILOT VALVE AND IN-LINE FILTER OF SOLENOID VALVE WARNING: Hydraulic lines are pressurized.

Do not carry out any service before releasing pressure. Depress the rubber cap on the tank several times.

To reach the solenoid valve in-line filter it will be necessary to remove the right hand guard.

The (P) por ts of right and left pilot valves (for operation and traveling) and solenoid valve are equipped with connector and filter. Dust, dirt and debris that adhere on the filter will decrease oil flow.

Dust, dirt or debris should not be allowed to enter the valve. Clean the filter periodically.

1. Move the machine to firm level ground, place the attachment in the oil check position, and stop the engine.

2. Release all pressure in the hydraulic system.

See page 5-23

Figure 45

BS04H222

1. INLINE FILTER 3. RIGHT PANEL 2. SOLENOID VALVE

8. After removal of the hose, remove the in-line filter assembly from the tee installed on the solenoid valve. After the removal, the oil holes of the tee and hose should be plugged.

9. Remove the case and the fitting, and remove the strainer.

BC02N443

Figure 44

3. Loosen 2 bolts (C) on the operating box to remove the cover.

4. Disconnect hose (A) connected to "P" port on the pilot valve first, then remove connector with filter (B). Plug the bore to prevent contamination.

10. Spray light oil or air on the strainer to clean.

Clean the inside of the case and check the O-ring for possible damage. Replace the O-ring if necessary.

11. Install the strainer on the fitting and fit it in the in-line filter case. Torque to specifications.

12. Install the in-line filter assembly on the solenoid valve and install the hose.

5. Wash and clean the filter with diesel fuel.

6. Check the O-ring for damages, and replace, if necessary.

7. After cleaning, install to the original position in reverse order.

5-30

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REPLACING THE RESERVOIR AIR FILTER (IF EQUIPPED)

1 2

3 5

4

6

Figure 46

BS04H266

1.

2.

3.

4.

ELBOW PILOT VALVE HOSE O-RING

CS00E528

1. Remove floor mat and disconnect hose (3) from "P" port on the pilot valve (2). After removal, the oil holes must be plugged to eliminate contamination.

2. Spray light oil or air into the elbow to clean.

Check O-ring for possible damage and replace if necessary.

3. Install elbow into "P" port on pilot valve (2).

Torque to specifications. Connect hose (3) and replace floor mat.

1.

2.

3.

4.

5.

6.

Figure 47

BUTTON NUT COVER FILTER SEAL BREATHER

1. Press the button (1) to release all pressure in the hydraulic reservoir.

2. Remove the nut (2) and the cover (3) from the breather.

3. Remove and discard the used filter (4).

4. Install a new element, making sure the seal (5) is facing upwards.

5. Install the cover (3) as well as the nut (2).

87458477NA

Issued 10-04

Bur

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AIR FILTER SERVICE SPECIFICATIONS Inspect and clean the element ......................................................................................................... Every 250 hours Replace the element ............................................................................ Every 1000 hours or after cleaning six times 7. Install the filter element

1. Open the engine compartment door.

2. Loosen the two clamps and remove the cover from the air cleaner.

3. Remove the filter element.

BS04H234

IMPORTANT: If exhaust smoke is abnormal (black) after cleaning the element, the element must be replaced.

BS04H263

Figure 49

BS04H235

Figure 50

Figure 48

1. OUTER ELEMENT 2. AIR CLEANER COVER WITH CLAMPS 3. INNER ELEMENT

CLEANING THE ELEMENT IMPORTANT: Always protect your face before using compressed air.

IMPORTANT: Compressed air pressure should not exceed 3 bar (43 psi).

NOTE: Do not use compressed air if there is oil or soot in the element. Replace the element if there is oil or soot in the element.

Use compressed air to blow from the inside of the element towards the outside at very low pressure.

The compressed air nozzle should be held at least 3 cm (1 in) from the inside wall of the element.

Cleaning is completed when no more dust comes out of the element.

INSPECTING THE ELEMENT

IMPORTANT: Install the Air Cleaner Cover with the "TOP" position mark facing up, but to avoid interference by intake hose, turn the air cleaner cover 25° to engine side.

4. Check the element for any external damage.

Replace the element in any damage is found.

5. Check the element for damage by placing an inspection lamp inside the element. Replace the element if light can be seen through any holes.

CLEANING THE AIR CLEANER HOUSING 6. Use a clean cloth to remove dust from the inside of the air cleaner housing and the air cleaner cover.

5-32

Issued 10-04

Bur

87458477NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

TRAVEL REDUCTION GEARS SERVICE SPECIFICATIONS Oil change .......................................................................... Every 2000 hours (after the first 500 hours of operation) Oil capacity .................................................................................. 0.35 liters (0.37 qt.) for each travel reduction gear Oil type ........................................................................................................................................135H EP- 85W-140 7. Allow the oil to drain.

DRAINING AND REFILLING 1. Park the machine on flat and level ground.

IMPORTANT: Check the condition of the drained oil. If the oil contains metal filings or foreign material, see your Dealer.

2 1 Figure 51

BC02N258

1. DRAIN PLUG 2. FILL PLUG

BCO2N260

2. Move the machine so that the drain plug (1) is in the bottom.

3. Stop the engine.

4. Pull the safety lock lever up into the locked position.

Figure 53

1. DRAIN PLUG 2. FILL PLUG

8. Apply RTV Silicone Sealant on the threads of the drain plug. Install the drain plug (1).

9. Fill the travel reduction gear with oil through the fill port (2) until oil comes up to the bottom edge of the fill port (2).

10. Apply RTV Silicone Sealant on the threads of the fill plug. Install the fill plug.

2

11. Repeat Steps 2 to 10 for the other travel reduction gear.

1

12. Travel slowly with the machine and make sure there are no leaks.

Figure 52

BC02N259

1. DRAIN PLUG 2. FILL PLUG

5. Place a receptacle of a suitable capacity under the drain port for the travel reduction gear.

6. Slowly remove the fill plug (2) and then the drain plug (1).

NOTE: Make sure to remove the plug slowly. The travel reduction gear can contain pressure. The pressure can force the plug and fluid out of the port when loosening the plug.

87458477NA

Issued 10-04

Bur

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

5-34

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-3 6-3 6-4

CHECKING THE CONDITION OF RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 TRACK ROLLERS AND IDLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roller oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining and Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING A BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Bucket Mount Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8 6-8 6-8 6-9 6-9

6-10 6-10 6-10 6-10

FAN AND ALTERNATOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Checking Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 INSPECTING AND CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 CHECKING FOR CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 FIRE EXTINGUISHER (NOT SUPPLIED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 METRIC TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric 4.8 T Capscrews and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric 7 T Capscrews and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric 10.9 T Capscrews and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Hoses and Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 10-04

Bur

87458477NA

6-14 6-14 6-14 6-15 6-15 6-16

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS MAINTENANCE SPECIFICATIONS Clean .......................................................................... Periodically and when the machine has been working in mud Check track tension ............................................................................................................................Every 50 hours Check the track pads ..................................................................................................... Every 10 hours or every day IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel.

Clean the tracks after work.

IMPORTANT: Avoid pivoting on the spot because this can wear out the tracks quickly and can also cause jamming of stones, rocks, etc. Avoid working in an area full of rock rubble or debris, pieces of reinforced concrete, or striated plates.

CLEANING THE TRACKS When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

BC02N261

Figure 2

3. Move the machine until the connecting links for the track are in the center position at the top of the track

Figure 1

BC02N262

1. Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

2. Put a support under the machine.

3. Operate the travel control lever for the raised track forwards and then in reverse to remove the mud.

4. Repeat for the other track.

BC02N262

Figure 3

4. Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

5. Put a support under the machine.

6. Use the travel control lever to move the raised track in reverse for 2-3 seconds.

7. Stop the engine and remove the starter switch key.

CHECKING TRACK TENSION 1. If necessary, clean the tracks. See Cleaning the Tracks.

2. Park the machine on flat and level ground.

87458477NA

Issued 10-04

Bur

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

CE-NA000

TO INCREASE TRACK TENSION 1. With the track raised, clean the grease fitting.

Figure 4

BC02N263

A. LOCATION FOR TRACK TENSION MEASUREMENT

TRACK TENSION MEASUREMENTS Type of Track

Measurement for Dimension A

Rubber Track Shoes

55 - 65 mm (2.2 - 2.6 in)

8. Measure the distance between the base of the undercarriage (Crawler frame) and the upper part of the track shoe. See the chart for Track Tension Measurements for the correct distance.

9. Do one of the following: A. If the track tension is correct, go to step 10.

B. If the track tension is not correct, see Adjusting Track Tension and adjust the track tension.

Figure 6

BC02N266

2. Connect the grease pump to the grease fitting.

Inject grease to get the correct track tension. See the chart for Track Tension Measurement.

3. Remove the grease gun and clean the grease fitting.

4. Lower the raised track to the ground.

5. Repeat steps 1, 2, and 3 for the other track.

10. Lower the raised track to the ground. Repeat Steps 3 to 8 for the other track.

6. Move the machine forward and backward to equalize the tension in the tracks.

ADJUSTING TRACK TENSION

7. Repeat the procedures to check the track tension.

This procedure is to be done after the track tension has been checked.

TO REDUCE TRACK TENSION 1. With the track raised, clean the grease fitting.

Figure 5 GREASE FITTING FOR TRACK TENSION ADJUSTMENT

BC02N264

6-4

Figure 7

BC02N265

1. GREASE FITTING

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BC02N268

Figure 8

BC02N267

Figure 9

1. GREASE FITTING A. CYLINDER

2. Loosen the grease fitting (1) approximately one turn to let grease flow out of the cylinder.

WARNING: Never completely unscrew the grease fitting to speed up the flow of grease.

The grease in the cylinder is under high pressure.

CE-NA000

3. When the correct track correct track tension is reached, tighten the grease fitting. See the chart for Track Tension Measurement.

NOTE: Tighten the grease fitting to a torque of 49 - 68.6 Nm (36 - 50.5 ft-lb).

4. Clean the grease fitting.

5. Lower the raised track to the ground.

6. Repeat steps 1, 2, and 3 for the other track.

7. Move the machine forward and backward to equalize the tension in the tracks.

8. Repeat the procedures to check the track tension.

87458477NA

Issued 10-04

Bur

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHECKING THE CONDITION OF RUBBER TRACKS Replace the tracks in any of the following cases:

3

2

A 1 BC02N269

Figure 13

BC02N271

Figure 10

1. GROUSER (LUG) DEPTH 2. STEEL LAYER (CORD) 3. METAL HUB (CORE)

Replace the tracks if the steel cords are broken by more than one half on one side.

3 2

1

2

Figure 14

BC02N272

BC02N270

Figure 11

A. 5 MM (0.2 IN) MINIMUM

1. REPAIR IS REQUIRED 2. REPAIR IS NOT REQUIRED 3. IF CRACK IS OVER 60 MM (2.4 IN), REPAIR IS REQUIRED

Replace the tracks if the steel cords are exposed by wear of the lugs over two links.

Figure 15

BC02N273

BC02N274

Figure 12

Replace the tracks if the metal core star ts to separate.

Replace the tracks if the steel cords are exposed over two links.

6-6

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Figure 16

BC02N275

Replace the tracks if the metal core star ts to separate from the track.

87458477NA

Issued 10-04

Bur

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACK ROLLERS AND IDLERS MAINTENANCE SPECIFICATION Replace Track Roller and Idler oil ...................................................................................................Every 2000 hours Roller oil capacity ................................................................................................................................... 60 cc (2 oz.)

Idler oil capacity.................................................................................................................................... 45 cc (1.5 oz.)

Oil type .......................................................................................................................................135H EP - 85W-140 ROLLER AND IDLER OIL CHANGE

Figure 17

BS04H260

1. TRAVEL MOTOR 2. SPROCKET 3. LOWER ROLLER

4. CRAWLER SHOE 5. UPPER ROLLER 6. IDLER

To change the gear oil in the rollers and idlers it will be necessary to remove the track for each respective side. Contact your dealer or service manual for this procedure.

6-8

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REPLACING A BUCKET REMOVAL

INSTALLING BUCKET

1. Operate the boom and the arm to remove load from the pins (4) and (5).

1. Clean and lubricate each pin and pin hole.

BC02N286

Figure 19

2. Move the bucket cylinder to match the pin bores of the bucket (6) and bucket link (8) with each other; then insert the pin (4) installing the shims (10).

3. Raise the boom up to lift the bucket slightly from the ground.

4. Move the arm (7) to match the pin bores of the bucket (6) and arm (7) with each other; then insert the pin (5) installing the shims (10).

5. Insert the lock pin (3) into pin (4) and (5), and attach the spring lock rings (2).

6. Roll the O-rings (1) into the normal position.

7. Lubricate the bucket links.

ADJUSTING BUCKET MOUNT GAP

Figure 18

BC02N285

1.

2.

3.

4.

O-RING LOCK RING PIN PIN

5.

6.

7.

8.

PIN 9. SEAL BUCKET 10. 10 SHIMS ARM BUCKET LINK

An adjusting device is provided to adjust the clearance between the bucket and the arm. When the clearance becomes large, adjust the clearance as follows.

2. Roll the O-rings (1) onto the bucket boss.

NOTE: Inspect the O-rings for damage. Replace the O-rings during assembly if required.

3. Remove the spring lock ring (2) and lock pin (3), then remove the pins (4) and (5) to remove the bucket (6).

NOTE: Do not to damage the dust seals (9) which are installed in both ends of the arm (7) and bucket link (8).

BC02N289

Figure 20

1. Lower the bucket to the ground to stabilize.

87458477NA

Issued 10-04

Bur

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Slightly lift boom to remove load from bucket pin connections to properly adjust bucket clearance.

Figure 23

BC02N291

6. Measure the total clearance X between the arm and bucket boss. The clearance is the existing total clearance. Exact clearance is obtained easily by using a thickness gauge.

BC02N290

1.

2.

3.

4.

5.

Figure 21

O-RING CAPSCREW SHIMS WASHER BUSHING

3. Roll the O-ring (1) from its normal position to the bucket boss to avoid damage.

4. Slightly swing to the left direction to slightly push the arm end to the bucket left side (where no adjusting mechanism of clearance is equipped).

B y c o n t a c t i n g t h e a r m a n d bu cke t , t o t a l clearance is obtained on one place.

Figure 24

BC02N292

7. If the measurement value is 1.0 mm (0.04 in) or more, decrease the clearance.

8. Remove shims (3) to recondition the clearance X after loosening 3-capscrew (2) with washer (4).

The clearance decreases by extruding the bushing (5), depending on the thickness of removed shims.

Example BC02N239

Figure 22

5. Set the safety lock lever to the LOCKED position and then stop the engine.

When X = 2mm Remove 3-shim (0.5 X 3 = 1.5 mm) Remained clearance = 2 - 1.5 = 0.5mm Tightening torque; 55 Nm (41 lb ft) 9. Tighten the 3-capscrew (2) with washer (4) equally to the specified tightening torque.

10. Return the O-ring (1) to the normal position.

(Groove between the arm and bucket bosses.)

6-10

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FAN AND ALTERNATOR DRIVE BELT MAINTENANCE SPECIFICATIONS Visual check . . . . . . . . .Every 10 hours or every day Check fan belt tension . . . . . . . . . . . Every 250 hours Belt deflection . . . . . . . . . . 8 to 10 mm (0.2 to 0.4 in) CHECKING DRIVE BELT Check the fan belt for correct tension, wear, and damage. Wrong belt tension may cause battery charge failure, engine overheating, or additional belt wear. Too much tension may cause belt or bearing damage.

Apply a force of 10 kg (22 lb) to the center of the belt between the pulleys. This will be the deflection.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear.

CHECKING FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1. Wipe clean the rod and bearing on the cylinder to be cleaned.

2. Operate normally for five or ten minutes.

3. Extend the cylinder rod.

4. Carry out the leak test.

ROD APPEARANCE

Figure 25

BS04H214

1. ATTACHING BOLT 2. ADJUSTING BOLT

3. ADJUSTING BOLT

IMPORTANT: If the engine runs with the drive belt loose, the drive belt can slip and cause the engine to overheat or the battery to receive insufficient charge.

TEST

CONCLUSION

Slight traces of oil when a Dry piece of paper is wiped over 20 cm (7.8 in) of the rod.

Normal

Slightly Paper remains stuck to rod greasy when run over rod.

Normal

Oily Paper remains stuck when placed on rod.

Normal

Very oily or Each time the cylinder rod weeping is extended, a ring of oil can be seen on the rod.

Each time the rod retracts, Leakage the excess oil drips from the gland.

See your Dealer

WARNING: Rotating parts can cause personal injury. Keep away from fan and belt when engine is running. make sure to stop engine before servicing.

CE-NA000

INSPECTING AND CLEANING THE MACHINE MAINTENANCE SPECIFICATIONS Inspect and clean . . . . . . . . . . . . . . . . . . Periodically Or whenever oil or grease has been spilled on the machine. Clean off with steam or a high pressure water jet.

Look for any leaks and check the condition of all pipes and hoses.

87458477NA

Issued 10-04

Bur

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER (NOT SUPPLIED)

PLASTIC AND RESIN PARTS

It is strongly recommended to have a fire extinguisher and to place it in the rear left-hand side compar tment in the bracket designed for the purpose.

When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

MAINTENANCE SPECIFICATION

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

Every month Examine the fire extinguisher and make sure it is not damaged.

Every six months Have an approved specialist empty and refill the powder in the fire extinguisher.

Every year Have an approved specialist examine the fire extinguisher.

WELDING ON THE MACHINE Whenever carrying out a welding operation on the un der carr iag e or up per str u cture carr iage a s authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Always connect the welding apparatus to the same structure that is being welded.

A. Never connect the welding apparatus to the undercarriage when welding on the upperstructure.

B. Never connect the welding apparatus to the upperstructure when welding on the undercarriage.

Never connect the welding apparatus ground to a component of the hydraulic system.

BC02N443

Figure 26

WARNING: Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your Dealer.

CE-NA000

6-12

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

METRIC TORQUE SPECIFICATIONS METRIC 4.8 T CAPSCREWS AND NUTS

MAINTENANCE SPECIFICATION Check . . . . . . . . . . . . . . Each day or every 10 hours

4.8 T Metric Hardware

(after the first 50 hours during the run-in period) At the end of each working day, check all mounting nu t s a n d s c r ew s fo r t i g h t n e s s a n d t i g h t e n i f necessary.

Make sure no hardware items are missing. If replacement is needed, make sure to use the same size of authorized genuine parts.

The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

Use the torque values in toque tables for proper tightening of capscrews.

T h e t o q u e t a bl e s a r e n o t a p p l i c a bl e fo r t h e capscrews holding plastic covers, etc. For proper tightening of such capscrews, consult with an authorized dealer. Over-tightening may cause damages on the parts to be fixed.

Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No information is provided for smaller size of capscrews, M 5 or less.

Make sure to tighten all capscrews and nuts to the correct torque values.

In case that the tightening torque is specified in the manual, use such torque values regardless to the table below.

4.8 T Metric Fine Thread No Lubrication Nominal Size

M8

P=1.0

Newton metres (Nm)

With Oil Lubrication

Poundinches (lb-in)

Newton metres (Nm)

Poundinches (lb-in)

11.3 ± 1.1

100 ± 10

9.5 ± 1.0

84 ± 9

M10 P=1.25

22.6 ± 2

200 ± 18

18.7 ± 2

166 ± 18

Nominal Size

Newton metres (Nm)

M12 P=1.25 M16 P=1.25

No Lubrication

With Oil Lubrication

Pound-Feet (lb-ft)

Newton metres (Nm)

Pound-Feet (lb-ft)

39.2 ± 4.0

29 ± 2.9

33.3 ± 3

25 ± 2.2

92.1 ± 9

68 ± 6.6

77.5 ± 8

57 ± 5.9

M20 P=1.5

186.3 ± 19

137 ± 14

155 ± 16

114 ± 11.8

M24 P=2

314 ± 29.4

232 ± 22

265 ± 29.4

195 ± 22

M30 P=2

637.4 ± 59

470 ± 44

530 ± 49

391 ± 36

M36 P=3

1069 ± 108

788 ± 80

892 ± 88.3

658 ± 65

4.8 T Metric Coarse Thread No Lubrication Nominal Size

These values do not apply if graphite or Molydisulfide grease or oil is used as a lubricant.

Newton metres (Nm)

With Oil Lubrication

Poundinches (lb-in)

Newton metres (Nm)

Poundinches (lb-in)

M6

P=1.00

4.4 ± 0.5

39 ± 4

3.7 ± 0.4

33 ± 4

M8

P=1.25

10.7 ± 1.1

95 ± 10

9 ± 0.9

80 ± 8

21.6 ± 2

191 ± 18

18 ± 1.8

159 ± 16

M10 P=1.50

No Lubrication

With Oil Lubrication

Nominal Size

Newton metres (Nm)

Pound-Feet (lb-ft)

Newton metres (Nm)

Pound-Feet (lb-ft)

M12 P=1.75

36.3 ± 4

27 ± 2.9

31.4 ± 3

23 ± 2.2

M14 P=2

57.9 ± 6

43 ± 4.4

49 ± 5

36 ± 3.6

M16 P=2

88.3 ± 9

65 ± 6.6

74.5 ± 7

55 ± 5.1

M18 P=2.5

121.6 ± 12

90 ± 8.8

103 ± 10

76 ± 7.4

M20 P=2.5

171.6 ± 17

126 ± 12.3

144 ± 13.7

106 ± 10.1

225.6 ± 19.6 166 ± 14.5

192 ± 19.6

142 ± 14.5

235 ± 29.4

174 ± 22

M22 P=2.5 M24 P=3

294 ± 29.4

217 ± 22

M27 P=3

431 ± 39.2

318 ± 29

353 ± 29.4

260 ± 22

M30 P=3.5

588 ± 58.8

433 ± 43

490.3 ± 49

361 ± 36

M33 P=3.5

794 ± 78.5

585 ± 58

666 ± 68.7

491 ± 51

M36 P=4

1030 ± 98

760 ± 72

863 ± 88.3

636 ± 65

BC02N294

87458477NA

Issued 10-04

Bur

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS METRIC 7 T CAPSCREWS AND NUTS 7 T Metric Hardware

10.9 T Metric Hardware

7 T Metric Fine Thread

10.9 T Metric Fine Thread

No Lubrication Nominal Size

Newton metres (Nm)

Poundinches (lb-in)

M8

P=1.0

METRIC 10.9 T CAPSCREWS AND NUTS

With Oil Lubrication Newton metres (Nm)

Poundinches (lb-in)

No Lubrication

With Oil Lubrication

Nominal Size

Newton metres (Nm)

Poundinches (lb-in)

Newton metres (Nm)

Poundinches (lb-in)

24.5 ± 2

216.8 ± 18

206 ± 2

1823 ± 18

M8

44.1 ± 4

390 ± 35

37.3 ± 4

330 ± 35

M10 P=1.25

48.1 ± 5

425.7 ± 44

41.2 ± 4

365 ± 35

M10 P=1.25

87.3 ± 9

773 ± 80

73.5 ± 7

651 ± 62

Nominal Size

Newton metres (Nm)

Nominal Size

Newton metres (Nm)

M12 P=1.25

85.3 ± 9

No Lubrication

P=1.0

With Oil Lubrication

Pound-Feet (lb-ft)

Newton metres (Nm)

Pound-Feet (lb-ft)

63 ± 7

71.6 ± 7

53 ± 5

No Lubrication

M12 P=1.25 154 ± 15.7

Pound-Feet (lb-ft)

With Oil Lubrication Newton metres (Nm)

114 ± 11.6 129.4 ± 12.7

95 ± 9.4

M12 P=1.25 196.1 ± 19.6 144 ± 14.5 168.7 ± 16.7 124 ± 12.3

M16 P=1.25 363 ± 39.2

M20 P=1.5

402.1 ± 39.2

296 ± 29

333.4 ± 29.4

246 ± 22

M20 P=1.5

725.7 ± 68.7

M24 P=2

686.5 ± 68.6

506 ± 51

568.8 ± 60

420 ± 44

M24 P=2

1235.6 ± 69

M30 P=2

1392 ± 137 1030 ± 101 1157 ± 118

854 ± 87

M30 P=2

2500 ± 255 1844 ± 188 2079 ± 206 1533 ± 152

M36 P=3

2334 ± 225 1721 ± 166 1942 ± 196 1432 ± 145

M36 P=3

4197 ± 422 3096 ± 311 3501 ± 353 2582 ± 260

7 T Metric Coarse Thread No Lubrication

268 ± 29

Pound-Feet (lb-ft)

304 ± 29.4

224 ± 22

535 ± 51

608 ± 60

448 ± 44

911 ± 51

1029.7 ± 98

760 ± 72

10.9 T Metric Coarse Thread

With Oil Lubrication

No Lubrication

Nominal Size

Newton metres (Nm)

Poundinches (lb-in)

Newton metres (Nm)

Poundinches (lb-in)

Nominal Size

M6

P=1.00

9.6 ± 1

85 ± 9

8.1 ± 0.8

72 ± 7

M6

P=1.00 17.36 ± 1.8

M8

P=1.25

P=1.25

With Oil Lubrication

Poundinches (lb-in)

Newton metres (Nm)

Poundinches (lb-in)

154 ± 16

14.7 ± 1.5

130 ± 13

Newton metres (Nm)

23.5 ± 2

208 ± 18

19.6 ± 2

173 ± 18

M8

42.2 ± 3.9

374 ± 35

35.3 ± 3.9

312 ± 35

M10 P=1.50

46.1 ± 4.9

408 ± 43

39.2 ± 4

347 ± 35

M10 P=1.50

83.3 ± 9

737 ± 80

70.6 ± 6.9

625 ± 61

Nominal Size

Newton metres (Nm)

Nominal Size

Newton metres (Nm)

No Lubrication

M12 P=1.75

Pound-Feet (lb-ft)

With Oil Lubrication Newton metres (Nm)

Pound-Feet (lb-ft)

79.4 ± 7.8

59 ± 6

66.7 ± 7

49 ± 5.1

M14 P=2

125.6 ± 12.7

93 ± 9.4

106 ± 10.8

78 ± 8

M16 P=2

191 ± 19.6

M18 P=2.5

264.8 ± 29

M20 P=2.5

372.7 ± 39

275 ± 29

313.8 ± 29

M22 P=2.5

500 ± 49

369 ± 36

421.7 ± 39

141 ± 14.5 160.8 ± 15.7 119 ± 11.6 195 ± 22

No Lubrication Pound-Feet (lb-ft)

M12 P=1.75 143.2 ± 14.7 105 ± 10.8 M14 P=2

With Oil Lubrication Newton metres (Nm)

Pound-Feet (lb-ft)

121 ± 11.8

89 ± 8.7

225.6 ± 19.6 166 ± 14.5 191.2 ± 18.6 140 ± 13.7

M16 P=2

343.2 ± 39

252 ± 29

284.4 ± 29.4

209 ± 22

M18 P=2.5

480.5 ± 49

354 ± 36

402.1 ± 39.2

296 ± 29

231 ± 22

M20 P=2.5

667 ± 68.6

491 ± 51

559 ± 58.8

412 ± 43

311 ± 29

M22 P=2.5

902 ± 88.3

665 ± 65

755 ± 78.5

557 ± 58

852 ± 87

912 ± 98.1

673 ± 72

225.6 ± 19.6 166 ± 14.5

M24 P=3

637 ± 68.7

470 ± 51

520 ± 49

383 ± 36

M24 P=3

1157 ± 117.7

M27 P=3

941.4 ± 98.1

694 ± 72

765 ± 78.5

564 ± 58

M27 P=3

1696 ± 166.7 1250 ± 123 1373 ± 137.3 1010 ± 101

M30 P=3.5 1284 ± 127.5

948 ± 94

1079 ± 108

796 ± 80

M30 P=3.5

2304 ± 236 1700 ± 174 1942 ± 196 1430 ± 145

M33 P=3.5

3108 ± 314 2292 ± 231 2608 ± 265 1923 ± 195

M36 P=4

4011 ± 402 2958 ± 296 3363 ± 333 2480 ± 246

M33 P=3.5

1726 ± 176 1273 ± 130 1451 ± 147 1070 ± 108

M36 P=4

2226 ± 226 1642 ± 166 1863 ± 186 1374 ± 137

BC02N295

6-14

BC02N296

Issued 10-04

Bur

87458477NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC HOSES AND TUBE FITTINGS

Hydraulic Hose

Sleeve Type Tube Fitting

Nominal Size 10 x 1.5

No Lubrication Spanner Size Newton metres Pound-inches (mm) (Nm) (lb-in) 19

44.1 ± 5

Nominal Size

No Lubrication Spanner Size Newton metres Pound-inches (mm) (Nm) (lb-in)

1/8

17

30 ± 5

22 ± 3.7

33 ± 3.7

1/4

19

30 ± 5

22 ± 3.7

22

49 ± 5

36 ± 3.7

15 x 2.0

27

147 ± 20

108 ± 14.8

3/8

18 x 2.5

32

177 ± 20

131 ± 14.8

1/2

27

79 ± 5

58 ± 3.7

3/4

36

118 ± 10

87 ± 7.4

1

41

137 ± 15

101 ± 11

22 x 3.0

36

216 ± 20

159 ± 14.8

28 x 4.0

41

275 ± 30

203 ± 22

35 x 5.0

55

441 ± 44

325 ± 32.5

BC02N297

BC02N298

Straight Threads with O-ring

Nominal Size

No Lubrication Spanner Size Newton metres Pound-inches (mm) (Nm) (lb-in)

1/8

14

17 ± 2

12.5 ± 1.5

1/4

19

36 ± 2

27 ± 1.5

3/8

22

74 ± 5

55 ± 3.7

1/2

27

108 ± 5

79.7 ± 3.7

3/4

36

162 ± 15

119 ± 11

1

41

255 ± 10

188 ± 7.4

BC02N299

87458477NA

Issued 10-04

Bur

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-16

Issued 10-04

Bur

87458477NA

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access to The Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check for Battery Fluid Level and Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing A Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4 7-4 7-4 7-5 7-5

CONNECTING A BOOSTER BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 ATTACHMENT (BOOM) LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Replacing Bulb for Attachment Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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NOTES

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CHAPTER 7 - ELECTRICAL

ALTERNATOR MAINTENANCE SPECIFICATION Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours

The fusible link (1) is an in-line fuse provided in the electric wiring for large current. It protects the electrical equipment and wiring from abnormal current like as an ordinary fuse.

Ask your Dealer to check the alternator.

If power does not come when the key switch is turned to the ON position, check the fusible link.

Make sure that the terminal protectors are correctly installed.

If necessary, replace the fusible link.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

WARNING: Whenever carrying out a welding operation on the machine (authorized by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator.

When reconnecting, check the markings on the wires.

FUSE PANEL The fuses protect the electrical system from excess current. If operation is not normal, a fuse may be blown.

IMPORTANT: Before changing fuses or relays, turn the starter key switch to the OFF (Shut Down) position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

CE-NA000

STARTER MOTOR MAINTENANCE SPECIFICATION Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the starter motor.

Make sure that the terminal protectors are correctly installed.

FUSES FUSIBLE LINK

Figure 1

BS04H253

FUSE

AMP

FUNCTION

1

30

Heater, Wiper (Optional)

2

30

Relay Solenoid

3

30

Work lamp

4

30

Horn, Cab lamp (Optional)

5

30

Engine stop solenoid

6

10

Battery relay, Instrument panel

The fuse box is located under the operator’s seat.

Remove the cover of the box.

NOTE: Spare fuses are located on the fuse panel.

Figure 1

BS04H254

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CHAPTER 7 - ELECTRICAL

BATTERY MAINTENANCE SPECIFICATION WARNING: Connecting auxiliary cables wrongly or short-circuit batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

Checking the charge state . . . . . . . . Every 50 hours NOTE: If the machine needs to be started using a booster battery, see Connecting A Booster Battery.

CE-NA000

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

CE-NA000

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

CE-NA000

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SB034

WARNING: Always store batteries in a safe place, out of the reach of children.

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

CE-NA000

ACCESS TO THE BATTERIES

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

Figure 2

BS04H258

To access the batteries, remove the left side cover and open the cover under the operator’s seat.

CE-NA000

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CHAPTER 7 - ELECTRICAL CHECK FOR BATTERY FLUID LEVEL AND SPECIFIC GRAVITY

3. Remove the caps (1) of each cell to check the fluid level.

Th e batt er y fluid easily de creases with high temperature in summer season.

4. If battery fluid level is low, refill the cell with distilled water up to the specified level 10 - 15 mm (0.4 - 0.6 in) above the plate.

Check the battery fluid level in the morning before starting operation.

Continuous use of the battery with low fluid lowers battery performance.

Check for the battery fluid level periodically, and if insufficient, refill the battery with distilled water before the engine start-up (before charging battery).

5. Make sure the air vent holes in the caps (1) are clean and securely tighten the caps (1).

6. If the terminals (2) are dirty, wash with warm water, then install it to the position applying grease or spraying rust preventive solution. If the terminal is oxidized, polish it with a wire brush or emery paper.

When it is difficult to obtain enough cranking speed at the engine start-up, check the battery fluid for its specific gravity. If it is insufficient, re-charging is required for the battery. Standard specific gravity for battery fluid 1.28 (at 20°C or 68°F).

NOTE: Measure the specific gravity of battery fluid with a gravimeter. The measured value varies depending on the ambient temperature.

REPLACING A BATTERY REMOVAL 1. Remove the terminal sleeves, disconnect the cable (negative terminal) then the cable (positive terminal).

2. Remove the nuts, the washers and the angle iron.

Figure 3

BC02N305

3. Remove the battery.

4. Clean the battery compartment.

1. CAP 2. TERMINAL

Check the indicator on the battery, and always keep it at a green color. Red color means insufficient battery fluid or battery charging.

INSTALLATION 1. Install a new battery. Clean the cables and battery terminals and coat them with grease.

1. Set the safety lock lever to the LOCKED position, then stop the engine.

2. Install the angle iron, the washers and tighten the nuts.

2. Remove the rear left-hand access panel and open the cover under the seat. The battery is located under the left operating box.

3. Connect the cable (positive terminal), the cable (negative terminal) then install the terminal sleeves.

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−).

CE-NA000

Figure 4

BC02N306

1. CAP 2. TERMINALS 87458477NA

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CHAPTER 7 - ELECTRICAL

CONNECTING A BOOSTER BATTERY WARNING: Connecting auxiliary cables wrongly or short-circuit batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

CE-NA000

Figure 7

BCO2N313

1.

2.

3.

4.

BS04H258

Figure 5

POSITIVE TERMINAL (DISCHARGED BATTERY) POSITIVE TERMINAL (AUXILIARY BATTERY) NEGATIVE TERMINAL (AUXILIARY BATTERY) ENGINE CONNECTION (TROUBLED MACHINE)

2. Connect one end of the red (+) booster cable to the positive (+) terminal (1) on the discharged battery.

3. Connect the other end of the red (+) booster cable to the positive (+) terminal (2) on the auxiliary (Normal) battery.

4. Connect one end of- the black (-) booster cable to the negative (-) terminal (1) on the auxiliary (Normal) battery 5. Connect the other end of the black (-) booster cable to the engine of the troubled machine.

6. Start the engine of the normal machine and let the engine run at high idle for approximately 10 minutes.

7. Start the engine of the troubled machine.

BCO2N312

Figure 6

M a ke s u r e t h a t t h e b o o s t e r b a t t e r y vo l t a g e corresponds to the voltage system of the machine.

1. Remove the cover from the battery.

8. Disconnect the booster cables in the following order: a. Engine connection (Troubled Machine) b. Negative Terminal (Auxiliary Battery) c. Positive Terminal (Auxiliary Battery) d. Positive Terminal (Discharged Battery) 9. Install the cover for the battery.

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ATTACHMENT LAMPS REPLACING BULB FOR ATTACHMENT LAMPS The attachment lamps develop high temperatures when illuminated, the service life of the lamps will be reduced if oil or grease is on the lens.

A 12 volt 55 Watt halogen bulb is used for the working lights.

When replacing either light bulb, hold it at the flange portion not touching with its glass portion.

4. Remove the rim (2) and lens (3) from the housing (4).

5. Remove the spring (6) from the socket (5).

6. Remove the bulb (7) from the socket (5).

IMPORTANT: Do not put your fingers on the new bulb 7. Install a new bulb (7) in the socket (5).

8. Put the spring (6) on the socket (5) into the lens (3).

9. Put the lens (3) and frame (2) in the housing and install the screws (1).

10. Install the lamp.

11. Connect the connector to the lamp.

Figure 8

BS04H251

LAMPS

1. Place the attachment on the ground, and set the safety lock lever to the LOCKED position, then stop the engine.

Figure 9

BCO2N309

1.

2.

3.

4.

5.

6.

7.

SCREW RIM LENS HOUSING SOCKET SPRING BULB

2. Disconnect the wiring connector and use a wrench to remove the lamp assembly with from the boom.

3. Remove the screws (1). Make sure to hold the rim (2) and lens (3) when removing the screws (1) to keep the lens (3) from falling out.

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NOTES

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SPEED AND GRADEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 BOOM SWING AND DOZER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 MACHINE OVERALL DIMENSIONS - ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 MACHINE OVERALL DIMENSIONS - CAB MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 WORKING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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CHAPTER 8 - SPECIFICATIONS

ENGINE Make.................................................................................................................................Yanmar 3TNV82A - SYB Type.........................................................................Water cooled, 4-cycle type Swirl chamber type diesel engine Number of cylinders ..............................................................................................................................................3 Bore/stroke ....................................................................................................... 82 mm x 84 mm (3.23 in x 3.31 in) Displacement ...........................................................................................................................1.331 L (81.2 cu in) Power EEC 80/1269 ....................................................................................................................15.9 kW/ 21.6 HP Speed rating .............................................................................................................................................2200 rpm Circuit ..........................................................................................................................................................12 volts Battery.....................................................................................................................................................1 x 12 volt Alternator..............................................................................................................................................12 V / 40 A)

HYDRAULIC COMPONENTS Hydraulic pump ........................................................................... Variable displacement axial piston + gear pump Hydraulic motor .......................................................................................................................... Axial piston motor Hydraulic Motor w/Reduction (travel) ................................................................................. 2 Axial piston, 2-speed Control valve ...........................................................................................................10 spool multiple control valve Cylinders ........................................................................................................................................... Double action

SPEED AND GRADEABILITY Travel Speed Low............................................................................................................................................2.3 km/h (1.4 mph) High ...........................................................................................................................................4.1 km/h (2.5 mph) Swing Speed ...............................................................................................................................................8.7 rpm Gradeability .............................................................................................................................................58% (30°)

BOOM SWING AND DOZER BLADE Boom Swing Angle Right.............................................................................................................................................................. 55° Left ................................................................................................................................................................ 60° Dozer strokes - Up / Down ........................................................................ 445 mm (17.5 in) / 335 mm (13.2 in)

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MACHINE OVERALL DIMENSIONS - ROPS CANOPY

Figure 1

BS04H239

A. ..................................................................................................................................................2 500 mm (8 ft 2 in) B. ................................................................................................................................................4 130 mm (13 ft 7 in) C. ..................................................................................................................................................1 590 mm (5 ft 3 in) D. ..................................................................................................................................................1 980 mm (6 ft 6 in) E. ..................................................................................................................................................1 400 mm (4 ft 7 in) F. .........................................................................................................................................................250 mm (9.8 in) G.................................................................................................................................................1 500 mm (4 ft 11 in) H. .........................................................................................................................................................1 250 (4 ft 1 in) I...........................................................................................................................................................250 mm (9.8 in)

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CHAPTER 8 - SPECIFICATIONS

MACHINE OVERALL DIMENSIONS - CAB MODEL

Figure 2

BS04H240

A. ..................................................................................................................................................2 500 mm (8 ft 2 in) B. ................................................................................................................................................4 130 mm (13 ft 7 in) C. ..................................................................................................................................................1 590 mm (5 ft 3 in) D. ..................................................................................................................................................1 980 mm (6 ft 6 in) E. ..................................................................................................................................................1 400 mm (4 ft 7 in) F. .........................................................................................................................................................250 mm (9.8 in) G.................................................................................................................................................1 500 mm (4 ft 11 in) H. .........................................................................................................................................................1 250 (4 ft 1 in) I...........................................................................................................................................................250 mm (9.8 in)

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CHAPTER 8 - SPECIFICATIONS

WORKING RANGE

Figure 3

BS04H241

DIMENSIONS FOR ROPS CANOPY

...........................................................................................................................1.12 m (3 ft 8 in) arm A) Maximum digging reach ................................................................................ 4 640 mm (15 ft 3 in) B) Maximum digging depth .................................................................................. 2 540 mm (8 ft 4 in) C) Maximum digging height ............................................................................... 4 470 mm (14 ft 8 in) D) Maximum dumping clearance ........................................................................ 3 170 mm (10 ft 5 in) E) Maximum digging depth - vertical wall............................................................. 2 320 mm (7 ft 7 in) F) Minimum swing radius ..................................................................................... 1 830 mm (6 ft 0 in)

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1.37 m (4ft 6 in) arm

4 890 mm (16 ft 1 in) 2 790 mm (9 ft 2 in) 4 690 mm (15 ft 5 in) 3 380 mm (11 ft 1 in) 2 560 mm (8 ft 5 in) 1 880 mm (6 ft 2 in)

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CHAPTER 8 - SPECIFICATIONS

Figure 4

BS04H242

DIMENSIONS FOR ROPS CAB

........................................................................................................... 1.12 m (3 ft 8 in) arm A) Maximum digging reach ................................................................................. 4 640 mm (15 ft 3 in) B) Maximum digging depth ................................................................................... 2 540 mm (8 ft 4 in) C) Maximum digging height .............................................................................. 4 260 mm (13 ft 11 in) D) Maximum dumping clearance ...........................................................................2 970 mm (9 ft 9 in) E) Maximum digging depth - vertical wall ............................................................. 2 320 mm (7 ft 7 in) F) Minimum swing radius ...................................................................................... 2 060 mm (6 ft 9 in)

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1.37 m (4 ft 6 in) arm 4 890 mm (16 ft 1 in) 2 790 mm (9 ft 2 in)) 4 470 mm (14 ft 8 in) 3 170 mm (10 ft 5 in 2 560 mm (8 ft 5 in) 2 080 mm (6 ft 10 in)

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CHAPTER 8 - SPECIFICATIONS

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Covers ................................................... 3-14 Air filter .............................................................. 5-32 Alternator ............................................................. 7-3

B Battery ................................................................. 7-4 Battery charge indicator lamp .............................. 3-8 Before Operating the Machine ............................. 4-3 Blade Linkage Lubrication ................................. 5-11 Boom and Arm Lubrication ................................ 5-12 Boom lamp .......................................................... 7-7 Boom Swing Function Switch ............................ 3-12 Boom Swing Switch ........................................... 3-10 Bucket Linkage Lubrication ............................... 5-11 Burn Prevention ................................................... 2-7

C Cab Door ............................................................. 3-3 Cab Lamp ............................................................ 3-4 Checking for cylinder leakage ........................... 6-11 Checking the condition of rubber tracks .............. 6-6 Control Lever Lubrication .................................. 5-10 Control Levers ................................................... 5-10 Control pattern ................................................... 3-12 Controls locking lever ........................................ 3-11 Cooling system .................................................. 5-16

D Daily inspections .................................................. 5-7 Decals .................................................................. 2-9 Deceleration Switch ........................................... 3-10 Dozer Blade Control Lever ................................ 3-13

E Engine ........................................................ 5-14, 8-3 Engine Coolant Temperature Indicator ................ 3-7 Engine Oil Change ............................................ 5-14 Engine oil pressure indicator lamp ...................... 3-8 Engine Oil Type ................................................... 5-6 Engine operation ................................................. 4-7 Environment ........................................................ 5-5

F Fan and alternator drive belt .............................. 6-11 Fire extinguisher ................................................ 6-12 Flluids and Capacities ......................................... 5-4 87458477NA

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Fuel Filter Replacement .....................................5-21 Fuel Handling Precautions ...................................2-7 Fuel level indicator ...............................................3-7 Fuel level indicator lamp .......................................3-8 Fuel system ........................................................5-19 Fuel System Bleeding ........................................5-20 Fuel Tank Draining .............................................5-22 Function Cancellation Lever ...............................3-11 Fuses ....................................................................7-3

G General Information ..............................................1-1 Grease Fittings ...................................................5-10

H Hazardous Chemical Precautions ........................2-7 Heater Switch .....................................................3-10 Horn Switch ..........................................................3-9 Hourmeter .................................................... 3-7, 5-3 Hydraulic Fluid Operating Temperature ...............4-6 Hydraulic Reservoir, Access and Level Check ...5-25 Hydraulic system ........................................ 5-24, 8-4 Hydraulic System, Releasing Pressure ..............5-23

I Identification Numbers ..........................................1-3 Idle position lever .................................................4-7 Inspecting and cleaning the machine .................6-11 Instrument panel ...................................................3-7

K Key Switch ............................................................3-9

L Left-Hand Control Lever .....................................3-12 Lifting the Machine .............................................4-12 Lowering Attachment in Emergency ...................4-14 Lubricating turntable teeth ..................................5-13 Lubrication ..........................................................5-10 Lubrication and Maintenance Chart .....................5-8 Lubrication Points ...............................................5-10

M Machine overall dimensions ......................... 8-4, 8-5 Machine storage .................................................4-16 Machine travel ......................................................4-9 Maintenance Precautions .....................................2-6 9-1

CHAPTER 9 - INDEX Moving a Disabled Machine .............................. 4-14

Nibbler and Breaker Switches ........................... 3-11

Steps and access handles ...................................3-5 Stopping the engine .............................................4-7 Storing the machine ...........................................4-16 Swing Tower Lubriction ......................................5-12

N O

T

One-piece boom/dipper/bucket lubrication ....... 5-11, 5-12, 5-13 Operating Precautions ......................................... 2-5 Operating temperature Bringing the machine up to ............................. 4-6 Operating the bucket ......................................... 4-15 Operating the machine ........................................ 4-3 Operating the machine in cold weather ............... 4-8 Operating the machine in hot weather ................. 4-8 Operating the machine in water ......................... 4-13 Operating the machine on sloping ground ......... 4-14 Operator Precautions .......................................... 2-4 Operator’s compartment accessories .................. 3-6 Operator’s compartment controls ........................ 3-6

Throttle Lever .....................................................3-13 Towing the machine ...........................................4-14 Track Rollers Oil change ........................................................6-8 Track rollers and Idler Wheels .........................6-8 Tracks ...................................................................6-3 Transporting the machine ...................................4-10 Travel reduction gears ........................................5-33 Travel Speed Switch ............................................3-9 Turntable Lubrication ..........................................5-13

P

W

Parking the machine .......................................... 4-14 Plastic and resin parts ....................................... 6-12 Power Supply (12Volt) ....................................... 3-10 Product Identification Number ............................. 1-3

Water Separator Draining and Cleaning ............5-21 Welding on the machine .....................................6-12 Windshield ............................................................3-3 Windshield Washer Fluid Reservoir .....................3-4 Windshield Wiper and Washer Switch ...............3-10 Working Lamp Switch .........................................3-10 Working range ......................................................8-6

R Radiator Core Cleaning ..................................... 5-16 Releasing pressure in the hydraulic system ...... 5-23 Replacing a bucket .............................................. 6-9 Replacing a lamp ................................................. 7-7 Right-Hand Control Lever .................................. 3-12 Rollers, Track ...................................................... 6-8 Run-in period ....................................................... 4-4

U Utility Safety .........................................................2-4 Utility Safety Rules Message ................................2-4

S Safety and Decals Safety Rules .................................................... 2-3 Safety Area .......................................................... 2-3 Seat Adjustment ................................................ 3-15 Seat Belt Operation ........................................... 3-15 Seat Belt Precautions .......................................... 2-8 Serial Numbers .................................................... 1-3 Servicing instructions ........................................... 5-3 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-2 Specific machine precautions .............................. 2-8 Starter motor ........................................................ 7-3 Starting and Stopping Precautions ...................... 2-5 Starting the Engine .............................................. 4-4 9-2

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