Case CX31 & CX36 Mini Excavator Operator’s Manual 6-37920 - PDF DOWNLOAD

CX31 and CX36 MINI-EXCAVATOR

Operator’s Manual Bur 6-37920NA

CX31 AND CX36 MINI-EXCAVATOR OPERATOR’S MANUAL

Part Number: 6-37920NA

CASE 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: Case, 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 CASE 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 © 2003 Case LLC. All Rights Reserved

Bur 6-37920NA Issued January, 2003 CASE is a registered trademark of Case, LLC.

TABLE OF CONTENTS Safety Precautions ................................................................................................................. Section 1 Machine Familiarization ......................................................................................................... Section 2 Basic Machine Operation ....................................................................................................... Section 3 Maintenance ........................................................................................................................... Section 4 Transportation ......................................................................................................................... Section 5 Specifications ......................................................................................................................... Section 6 Troubleshooting ...................................................................................................................... Section 7 Optional Equipment................................................................................................................ Section 8 Specifications (EPA Engine) .................................................................................................. Section 9

I

GENERAL INFORMATION 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 CASE 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 CASE Dealer.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centres or from an approved organization.

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

Always keep this manual in the operator s compartment. 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 CASE Dealer.

Your CASE 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.

Materials and specifications are subject to change without notice.

II

FOR ORDERING For ordering parts and service, inform an authorized dealer of your machine s Serial Number and Engine Serial Number stamped in the locations, and Hourmeter read, shown on the illustrations below. For future reference, record these Serial Numbers in the spaces provided below:

MACHINE NO.

ENGINE NO.

NOTE The numbers in the illustrations are for explanation only and differ from actual numbers.

III

NOTES

IV

SECTION 1

SAFETY PRECAUTIONS TABLE OF CONTENTS 1.1 GENERAL SAFETY INFORMATION .................................................................................................... 1-2 1.2 SAFETY PRECAUTIONS ..................................................................................................................... 1-3 1.3 PRE-START SAFETY ........................................................................................................................... 1-5 1.4 SAFETY DURING OPERATION .......................................................................................................... 1-11 1.5 INSPECTION & MAINTENANCE SAFETY .......................................................................................... 1-19 1.6 BATTERY SAFETY ............................................................................................................................. 1-26 1.7 WARNING LABELS & DECALS ........................................................................................................... 1-27 1.8 PROHIBITED MACHINE OPERATION ................................................................................................ 1-34 1.9 END OF WORK SHIFT SAFETY ......................................................................................................... 1-36 1.10 PRECAUTIONS FOR TRANSPORTATION ........................................................................................... 1-37 1.11 TOWING THE MACHINE ..................................................................................................................... 1-38

Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection or maintenance of this machine, attachment or systems. CASE cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by CASE is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance and/or repair procedures you choose.

1-1

SECTION 1 - SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION

Do not operate or perform any maintenance on this machine until all instructions found in this manual have been thoroughly read and understood.

Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death.

Always keep this manual in the operators seat pocket.

If it is missing or damaged, place an order with an authorized dealer for a replacement.

If you have any questions, please consult an authorized dealer.

1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel.

Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

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3. Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words DANGER , WARNING and CAUTION . a. DANGER - Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

b. WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

c. 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 possible damage to the machine and its components and is represented as follows:

4. It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by CASE. 5. While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

6. Continue studying this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

SECTION 1 - SAFETY PRECAUTIONS 1.2 SAFETY PRECAUTIONS

The proper and safe lubrication and maintenance for this machine, recommended by CASE, is outlined in this OPERATORS MANUAL for this machine.

Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand this OPERATORS MANUAL before performing any lubrication or maintenance.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components.

Weight of components table is shown in Page 69 SPECIFICATIONS.

The following is a list of basic precautions that must always be observed.

1. Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

3. Disconnect the battery and hang a Do Not Operate tag in the Operators Compartment. Remove ignition keys.

4. If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a Do Not Operate tag in the Operators Compartment.

5. Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

Do not operate this machine unless you have read and understand the instructions in this OPERATORS MANUAL. Improper machine operation is dangerous and could result in injury or death.

6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

7. Lower the bucket, blade, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade or other attachment is blocked correctly to prevent it from dropping unexpectedly.

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SECTION 1 - SAFETY PRECAUTIONS 8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud, grease, oil or debris from steps, walkways or work platforms before using. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

Refer to item L on page 1-7 .

9. To avoid back injury, use a hoist when lifting components which weigh 20 kg (45 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

11. Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.

12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.

14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.

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16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete.

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Do not fail to lower the attachment and place the bucket to the ground before starting the work.

19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pinhole leaks.

20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

22. Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing.

Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

SECTION 1 - SAFETY PRECAUTIONS 1.3 PRE-START SAFETY Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow. Read, understand and follow all safety precautions found in this manual and on the machine thoroughly before operating the machine.

A. OBSERVE SAFETY PRECAUTIONS Follow all safety rules, precautions, and operating procedures. If there are other personnel and flagmen working in the area, have them observe the specified signs.

B. WEAR PROTECTIVE CLOTHING Wear well fitting safety shoes, hard hat, and working clothes, and put on protective glasses, face shield, ear protection and gloves. When necessary, wear reflective vest.

Do not wear the working clothes with adhered oil, since it is easy to catch fire.

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WEAR PROTECTIVE CLOTHING C. READ and UNDERSTAND THE OPERATION & MAINTENANCE MANUAL Before operating the machine, read and understand this OPERATION & MAINTENANCE MANUAL thoroughly in order to use the machine effectively and safely.

D. KEEPOPERATION&MAINTENANCEMANUALINSTORAGE Keep this MANUAL in the specified storage located behind the operators seat for quick reference. Should the OPERATION & MAINTENANCE MANUAL become lost or damaged, contact an authorized dealer to order the OPERATION & MAINTENANCE MANUAL. In the case of ROPS canopy, keep this manual in the storage box of the roof.

ZL11V04204

PM1-03

READ MANUAL / KEEP IN STORAGE

1-5

SECTION 1 - SAFETY PRECAUTIONS E. DONOTOPERATEMACHINEEXCESSIVELYTIREDOR UNDER THE INFLUENCE OF DRUGS Your poor physical condition causes improper reactions. Voluntarily refrain from operating the machine when feeling excessively tired, and never operate the machine under the influence of drugs.

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REFRAIN POOR PHYSICAL CONDITION F. PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the first aid kit is located for easy access in case of emergency.

Prepare beforehand the communication means in case of any emergency, and take note of telephone numbers for emergency contact.

PV1-05

PREPARE FOR EMERGENCIES G. ENSURE SAFETY AT THE WORK SITE Know the work area! Before operating the machine, carefully survey and record the land and work site features to prevent the machine from falling or the soil from caving in.

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H. ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE Before leaving the operator’s seat, move the safety lock lever to the “LOCKED” (Up) position.

This will not allow operation of any hydraulic controls should they be accidentally moved. If the lever is not set to the "LOCKED" position and hydraulic controls are touched accidentally, the machine may move suddenly resulting in serious injury.

Also before leaving the machine, lower the bucket to the ground, place the safety lock lever in the “LOCKED” (Up) position, stop the engine and remove the starter switch key.

1-6

WORK SITE SAFETY-KNOW THE AREA

LOCKED (UP) POSITION

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SAFETY LOCK LEVER

SECTION 1 - SAFETY PRECAUTIONS I . SIGNS, SIGNALS & FLAGMEN Install signs on soft shoulders and ground areas, have a flagman direct the operation if necessary. The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

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SIGNS, SIGNALS & FLAGMEN PV1-09

J. KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Never use fire near the machine. Securely tighten all fuel and oil caps. Keep fuel and oil in the designated storage areas. Promptly clean up any all spills and dispose of waste properly.

KEEP FIRE AWAY FROM FUEL AND OIL K. SURELY INSTALL SAFEGUARD Confirm that all guards and covers are securely and properly installed. If damaged, immediately restore them to proper condition.

Do not operate the machine without guards or covers. Make sure to maintain them in normal condition.

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SURELY INSTALL SAFEGUARD L. MOUNTING & DISMOUNTING MACHINE When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts. Remove slippery materials, such as lubricants, and mud. Always place the cab entrance parallel to the tracks (crawlers) before stopping the engine for dismounting.

PVK1-11

MOUNTING & DISMOUNTING MACHINE 1-7

SECTION 1 - SAFETY PRECAUTIONS M. PAY ATTENTION TO WORKING MACHINE Do not approach a working machine. Make sure to make visual contact with the operator before approaching a working machine.

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PAY ATTENTION TO WORKING MACHINE N. USETHEPROPEROPTIONALATTACHMENT Use only optional attachments designed for and approved by CASE. Read, understand and follow all instructions in the manual accompanying the optional attachment. Use of any optional attachment not approved by CASE in writing, can cause serious injury to personnel, damage to the machine and its components and shorten the life of the machine. Contact an authorized dealer for optional attachments available for the machine.

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USE PROPER ATTACHMENT O. PREVENT FIRES Leaking or spilled fuel, lubricants and hydraulic oil are fire hazards. Clean and properly dispose of spills as they occur. Repair or replace all leaking components to prevent fire. Also, clean the machine regularly removing all debris to help prevent fires, pay particular attention to removal of leaves, sticks, paper etc. Keep fire extinguisher in an accessible area and know how to use the fire extinguisher should a fire occur.

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PREVENT FIRES-CLEAN UP SPILLS P. CONFIRMOPERATINGLEVERPATTERNS Slowly operate the control levers to confirm the operating patterns in advance.

The figure shows the standard operating system, specified in ISO. Refer to page 2-9 for more details regarding the different operating control functions.

YN20T01089P1 PV1-15

CONFIRM OPERATING PATTERNS 1-8

SECTION 1 - SAFETY PRECAUTIONS Q. KEEP CLEAN CAB FLOOR AND DRIVER'S SEAT Do not place any parts and tools in the driver's cabin to prevent injury due to slippage and stumbling. Remove any debris from the cab floor, control levers, handrails, etc. Make sure to keep all operating controls clean at all times

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KEEP CLEAN AROUND DRIVER S SEAT R. HOW TO HANDLE LIFE HAMMER-CAB only A life hammer is provided on the right side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab. In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.

CUTTER LIFE HAMMER

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HOW TO HANDLE LIFE HAMMER-CAB ONLY S. PERFORM PRE-START INSPECTION Walk around the machine before starting the machine, perform a PRESTART inspection of the machine and make note of any abnormality.

If any problems are found, repair or replace defective components immediately. DO NOT OPERATE THE MACHINE until all problem areas are properly repaired. Always keep the windshield, working lamps, and mirrors clean for good visibility.

PV1-18

PERFORM PRE-START INSPECTION

DO NOT OPERATE

T. TAG OUT MACHINE DURING MAINTENANCE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operators controls a DO NOT OPERATE tag to warn persons not to start the machine. Order tag Part No. LC20T01001P1. Make sure to inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

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TAG-OUT MACHINE 1-9

SECTION 1 - SAFETY PRECAUTIONS U. USE CAUTION NEAR NOISE If noise is high during operation, hearing loss may result. Approved hearing protection should be used if personnel will be exposed to high noise levels for a long period of time.

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USE CAUTION NEAR NOISE

V. AVOID HOT SURFACES & AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high.

Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters.

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AVOID HOT SURFACES & AREAS

1-10

SECTION 1 - SAFETY PRECAUTIONS 1.4 SAFETY DURING OPERATION A. PASSENGERS This equipment is not intended or designed for the transportation of persons. Never allow persons to ride on the machine. Serious injury or death can result from allowing passengers on or in the machine.

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NO PASSENGERS B. STARTING ENGINE Start engine from the operator’s seat. Do not short circuit the starter circuit or battery to start the engine. This may cause serious injury or cause damage to the electrical system.

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DO NOT SHORT CIRCUIT C. HORN BEFORE STARTING ENGINE Sound the horn before starting the engine to alert people that the machine is being started.

Make sure no one is near the machine.

HORN SWITCH

Do not start the engine if the machine has been tagged out.

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SOUND HORN BEFORE STARTING D. CHECK AFTER STARTING ENGINE Make sure to check machine for proper functioning after starting the engine. Slowly cycle attachments, swing, and travel functions in an area with sufficient space, without obstacles, and personnel. Failure to do so could result in injury or machine damage. Make note of any abnormalities and repair as needed.

PV1-25

CHECK AFTER STARTING ENGINE 1-11

SECTION 1 - SAFETY PRECAUTIONS E. WARM UP MACHINE BEFORE OPERATION Take a sufficient time to warm up the machine, especially at cold season, otherwise the response of machine against the operation of operating lever is delayed which may cause injury and / or machine damage.

RED

WHITE

BLUE

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WARMING UP OPERATION F. CONFIRM OPERATING CONTROL PATTERN Slowly operate the control levers to confirm the operating patterns in advance. Make sure the operation control pattern is according to the indication plate.

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CONFIRM OPERATING PATTERN G. CONFIRM TRAVEL DIRECTION Make certain of the location of the travel motors before operating travel.

Pay attention that in the case where the travel motors are in the front side, the travel function is reversed.

Sound horn before moving the machine to inform any personnel around the machine that the machine is now in operation.

CONDITION WHERE THE TRAVEL DIRECTION IS REVERSED

TRAVEL DIRECTION TRAVEL MOTOR

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KNOW TRAVEL MOTOR POSITION H. DO NOT HIT THE CAB WITH ATTACHMENT Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

CAUTION FOR INTERFERENCE

PV1-29

DO NOT HIT CAB 1-12

SECTION 1 - SAFETY PRECAUTIONS I . SWINGING FUNCTION Make certain the swing area of machine is clear of all persons and obstacles before operating swing controls. Sound horn before swinging machine. If necessary, have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

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SLEW / SWING / TRAVEL SAFETY J. TRAVELING ON SLOPE Use extreme caution when traveling on slopes, machine could turnover or slide causing injury or machine damage.

Keep the bucket at the height 30 ~ 40 cm (12 ~ 16 inch) above the ground level, and wear the safety belt at all times.

Never make a change of direction on the slope or cross over the slope.

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PAY ATTENTION ON SLOPE K. FROZEN & SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites. Operate all controls slowly and cautiously to prevent sudden movements such as start/stop/turn, that may cause the machine to unexpectedly shift, slide or move. Even on the slightest slope, when snow is present or work area is frozen, it can allow a machine to unexpectedly move. Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

Be careful for frozen ground that becomes soft along with the increase of ambient temperature.

L. TRAVEL Position the attachment as shown in illustration before beginning travel. On rough terrain move the machine at slow speeds, and do not turn suddenly. Avoid travelling over obstacles. Should it become necessary to travel over an obstacle, keep the attachment low to the ground and travel at extremely slow speed.

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USE EXTREME CAUTION ON FROZEN SURFACES OR SNOW

90˚~110˚

30cm~40cm (12~16in)

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TRAVEL POSTURE 1-13

SECTION 1 - SAFETY PRECAUTIONS M. GROUND STABILITY Be certain the condition of the work site is stable and capable of supporting the machine weight during operation. Do not operate attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting a work hazard. Position the crawler at right angle to shoulder and the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

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WORK ON STABLE GROUND N. LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load. NEVER USE BUCKET TEETH TO LIFT OR MOVE HEAVY LOADS.

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USE PROPER LIFTING DEVICES

O. OPERATING ON INCLINES OR SLOPES Operation of this machine on an incline or slope may cause the machine to become unstable or unbalanced. Work up and down inclines or slopes, never across. Never slew/swing or turn machine around on slopes. Build a level area for the machine to operate. Operate controls carefully to prevent sudden movements which may cause the machine to slide or tip over.

P. WORKING AROUND ELECTRIC POWER LINE If it is suspected that utility lines such as phone or electrical power are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines. Keep a sufficient distance away from electrical lines during operation. See chart below for minimum distances.

PV1-36

BUILD BANKING FOR SLOPE OPERATION

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1-14

KEEP A SAFE DISTANCE FROM UTILITIES

SECTION 1 - SAFETY PRECAUTIONS Q. WORKING AROUND UTILITY LINES UNDERGROUND At the work around presumable place of laying power, water or gas line under the ground, ask the actual location of them to the organization concerned, give a trial digging, and proceed the work with care after confirmation for nonexistence of them or location of them.

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CHECK LOCATION OF UTILITIES R. PARKING THE MACHINE Always park the machine on a firm, level surface.

If no firm level surface is available, block the crawler and lower bucket and dozer blade to the ground to help prevent machine movement.

Should the machine be parked on a roadway, move the machine to the shoulder to allow passing of traffic. Also post reflective warning signs and markers at a distance from the machine to safely warn motorists. Refer to local code and regulations regarding the posting of work area warnings and markers.

BUCKET DOZER BLADE BLOCK

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PARKING SAFETY S. RESTRICTED WORK AREAS In work sites with limited height and slew/swing areas such as tunnels, bridges, around electrical power lines, other utilities, or inside structures, use extreme caution in keeping the machine and its attachment at a safe distance to prevent personal injury and / or equipment or structure damage.

Use a flagman to guide the operator.

PV1-40

USE EXTREME CAUTION AT RESTRICTED AREA T. DO NOT WORK UNDER PRECIPICES Don't dig under the precipice. It causes for falling rocks or loosening of the precipice resulting in injury and / or machine damage.

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DO NOT DIG UNDER PRECIPICE 1-15

SECTION 1 - SAFETY PRECAUTIONS U. WORK WITH SUFFICIENT LIGHTING When working in dark places, turn on the working light. And if required, provide additional lighting facilities to ensure the visual field.

Stop working when it is impossible to ensure the visual field due to fog, snow or rain.

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WORK WITH SUFFICIENT LIGHTING V. SET LIMITS TO WORKING AREA Set limits around the working area to avoid collision or personal injury. Make sure to check for obstacles and personnel while swinging. Use a flagman to guide the operator whenever necessary.

PV1-44

SET LIMITS TO WORKING AREA W. CAUTION FOR WORK IN URBAN AREAS It is dangerous to allow other personnel to enter into the working area.

Make the working area off-limits to other people providing caution plates.

Make sure to provide a flagman in working areas with heavy traffic to avoid accidents.

PV1-45

USE A FLAGMAN WHEN NECESSARY X. PROHIBITION TO USE NON-SERVICED MACHINE The use of non-serviced machine may cause for an unexpected accident or breakdown.

Stop operation of a faulty machine. Make sure to repair any abnormalities before resuming operation.

PV1-46

DO NOT USE NON-SERVICED MACHINE 1-16

SECTION 1 - SAFETY PRECAUTIONS Y. SLIPPERY GROUND SURFACE Use caution when operating machine on boards or steel plates. Boards and steel plates become very slippery when wet.

Pay special attention when working on inclined areas.

Provide a device to prevent skidding and proceed to work with extra care. Piled up tree leaves or branches also may cause skidding.

PV1-47

PAY ATTENTION AT SLIPPERY SLOPE Z. STRENGTHEN SOFT GROUND When working on a soft ground or marshy area, the machine may sink.

Provide logs or lumber to pave horizontally to prevent the machine from sinking.

Frozen ground becomes soft along with the increase of ambient temperature.

PV1-48

STRENGTHEN SOFT GROUND AA. LOOSENED GROUND AFTER RAIN After raining, there is a possibility of getting into danger of tumbling down or falling down of the machine with vibration and weight of the machine due to loosened shoulder of road.

Pay attention to loosened precipice or shoulder of road, and do not access to such place without care.

PV1-49

PAY ATTENTION TO LOOSENED GROUND BB. LOOSENED GROUNDAFTER EARTHQUAKE OR DYNAMITING Pay attention to the loosened precipice or shoulder of road, and falling rocks. Also pay attention to the unexploded dynamite.

PV1-50

PAY ATTENTION TO LOOSENED GROUND 1-17

SECTION 1 - SAFETY PRECAUTIONS CC. BOOM, ARM & ATTACHMENTS Give the work you are doing your undivided attention. Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

PV1-30

SLEW / SWING SAFETY DD. STABILIZE ATTACHMENTS Stabilize all attachments removed from the machine to prevent the attachment falling over.

PV1-51

STABILIZE ATTACHMENTS

1-18

SECTION 1 - SAFETY PRECAUTIONS 1.5 INSPECTION SAFETY

&

MAINTENANCE

A. UNDERSTAND INSPECTION/MAINTENANCE PROCEDURES Incorrect maintenance may cause not only damages on the machine, but also injury.

Make sure to read and fully understand the maintenance procedures and safety precautions described in the operation and maintenance manual before performing any maintenance in this machine.

PV1-52

UNDERSTAND PROCEDURES

B. MEETING PRIOR TO WORK To prevent any accidents or injury due to errors, have a meeting before start working. When a flagman is provided, make sure that all signals are understood accordingly.

PV1-53

MEETING PRIOR TO WORK

C. ORGANIZE AND CLEAN UP WORKING AREA Organize and clean up the working area. Remove any obstacles and also remove any grease, oil, paint, broken pieces, etc., from the working area to avoid injury.

PV1-54

CLEANING UP WORKING AREA

1-19

SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE

D. “TAG-OUT” MACHINE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operator’s controls a "DO NOT OPERATE" tag to warn persons not to start the machine.

Order tag part No. LC20T01001P1. Also inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

PV1-19

TAG-OUT MACHINE E. TOOLS & EQUIPMENT Use the proper tools and equipment for the task at hand. Know the proper use of the tools and equipment before starting any inspection or maintenance procedures.

PV1-55

USE PROPER TOOLS F. SET THE ATTACHMENT Always set the machine in the hydraulic oil check position on firm level ground before attempting any inspection or maintenance procedures to the machine. If it is not possible to put the machine in this position, secure the boom, arm and attachment to help prevent sudden movement.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

HYDRAULIC OIL LEVEL CHECK POSITION

DOZER BLADE

BUCKET

PV1-56

HYDRAULIC OIL LEVEL CHECK POSITION G. CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis. Be careful not to allow water to reach electrical components. Serious damage can occur to the electrical system by allowing water to reach the electrical components. Never clean inside of cab, or electrical components with pressurized water or steam.

PV1-57

KEEP MACHINE CLEAN 1-20

SECTION 1 - SAFETY PRECAUTIONS H. STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE “LOCKED” (UP) POSITION before attempting any inspection or maintenance procedures to the machine. Failure to stop engine could result in serious bodily injury or death.

PV1-58

STOP ENGINE / ENGAGE SAFETY LOCK LEVER PV1-09

I . REFUELING Move the machine to a well ventilated area for refueling. Use only specified fuel as described in the MAINTENANCE section of this MANUAL. Immediately clean up all spilled fuel and dispose of properly. After refueling is complete, securely tighten fuel cap.

Never use the fuel for cleaning.

REFUELING J. SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the crawler/frame. NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

90˚~110˚ SUPPORT

PV1-59

SUPPORT THE MACHINE K. HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. SMALL (PINHOLE) LEAKS CAN BE DANGEROUS IF CONTACT WITH SKIN OR EYES IS MADE. Wear approved safety glasses or face shield, gloves, hard hat, safety shoes and work clothes during all inspection and maintenance procedures. Seek for immediate medical assistance if injury occurs.

PV1-60

CHECKING FOR HIGH PRESSURE LEAKS 1-21

SECTION 1 - SAFETY PRECAUTIONS L. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES. PV1-61

RELEASE HYDRAULIC TANK PRESSURE M. CARE ABOUT VENTILATION Maintenance for the machine indoor or in the place with poor ventilation may cause poisoning by gas.

Pay special attention to ventilate any exhaust gas, fuel, cleaning oil, paint or similar articles.

Ensure proper ventilation to the working area when the machine is operated indoor. Provide a ventilating fan, if required.

PV1-62

CARE ABOUT VENTILATION N. PREVENTIVE AGAINST FIRE It is unavoidable to handle flammable materials such as battery, fuel, lubricating oil, etc. in a maintenance area; therefore, follow the general guidelines to prevent fire: • Use a nonflammable cleaning oil to clean the parts, etc.

• Extinguish any bare fire possible to inflame.

• Provide an appropriate fire fighting equipement such as fire extinguisher.

• Refrain from smoking during maintenance work.

• Put away any flammable materials when grinding work or welding work.

PV1-63

PREVENTIVE MEASURE AGAINST FIRE

O. USE APPROVED WORK LIGHTS Use only approved work lights when performing inspection and maintenance procedures to prevent possible fire or explosion. Certain types of work lights should not be used due to the possibility of ignition of certain flammable gasses and fluids from the machine.

PV1-64

USE APPROVED WORK LIGHTS 1-22

SECTION 1 - SAFETY PRECAUTIONS P. DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Never apply heat to hydraulic equipment or piping, such as welding, soldering, heating with torch, etc.

Heating of hydraulic components or piping will cause gas expansion, which can easily catch fire and / or explode.

Q. WORKING ABOVE GROUND There exists danger of falling when working on areas above ground. Be careful not to approach edges.

PV1-65

DO NOT HEAT HYDRAULIC PIPING

• Make sure to use the appropriate equipment, such as ladders or a manlift when working above ground. In addition, strap yourself to the proper equipment accordingly.

• Avoid spillage of any oil or grease.

• Do not leave any tools around the working area.

• Use extreme caution to avoid slipping while walking.

• Never jump into or from climbing equipment.

Use a step-ladder or handrail and securely maintain a three point contact while mounting or dismounting at all times.

PV1-66

TAKE CARE AT ELEVATED SPOT

• Make sure to read the manlift equipment operator’s manual before using.

• Comply with climbing equipment weight ratings.

R. DO NOT DROP TOOLS AND PARTS Dropping of any tools and parts in the working area may cause injury or faulty machine operation.

Do not leave any tools or articles in the working area or component compartment. Make sure to store all tools properly when the work is completed.

S. ELECTRICAL SYSTEM Before performing any inspection or maintenance to the electrical system, or performing any welding procedures, disconnect the negative(–) cables from the battery terminals. Not disconnecting the negative(–) cable could cause extensive damage to the electrical system.

PV1-67

DO NOT DROP OFF TOOLS AND PARTS WHEN REMOVING, REMOVE THE NEGATIVE TERMINAL FIRST

PV1-68

ELECTRICAL SYSTEM PRECAUTION 1-23

SECTION 1 - SAFETY PRECAUTIONS T. CAUTION TO MODIFICATION CASE will not be liable for any injury or damages due to equipment modification without approval.

When any modification is intended, consult with an authorized dealer in advance.

PV1-69

CAUTION TO MODIFICATION U. AFTER COMPLETION OF MAINTENANCE WORK Always, make sure to check machine for proper functioning when any maintenance is completed: • After any maintenance work is completed, operate the engine at low idle, and check for leakages and abnormalities.

• Slowly operate each machine function to confirm proper operation.

• Increase the engine speed gradually, and again check for leakages and abnormalities.

• Operate each operating lever normally to confirm smooth operation.

PV1-25

CONFIRM SMOOTH OPERATION

V. DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc. according to federal, state and local codes and regulations regarding hazardous waste disposal. Contact local authorities for proper disposal methods of such materials.

PV1-70

DISPOSE OF WASTE PROPERLY

1-24

SECTION 1 - SAFETY PRECAUTIONS W. GENERAL GUIDELINES FOR WELDING Welding work must be performed by a certified welder with sufficient experience. In addition, safety practices must be followed by any personnel involved in such work. Identify all cracks to be repaired or areas to be welded by thoroughly cleaning the suspected surface, remove paint, and check with dye penetrant or magnetic particle testing. The life expectancy of the welded area depends on the work quality and the attention given to details during welding.

• Avoid welding structures with surface temperature below 16°C (60°F). If needed, preheat surface to handtouch. In cases where the machine components are extremely cold, it is recommended that the components be brought inside and allow them to warm to 16°C ~ 20°C (60°F ~ 70°F) for at least 12 hours prior to welding.

• Remove paint from any surface to be heated or welded. Painted surfaces give off unhealthy gasses when heated or welded. Use mask and proper skin protection when removing paint from any surface. When removing paint sanding, do not breath the generated dust. Make sure to use plenty soap and water to rinse the surface to be welded, since chemicals will generate unhealthy gasses when heated and / or welded.

• Provide a fire extenguisher reachable at all times while performing grinding, heating, or welding.

• Make sure to clean oil and / or flammable materials from any surface to be cut.

• Protect all flammable parts and surfaces from sparks and / or flames.

• Make sure to perform work in a well ventilated area.

• Keep sparks and flames away from paint and / or solvent.

• Keep sparks and flames from cylinder rods, seals, electrical wires, and / or hydraulic hoses.

X. CRAWLER SHOE TENSION The grease used to adjust the crawler shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting crawler shoe tension. KEEP FACE, HANDS AND LEGS AWAY FROM THE GREASE NIPPLE AREA. Carefully and slowly loosen the grease nipple when lessening crawler shoe tension. Never loosen grease nipple more than one complete turn.

Refer to page 4-16 for the procedures to adjust the tension on the crawler shoe.

PV1-72

USE CAUTION WHEN ADJUSTING CRAWLER

Y. PAYING ATTENTION TO BROKEN PIECES WHEN HAMMERING Flying particles may cause injury when hammering tempered parts, such as pin, edge, tooth, bearing, etc.

Wear protective clothes such as protective glasses, safety hat, etc. during maintenance.

PV1-73

USE CAUTION WHEN HAMMERING PV1-71

PAY ATTENTION TO WELDING WORK 1-25

SECTION 1 - SAFETY PRECAUTIONS 1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes. Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

PV1-74

WEAR PROPER PROTECTIVE CLOTHES

B. KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or flames and do not smoke when working with batteries. Explosive hydrogen gas is produced by the electrolyte (acid) in the batteries. Always work with batteries in a well ventilated area.

C. CHARGING BATTERY Charge battery off of and away from machine in a well ventilated area. When charging battery, remove cell caps to allow gasses to escape.

Avoid breathing gasses from battery.

D. USING BOOSTER CABLES

PV1-75

KEEP AWAY FROM FIRE OR FLAMES CABLE CONNECTING ORDER CABLE DISCONNECTING ORDER

• If using another machine or vehicle to boost batteries, make certain the machine or vehicle DOES NOT touch the disabled machine.

• Make certain of the positive (+) and negative (–) terminals on the booster battery and the disabled machine before connecting booster cables.

(RED)

NORMAL BATTERY

DISCHARGED BATTERY

• Connect the positive (+) cable first, then connect negative (–).

• When disconnecting, disconnect the negative (-) cable first, then disconnect the positive (+) cable.

• Refer to BASIC MACHINE OPERATION section of this manual for proper procedures for use of booster cables.

E. OTHER PRECAUTIONS • Pay attention to danger of sparks triggered off by erroneous connection between the positive (+) terminal of battery and the machine body with a tool, etc.

• Make certain of tightening the battery caps.

• Securely tighten up the battery terminals.

• Leave the waste battery to a specialist for disposal.

1-26

(BLACK) TO THE ENGINE OF THE TROUBLED MACHINE

PV1-76

IMPROPER BOOSTER CABLE CONNECTIONS CAN CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY. CONNECT BOOSTER CABLES USING FOLLOWING PROCEDURE. 1. Connect booster cable to positive (+) battery terminal of discharged battery. Connect other end of booster cable to positive battery terminal of normal battery.

2. Connect other booster cable to negative (-) battery terminal of normal battery. Connect other end of booster cable to engine of troubled machine.

3. Start engine and remove booster cables in reverse order.

SECTION 1 - SAFETY PRECAUTIONS 1.7 WARNING LABELS & DECALS Warning labels and decals are affixed to the machine to remind operators and personnel specific safety precautions in certain areas of the machine. The following are illustrated examples of all warning labels and decals along with their locations.

NOTICE FOR WARNING LABELS & DECALS • Do not take away the attached warning labels and decals.

• Use a cloth, water, and detergent to clean the labels. Never use organic solvents or gasoline.

• Confirm whether labels can be easily read.

If words or illustrations are illegible, clean off or replace the labels.

• If labels are damaged, missing or illegible, replace them with new ones.

Contact your authorized dealer for new labels.

LOCATION OF WARNING LABELS & DECALS

1-27

SECTION 1 - SAFETY PRECAUTIONS

1-28

SECTION 1 - SAFETY PRECAUTIONS

1-29

SECTION 1 - SAFETY PRECAUTIONS

1-30

SECTION 1 - SAFETY PRECAUTIONS

1-31

SECTION 1 - SAFETY PRECAUTIONS

1-32

SECTION 1 - SAFETY PRECAUTIONS

1-33

SECTION 1 - SAFETY PRECAUTIONS 1.8 PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this OPERATORS MANUAL while operating this equipment.

PV1-77

DO NOT USE TRACTIVE FORCE

A. DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT. Doing so will exert excessive force on the machine structure, front end attachments and could cause severe equipment damage. Use crawlers for normal travel operations only.

B. DO NOT USE THE MACHINE’S SLEWING / SWINGING FORCE FOR OPERATIONS. Doing so will exert excessive force to the machine structure, front end attachments and shorten life of the slewing/swinging system of the machine. Also, serious injury or death could result from such operations.

PV1-78

DO NOT USE SLEWING / SWINGING FORCE

C. DO NOT PERFORM “HAMMERING” OPERATIONS WITH THE BUCKET. Performing operations such as hammering and piling will cause extensive damage to the machine and its components. These types of operations can also result in serious injury or death.

PV1-79

D. DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE. This machine is designed and manufactured for digging, loading and ground leveling operations only. Any other use can exert excessive force to the machine, its components, its systems and result in serious bodily injury or death to the operators and other personnel working in the vicinity of or with the machine.

DO NOT HAMMER WITH ATTACHMENT

PV1-35

USE ONLY FOR INTENDED PURPOSE 1-34

SECTION 1 - SAFETY PRECAUTIONS E. DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY. Extending the bucket and arm cylinders to stroke end to clean debris from the bucket, will cause impact to the bucket cylinder causing cylinder damage. Use high pressure water or manually remove stubborn material from the bucket.

ALLOWANCES

PV1-80

DO NOT OPERATE CYLINDER TO STROKE END F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts. Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

PV1-81

DO NOT OVER EXERT THE MACHINE G. CAUTION FOR DOZER BLADE NOT TO HIT OBSTACLES. Pay attention to the dozer blade not to hit any obstacles such as rock lump.

It may cause damages to the dozer blade and cylinder.

PV1-82

DO NOT HIT ROCK, ETC. BY DOZER H. CAUTION FOR FOLDING UP ATTACHMENT. When the attachment is folded up to travel or transport, pay attention to the bucket not to hit the dozer blade.

PV1-83

DO NOT HIT DOZER BY BUCKET 1-35

SECTION 1 - SAFETY PRECAUTIONS I . DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END. When the dozer blade is used as an outrigger, do not support the machine at one end of the dozer blade, but surely at both ends.

PV1-84

DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END J. CAUTION FOR DEEP EXCAVATION. Pay attention during deep excavation with the dozer blade in front. The boom cylinder could come in contact with the dozer blade.

Place the dozer blade in the back of the machine for deep excavations, unless the working area does not permit it.

1.9 END OF WORK SHIFT SAFETY Perform all of the following procedures after each shift is complete to insure the machine it in optimal operating condition for the next shift or job site.

A. Move the machine to a firm, level surface.

B. Lower attachment to the ground.

C. Refill fuel tank to full mark to reduce air volume and condensation (moisture). This will decrease the possibility of freezing in the fuel tank, rusting due to moisture and other problems associated with start up and operation.

D. Close and secure all windows in place to prevent water or moisture reaching the electrical components of the machine (CAB only).

E. Thoroughly clean and inspect the machine. Perform lubrication maintenance and repair or replace any problem areas found before restarting the machine.

F. If performing the machine in cold climates, it may be necessary to remove the batteries from the machine and store in a warm well ventilated area.

Install the batteries in the machine before next start up. This will help prevent premature battery deterioration.

G. Remove key from key switch and lock all doors and access panels.

1-36

PV1-85

TAKE CARE FOR DEEP EXCAVATION

PV1-86

END OF WORK SHIFT SAFETY

SECTION 1 - SAFETY PRECAUTIONS 1.10 PRECAUTIONS FOR TRANSPORTATION Use the following general guidelines for loading or unloading the machine to the transportation vehicle: • Loading and unloading of the machine must be carried out on firm leveled areas away from the road shoulder. Do not use the attachments to load or unload the machine from the trailer.

• When needed, use a ramp capable of withstanding the machine weight. Check the ramp’s width, length and thickness to secure the loading / unloading work. And when much warp appears on the ramp structure, support them with safety blocks or alike.

PV1-87

TAKE CARE FOR LOADING / UNLOADING

• Remove any mud, oils and grease from the ramp surface as well as from crawler shoes on the machine, to prevent the machine from side skidding.

• Do not change the traveling direction on the ramp. When required, back down the machine to the ground, reposition and try it again.

• Always use low travel speed for loading or unloading from the trailer.

• After loading the machine, shut off the engine and set the safety lock lever to “LOCKED” up position.

• Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer.

Provide chock blocks to the machine crawlers, to avoid any movement of the machine.

• Protect wire rope against edges providing pad.

15˚

PV1-88

USE RAMP FOR LOADING AND UNLOADING LOCKED (UP) POSITION

PAD FOR EDGE

PAD FOR EDGE

• While transporting, observe legal regulations concerned, keeping the safety in mind.

WIRE ROPE

• Select the routing taking overall height and length of the truck into consideration.

PV1-89

SECURE FROM MOVEMENT

• Refer to Section 5 “TRANSPORTATION” for the details of loading, unloading and fixing procedures of the machine.

OVERALL HEIGHT

OVERALL LENGTH

PV1-90

OBSERVE LEGAL REGULATION 1-37

SECTION 1 - SAFETY PRECAUTIONS 1.11 TOWING THE MACHINE 1. If the machine should become stuck in soft soil areas it may be necessary to tow the machine. Attach a wire rope or chain, with the capacity to pull the machine out, to the lower frame axles.

2. Attach other end to the vehicle used to pull the machine. Operate the machine’s travel lever in the proper direction while pulling with the other vehicle.

• While towing, do not enter between the machine and towing vehicle.

• Do not apply a shock load onto the towing rope.

• Do not use eyes on machine lower frame to tow machine.

• Keep the wire rope horizontally, and perpendicularly to the crawler frame.

• Tow the machine slowly at low speed mode.

• For the towing of the machine body, provide pads to be applied to the corner of crawler frame to prevent the wire rope and crawler

NOTE : Do not pull machine utilizing the brackets welded on the lower plates of the carbody.

These brackets are provided for pulling lightweight objects. See figure for better reference.

1-38

PVK1-91

TOW MACHINE PROPERLY

SECTION 2

MACHINE FAMILIARIZATION TABLE OF CONTENTS 2.1 FAMILIARIZATION ................................................................................................................................... 2-2 2.2 GENERAL MACHINE NOMENCLATURE ................................................................................................. 2-2 2.3 OPERATOR CAB NOMENCLATURE ........................................................................................................ 2-3 2.4 COMPONENT & CONTROLS NOMENCLATURE ..................................................................................... 2-4 A. Monitor Panel (Gauge Cluster) ........................................................................................................ 2-4 A.1 Meters .................................................................................................................................... 2-4 A.1.a Coolant Temperature MeteR ........................................................................................... 2-4 A.1.b Fuel Meter ...................................................................................................................... 2-4 A.1.c Hour Meter ..................................................................................................................... 2-4 A.2 WARNING LAMPS ................................................................................................................. 2-5 A.2.a Battery Charge Lamp (Red) ............................................................................................ 2-5 A.2.b Engine Oil Pressure Lamp (Red) .................................................................................... 2-5 A.2.c Coolant Temperature Lamp (Red) .................................................................................... 2-5 A.2.d Low Fuel Warning Lamp (Red) ........................................................................................ 2-5 A.3 Indicator Lamps ..................................................................................................................... 2-5 A.3.a High (2nd) Travel Speed Lamp (Yellow). .......................................................................... 2-5 B. Switches ........................................................................................................................................ 2-6 B.1 Starter Switch ....................................................................................................................... 2-6 B.2 Travel Speed Select Switch ................................................................................................... 2-6 B.3 Horn Switch ........................................................................................................................... 2-6 B.4 Deceleration Selector Switch (Option) ................................................................................... 2-7 B.5 Working Light Switch ............................................................................................................. 2-7 B.6 Cab Heater Switch (Canopy Option) ...................................................................................... 2-7 B.7 Wiper Switch ......................................................................................................................... 2-7 C. Levers and Pedals .......................................................................................................................... 2-8 C.1 Safety Lock Lever ................................................................................................................. 2-8 C.2 Operating Levers (ISO Operating Pattern) ............................................................................. 2-9 C.3 Travel Control Levers ............................................................................................................. 2-9 C.4 Throttle Lever ....................................................................................................................... 2-10 C.5 Dozer Operating Lever .......................................................................................................... 2-10 C.6 Boom Swing Operating Pedal ............................................................................................... 2-11 C.7 Nibbler & Breaker Operating Pedal ....................................................................................... 2-11 D. Guard with Locking Device & Covers ............................................................................................. 2-12 E. Seat Front to Back Adjustment ...................................................................................................... 2-12 F. Electrical Equipment ...................................................................................................................... 2-13 F.1 Working Light Switch ............................................................................................................. 2-13 F.2 Fuse Box (Main) .................................................................................................................... 2-13 2.5 STORAGE & OTHERS ............................................................................................................................ 2-14 A. Storing Place for Manual ......................................................................................................... 2-14 B. Tools ........................................................................................................................................ 2-14 C. Grease Gun ............................................................................................................................. 2-14 2.6 SEAT BELT ............................................................................................................................................. 2-15 2.7 CAB ........................................................................................................................................................ 2-16

2-1

SECTION 2 - MACHINE FAMILIARIZATION 2.1 FAMILIARIZATION All operators, service mechanics and personnel responsible for operation, inspection and maintenance of the machine should become thoroughly familiar with the controls and components and their functions before working with or on this equipment.

Study the information in this section to become familiar with the controls and components of this machine.

2.2 GENERAL MACHINE NOMENCLATURE The Nomenclature drawing below points out locations of major components of the CASE Hydraulic Excavator (TYPICAL).

Study these areas and locate these components on the machine. Specific information regarding these components are explained on the following pages of this section.

CAB

P2-2-1

PW-2-1

2-2

SECTION 2 - MACHINE FAMILIARIZATION 2.3 OPERATOR CAB NOMENCLATURE The operator cab nomenclature, see Figure below, points out locations of operator controls of the CASE Hydraulic Excavator operator cab (Typical). Study these areas and locate these components on the machine.

Specific information regarding these components are explained on the following pages of this section.

TRAVEL SPEED SELECT SWITCH HORN SWITCH

LEFT TRAVEL LEVER

RIGHT TRAVEL LEVER

LEFT OPERATING LEVER

BOOM SWING OPERATING PEDAL RIGHT OPERATING LEVER

SAFETY LOCK LEVER (LEFT)

SAFETY LOCK LEVER (RIGHT)

NIBBLER & BREAKER OPERATNG PEDAL DOZER OPERATING LEVER

WORKING LIGHT SWITCH

MONITOR PANEL (GAUGE CLUSTER)

DECEL SWITCH (Option) HEATER SWITCH (CAB spec.Option)

THROTTLE LEVER

WIPER SWITCH (CAB spec.Option)

OPERATOR SEAT

STARTER SWITCH

PM2-05

rear, right and left direction * Front, In this manual, the front, rear, right and left directions are based on the conditions where the travel motors are positioned at the rear and the operator is facing the direction in which the machine advances (forward).

PAM-2-2

2-3

SECTION 2 - MACHINE FAMILIARIZATION 2.4 COMPONENT & CONTROLS NOMENCLATURE The following information provides a brief description and function of the components and controls of the CASE Hydraulic Excavator.

All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

PAE-2-4-1

A. MONITOR PANEL (GAUGE CLUSTER) The monitor consists of the following: A.1 METERS A.2 WARNING LAMPS A.3 INDICATORS. A.1 METERS A.1.a COOLANT TEMPERATURE METER This indicates the temperature of the WHITE engine coolant water, and operates BLUE when the starter switch is turned to the "ON" position.

PM2-08 The temperature is normal in the white range. If the indicator enters the red range, let the engine run in low idle until the temperature cools down and the indicator moves back into the white range.

RED

2-4

A.1.b FUEL METER This indicates the amount of fuel.

WHITE F : Full tank is about 15 liters (4.0 gal) The gauge indicates the residual RED volume of fuel in the fuel tank. Make sure to refuel when the indicator is PM2-09 approaching to the "E" point. Refill the fuel tank with diesel fuel only. Normally the gauge takes time to move up to the apropiate leve after turning the key switch to the ON position.

A.1.c HOURMETER The hourmeter indicates the total time the engine has run.

Even if the machine is not moving, the meter continues to count as long as the engine is running, regardless of the engine speed.

PM2-10 While the engine is running, the indicator flashes to show that the hourmeter is active.

Use the hourmeter as reference for maintenance.

SECTION 2 - MACHINE FAMILIARIZATION A.2 WARNING LAMPS

When any of the warning lamps are illuminated, immediately stop the work. Then investigate the cause for it, and carry out appropriate inspection and maintenance referring to the Section "INSPECTION AND MAINTENANCE."

PR-2-9

PR-2-8

A.2.a BATTERY CHARGE LAMP (Red) This is to warn an abnormality in the battery charging system during engine running. This indicator will illuminate when the starter switch is turned to the "ON" position, and should turn off after the engine is started.

Check the charging system if this indicator does not turn off after the engine is started. See Section 4 (Maintenance) for details.

A.2.b ENGINE OIL PRESSURE LAMP (Red) This warning lamp will illuminate if the engine oil pressure drops abnormally while the engine is running.

Stop the engine and check the quantity of engine oil.

(Refer to page 3-4 .)

The engine may suffer severe damage if the machine is operated with the engine temperature lamp illuminated.

NOTES 1. If the engine is overheating, stop operation immediately and let the engine run at idling to lower the engine temperature.

2. Once the coolant has cooled down, stop the engine.

3. Once the engine temperature lowers, inspect the coolant level, fan belt, clogging of radiator core, etc. Refer to Section 4 (Maintenance) for details.

DO NOT PERFORM ANY KIND OF MAINTENANCE ON AN ENGINE THAT HAS JUST STOPPED WORKING. FLUIDS AND SURFACES WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL BEFORE PROCEEDING TO INSPECTION AND/OR MAINTENANCE.

The engine may suffer sever damage if the machine is operated with the engine oil pressure lamp illuminated.

SF2-103

PM2-14

A.2.c COOLANT TEMPERATURE LAMP (Red) If the coolant temperature rises abnormally, this warning lamp lights.

The coolant temperature may rise abnormally if the engine is run with an excessive load.

A.2.d LOW FUEL WARNING LAMP (Red) If the fuel is low, a warning lamp lights. Stop the engine immediately and add fuel.

A.3 INDICATOR LAMPS These lamps indicate the working conditions.

A.3.a HIGH (2ND) TRAVEL SPEED LAMP (Yellow).

This indicator will be illuminated when the travel speed is switched to high (2nd) speed.

The travel speed selector switch is Y2-281 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".

2-5

SECTION 2 - MACHINE FAMILIARIZATION B. SWITCHES 2

3

9

4 5 6

8

7 9

1

PM2-25

NO. 1 2 3 4 5 6 7 8 9

B.2 TRAVEL SPEED SELECT SWITCH 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 PR-2-29 speed is automatically set to LOW. Select the desired speed before starting to travel.

SWITCH STARTER SWITCH TRAVEL SPEED SELECT SWITCH HORN SWITCH DECELERATION SWITCH WORKING LIGHT SWITCH HEATER SWITCH (CANOPYS OPTION) WIPER SWITCH (CAB SPEC.) SOCKET OF 12V POWER SOURCE HORN SWITCH

B.1 STARTER SWITCH This is used to start or stop the engine.

TRAVEL THE MACHINE IN LOW SPEED ON SLOPES AND AT LOADING/UNLOADING THE MACHINE ON A TRUCK/TRAILER. SUDDEN CHANGE OF THE MACHINE TRAVEL SPEED MAY CAUSE THE MACHINE TO ROLL OVER. ...................Select this speed when traveling on rough or soft terrains, LOW (1st) speed slopes, in narrow places, when powerful tractive force is required, or loading or unloading from a truck/trailer.

See page 6-8 for speed.

........................Set to HIGH when traveling on flat, hard ground.

See page 6-8 for speed.

HIGH (2nd) speed

PR-2-28

HEAT..........When engine start up is difficult due to cold climate, turn the key to this position to activate the pre-heating and the glow lamp indicator will illuminate. Hold the key in this position for around 15 seconds and then turn the key to the START position to start the engine. Release key after engine starts.

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

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

START......Turn the key to this position to start the engine and release it after the engine starts, the key will automatically return to the "ON" position.

2-6

B.3 HORN SWITCH Depress this switch, provided on the top of left operating lever, to sound the horn.

PV-6

Sound horn before starting the engine, travelling, swinging or operating the attachments.

SECTION 2 - MACHINE FAMILIARIZATION B.4 DECELERATION SELECTOR SWITCH Press this switch during the engine rotation to shift the engine to the low speed.

Press this switch again to release the deceleration function. When you PM2-30 are waiting the dumping or the next work, fuel cost and noise generation can be reduced by this release. Turn the starter switch from "ON" to "OFF" to automatically release the deceleration function.

B.8 SOCKET OF 12V POWER SOURCE You can use it if you open cap and insert the socket for the car accessories.

B.5 WORKING LIGHT SWITCH This is used for the boom and frame working lights.

OFF - ON

B.9 TRAVEL ALARM SELECT SWITCH (OCEANIA SPEC.) The travel alarm switch is located on the left side panel.

When travel is engaged the alarm sounds automatically.

OFF

ON

PWA-2-6

NOTE : It can not be used for the cigarette lighter.

PM2-31

B.6 HEATER SWITCH (CANOPY Option) This is used to warm up the cab interior.

OFF OFF ; Stop L L ; Low speed drive of fan H H ; High speed drive of fan PM2-32

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

B.7 WIPER SWITCH (CAB spec.)

This is used for the wiper and WASH washer fluid.

WASH (Left) ; OFF Spraying washer fluid.

ON WASH OFF ; Stop PM2-33 ON ; Operating wiper WASH (Right) ; Operating wiper and spraying washer fluid.

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

2-7

SECTION 2 - MACHINE FAMILIARIZATION C. LEVERS AND PEDALS 2

7

3

6

2

No. Operating Levers and Pedals 1

1 5

4

1

Safety lock levers

2

Right/ Left operating levers

3

Travel levers with pedals

4

Throttle lever

5

Dozer operating lever

6

Boom swing operating pedal

7

Nibbler & Breaker operating pedal

PM2-34

C.1 SAFETY LOCK LEVER The safety lock lever is provided to prevent any unexpected operation due to involuntary movement of the operator s control levers.

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 LEVER IN THE DOWN POSITION. NOTE THAT EVEN WHEN THE SAFETY LOCK LEVER IS SET IN THE LOCKED (UP) POSITION, THE FUNCTIONS FOR DOZER AND BOOM SWING ARE STILL ACTIVATED. For the machine with canopy, the operation of either safety lock lever is effective for locking and unlocking. * LOCKING HYDRAULIC SYSTEM When the safety lock lever is set in the "LOCKED (UP) Position" the hydraulic system is shut down, except the dozer blade and the boom swing functions.

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

NOTE : When the safety lock lever is set to the "LOCKED" (UP) position, each attachment and swing motor are locked simultaneusly 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.

2-8

PWE-2-7

ED

PWE-2-8

SECTION 2 - MACHINE FAMILIARIZATION C.2 OPERATING LEVERS (ISO OPERATING PATTERN) C.2.a STANDARD OPERATION These two levers activate each operation as illustrated in the right.

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

All functions can be activated simultaneously.

C.2.b J/D MULTI CONTROL SHIFTING In the J/D multi control shifting the Boom and Arm functions are opposite to the ISO system.

PME-2-11

ISO OPERATING PATTERN LH OPERATING LEVER

RH OPERATING LEVER

5

ARM OUT

1

BOOM DOWN

6

ARM IN

2

BOOM UP

7

SLEWING LEFT

3

BUCKET IN

8

SLEWING RIGHT

4

BUCKET OUT

C.3 TRAVEL CONTROL LEVERS The travel levers are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward. These controls have 2 basic operational functions:

Use caution to avoid coming in contact with other machine functions while travelling.

Make sure to know the location of the travel motors before operating the travel function THE TRAVEL FUNCTIONS DESCRIBED BELOW ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR S CAB. (A): Push both levers forward to travel Forward.

(B): Pull both levers back to travel in Reverse.

(C): Neutral (Release levers in the center position to stop the travel function) Refer to page 3-17 for changing travel direction.

PME-2-14

2-9

SECTION 2 - MACHINE FAMILIARIZATION C.4 THROTTLE LEVER The throttle control lever is located to the right side of the operator s seat and 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 reverse to set the engine in high idle.

THROTTLE LEVER

(A)

(B)

PAE-2-10

C. 5 DOZER OPERATING LEVER This lever is to bring the dozer up or get it down.

EVEN THOUGH THE SAFETY LOCK LEVER IS SET AT LOCKED POSITION, THIS LEVER IS NOT LOCKED. WHILE THE ADJUSTING CRAWLER FRAME WIDTH OR DOZER OPERATION IS NOT CARRIED OUT, DO NOT TOUCH THIS LEVER, OTHERWISE IT MAY CAUSE A SEVERE INJURY. OPERATION * DOZER This lever is to control the dozer up or

down function.

(E) : Dozer down (Push the lever forward.)

(F) : Dozer up (Pull the lever back.)

2-10

DOZER OPERATION

(E)

(F)

DOZER

(F)

(E)

PAE-2-12

SECTION 2 - MACHINE FAMILIARIZATION C.6 BOOM SWING OPERATING PEDAL The boom swing control pedal is located to the right of the travel levers, see Fig. PM-244, and it is used to operate the boom swing function.

LOCK THE BOOM SWING CONTROL PEDAL WHEN THIS FUNCTION IS NOT OPERATED, FAILURE TO DO SO MAY CAUSE SERIOUS ACCIDENTS. (A) : Depress the pedal to the right to activate the boom Right-Swing function.

(B) : Depress the pedal to the left to activate the boom Left-Swing function.

PM2-44

C.7 NIBBLER & BREAKER OPERATING PEDAL This pedal, located to the left side of the travel control levers, is used to operate the optional attachment such as the Nibbler & Breaker.

LOCK THE OPTIONAL PEDAL WHILE THIS FUNCTION IS NOT OPERATED, FAILURE TO DO SO MAY CAUSE SERIOUS ACCIDENTS.

PM2-46

Refer to Section 8 OPTIONAL EQUIPMENT, page 8-2, for the operation of hydraulic nibbler & breaker.

The pedal lock becomes effective by means of pushing the pedal down forward as illustrated in Fig. PM2-47.

PM2-47

2-11

SECTION 2 - MACHINE FAMILIARIZATION D. GUARD WITH LOCKING DEVICE & COVERS A locking mechanism is provided for the engine

MAKE SURE TO STOP THE ENGINE WHEN THE ENGINE GUARD OR RADIATOR COVER IS OPENED. guards. Use the key to open and close engine guards. See Fig. PM2-55 for better reference.

D.1 Opening [1] Insert the key.

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

[3] Fit the cover in the open position with the rod.

D.2 Locking [1] Return the rod to the original position, and fix it into the holder.

[2] Close the cover.

[3] Insert the key, and turn it in a counterclockwise direction to lock the cover. Then remove the key.

PRE-2-54

KEY CYLINDER

PM2-55

NOTE Make sure to insert the key completely for proper operation; otherwise damage may occur to the key or locking mechanism

Always, make sure to use the open door lock rod to secure the engine covers whenever they are in the open position.

PM2-56

E. SEAT FRONT TO BACK ADJUSTMENT a. Pull the seat adjustment lever to right side. b. Move the seat forward or backward to desired position. c. Release the lever to lock the seat in position.

PAE-2-31

2-12

SECTION 2 - MACHINE FAMILIARIZATION F. ELECTRICAL EQUIPMENT F.1 WORKING LIGHT SWITCH A working light is provided on the boom to improve the visual field during poor lighting conditions.

To turn ON or OFF the working light, use the switch provided on the left operating lever portion.

Refer to page 4-25 for the replacement of the light bulb.

PM2-58

F.2 FUSE BOX (Main)

Be sure the starter switch is in the "OFF" position when replacing fuses.

SPARE FUSE

The fuses protect the electrical system from excess current. If operation is not normal, a fuse may be blown. Replace blown or faulty fuses with the spare fuses as follows.

Replace any fuse generating white powder on it or in case that some looseness exists between the fuse and fuse holder.

PM2-59

NOTE : (a) When replacing a fuse, replace it with one of the same capacity. (b) The spare fuses are stored in the back side of fuse box cover.

NOTE : Refer to Section 4-MAINTENANCE, page 435, for more details on replacing fuses.

PM2-61

2-13

SECTION 2 - MACHINE FAMILIARIZATION 2.5 STORAGE & OTHERS A. STORING PLACE FOR MANUAL Store the manual in the storage box provided on the back of seat.

PAE-2-30

B. TOOLS Use the standard tools supplied with the machine for the maintenance work.

Refer to page 4-9 for the details of the tools.

PA-2-26

C. GREASE GUN (OCEANIA SPEC.) Use the grease gun supplied with the machine for lubrication. After use, fold the grease gun handle, wipe off the grease adhered to the nozzle with cloth and store it in place.

NOTE : Handling and Precaution for Grease Gun. Always, facilitate air bleeding from the grease gun by fully opening the lever and fill grease to the section line portion, see Fig, PAE-2-28.

Always, operate the lever at full open or full close condition, otherwise the grease in the cartridge is not sucked up.

Some air may mix into the cartridge from the fixing thread up to the next use of the grease gun, causing difficulty to extrude grease. When this hapens, remove the cartridge, bleed the air mixed in, and reset it.

PA-2-27

PAE-2-28

2-14

SECTION 2 - MACHINE FAMILIARIZATION 2.6 SEAT BELT ATTACH BELT ENDS AROUND WAIST

Fastening / Unfastening 1. Confirming no twisting on the seat belt, fully insert the other side into the buckle until engaging is heard.

2. Adjust the belt length so that there is no slackness.

3. Push down the red button on the buckle to unfasten the seat belt.

Inspect seat belts daily. Replace seat belt if it shows deformation or damage. Always, make sure the seat belt support capscrews are properly tighten.

TIGHTEN BY PULLING LOOSE END

PV2-29

RELEASE BY DEPRESSING RED BUTTON

PV2-30

2-15

SECTION 2 - MACHINE FAMILIARIZATION 2.7 CAB (OPTION) The following equipment are provided for the cab to ventilate or to facilitate operation.

DOOR KNOB

1

When using the equipment in the cab, set the safety lock lever to the locked position to avoid unexpected machine movement if a work lever is accidentally contacted which could cause personal injury. a. Locking cab door To lock the door in the open position, slide the door fully until locks on the catch located on the rear of the cab. b. Unlocking door from inside To unlock the door, pull the lever (1) backward.

KEY

PM2-104

2

ENSURE TO PULL OFF THE COUPLER OF THE WIPER HARNESS BEFORE ACCOMMODATING THE FRONT WINDOW.

PM2-48

c. Opening the upper windshield The upper windshield can be stored in the ceiling of the cab interior.

2

1. Park the machine on a level / solid ground and stop the engine.

2. Disconnect the connector (2) for the wiper motor.

3. Lock the machine with the safety lock lever.

4. Pull the lock pin (3) on the right and left at the top of the upper windshield (2) inwards and unlock it.

PVK2-33

5. Grip the lower handle by your left hand and the upper handle by your right hand from inside the cab, draw them up and lock the lock pin (3) at the back of the ceiling.

FRONT WINDOW DROPS

LOCK ZL11H06008

When parking the machine, be sure to lock the lock pin (3). Otherwise the upper windshield may fall down.

2-16

3

PM2-49

SECTION 2 - MACHINE FAMILIARIZATION d. Closing the upper windshield 1. Park the machine on a level / solid ground and stop the engine.

2. Lock the machine with the safety lock lever.

3. Unlock the lock pin (1).

4. Grip the handle at the bottom of the upper windshield by your left hand and the handle at the top of the upper windshield by your right hand.

Then bring down the upper windshield gently.

5. Be sure to lock the RH and LH lock pins (1).

PV2-35

6. Connect the connector for the wiper motor.

When closing or opening the upper windshield, be careful not to catch your hand in the windshield.

PV2-36

e. Lower windshield After storing the upper windshield, lift the lower windshield by using both your hands to remove it from the window frame.

1. Remove the lower windshield from window frame.

2. Position lower windshield on rear holder (1).

PV2-37

f. Room lamp ON ....... The lamp turns ON. OFF ..... The lamp remains OFF.

PV2-38

2-17

SECTION 2 - MACHINE FAMILIARIZATION g. Open / close the window on the right side 1. Release the lock (3) and move the slide glass.

2. Close the window by returning the slide glass to the normal position and lock it.

PV2-39

h. Supply washer liquid The washer tank is installed on the right and front side of cab.

1. Check the washer tank for liquid level.

2. When the liquid quantity falls short, remove cap and supply the automobile washer liquid.

PV2-40

2-18

SECTION 3

BASIC MACHINE OPERATION TABLE OF CONTENTS 3.1 PRE-START CHECK ................................................................................................................................. 3-2 A. Brief Check of Machine .......................................................................................................................... 3-2 B. Check Before Operation ......................................................................................................................... 3-3 C. Confirmation Before Starting Machine Engine ....................................................................................... 3-8

3.2 STARTING AND STOPPING MACHINE ENGINE. .................................................................................... 3-9 A. B. C. D.

Start-up Under Normal Conditions .......................................................................................................... 3-9 Start-up Under Cold Conditions ............................................................................................................ 3-10 Start-up With Booster Cables ............................................................................................................... 3-11 Connecting/Disconnecting Booster Cables .......................................................................................... 3-12

3.3 STOPPING MACHINE ENGINE ............................................................................................................... 3-13 3.4 INSPECTION AFTER STARTING MACHINE ENGINE ............................................................................ 3-14 A. Exhaust Gas Color, Abnormal Sound & Smell .................................................................................... 3-14 B. Check Each Switch & Lever ................................................................................................................. 3-15 C. Check Monitor Panel ............................................................................................................................. 3-15

3.5 MACHINE WARM UP ............................................................................................................................... 3-16 A. Warming Up Engine ............................................................................................................................... 3-16 B. Warming Up Hydraulic Oil ..................................................................................................................... 3-16

3.6 MACHINE OPERATION ........................................................................................................................... 3-17 A. Machine Travel ...................................................................................................................................... 3-17 B. Stop Traveling ........................................................................................................................................ 3-18 C. Travel Precautions ................................................................................................................................. 3-18 D. Care On Up/Down Slope ....................................................................................................................... 3-19 E. Machine Operation In Water/On Soft Ground ....................................................................................... 3-20 F. Getting Out of Soft Ground ................................................................................................................... 3-21 G. Slewing Operation ................................................................................................................................. 3-22

3.7 PRACTICES TO IMPROVE EFFICIENCY ................................................................................................ 3-23 A. Digging ................................................................................................................................................. 3-23 B. Loading ................................................................................................................................................. 3-25 C. Works In Narrow Space ....................................................................................................................... 3-25 D. Minimum Slewing Position ................................................................................................................... 3-25

3.8 MACHINE PARKING ................................................................................................................................ 3-26 3.9 CHECK & CONFIRMATION AFTER WORK ............................................................................................. 3-26 3.10 PRECAUTIONS AFTER OPERATION .................................................................................................... 3-27 3.11 MEASURES AFTER EMERGENCY STOP ............................................................................................ 3-27 3.12 LOCKING UP WITH KEY ....................................................................................................................... 3-28 3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE ............................................ 3-29 A. Releasing Lock For Travel Motor .......................................................................................................... 3-29 B. Lowering Bucket .................................................................................................................................... 3-33 C. Lowering Arm & Boom .......................................................................................................................... 3-34 D. Slewing Upper Slewing Structure ......................................................................................................... 3-34

3.14 CAUTION ON USING RUBBER CRAWLER SHOES .............................................................................. 3-35 A. How To Use Well .................................................................................................................................... 3-35 B. Prohibited Work ..................................................................................................................................... 3-35 C. Caution On Use ..................................................................................................................................... 3-36

3.15 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS .......................................................... 3-38 A. B. C. D.

Operation In Extreme Cold ................................................................................................................... 3-38 Operation At Seashore Or Salty Climate ............................................................................................. 3-39 Care For Electrical Equipment ............................................................................................................. 3-39 Operation In Dusty Areas ..................................................................................................................... 3-39

3.16 PERCAUTIONS WHEN STORING THE MACHINE FOR A LONG TIME ................................................. 3-40 3-1

SECTION 3 - BASIC MACHINE OPERATION 3.1 PRE-START INSPECTION A. DAILY INSPECTION OF MACHINE Before starting the engine, walk around the machine to check for any loose nuts and capscrews, any oil, fuel or coolant leakage, and the condition of attachment and hydraulic system. Check for any looseness in the electrical wiring and for any accumulated material ( leaves, dirt, etc).

NOTE The daily inspection must be carried out in accordance with the instructions provided in this MANUAL.

5

3 7

2 6

4

1

PM3-01

1. Check the engine for any oil, fuel or coolant leakage.

Repair as required.

2. Check the area around the engine and radiator for any accumulated material and remove as required.

3. Check the hydraulic equipment, hydraulic oil tank, hoses, and joints for oil leakage, and repair as required.

4. Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the cap screws for looseness.

3-2

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the guards, steps and handrails for damage, and the capscrews for looseness.

Repair and tighten capscrews as required.

7. Verify that the gauges and the monitor panel (gauge cluster) function properly.

SECTION 3 - BASIC MACHINE OPERATION B. INSPECTION BEFORE OPERATION The following items should be inspected before starting machine operation: 1. CHECK COOLANT LEVEL

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. ALLOW ENGINE TO COOL DOWN BEFORE REMOVING RADIATOR CAP.

The radiator reserve tank is provided on the right side of the engine compartment, see Fig. PAE-3-2.

[1] Check the coolant level with cold engine.

[2] Open engine cover to check the coolant level in the radiator reserve tank. The coolant level should be between the lines of FULL and LOW. NOTE : Engine coolant level is higher than normal when the engine is warm. The coolant level will lower with engine temperature.

RADIATOR

(B )

(A )

Maintain coolant level at the full mark with engine cold.

Refer to page 4-7 for engine coolant specifications.

[3] Open radiator expansion tank cap (A) to refill with proper coolant mixture.

Check the radiator coolant level when the coolant level in the reserve tank drops below the LOW level mark.

Make sure to check the engine cooling system for leakages and repair as needed, before resuming operation.

[4] See Fig. PAE-3-2 and Z2-303P for reference. Remove the radiator cap (B), and check for proper coolant level.

[5] Refill radiator with proper coolant mixture.

[6] Install radiator cap (B) and tighten securely.

FULL LOW

RADIATOR RESERVE TANK PW3-01

3-3

SECTION 3 - BASIC MACHINE OPERATION 2. CHECK COOLANT LEAKAGE If the coolant level in the radiator reserve tank does not lower, but the coolant inside the radiator does, there is a possibility of air leakage in the cooling system. Make sure coolant level is to specifications and pressurize system to check for leakages. Consult with an authorized dealer for advise and/or repairs.

Make sure to repair leakages before resuming operation.

3. CHECK ENGINE OIL LEVEL NOTE : Make sure the machine is on firm level when checking engine oil level.

Always make sure to check engine oil level before starting the engine.

Keep the engine to a standstill for at least 30 minutes, when checking engine oil level after working, [1] Use the ignition key to unlock and open engine covers.

[2] Pull out engine oil dipstick (G), clean it and insert it fully into its sleeve. Remove dipstick to check oil level. Oil level should be between the marks "H" and "L".

If the oil is heavily contaminated or deteriorated, change it regardless of periodical schedule.

Refer to page 4-7 for oil specifications.

[3] If needed, remove the filler cap (F) to refill.

Make sure to check the oil level again after refilling.

[4] Clean engine oil filler cap (F), before installing.

[5] Close the engine cover and secure it with key.

3-4

PMJ-3-11

PAE-3-3

SECTION 3 - BASIC MACHINE OPERATION 4. CHECK HYDRAULIC OIL LEVEL BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

NEVER PERFORM MAINTENANCE OR INSPECTION ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW SUFFICIENT TIME TO THE MACHINE TO COOL OFF. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. 4-1 Check [1] Move the machine to firm level ground and set it in the hydraulic oil level check position, as shown in Fig. PAE-1-22.

[2] Check the oil level through sight level gauge provided on the side of the hydraulic tank. Hydraulic oil level should be between H and L. Oil level varies depending on oil temperature.

Check the oil level referring to the followings.

Before starting : "L" level [oil temp.10-30°C (50-86°F)] Normal operation : "H" level [oil temp.50-80°C (122-176°F)]

PAE-1-22

STAY

NOTE : Avoid overfilling. It causes damages on hydraulic equipment or oil spouting.

4-2 Refill with oil when the level is below "L." Refer to page 4-7 for the recommended oil to be used.

[1] Open the cover on the top of the hydraulic oil tank, and support it by the stay.

[2] Release the internal pressure of the tank according to the item "Releasing internal pressure of hydraulic oil tank and hydraulic system" in page 413 .

[3] Ensure that the internal pressure of the hydraulic oil tank is completely released, loosen the capscrews (1), remove the cover (2), and replenish the specified hydraulic fluid from the oil supply port till the specified level.

[4] Check the O-ring (3) of the cover, and if wear or damage is recognized, exchange it.

[5] Install the cover (2) and fasten with the capscrews at the specified torque. Tightening torque:2.4 ± 0.20 kgf.m (17.4±1.4 lbf.ft) [6] Start the engine and perform operation lightly five to ten times while moving each cylinder uniformly. Then return the machine to the posture for hydraulic oil level inspection.

[7] Stop the engine and check the oil level. If the amount of oil is insufficient, replenish the oil.

[8] Remove the stay and return the cover to the normal position.

AIR BREATHER (VALVE) PW-3-06

1

2

3

PW-3-07

H

L LEVEL GAUGE PW-3-08

3-5

SECTION 3 - BASIC MACHINE OPERATION 5.CHECK FUEL LEVEL

MAKE SURE TO USE DIESEL FUEL ONLY, AND STOP ENGINE BEFORE REFILLING. BE CAREFUL NOT TO OVERFLOW FUEL AT REFILLING. CLEAN UP ALL SPILLED FUEL TO PREVENT FIRE. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

HE AT

OFF

ON T AR ST

[1] Turn ignition key (1) to "ON" position to illuminate the monitor panel.

[2] Check the fuel gauge (2), and remove filler cap (3) to refuel if needed.

[3] Refer to page 4-7 for fuel specifications.

Fuel tank capacity: 15 liter (4.0 gal) [4] Do not remove fuel tank strainer (4) for refilling to avoid contamination.

[5] After refueling, install fuel cap (3) and tighten securely.

Close the engine cover and use key to lock it properly.

2 1 PM3-09

We recommend to refuel at the end of the workshift.

Refueling should be done to full mark to reduce air volume (condensation). Failure to do so could create problems such as rusting and fuel freezing, as well as other associated problems.

3

NOTE : If the machine runs out of fuel during operation, air may get mixed in the fuel lines. Proceed to bleed the air out of the fuel system as indicated in page 4-15.

4

PM3-10

6. CHECK FOR FUEL LEAKAGE Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leakage may be caused by faulty drain plug (A), crack on hose in fuel line, loosened hose clip, etc. Make sure to stop the engine immediately if any fuel leakage is found. Repair fuel leakage before resuming operation.

(A) FUEL TANK

WATER SEPARATOR

FUEL HOSE PM3-11

3-6

SECTION 3 - BASIC MACHINE OPERATION 7. CHECKING BELT

ROTATING PARTS CAN CAUSE PERSONAL INJURY. KEEP AWAY FROM FAN AND BELT WHEN ENGINE IS RUNNING. MAKE SURE TO STOP ENGINE BEFORE SERVICING. Check the fan belt for insufficient tension, wear, and damage. Insufficient belt tension may cause battery charge failure, engine overheating, or abnormal belt wear.

Likewise, If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

Apply a force of 10 Kg (22 lb) to the center of belt between pullies, and measure the belt deflection. The table below shows normal condition.

Fan Belt defelection

STOP

10kg (22lb)

GENERATOR

8-10 mm (0.31-0.39 in)

See the section, MAINTENANCE (EVERY 250 HOURS), for details on the inspection and adjustment procedure for the belt.

PULLEY PAE-3-10

3-7

SECTION 3 - BASIC MACHINE OPERATION C. CONFIRMATION BEFORE STARTING MACHINE ENGINE 1. CHECK WARNING LAMPS

CARELESS MOVEMENT OF ANY OPERATING LEVERS MAY CAUSE SUDDEN MOVEMENT OF THE MACHINE. MAKE SURE TO SET THE SAFETY LOCK LEVER TO THE "LOCKED" (UP) POSITION BEFORE LEAVING THE CAB. REMEMBER THAT THE FUNCTIONS FOR DOZER AND BOOM SWING ARE STILL ACTIVE, EVEN WITH THE SAFETY LEVER ON THE LOCKED (UP) POSITION. Before starting the engine, check the warning lamps and indicator lamps according with the following procedures: [1] Make sure the safety lever is in the "LOCKED" (up) position.

[2] Make sure all control levers are in the "NEUTRAL" position.

[3] Use the ignition key and the table below (as reference) to check all warning lamps and indicators for proper functioning.

[4] Do not operate the machine under faulty conditions. Consult with an authorized dealer if necessary. Refer to page 2-5 and make sure all warning lights and indicators function properly. Repair any mal functioning before resuming operation.

RED:WARNING LAMP

1

YELLOW:INDICATION LAMP OFF

2 3

HEAT

ON START

4 5 PM3-15

Key Operation Lamp Engine Oil 1 Pressure Lamp Battery Charge 2 Lamp Engine Coolant 3 Temp. Lamp Low Fuel 4 Warning Lamp 2nd Speed Travel 5 Lamp

OFF HEAT OFF

ON START ON

Pre-Heating Before Start Just After

Light OFF Light ON Light OFF Light OFF Light ON Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF P3-8

NOTE : Make sure all warning lamps and indicators function properly before operating the machine.

2. CHECK WORKING LIGHT While the key position in the starter switch is being "ON" position, turn on the working light switch to check the lightening of working light.

If it does not lighten, presumably the light bulb is burned out or electrical wire is broken. Repair it referring to page 4-25 .

3-8

WORKING LIGHT PAE-3-12

SECTION 3 - BASIC MACHINE OPERATION 3.2 STARTING AND STOPPING MACHINE ENGINE A. START-UP UNDER NORMAL CONDITIONS [1] Make sure that safety lock lever (1) is set to the "LOCKED" (up) position.

[2] Make sure all control levers are set to the "NEUTRAL" position.

[3] Slightly move the throttle control lever (2) from the low idling position.

[4] Turn the ignition key (3) to the START position to start the engine and release after starting the engine.

Release the ignition key immediately after the engine starts.

The key will return to the "ON" position by itself.

PWE-2-7

(2)

MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING TRAVELLING AND MAKE SURE TO SOUND HORN BEFORE STARTING THE ENGINE. NOTE : (a) Do not increase the engine speed (high idling) with cold engine. (b) Do not hold the ignition 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.

PAE-3-13

PAE-3-14

3-9

SECTION 3 - BASIC MACHINE OPERATION B. START-UP UNDER COLD CONDITIONS In cold weather, due to the increase in oil viscosity and decrease in battery performance, starting the engine may be difficult. Use the preheater to start the engine easily under these conditions.

THROTTLE LEVER

[1] Perform steps [1] - [3] mentioned in START-UP UNDER NORMAL CONDITIONS shown on the previous page.

PAE-3-15

[2] Turn the key (3) to the HEAT position and hold position or 15 seconds to preheat before starting.

[3] Turn switch key to the START position to start the engine.

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

PAE-3-16

[4] Release the key switch immediately after starting the engine. The key will return to the ON position by itself.

3-10

SECTION 3 - BASIC MACHINE OPERATION C. START-UP WITH BOOSTER CABLES Observe the following precautions when using booster cables to jump-start the battery.

FLAMMABLE GAS (HYDROGEN GAS) IS GENERATED IN THE BATTERY. DO NOT ALLOW SPARKS OR FLAMES TO COME IN CONTACT WITH BATTERIES TO AVOID TRIGGERING AN EXPLOSION. DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLED MACHINE. WEAR HARD HAT, APPROVED SAFETY GLASSES OR FACE SHIELD, GLOVES AND OTHER SAFETY EQUIPMENT WHEN WORKING WITH BATTERIES. NEVER ALLOW THE BOOSTER CABLE CLIPS TO COME IN CONTACT WITH EACH OTHER ONCE CONNECTED TO A BATTERY. THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC CAUSING SPARKS. MAKE SURE TO CONNECT THE BOOSTER CABLE TO A GROUND SURFACE IN THE ENGINE COMPARTMENT AS FAR AS POSSIBLE FROM THE BATTERY. WHEN THE BATTERY FLUID IS FROZEN, DO NOT START UP THE ENGINE WITH ANOTHER POWER SOURCE. FOLLOW THE ORDER INDICATED IN THE NEXT PAGE FOR CONNECTING OR DISCONNECTING THE BOOSTER CABLES.

PAE-3-17

NOTE : Select suitable size for the booster cables and clips according to battery size.

Use the booster cables and clips without any damages or corrosion.

PAE-3-18

3-11

SECTION 3 - BASIC MACHINE OPERATION D. CONNECTING/DISCONNECTING BOOSTER CABLES Make sure the key switch is in the OFF position before connecting the booster cables. Proceed as follows to connect and disconnect the boosting cables:

ERRONEOUS CONNECTION OF BOOSTER CABLES MAY CAUSE EXPLOSION OF THE BATTERIES. PAY SPECIAL ATTENTION TO CONNECT AND DISCONNECT THE BOOSTER CABLES. THE ELECTRICAL SYSTEM OF THIS MACHINE WORKS WITH 12 V DC. [1] [2] [3] [4]

[5]

[6]

[7]

Set the key switch to "OFF" for both normal vehicle and troubled machine.

Refer to page 2-11 and remove the left side cover.

Then open the cover under the operator s seat.

Remove the cover from the battery terminals.

Connect the booster cable (red) clip to the positive (+) terminal on the battery of troubled machine.

Connect the clip from the other end of the positive (+) booster cable (red) to the positive (+) terminal on the battery of normal vehicle.

Connect the booster cable (black) clip to the negative (-) terminal on the battery of normal vehicle.

Finally, connect the clip from the other end of the negative (-) booster cable (black) to the engine body (hook, etc.) of troubled machine, away from the battery.

BATTERY PM3-25

PA3-20

DO NOT CONNECT THE NEGATIVE (-) BOOSTER CABLE TO THE MACHINE CARBODY (LOWER STRUCTURE) [8] Start the engine of normal vehicle, and operate it for around 10 minutes at high idling.

[9] Start the engine of troubled machine.

[10] After starting the engine of troubled machine, remove the booster cables in the reverse order of the above connection.

[11] Make sure to check and repair the cause of the problem of the charging system on the troubled machine.

3-12

PRE-3-11

SECTION 3 - BASIC MACHINE OPERATION 3.3 STOPPING MACHINE ENGINE Make sure to idle the engine for at least 5 minutes before machine shut down.

THROTTLE LEVER

When the machine is suddenly stopped while high speed operation of the engine, temperature of the engine is rapidly increased causing deterioration of engine oil and seizure of seals.

[1] Normally, place the attachment on the ground before stopping the engine (except for special situations).

[2] Make sure to place the safety lock lever in the LOCK (up) position before leaving the cab.

[3] Push the throttle lever all the way forward to low idle position for about 5 minutes.

Operate the engine at idling for a while to lower the coolant temperature.

[4] Turn the starter key to OFF to stop the engine.

[5] Remove the ignition key.

PAE-3-15-1

OFF HEAT

ON START

STARTER KEY PA3-22

3-13

SECTION 3 - BASIC MACHINE OPERATION 3.4 INSPECTION AFTER STARTING MACHINE ENGINE Check and ensure the following items after starting the engine: A. EXHAUST GAS COLOR, ABNORMAL SOUND & SMELL While operating the engine, check the following items.

[1] Check for abnormal exhaust color during the engine operation.

Avoid continuous operation if the engine exhaust is black. Black exhaust is an indication of an excessive rich fuel/air mixture. Check and service the engine accordingly if this condition is present.

[2] Stop operation immediately when any abnormal sound exists during the machine operation. Check the cause of the abnormal sound, and repair as needed.

[3] Avoid the operation at the speed range with resonance. There may be a certain rotating speed range at which the vibration suddenly becomes large due to resonance. Avoid the operation at such speed range because some parts may be damaged due to vibration.

[4] If burning smell or smoke is generated, immediately stop the engine. Check for any abnormalities and repair as needed before resuming operation.

CARELESS CONTACT WITH ANY OPERATING LEVER WILL CAUSE UNEXPECTED SUDDEN MACHINE MOVEMENT. STANDING OR SHIFT BODY POSITION OF THE OPERATOR AFTER SECURELY SETTING THE SAFETY LOCK LEVER AT "LOCK" (UP) POSITION. MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING TO TRAVEL AND MAKE SURE TO SOUND HORN BEFORE STARTING OPERATION.

NOTE : When ever necessary, consult with an authorized dealer for appropriate repairs.

PAE-3-23

NOTE : Do not apply any heavy load on to the new engine for the first 50 hours operation.

Confirm the LIGHT-OFF for each warning lamp.

Carefully listen to any abnormal sound.

Check leakages for oil and water around the engine.

At the first engine start-up of the day, operate the engine for around 5 minutes with no load to warm up the engine and reach oil to every part of the engine.

3-14

SECTION 3 - BASIC MACHINE OPERATION B. CHECK EACH SWITCH & LEVER After warming up the engine, check the following items: NOTE : Appropriate operation temperature range for hydraulic oil is 50 to 80°C (122 to 176°F). Avoid machine operation when the hydraulic oil temperature is below 20°C (68°F). Failure to do so will reduce the life of the hydraulic components.

LOCK

LOCK LEVER * SAFETY [1] With the engine running, set the safety control lever to the "LOCKED" (up) position.

[2] Move all control levers, except the dozer/width and boom swing control lever.

[3] Make sure that all functions, except the dozer/ width and boom swing functions, are not active when the safety control lever is in the LOCKED (up) position.

[4] Ensure that the travel levers are mechanically locked and do not move at all.

NOTE : When any abnormalities are found, immediately stop the engine, proceed with the appropiate repairs, and request assistance from an authorized dealer if necessary.

C. CHECK MONITOR PANEL (GAUGE CLUSTER) Check all gauges and indicators on the gauge cluster, after starting the engine. Confirm that engine temperature gauge and fuel level gauge work properly.

PM3-30

2 3 1

4

PM3-31

3-15

SECTION 3 - BASIC MACHINE OPERATION 3.5 WARMING UP ENGINE A. ENGINE WARM-UP

AVOID RAPID SPEED INCREASE OF ENGINE SPEED WITH A COLD ENGINE. DO NOT IDLE THE ENGINE FOR MORE THAN 20 MINUTES. EXTENDED PERIODS OF IDLING REDUCE THE LIFE OF THE ENGINE.

Set the throttle lever in the middle position, between the low idling and high idling (see Fig. PAE-3-26), and operate the engine for around 5 minutes with no load.

PAE-3-26

RIGHT OPERATING LEVER BUCKET IN

BUCKET OUT

B. WARMING UP HYDRAULIC OIL Appropriate operation temperature range for hydraulic oil is 50 to 80°C (122 to 176°F). Avoid machine operation when the hydraulic oil temperature is below 20°C (68°F). Failure to do so will reduce the life of the hydraulic components.

[1] Set the throttle lever in the "MIDDLE SPEED" position.

[2] Set the safety control lever in the "UNLOCK" (down) position, see Fig. PAE-3-27.

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

[4] Operate the bucket control lever to retract it or extend it completely against relief, see Fig. PAE3-27. Hold this position for one minute, then release lever and wait for another minute before repeating process. Repeat this procedure at least 10 times or until the temperature of the pilot hydraulic oil is safe for smooth attachment operation.

[5] After warming up hydraulic oil, slowly extend and retract each cylinder several times, and actuate traveling and slewing motors to complete the warm-

In extremely cold climate it may be necessary to increase the warm-up time to ensure proper and safe operation. When operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions. Likewise, cold hydraulic oil will not provide adequate lubrication to hydraulic components; thus, reducing the life expectancy of the machine.

3-16

UNLOCK

PWA-3-27

SECTION 3 - BASIC MACHINE OPERATION 3.6 MACHINE OPERATION The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of these instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment. Each operator must read thoroughly, understand, and follow these basic instructions along with all safety precautions found in this manual and on the machine before operating this equipment.

PAE-3-28

MAKE CERTAIN THE SWING AREA OF MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE OPERATING. KNOW THE POSITION OF THE TRAVEL MOTORS BEFORE STARTING THE TRAVEL FUNCTION AND MAKE SURE TO SOUND HORN BEFORE STARTING THE ENGINE. IF ANY ABNORMALITY IS FOUND DURING THE MACHINE OPERATION, IMMEDIATELY STOP WORKING. MAKE SURE TO REPAIR ANY FAULTY CONDITIONS BEFORE RESUMING OPERATION. NORMAL POSITIONING OF THE MACHINE FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR S CAB. 1. Forward/Reverse Travel [1] Make sure the safety control lever is in the "UNLOCK" down position. Operate the boom, arm, and bucket control levers to raise the attachments from the ground.

[2] Pull the dozer operating lever to raise the dozer.

[3] To move the machine forward, push both (right and left) travel levers toward the front of machine.

To move the machine in reverse, pull back both travel levers.

Travel speed changes depending on how far you push or pull the levers.

PAE-3-29

PAE-3-30

2. Pivot turn · Push the left travel lever toward front of machine to turn machine RIGHT (PAE-3-30). · Push the right travel lever toward front of machine to turn machine LEFT. · Pull the left travel lever back to turn machine RIGHT in reverse. · Pull the right travel lever back to turn machine LEFT in reverse.

3. Counter Rotating Machine (PAE-3-31) To counter rotate machine to the left, pull left travel lever back and push right travel lever forward.

To counter rotate machine to the right, pull right travel lever back and push left travel lever forward.

PAE-3-31

3-17

SECTION 3 - BASIC MACHINE OPERATION 4. Travel Speed Shifting (1st/2nd) [1] For fast travel speed, depress and release the travel speed selector switch once before operating the travel controls. The fast lamp indicator (A) will illuminate in the cluster gauge.

[2] Start the machine travel by operating the travel levers.

[3] To return to SLOW travel speed, stop travel and depress and release the travel speed selector switch once.

NOTE: The travel speed is always reset to SLOW speed every time the key switch is turned to the OFF position.

(A)

PM3-41

B. STOP TRAVELLING (PAE-3-21)

When the operation for the attachment or slewing is inevitable during traveling, pay attention not to operate it rapidly.

[1] Put the travel levers of left and right at neutral position to stop the machine travel.

Avoid to stop the machine travel suddenly. Stop the machine travel as slowly as possible.

PAE-3-21

C. TRAVEL PRECAUTIONS USE A FLAG-MAN WHEN TRAVELING ON THE SHOULDER OF A ROAD OR IN CONFINED AREAS. NEVER ALLOW PERSONS TO RIDE ON THE MACHINE. [1] Make certain the travel motor location is known before performing any travel operation. Travel with travel motors in the back of the machine for long distance travel.

[2] Travel on flat and firm ground and in straight lines (or large angles) as much as possible. When turning the machine, move forward and backward alternately as much as possible instead of making one sharp (pivot) turn.

[3] Check the strength of bridges and road shoulders, and reinforce them if necessary.

[4] Be careful not to come into contact with bridges or electrical power lines.

[5] When traveling on rough ground, use low (1st) speed to reduce the shock to the machine.

[6] Do not allow large or heavy objects to strike travel motors. Likewise, do not travel over large objects such as boulders, rocks, etc.

3-18

PAE-1-12

PMJ-1-9

SECTION 3 - BASIC MACHINE OPERATION [7] On a snowy or icy road, travel with slower speed avoiding any sudden start, sudden stop and sudden slewing.

[8] For loading/unloading at the transport, remove any mud clogged in the crawler shoes to prevent the machine from side skidding on the ramps.

Refer to page 5-2 for the usage of ramps, etc.

PAE-3-33

D. CARE ON UP/DOWN SLOPE

NEVER TAKE SUCH TRAVELING MANNER AS CHANGING DIRECTION ON A SLOPE OR CROSSING A SLOPE. ONCE GET DOWN TO A FLAT GROUND AND TAKE A DETOUR, KEEPING IN MIND THE SAFETY TRAVELING. RAISE THE BUCKET 30 TO 40 CM (12~16 IN) ABOVE THE GROUND LEVEL, WHILE TRAVELING. AND DO NOT GET DOWN THE SLOPE WITH REVERSE TRAVELING. WHEN THE MACHINE IS SKIDDED, IMMEDIATELY GET DOWN THE BUCKET AND TAKE BRAKING. THE SLEWING ON A SLOPE MAY CAUSE THE MACHINE TURNING OVER DUE TO LOSING BALANCE ON THE MACHINE. IT IS QUITE DANGEROUS TO SLEW TO DOWN SIDE OF THE SLOPE WITH A FULL LOAD IN THE BUCKET. WHEN SUCH WORK IS INEVITABLE, MAKE THE GROUND LEVEL ON THE SLOPE TO SECURE THE FLAT WORKING AREA. NEVER TRAVEL ON THE SLOPE MORE THAN 30° GRADIENT. WHEN PARKING ON THE SLOPE IS INEVITABLE, MAKE SURE TO APPLY SKIDS TO THE CRAWLERS AND GET DOWN THE BUCKET TO THE GROUND.

PMJ-3-34

PMJ-1-15

[1] The max gradeability of the machine is 58% (30°).

[2] While getting down slope, slowly operate the travel levers.

[3] Travel slope with low speed (1st speed).

[4] While traveling slope, keep the bucket at 30~40 cm (12~16 in) of height above the ground level, and travel with low speed.

PAE-3-34

3-19

SECTION 3 - BASIC MACHINE OPERATION [5] When the engine is stalled on a slope, place the attachment on the ground, and make sure each operating lever is in the neutral position. Then start the engine again.

[6] If it is difficult to climb a slope with the travel motor due to skidding crawlers, etc., the power of the arm can be utilized to pull up the machine with the bucket engaged on the ground.

[7] When parking the machine on a slope, even if it is a short time of period, place all attachments on the ground, place each operating lever in the neutral position, set the safety control lever to the "LOCK" (up) position and block the crawlers.

NOTE : When the hydraulic oil is not warmed up sufficiently, the machine may not be able to display its full performance. Make sure the machine is sufficiently warmed up before climbing a slope.

PAE-1-17

E. MACHINE OPERATION IN WATER/ON SOFT GROUND NOTE : Pay attention not to immerse the slewing bearing, slewing pinion and swivel joint into the water or mud.

If the machine is operated in water or mud, the slewing bearing and others may be worn abnormally. Immediate replacement of grease or overhaul of the slewing bearing, etc. is required.

SURFACE

SLEWING BEARING

RIVERBED

(A) UPPER ROLLER PWJ-3-28

[1] Where a river bed is flat and water flow is slow, the machine may be operated in a water-depth to the upper rollers (A).

[2] Operate the machine in the water with care checking river bed conditions with bucket, etc. And never enter into the water of the depth beyond (A)(PWJ3-28).

[3] On a soft ground, the machine body sinks little by little in some cases. Therefore, pay full attention to the machine at all times during operation.

[4] After traveling in seawater, thoroughly wash up the machine to remove salt.

[5] Make sure to lubricate bucket pins and bushing every 4 hours if working with materials in wet conditions, supply grease with a grease gun until grease purges.

3-20

PAE-3-36

SECTION 3 - BASIC MACHINE OPERATION F. GETTING OUT OF SOFT GROUND If possible, avoid traveling on soft ground.

Avoid getting caught in the mud. In the event that the machine gets caught in the mud, get out of it as follows: (a) ONE CRAWLER SHOE GETS CAUGHT IN MUD When either side of crawler shoes gets caught in the mud, lay logs or boards on the mud to form a base.

Operate the boom and arm to form an angle between boom and arm of about 90 ~ 110° and push on the ground with the bottom of the bucket to lift the machine body up to climb on the logs or boards (PMJ-339).

PMJ-3-39

(b) BOTH CRAWLER SHOES GET CAUGHT IN MUD When both sides of crawler shoes get caught in mud and the machine does not move due to skidding, provide logs and boards, as described in the above section. And firmly catch the hard ground on which the machine should get out of mud with the bucket, and pull up the machine toward the hard ground with the same operation of digging (PMJ-3-40).

PMJ-3-40

In case the machine is not able to travel because its crawler is stuck in mud, sand or gravel on the soft ground, take each crawler off the ground by pushing the boom and arm against the ground, scrape off mud, sand and gravel and then get the machine out of the trouble. Gravel and mud may be cleared if you rotate the raised crawler back and forth.

Operate the machine at the operator's seat. Do not allow any person to come near the machine.

PMJ-3-41

3-21

SECTION 3 - BASIC MACHINE OPERATION G. SLEWING OPERATION SLEWING PATTERN (ISO)

OPERATION OF THIS MACHINE ON AN INCLINE OR SLOPE MAY CAUSE THE MACHINE TO BECOME UNSTABLE OR UNBALANCED. MAKE CERTAIN THE SLEWING AREA OF THE MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE SLEWING. WORK UP AND DOWN INCLINES OR SLOPES, NEVER ACROSS. NEVER SLEWING OR TURN MACHINE AROUND ON SLOPES. OPERATE CONTROL LEVERS CAREFULLY TO PREVENT SUDDEN MOVEMENTS WHICH MAY CAUSE THE MACHINE TO SLIDE OR TIP OVER. BUILD A LEVEL AREA FOR THE MACHINE TO OPERATE. USE A FLAGMAN TO GUIDE THE OPERATOR.

LEFT OPERATING LEVER SLEWING RIGHT SLEWING LEFT

PWA-3-37

PMJ-1-15

3-22

SECTION 3 - BASIC MACHINE OPERATION 3.7 PRACTICES TO IMPROVE EFFICIENCY

SWINGING ON A SLOPE MAY CAUSE THE MACHINE TO BECOME UNSTABLE OR UNBALANCED. DO NOT SWING DOWN SIDE OF THE SLOPE WITH A FULL BUCKET. WHEN WORKING IN SLOPES, BUILD A LEVEL AREA FOR THE MACHINE TO OPERATE SAFELY. MAKE CERTAIN THE SWING AREA OF THE MACHINE IS CLEAR OF PEOPLE AND OBSTACLES BEFORE SWINGING. A. DIGGING [1] Use Arm In Action Operate the bucket at shallow depth, use the arm mainly, and use the bucket as required, in action to fill the bucket. Setting the bucket too deep will decrease the machine's efficiency.

[2] Maximum Digging Force Position The attachment will provide maximum digging force when the arm and boom are at 90° -110° of each other. Operate slowly to get maximum digging force.

[3] Bucket Teeth Direction Always point bucket teeth in the direction the machine will be digging, and operate the bucket at shallow depth, to reduce digging resistance and the possibility of bucket teeth damage.

[4] Operate Boom Smoothly Always begin and end boom operation slowly with smooth, careful movement of the control lever. Do not perform sudden starts and stops, especially sudden stops during dropping, of the boom as this creates unnecessary stress on the machine and its components.

NOTE : Other than showing in the below sketches, wider range of the machine application is obtainable by means of utilizing the optional attachments.

Refer to page 4-29 for changing the bucket.

PME-3-4

PMJ-3-43

[5] Cleaning Sand & Soil from Bucket Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

PAE-3-43

3-23

SECTION 3 - BASIC MACHINE OPERATION 1. DITCH DIGGING The working efficiency is much improved by means of setting the bucket suitable for trench digging and setting the machine in parallel to the trench to be digged (PMJ-3-44).

For wide ditch digging, dig both sides portions at first, then dig the center portion.

2. USING THE DOZER [1] The dozer is used to push the soil back to digged ditch, or for ground leveling.

[2] Scrape the soil laid on the ground at its upper or side face with the dozer. Adjust the height of dozer with the dozer control lever to avoid overloading the engine.

PMJ-3-44

PMJ-3-45

3. OFFSET DIGGING

CAREFULLY OPERATE THE ATTACHMENT PAYING ATTENTION TO THE SURROUNDING CONDITIONS, SINCE THE BOOM SWING OPERATING RANGE IS WIDE.

(A) (B)

(A)

(B)

Operate the control lever right and left keeping the switch on the grip of the left control lever pressed, and the boom swings right and left.

Switch..............................Pressed (ON) Operate lever right...........Right swing Operate lever left.............Left swing

THE SWING OPERATION DOES NOT STOP EVEN IF THE SWITCH IS OFF IN THE SWING OPERATION. TO SWITCH THE SWING AND SLEWING MOTIONS, PLACE THE LEFT CONTROL LEVER TO THE NEUTRAL POSITION ONCE. PWA-3-58

3-24

SECTION 3 - BASIC MACHINE OPERATION B. LOADING [1] The working efficiency is improved, if the dump truck is set at the position so that the slewing angle becomes minimum keeping a good visual field of the operator.

[2] It is recommended that loading be started from the front side of the dump truck body. This will make loading easier and more soil can be loaded than loading from the side (PMJ-3-47).

PMJ-3-47

C. WORKING IN NARROW SPACE The position shown (PR-1-44) is available for slewing in narrow spaces.

D. MINIMUM SLEWING POSITION [1] Extend arm cylinder and bucket cylinder to maximum length, and fold bucket.

[2] Extend boom cylinder to maximum length.

[3] Keep the switch on the left control lever depressing and operate the left control lever left.

[4] Handle operating lever to swing boom.

NOTE : Use care to protect attachment from interference.

PR-1-44

* MINIMUM SLEWING RADIUS

3-25

SECTION 3 - BASIC MACHINE OPERATION 3.8 MACHINE PARKING

ALWAYS PARK THE MACHINE ON A FIRM, LEVEL SURFACE. AVOID PARKING ON A SLOPE. WHEN PARKING ON A SLOPE IS INEVITABLE, MAKE SURE BUCKET TEETH ARE DUG IN THE GROUND, REST THE DOZER BLADE ON THE GROUND, AND BLOCK THE CRAWLERS. MAKE SURE TO SET THE SAFETY LOCK LEVER TO THE "LOCKED" (UP) POSITION TO AVOID ANY UNEXPECTED MACHINE MOVEMENT AND STOP THE ENGINE BEFORE LEAVING THE CAB. [1] Place both travel levers (1) in the "NEUTRAL" position.

[2] Set the throttle lever (2) to "LOW IDLING" position.

[3] Place the bucket on the ground.

[4] Place the dozer blade on the ground.

[5] Block the crawlers.

[6] Set the safety lock lever (3) to the "LOCKED" (up) position.

PAE-1-17

3

1

3

2

PMA-3-90

PME-3-23

3.9 CHECK & CONFIRMATION AFTER WORK Regularly check the monitor panel (gauge cluster) for warning lamps and indicators.

[1] If the fuel is insufficient, fully refill the tank with fuel, after stopping the engine.

[2] If any trouble is indicated with the warning lamps for the coolant temperature and/or engine oil, move the machine to a safe place, immediately stop the engine, and repair as necessary before resuming operation. Refer to page 4-21 for the "INSPECTION & MAINTENANCE CHART" for details on preventive maintenance.

3-26

PMA-3-91

SECTION 3 - BASIC MACHINE OPERATION 3.10 PRECAUTIONS AFTER OPERATION [1] Check for any oil or coolant leakage. Check the attachment, exterior, and travel system components. Repair as needed before resuming operation.

[2] Fully refIll with fuel. However, do not overfill (to the top of the tank) to avoid overflowing due to fluid expansion under normal temperature.

[3] Remove mud, etc., adhered to the traveling components.

YN-3-52

3.11 MEASURES AFTER EMERGENCY STOP Avoid emergency stops of the engine as much as possible.

It should be kept in mind that the engine is to be operated for around 5 minutes with no load (to disipate heat), before stopping the engine.

The most important matter is to always pay attention to safety so that the emergency stop of the engine will not be required.

When the emergency stop of the engine is inevitable due to dangerous condition or trouble on the machine, take the the following preventive measures to avoid any injury or damages to the machine.

Do not restart the engine until its temperature is completely lowered.

SUDDEN STOP OF THE ENGINE JUST AFTER OPERATION IN HIGH SPEED CAUSES A SUDDEN RISE OF ENGINE TEMPERATURE RESULTING IN DETERIORATION OF OIL, SEIZURE OF SEALING COMPONENTS, ETC.

3-27

SECTION 3 - BASIC MACHINE OPERATION [1] Even if the engine ceases its operation, keep the safety lock lever in the "LOCKED" (up) position.

[2] When the emergency stop is done without placing the bucket on the ground, support it with safety blocks under the attachment or the bucket, and block the crawlers.

[3] When the emergency stop is activated on a slope, block both crawlers at their lower sides.

[4] Make sure to set limits around the machine while it is down for repairs and tag it properly. Use DO NOT OPERATE tag P/N: YN20T01320P1.

[5] Consult with an authorized dealer for repairs if needed.

[6] After an emergency stop, do not restart the engine until the temperature of the engine is completely lowered.

PAE-1-17

PAE-3-46

3.12 LOCKING UP WITH KEY Make sure to use the ignition key to lock the following items: (a) Engine guard (b) Cab door (c) Tank cover for hydraulic oil (d) Cover for tool keeping

KEY CYLINDER

PM2-55

3-28

SECTION 3 - BASIC MACHINE OPERATION 3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE A. RELEASING LOCK FOR TRAVEL MOTOR While travel motors are at a standstill, they are hydraulically locked by the counter balance valve, and also mechanically locked by the brake system. When the machine becomes unable to travel due to failure on the travel motors, etc., it is possible to temporarily move the machine by means of releasing lock for the travel motor with either of the following methods:

PEE-4-103

AVOID CONTAMINATION OF REDUCTION UNITS WHILE THEIR COVERS ARE REMOVED. A-1) REMOVING GEARS *This is the preferred method.

MAKE SURE TO APPLY SAFETY BLOCKS TO FRONT AND BACK SIDES OF CRAWLER SHOES BEFORE REMOVING THE GEARS FROM THE TRAVEL REDUCTION UNITS. PROVIDE A SUPPORT FOR THE ATTACHMENT IF NECESSARY.

1. Provide a container under the travel motor to collect drained oil, see (PEE-4-101).

Slowly remove to plug (4), then remove lower plug to drain reduction unit oil.

Plug (4): 8 mm hex. bore

Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

PEE-4-102

4

CONTAINER PEE-4-101

3-29

SECTION 3 - BASIC MACHINE OPERATION 2. Insert a (flat) screwdriver into gap between the body (1) and the snap ring (3), to remove the snap ring(3).

3. Remove the cover (2) together with the snap ring (3).

PEE-4-107

4. Remove the carrier assy (6) from the reduction unit and protect it from contamination and/or damage.

NOTE: the sprocket for this crawler becomes free from the travel motor.

5. Temporarily install the cover (2).

6. Repeat steps 1 through 5 on the opposite travel reduction unit to remove the carrier assy (6).

Toe the machine to a safe place to proceed with the appropriate repairs.

PEE-4-106

Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

NOTE : After all repairs are made, reinstall the carrier assy (6) on both travel reduction units in reverse order and make sure to use fresh gear oil. Refer to Maintenance Section (4) for proper oil and capacities.

3-30

SECTION 3 - BASIC MACHINE OPERATION A-2) REMOVING SPOOL AND BRAKE 1. Remove the track links according to the instructions "REMOVAL OF RUBBER CRAWLER SHOE" in page 4-16.

2. Make sure to use safety blocks under the crawler frames (travel motor side) 3. Remove the travel motor covers (1) from both sides of lower frame loosening three capscrews (2).

PAE-3-49

4. Provide an empty container to catch drain oil, then disconnect the hoses, see (PAE-3-50). Make sure to release hydraulic system and tank pressure, see page 4-13. Make sure to mark all hydraulic lines connecting on travel motors and remove them.

Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized dealer to obtain the proper caps and plugs to be used on this machine.

PAE-3-50

5. Remove the socket capscrews (3) to remove the travel motor from the lower (crawler) frame. Gradually loosen the capscrews paying attention not to drop off the travel motor.

8-Socket capscrew (3): M10x20 6. Remove the plug (4).

Plug (4): 27 mm of hex. size

PAE-3-51

3-31

SECTION 3 - BASIC MACHINE OPERATION 7. Remove the spool (5). Be careful not to damage the spool during removal. Place spool (5) and loose parts (6) and (7) in a clean container with clean oil to protect them from rust and contamination.

8. Install plugs (4) to prevent contamination.

PAE-3-52

9. Remove 7-socket capscrew (12), and separate the bodies (10) and (11) from assembly, see (PEE-2104).

Make sure to contain oil spillage and dispose of all hazardous waste in accordance with local government regulations.

10. Remove 10-spring (13) for parking brake.

11. Temporarily reassemble bodies (10) and (11) in without springs (13).

12. Install the travel motor to the lower (crawler) frame and reinstall hydraulic lines.

PEE-3-104

13. Repeat steps 3 through 12 on the opposite track side to remove the other travel motor.

14. Install track chains in accordance with "INSTALLATION OF RUBBER CRAWLER SHOE" in page 4-17, and move the machine to a safe place to proceed with repairs.

By removing the spools and springs, the travel motors are released from locked condition.

Move the machine to a safe place and call a service-man as mentioned in Item A-1).

NOTE : After all repairs are made, reinstall the counter balance spools and brake springs on both travel motors. Make sure hydraulic oil level is to specifications.

Refer to Maintenance Section (4) for proper oil and capacities.

3-32

Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized dealer to obtain the proper caps and plugs to be used on this machine.

SECTION 3 - BASIC MACHINE OPERATION B. LOWERING BUCKET

This procedure is to be used only as an emergency to lower the position of the bucket. Extreme caution should be exercized since the weight of the bucket will tend to move the bucket abruptly when the lines are disconnected.

Make sure to block the attachments to avoid sudden changes in their position. Slowly remove hydraulic lines until oil pressure is completely released. Then control the bucket movement by slowly removing the block.

To lower the bucket position, proceed as follows: When the bucket is in digging position (A) (bucket cylinder completely extended, see PAE-3-53), disconnect hose (H) side, see PAE-3-54. Conversely, when the bucket is in dump position (B) (bucket cylinder completely retracted, see PAE-3-53), disconnect the hose (R) side, see PAE-3-54.

PAE-3-53

Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized dealer to obtain the proper caps and plugs to be used on this machine.

Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

PAE-3-54

3-33

SECTION 3 - BASIC MACHINE OPERATION C. LOWERING ARM & BOOM

This procedure is to be used only as an emergency to lower the position of attachment. Extreme caution should be exercized since the weight of the attachments will tend to drop them abruptly when the lines are disconnected.

Make sure to block the attachments to avoid sudden changes in their position. Slowly remove hydraulic lines until oil pressure is completely released. Then control the attachment movement by slowly removing the blockage.

DO NOT ENTER INTO THE AREA UNDER ATTACHMENTS, WHILE LOWERING THEM.

PAE-3-55

1. Lowering Arm (Step 1) Gradually loosen the hose of rod side connected to the arm cylinder.

2. Lowering Boom (Step 2) Gradually loosen the hose of head side connected to the boom cylinder.

PAE-3-56

Clean up all spilled oil. Dispose of all hazardous waste in accordance with local government environmental regulations.

3. Keep the attachment at 30-40 cm (12-16 in) above ground level, taking the occasion of moving the machine into consideration.

4. Securely retighten the hoses not to lower the attachment anymore.

5. After moving the machine to a safe place, touch the attachment with the ground.

6. Call up a serviceman to have the machine investigated.

D. SLEWING UPPER SLEWING STRUCTURE The upper slewing structure has no braking system.

Therefore, it is possible to slew the upper slewing structure by means of pushing the attachment with a few persons.

3-34

NOTE : If necessary, contact an authorized dealer for advise and/or repairs.

SECTION 3 - BASIC MACHINE OPERATION 3.14 CAUTION ON USING RUBBER CRAWLER SHOES A. PROPER USAGE The rubber crawler shoe offers excellent features which a steel crawler shoe does not possess.

However, if it is used in the same way as the steel crawler shoe, then its advantages can not be fully taken. Operation of the machine varies upon site and working conditions.

Comparison between rubber and steel crawler shoes:

Rubber shoe Steel shoe Less vibration Smooth run Low noise Harmless for paved road Easy handling Not damageable Large traction force ; Excellent

; Good

the rubber crawler shoe displays many ad* Although vantages because of its material properties, it has disadvantages in terms of strength. It is therefore necessary to get fully familiar with the characteristics of the rubber crawler shoe and observe what are prohibited and cautioned against, in order to extend the service life of the rubber crawler shoe and have it fulfill its advantages to a maximum possible extent.

Read thoroughly "CAUTIONS ON USING RUBBER SHOES" before use.

OF RUBBER CRAWLER SHOE *GUARANTEE Guarantee does not cover such damages done to the rubber crawler shoe that result from improper working and/or operation as: execution of site work in such places where there are steel plates, U-drains, block corners, sharp slashed gravel and stones, ferroconcrete debris, metal scraps and others which may tear off the rubber crawler shoe, and neglect to observe prohibited operations.

; Ordinary

B. PROHIBITED WORK Do not carry out the following operations: [1] Do not operate and/nor travel in gravel-mixed land, rugged and solid rock bed, ferroconcrete, iron scraps, edges of iron plates.

PMJ-3-66

[2] Do not operate and/nor travel in such places as river beds where there are lots of stones of different sizes. The rubber crawler shoe tends to be damaged or come off from the rollers as the result of being caught in the grooves on the rubber crawler shoes. The service life of the rubber crawler shoe will be reduced if soil is pushed by force when the rubber crawler shoe is slipping.

PR-3-70

[3] Do not let oil, fuel, solvents, etc., come in contact with rubber shoes. If it does, wipe it off with a cloth immediately.

Do not travel on a puddle of oil, etc. on the road surface.

PR-3-71

3-35

SECTION 3 - BASIC MACHINE OPERATION [4] Do not enter such hot places as an open-air fire, and steel plate left in the open sun.

Do not work in asphalt leveling.

[5 When storing the machine for long periods (more than three months) , keep it indoors which will not be exposed to direct sunshine and rain.

Refer to page 3-40 for the storing procedures.

PMJ-3-67

[6] If the machine travels using one side crawler, with the crawler of another side floating, the rubber crawler shoe may come off from the rollers or be damaged.

PMJ-3-68

C. CAUTIONS ON USAGE Use care of the following when working: [1] Rubber shoes slip easily on icy surfaces Take the necessary safety precautions, such as not driving on snowy/icy slopes.

[2] Avoid making a spin turn on a concrete road.

[3] Avoid abrupt change of directions because it will cause early wear or chipping of the rubber crawler shoe.

PMJ-3-69

[4] Exercise care so that the rubber crawler shoe is not damaged by the bucket while working.

[5] Do not operate the machine by pressing the bucket against concretes and walls.

[6] When the machine is lifted up by the attachment, lower it slowly.

PR-3-75

3-36

SECTION 3 - BASIC MACHINE OPERATION [7] If the machine is operated in salty or corrosive places, the adhesion of the core metal of the shoe will get loose. Refrain from using the shoe, or wash it with water after use.

[8] The rubber shoe should be used within -25° C to +55° C (-13° F to 13° F) , considering the physical properties of rubber.

PR-3-76

NOTE : Use the rubber shoe under proper tension to prevent it from coming off from the rollers. Operate the rubber shoe carefully even when tensioning is proper.

[9] Avoid changing direction of the machine on ground with difference in level (about 20 cm/8 in). When crossing over a place where there is a difference in level, do it at right angles to the difference in level, see (PMJ-3-70).

PMJ-3-70

[10] When climbing back on a slope, avoid changing direction of the machine while climbing on a point between a level ground and the slope, see (PMJ3-71).

PMJ-3-71

[11] If you travel on a slope or a concave with one side of the machine lifting, it will damage the rubber crawler shoe. Always travel with both sides of the machine level.

PMJ-3-72

[12] Do not change direction of the machine with the rubber crawler shoe on ground with high spots, see (PMJ-3-80) as it will cause the rubber crawler shoe to come off or be damaged.

PMJ-3-80

3-37

SECTION 3 - BASIC MACHINE OPERATION 3.15 MACHINE OPERATION IN ADVERSE WEATHER CONDITION A. OPERATION IN EXTREME COLD

When the temperature is extremely low, oil flow is reduced due to increased viscosity, making startup difficult. Coolant may freeze damaging radiator and/or engine.

[1] FUEL AND OIL Use fuel and oil of high quality and low viscosity for each system. See MAINTENANCE section, "LUBRICANT, FUEL & COOLANT SPECIFICATIONS" page 4-7 for details.

[2] COOLANT When operating or storing the machine in cold regions, the ratio of mixing antifreeze into the cooling system should conform with the lowest predicted ambient temperature. If coolant freezes, the radiator, crankcase and cylinder head may be damaged.

When shipped from the factory, the machine contains coolant mixed with all-season-type LONG LIFE COOLANT. When operating or storing the machine in extreme cold, inspect the coolant to maintain proper concentration.

NOTE : In extremely frigid climates, covering the radiator is a method to aid the machine warm up. If necessary to maintain temperatures, cover the outer edges of the radiator, leaving an opening in the center part of the cover; thus, avoiding fan overload.

Keep a close watch on the cluster gauge for warning icons during operation. It may be necessary to use coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting. Likewise, mix coolant to a protection temperature of 5 °C (9°F) lower than the machine will experience during operation, storage or transport.

3-38

[3] BATTERY When the ambient temperature lowers, the charging performance goes down or the battery may freeze. Keep the charging rate as close as possible to 100%. Cover the battery with insulation material.

Perform test on the battery. We recommend the test be performed at room temperature for best results. Use a hydrometer to check the specific gravity of each cell and compare the readings with Temp.of battery -10° C fluid (14° F) Charging rate

0° C (32° F)

20° C (68° F)

100%

1.28

1.27

1.26

90%

1.26

1.25

1.24

80%

1.24

1.23

1.22

75%

1.23

1.22

Do not measure the specific gravity of battery fluid just after operation.

NOTE : Keep battery terminals free of ice and snow to avoid short circuits. Check the battery electrolyte (acid) level frequently and fill as needed with distilled water.

In extremely cold climates, remove the battery and store it overnight at room temperature.

[4] AFTER OPERATION Mud and water adhering to the machine may freeze interfering with proper machine operation. Use the following general guidelines as reference to prevent malfunctions: Remove mud and water adhering to the machine.

Remove water adhering to the travel system thoroughly and park on dry ground to prevent the travel system from freezing.

Retract the cylinder rods to minimum length to reduce exposed area of the rods. This will prevent mud or water on the rod faces from damaging the seal.

SECTION 3 - BASIC MACHINE OPERATION B. OPERATION AT SEASHORE OR SALTY CLIMATE [1] BEFORE OPERATION Check all mounting hardware for proper tightness.

Torque to proper value to aid in preventing salt from entering the machine systems.

Apply grease to the electrical equipment as required to prevent corrosion.

[2] AFTER OPERATION Wash the machine thoroughly to remove salt.

Apply oil or grease as necessary to prevent corrosion.

C. CARE FOR ELECTRICAL EQUIPMENT The electrical equipment is especially sensitive to water. Be careful not to expose the electrical equipment to water when washing the machine or during rain. The electrical components (relays, fuses, etc.) are installed at the operator's seat of the machine.

Never expose the operator's seat to water.

D. OPERATION IN DUSTY AREAS [1] AIR CLEANER Clean or replace the element at adequate interval.

See Maintenance Section for details.

[2] RADIATOR Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

[3] FUEL Be careful not to let contamination in the fuel when refueling. Inspect the elements and filters at adequate interval.

[4] ELECTRICAL EQUIPMENT Clean the starter and generator especially, at adequate interval, to prevent dust from accumulating. See Maintenance Section for details.

3-39

SECTION 3 - BASIC MACHINE OPERATION 3.16 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD When storing the machine for more than one month, observe the following points to prevent the machine function from deteriorating.

Item

Action

Washing machine

Wash the machine thoroughly.

Check the travel system for any malfunctions and service as required. Lubricate every required part.

Lubrication

Check the lubrication oil to make sure it is at the proper level and for contamination. Replenish if necessary, and change if contaminated.

Lubricating oil deteriorates even when the machine is not used.

Be sure to check the oil before operating the machine again.

Apply sufficient rust inhibiters to portions where rust is likely to occur, especially the exposed rod of the cylinders.

Battery

Remove the negative terminal from battery and cover the battery, or remove the battery from the machine and store it at room temperature placing it over a wood deck.

Charge the battery once a month to replenish spontaneous discharging.

Coolant

If there is a possibility that the coolant may freeze, add antifreeze in the coolant. Normally, long life coolant is mixed in, so it is not necessary to change the coolant.

Dust and humidity prevention PMJ-3-76

Keep the machine in a dry place indoors. If the machine must be kept outdoors, lay wood block on the flat ground and protect the machine with cover.

Park the machine with the exposed piston rod of the cylinder retracted as much as possible.

Get down the bucket to the ground and set the skids to the crawler.

Periodical operation for lubrication (during storage)

Operation after long term storage

3-40

If the oil film on the parts is insufficient and rust occurs, abnormal wear may occur when the machine is operated.

Start the engine and operate the machine and attachment, etc. once a month to lubricate all of the parts.

Before starting the engine, check the engine oil and coolant level, and replenish if insufficient.

Wipe off the rust inhibiter from the cylinders and piston rod thoroughly.

Apply rust inhibiters to the cylinder rods after the above operation.

After starting the engine, warm up the machine completely. Repeat traveling, slewing, and digging several times to lubricate each part of the machine.

Ensure proper ventilation during warming-up operation.

Before placing the machine back into operation, proceed as follows before starting up.

Fully wipe off the rust inhibiters from the cylinders and piston rods.

Refill fluids to proper levels and lubricate as required.

SECTION 4

MAINTENANCE TABLE OF CONTENTS 4.1 GENERAL INFORMATION ....................................................................................................................... 4-3 4.2 GENERAL SAFETY & PRECAUTIONS ................................................................................................... 4-4 4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS ............................................................................... 4-7 4.4 FILTERS & ELEMENTS, AND BUCKET .................................................................................................. 4-8 4.5 ACCESSORY TOOLS .............................................................................................................................. 4-9 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS ..................................................................... 4-10 4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES ....................................................... 4-11 4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINT ............................................................................... 4-12 4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC OIL SYSTEM ................................................... 4-13 4.10 PRESSURIZING HYDRAULIC OIL TANK .............................................................................................. 4-14 4.11 BLEEDING AIR IN FUEL SYSTEM ...................................................................................................... 4-15 4.12 REPLACEMENT OF RUBBER CRAWLER SHOE ................................................................................. 4-16 A. Removing Rubber Crawler Shoe ..................................................................................................... 4-16 B. Installing Rubber Crawler Shoe ....................................................................................................... 4-17 C. Check and Adjustment of Tension On Crawler Shoe ....................................................................... 4-18 4.13 INSPECTION AND MAINTENANCE CHART ........................................................................................ 4-21 4.14 WHEN REQUIRED ................................................................................................................................ 4-24 A. Cleaning Radiator Cores ................................................................................................................. 4-24 B. Cleaning or Replacement of Radiator Cap ....................................................................................... 4-24 C. Replacement of Working Light ........................................................................................................ 4-25 D. Reconditioning Bucket .................................................................................................................... 4-26 1. Check for Abrasion/Damages On Tooth Point & Side Cutter ...................................................... 4-26 2. Replacing Tooth Points .............................................................................................................. 4-27 3. Replacing Side Cutter ............................................................................................................... 4-28 E. Replacement of Bucket .................................................................................................................. 4-29 1. Removal of Bucket .................................................................................................................... 4-29 2. Installing Bucket ....................................................................................................................... 4-30 3. Adjusting Bucket Mount Gap ..................................................................................................... 4-30 F. Inspecting Rubber Crawler Shoe ..................................................................................................... 4-32 G. Lubrication For Operating Levers .................................................................................................... 4-34 H. Checking Electrical Wiring and Fuses ............................................................................................. 4-34 4-15 8-HOUR (DAILY) INSPECTION AND MAINTENANCE .......................................................................... 4-36 A. Check External Conditions of Machine ........................................................................................... 4-36 B. Check Capscrews and Nuts For Looseness and Dropping Off ........................................................ 4-36 C. Check Each Cylinder, Piping and Hose For Leakage and Damages ................................................ 4-37 D. Check Travel System For Leakage and Abrasion ............................................................................ 4-37 4.16 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE .................................................................... 4-38 A. Adjusting Crawler Tension ............................................................................................................... 4-38 B. Greasing Pins Around Bucket ......................................................................................................... 4-38 C. Draining Water from Water Separator and Cleaning ......................................................................... 4-39 D. Draining Water and Deposits from Fuel Tank ................................................................................... 4-40 E. Check Battery Fluid Level and Specific Gravity .............................................................................. 4-41 4-1

4.17 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE ................................................................. 4-42 A. Greasing Attachment and Dozer Pins ............................................................................................. 4-42 B. Oil Change for Engine ..................................................................................................................... 4-43 C. Greasing To Slewing Bearing .......................................................................................................... 4-43 D. Adjustment for Belt Tension ............................................................................................................ 4-44 E. Adjustment for Fan Belt .................................................................................................................. 4-44 F. Replacement of Engine Oil Filter ..................................................................................................... 4-45 G. Cleaning Engine Fuel Filter ............................................................................................................. 4-46 H. Checking Radiator Hose ................................................................................................................. 4-47 I. Replacing Radiator Hose ................................................................................................................. 4-47 J. Checking/Cleaning/Replacing Air Cleaner Element .......................................................................... 4-48 1. Check Element ......................................................................................................................... 4-48 2. Cleaning Element ...................................................................................................................... 4-48 4-18 500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE ................................................................. 4-49 A. Replacement of Element ................................................................................................................ 4-49 B. Replacement of Hydraulic Return Filter ........................................................................................... 4-50 C. Replacement of Fuel Filter .............................................................................................................. 4-51 4.19 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE ............................................................. 4-53 A. Replacement of Coolant ................................................................................................................. 4-53 B. Check and Adjustment for Valve Clearance .................................................................................... 4-54 C. Check and Adjustment for Starter And Generator ........................................................................... 4-54 4.20 2000-HOUR INSPECTION AND MAINTENANCE ................................................................................. 4-55 A. Oil Change In Hydraulic Oil Tank and Cleaning of Suction Strainer ................................................. 4-55 B. Cleaning Line Filter of Pilot Valve and In-line Filter of Solenoid Valve .............................................. 4-57 C. Oil Change for Travel Speed Reduction Unit ................................................................................... 4-59 D. Gear Oil Change for Lower Roller and Idler ..................................................................................... 4-60 1. Lower Roller .............................................................................................................................. 4-60 2. Idler ........................................................................................................................................... 4-62 3. Upper Roller .............................................................................................................................. 4-62 E. Replacement of Grease in Slewing Grease Bath ............................................................................ 4-63 F. Check and Adjustment for Fuel Injection Timing .............................................................................. 4-63 G. CHECK AND ADJUSTMENT FOR CONTACT SURFACE OF INTAKE AND EXHAUST VALVE ................ 4-63

4-2

SECTION 4 - MAINTENANCE 4.1 GENERAL INFORMATION

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES ON THIS MACHINE , ITS SYSTEMS OR COMPONENTS.

A. It is recommended by CASE, that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition.

B. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance as they will guide the technician step by step for each procedure. Also, refer to the Inspection and Maintenance Charts for general service interval recommendations.

C. Basically, lubrication and maintenance intervals are determined by the hourmeter. If performing lubrication and maintenance according to calendar time is preferred, the hourmeter reading corresponds to the lubrication and maintenance period (daily, weekly, monthly, etc.) in calendar time; thus calendar time can be used. Items for which service time cannot be specified are explained in the section WHEN REQUIRED.

NOTE: Make sure to consult with an authorized dealer for the adjustment, disassembling and repair of the engine, reduction gear and electronic equipment (controller, etc.).

SK32004001

NOTE : The inspection and maintenance charts provided in this section give only general time intervals.

It may be necessary to develop a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions such as severe applications, work in dusty or humid circumstances, etc.

D. Use only specified oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition.

Furthermore, use the oils and greases with the specified viscosity depending on the ambient temperature.

Store the vessels and containers indoor for the oils, fluids and greases, taking suitable measures to prevent them from invading dust, water, etc.

SK32004003

4-3

SECTION 4 - MAINTENANCE 4.2 GENERAL SAFETY & PRECAUTIONS Do not carry out any other inspection and maintenance procedures than specified in the manual. Carry them out by parking the machine at a flat and conveniently situated place.

A. KEEP MACHINE CLEAN Thoroughly clean machine before performing inspection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also reduce the risk of hydraulic system contamination when machine is clean.

SK32004004

B. CONFIRMATION FOR HOUR-METER Read the hourmeter daily, and check with the scheduled maintenance book. See pages 4-21~4-23 for better reference. Proceed with any maintenance as required.

PM2-10

C. STOP ENGINE Never attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool. Otherwise, there is a possibility of danger that your hand may be caught in the cooling fan or fan belt resulting injury. If it is inevitable to operate the engine for the inspection or maintenance, carry out the work with a pair of two persons. And either person makes the engine ready to stop at any time at the signal of the partner.

PMJ-4-2

D. "TAG-OUT" MACHINE Before beginning any inspection or maintenance procedures, secure a " DO NOT OPERATE" tag to the operator s console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine.

PMJ-1-9

E. OBSERVE PRECAUTIONS Start the inspection and maintenance work fully understanding the contents of safety precautions indicated on the machine decals.

PAE-4-1

4-4

SECTION 4 - MAINTENANCE F. HOT SURFACES & FLUIDS Use cautions and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after machine has been stopped. Allow machine to cool down before performing maintenance procedures.

WARM ENGINE OIL Engine oil should have a temperature of between 20~40° C (68~104° F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature.

G. USE CAUTION IN REGARD TO THE INTERNAL PRESSURE Release the internal pressure before removing the hydraulic system, air system, or fuel system; piping or coupling of the cooling system; other related parts to which internal pressure is applied. See page 413 TO RELEASE INTERNAL PRESSURE.

H. PREVENT CONTAMINATION Always cap or plug lines when hydraulic components are removed to prevent hydraulic system contamination that can be caused by dirt, dust and debris entering a line or port.

PR-1-38

YRM-4-41

YRM-4-42

I. INSPECT WASTE OILS AND FILTERS Before disposal, inspect all waste oils, fluids and filters for debris and foreign material. It is recommended to cut open the oil filters to determine any abnormal wear.

PMJ-4-4

J. CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not remove it at refilling fuel, oil or fluid.

PWJ-4-1

4-5

SECTION 4 - MAINTENANCE K. DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

Dispose of all hazardous waste in accordance with government environmental regulations, laws and codes.

PA-4-2

L. KEEP THE MOUNTING FACE CLEAN After removing the O-ring or gasket, clean the installing face, and replace with a new one. When installing the O-ring or gasket, apply a thin layer of oil to the seal, and install securely.

PR-4-5

M. PROVIDING LOCKING DEVICE When the inspection or maintenance is carried out under the attachment, provide proper support or blocks to secure the attachment.

PW-1-1

N. CAUTION AT CHANGING BUCKET Never insert your finger into the pin bore.

When aligning the pin bores, never insert your finger, hand or arm into the pin bore. The alignment must be carried out visually.

PW-1-2

O. DUSTY CIRCUMSTANCES When the machine is operated in dusty circumstances, take the precaution of doing as follows.

Frequently check the alarm lamp for the air cleaner clogging. Clean up the air cleaner element more frequently than the specified interval.

Clean up the radiator core more frequently than the specified interval to prevent it from clogging.

Clean up and replace the fuel filter element more frequently than the specified interval.

Clean up the electric equipment, especially for starter and generator, not to allow deposit of dust on them.

4-6

PMJ-4-95

SECTION 4 - MAINTENANCE 4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, grease, fuels and coolants in various climates and certain working conditions.

* Indicates type of oil shipped with the machine from factory.

4-7

SECTION 4 - MAINTENANCE 4.4 FILTERS & ELEMENTS, AND BUCKET Replace consumable parts, such as filters and elements, during the periodical maintenance or before the service life. The machine can be used economically if the consumable parts are changed properly and timely.

B 7 (Right)

7 (Left) 8

1

6 5 4

2

PW-5-3

4-8

SECTION 4 - MAINTENANCE 4.5 ACCESSORY TOOLS

1

TOOL NAME PIPE

PART No.

REMARKS FOR GREASE NIPPLE OF IDLER ADJUSTER

PM01T01002P1

2

GREASE GUN (OCEANIA SPEC.)

PW01T00003F1

3

TOOL CASE

PW01T01005P1

4

WRENCH

PV01T01004P1

5

LABEL (WARNING TAG)

LC20T01001P1

DISCHARGE PRESSURE 250kg/cm2(3560psi) CARTRIDGE 400cc(24cu-in)

FOR ENGINE OIL FILTER

do not operate

No.

If tools become lost or damaged, contact an authorized dealer to order the tools.

4-9

SECTION 4 - MAINTENANCE 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance. Retighten the loose bolt and install new ones when ever lost. For the new machine, checking and retightening of bolts and nuts must be carried out at the first 50 hours operation. When replacement is needed, make sure to use the same size of authorized genuine parts.

Refer to the table below for proper tightening of capscrews.

The table below is not applicable for the 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.

In case that the tightening torque is specified in the manual, use such torque values regardless to the table below.

Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M 5 or less.

PAE-4-4

4-10

SECTION 4 - MAINTENANCE

4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES A. SLEEVE TYPE TUBE FITTINGS Tube size ODX Thickness (mm) Spanner size (mm)

Tightening torque kgf m (lbf ft)

10 X 1.5

19

4.5 + - 0.5 (33 + - 4)

15 X 2.0

27

15 + - 2.0 (110 + - 14)

18 X 2.5

32

18 + - 2.0 (130 + - 14)

22 X 3.0

36

22 + - 2.0 (160 + - 14)

28 X 4.0

41

28 + - 3.0 (200 + - 22)

35 X 5.0

55

45 + - 4.5 (330 + - 33)

Z2-0061

B. JOINTS FOR PIPING (O-RING SEALING TYPE) Nominal screw size (PF)

Spanner size (mm)

1/8

14

1.7 + - 0.2 (12 + - 1)

1/4

19

3.7 + - 0.2 (27 + - 1)

3/8

22

7.5 + - 0.5 (54 + - 4)

1/2

27

11.0 + - 1.0 (80 + - 7)

3/4

36

+ 1.0 (119 + 7) 16.5 -

1

41

Tightening torque kgf m (lbf ft)

Z2-0081

C. HYDRAULIC HOSES Nominal screw size (PF)

Spanner size (mm)

Tightening torque kgf m (lbf ft)

1/8

14

+ 0.2 (11 + 1.5 - 1)

1/4

19

+ 0.5 (22 + 3.0 - 4)

3/8

22

+ 0.5 (36 + 5.0 - 4)

1/2

27

+ 0.5 (58 + 8.0 - 4)

3/4

36

12.0 + - 1.0 (87 + - 7)

1

41

14.0 + - 1.5 (101 + - 11)

Z2-0051

NOTE : All torque values are subject to a dry condition.

4-11

SECTION 4 - MAINTENANCE 4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINT The following two types of joint are used on the joint part of hose piping.

A. METAL JOINT (30° Flare type) Sealing is performed with metal compression of the opening of connector (tee, elbow) and hose. Use cautions to disassemble and assemble it to protect the damage on the seat surface.

B. O-RING SEAL JOINT Hose fitting is equipped with O-ring which seals the oil pressure on the joint and protects it from oil leakage.

The tightening torque of the joint of each hydraulic hose is determined by the diameter of the hose fitting screws. In case of any abnormality detected, the hose piping joint should be repaired or replaced according to the following procedure even before the periodic inspection of the hydraulic unit.

O-RING [1] At reassembling, be sure to replace the O-ring with a new one.

[2] Where the union is loosened and oil is leaked, never tighten it as it is. Install a new O-ring and check that the O-ring is securely fitted, and then tighten it.

[3] Never install a damaged and deteriorated O-ring even if it is new one. The use of an O-ring other than specified, causes oil leakage and short life of hydraulic equipment, because the material and hardness differ even if they are the same size.

JOINT [1] Care must be exercised not to damage hose, pipe and O-ring groove face and seal face (dent, etc.) of hydraulic equipment. The use of a damaged parts causes oil leakage.

[2] Use care to prevent contamination.

Fitting with foreign materials inside causes oil leakage.

HOSE [1] The hose should not be twisted and sharply bent for installation.

If the hose is twisted or sharply bent, the life of the hose is decreased.

[2] Clean the joints and surrounding of joints, and remove and dry the cleaning solvent completely prior to installing the joints.

PME-4-13

*

*

*

4-12

PME-4-14

SECTION 4 - MAINTENANCE 4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM Release the internal pressure of hydraulic system before carrying out maintenance work such as hydraulic oil change, return filter change, suction strainer cleaning, cylinder repair.

Pressurize the hydraulic oil tank after maintenance and releasing air in the system.

A. RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

PAE-1-22

AIR BREATHER

STAY

HYDRAULIC OIL TANK PW-5-4

[1] Make the machine to "Hydraulic Oil Inspection Position" as shown in the right sketch, by means of fully contracting the arm cylinder and bucket cylinder, lowering the boom to get down the bucket to the ground, and lowering the dozer to the ground.

In case of hydraulic pilot type, operate the lever for releasing the internal pressure just before stopping the engine in a low idle condition.

NOTE : The internal pressure of the hydraulic system can be released only by the above method.

[2] In case of the manual type, operate the lever after stopping the engine to release the internal pressure.

[3] Turn the getting on/off shutoff lock lever to the "LOCKED" position.

[4] Stop the engine (stator switch to the "OFF" position).

[5] Open the cover on the top of the hydraulic oil tank, and support it with the stay.

[6] Press the rubber cap of the air breather on the top of the hydraulic oil tank several (five to seven) times to release the internal pressure of the tank.

Now inside pressure in the hydraulic oil tank is fully released. Proceed the inspection and maintenance procedures for the hydraulic system.

4-13

SECTION 4 - MAINTENANCE B. BLEEDING AIR IN HYDRAULIC SYSTEM Bleed the air contained in the hydraulic circuit after performing maintenance to the hydraulic system.

[1] Referring to page 3-9 , start the engine, and operate the engine at low idle for around 5 minutes. Then proceed as follows: [2] With the engine running in low idle, extend and retract each cylinder 4 - 5 times. However, do not extend and/or retract each cylinder to the end of its stroke yet.

[3] Repeat extending and retracting each cylinder 2 - 3 times but now to the end of its stroke.

[4] Air bleeding for the hydraulic circuit has been completed. Stop the engine and let it set for more than 5 minutes to dissipate the air bubbles in the hydraulic oil tank.

PME-4-21

NOTE : If engine speed is at high idle during the bleeding, the piston and packings may be damaged due to the air contained in the cylinder.

4.10 PRESSURIZING HYDRAULIC OIL TANK After having performed maintenance to the hydraulic system, make sure to pressurize the hydraulic tank as follows; [1] Start the engine and keep low idling under the condition where the air plug on the hydraulic oil tank is open.

[2] Slowly and gradually extend each cylinder to its stroke end to obtain the "Hydraulic Oil Tank Pressurization Position". (PME-4-22) [3] Tighten plug + 0.3 kgf m (22 + 2 lbf ft) Tightening torque : 3.0 [4] Ensure that the tank is free from oil leakage, and close the tank cover. Operate the attachments and retract the cylinder rods to pressurize the hydraulic tank.

NOTE : If the hydraulic oil tank is not pressurized, the hydraulic pump could be damaged. Make sure to pressurize it.

4-14

PME-4-22

AIR PLUG

PFE-4-2

SECTION 4 - MAINTENANCE 4.11 BLEEDING AIR IN FUEL SYSTEM If air enters the fuel system, the engine may become hard to start or it will malfunction. Bleed the air whenever the fuel tank is empty, the water separator is drained, or the fuel filter element is replaced.

[1] Set the safety lock lever at "LOCKED" position, and stop the engine.

[2] Make sure to fill the fuel tank.

[3] Ensure that the handle of fuel filter and water separator are set in "OPEN" position.

[4] Unscrew the air bleeding plug on the top of the water separator by a few turns with a Phillips screwdriver.

[5] Turn the starter switch to the "START" position to start the engine. The engine will rotate without load to feed fuel.

[6] When fuel without bubbles is found to come out from the air bleeding plug hole, close the air bleeding plug.

WATER SEPARATOR

AIR PLUG HANDLE CLOSE OPEN FUEL FILTER

NOTE : Don t operate the starter continuously for 15 seconds or more.

If it is necessary to crank for 15 seconds or more, stop cranking once, and start cranking again by setting it at "START" position after approx. 30 seconds.

PM5-34

PME-4-25

By moving the priming lever at the side of fuel injection pump up and down, the fuel is fed while the engine is stopped.

Therefore, release the air beforehand, and the worktime is shortened.

Additional Information : In case of the machine with an automatic air bleeder (optional specification), turn the stator switch key to the "ON" position to actuate the fuel feed pump to enable air bleeding.

PME-4-26

4-15

SECTION 4 - MAINTENANCE 4.12 REPLACEMENT OF RUBBER CRAWLER SHOE

This work must be carried out by two people. The operator operates the machine in accordance with the signal of the partner. The rubber crawler shoe replacement is carried out lifting the machine body.

Erroneous falling of the machine body during the work on the crawler shoe is quite dangerous. Do not operate any other attachments than the crawler.

Grease in track tensioning mechanism is under extreme high pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call an authorized CASE service dealer for assistance.

Before removing the rubber crawler shoe, ensure that the pressure inside grease has been completely released. Then turn the sprocket.

It is quite dangerous to allow the spouting out of grease with any procedures other than the one described in the "REMOVING OF RUBBER CRAWLER SHOE" below. If the tension on the crawler shoe is not released, consult with an authorized dealer for its repair.

A. REMOVING RUBBER CRAWLER SHOE [1] Operate boom, arm, and bucket to set the attachment on the ground as shown in (PMJ-1-31).

Slowly and gradually lower the boom to lift one side of the machine.

[2] Support the lower travel structure of the machine with safety supports.

[3] Slowly loosen the grease nipple(1) on the grease cylinder to allow to discharge the grease and release tension.

[4] Slowly loosen the grease nipple less than one turn.

[5] Engage some steel pipes into the rubber crawler shoe, then slowly rotate the sprocket backward.

When the rubber crawler shoe floats from the steel pipes, slide the shoe to the side to remove it.

PMJ-1-31

PME-3-79

PRE-3-83

4-16

SECTION 4 - MAINTENANCE B. INSTALLING RUBBER CRAWLER SHOE [1] Operate boom, arm, and bucket to set the attachment on the ground as shown (PMJ-1-31).

Slowly and gradually lower the boom to lift one side of the machine.

[2] Support the lower travel structure of the machine with a safety support, etc.

[3] Engage the rubber crawler shoe with the sprocket and hang it on the idler.

[4] Slowly rotate the sprocket backward and push the rubber crawler shoe into its position, then stop the rotation.

PMJ-1-31

[5] Engage a steel pipe into the rubber crawler shoe, and rotate the sprocket backward again to securely engage the rubber crawler shoe with the idler.

[6] Stop the rotation of sprocket to ensure that the rubber crawler shoe is securely engaged to the sprocket, idler and lower rollers.

[7] Referring to the next Item "C", carry out the check and adjustment of tension on rubber crawler shoe.

[8] After confirming the engagement of rubber crawler shoe to the sprocket, idler and lower roller, and also the proper tension on the rubber crawler shoe, place the machine on the ground.

PRE-3-84

LOWER ROLLER

METAL CORE

RUBBER SHOE

STEEL CORD IDLER

TRAVEL MOTOR SPROCKET

PMJ-3-74

4-17

SECTION 4 - MAINTENANCE C. CHECK AND ADJUSTMENT OF TENSION ON CRAWLER SHOE An appropriate adjustment of tension on the rubber crawler shoe is important not only for prolonging the service life of the rubber crawler shoe and machine but also preventing the rubber crawler shoe from coming out of place.

Since checking and adjustment for the tension on the rubber crawler shoe is carried out with the machine lifted, it is quite dangerous if the machine is erroneously dropped to the ground. Never move the machine while checking and adjusting it. Work has to be performed be two people, and the operator must operate the machine in accordance with the signal of the partner.

PME-4-56

RUBBER CRAWLER SHOE Since the abrasion of the rubber crawler shoe varies depending on the working conditions and the nature of the soil, a frequent check is required for wear and the tension condition. Especially, on the new rubber crawler shoe, there is an initial stretch.

Therefore, frequently check crawler tension during the first 30 hours on a new machine or new tracks.

1. CHECK [1] Move the rubber crawler shoe so that the jointing part (M mark) comes to the upper center position.

See Fig.PNE-4-57.

[2] Slewing the upper structure to place it at 90° (right angle) to the crawler frame. Operate boom, arm, and bucket to set the attachment on the ground as shown (PMJ-1-31). Slowly and gradually lower the boom to lift one side of the machine.

[3] Measure the clearance (A) between the lower face of crawler frame and the upper face of crawler shoe at the center position of crawler frame.

Proper value (tension) (A) mm : Rubber shoe ; 60~70mm (2.4~2.8 in) Steel shoe ; 110~120mm (4.3~4.7 in) [4] If the tension is not proper, adjust it referring to the next item 2. ADJUSTMENT.

NOTE : The machine operation with loosened rubber crawler shoe causes the rubber crawler shoe to come out of place and wear prematurely.

4-18

PNE-4-57

PMJ-1-31

LOWER ROLLER

CRAWLER FRAME

A

RUBBER CRAWLER SHOE

A

STEEL CRAWLER SHOE

PM5-43

SECTION 4 - MAINTENANCE 2. ADJUSTMENT It is required to adjust the tension on the crawler shoe depending on the working place of the machine. When working at the place with a lot of gravel or round stones, looser tension (upper limit range of tension) is preferable. And at hard ground, stronger tension (lower limit range of tension) is preferable.

Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call an authorized service dealer for assistance.

2-1) MAKING TENSION STRONGER Provide a grease gun.

[1] Feed grease to the grease nipple (1) with the grease gun so that proper tension on the crawler shoe is obtainable.

PRE-3-82

[2] Move the machine forward and backward to equalize the tension on both crawler shoes of left and right.

[3] Again check the tension on the crawler shoes, and repeat the adjustment to obtain the proper tension on both crawler shoes.

NOTE: When the tension on the crawler shoe is still loose even grease is supplied to the grease nipple, it is presumable that some faulty conditions may exist on the seal in the cylinder or machine body. Request the repair to an authorized dealer.

PME-4-9

PRE-4-74

4-19

SECTION 4 - MAINTENANCE 2-2) MAKING TENSION LOOSER

Grease in track tensioning mechanism is under extreme high pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call an authorized service dealer for assistance.

[1] Gradually loosen the grease nipple (1) to discharge grease.

Do not loosen the grease nipple (1) more than one turn.

[2] Move the machine (crawler shoe) forward and backward, when grease does not discharge ade q u a t e l y.

[3] Tighten up the grease nipple.

Tightening torque : 6 + - 1kgf m (43 + - 7 lbf ft) Move the machine forward and backward to ensure the correct tension on the crawler shoes.

Again check the tension, and if it is not correct, adust it again.

PRE-4-75

PME-4-61

4-20

SECTION 4 - MAINTENANCE 4.13 INSPECTION & MAINTENANCE CHART Follow the chart below for recommended intervals of regular inspection and maintenance procedures.

Perform inspection and maintenance according to the calendar time or operation time shown by the hourmeter, whichever comes first.

See the inspection and maintenance procedure mentioned below for details.

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE.

Symbols and their meanings ; ....................Necessary regular inspection item to hour meter. ...................Only first replacing performed. ..................Inspection and / or maintenance is needed.

*

Components

Interval Item

Engine oil

Engine oil filter

When Pre- Every Every Every Every 3 6 12 2,000h Lubricant Reference re- opera- week ,etc. tion months months months page quired (Replacing part) 8h 50h 250h 500h 1,000h

Check level

3-4

*

Change

(First)

Change

(First)

Drain / Water separator Clean

*

Engine oil 4-43 Cartridge

4-45

Element

4-39

Clean

4-46

ENGINE

Fuel filter Change

Air cleaner element

Element

Check / Clean Change

4-48 Element

Check level Radiator coolant Change

4-50

4-48 3-3

Tap water (LLC)

4-51

Check leakage

3-4

Check

3-7

Adjust

4-44

Fan belt

4-21

SECTION 4 - MAINTENANCE

FUEL SYSTEM

ENGINE

Components

Interval Item

When Pre- Every Every Every Every Lubricant Reference 3 6 12 2,000h re- opera- week ,etc. months months months page quired tion (Replacing part) 8h 50h 250h 500h 1,000h

Radiator core

Clean

4-24

Radiator cap

Clean

4-24

Hoses in cooling Check / Change system

4-47

Check color, sound, smell of exhaust gas

3-14

Valve clearance Check / Adjust Check / Compression Adjust pressure

4-52

Injection timing

Check / Adjust

4-62

Starter and generator

Check / Adjust

4-52

Check level

3-6

Fuel Fuel tank

4-62

Drain water and deposits

4-40

Check leakage

3-6

UPPER FRAME

HYDRAULIC SYSTEM

Check level

4-22

3-5

Hydraulic oil Change HydraSuction Clean / ulic strainer Change tank Return filter

Change

*

(First)

Hydraulic oil

4-53

Strainer

4-53

Element

4-49

Check oil leakage and damage of pipings and hoses

4-37

Check oil leakage and damage of cylinders, etc.

4-37

Line filter Inline filter

4-55

Clean

Slewing bearing Grease

Grease

4-43

Grease in slewing grease bath

N.L.G.I No.2 Lithium base MoS2 grease

4-62

Change

SECTION 4 - MAINTENANCE Components

Interval Item

LOWER FRAME

Travel reduction Oil motor Change

When Pre- Every Every Every Every Lubricant Reference 3 6 12 2,000h re- opera- week ,etc. months months months page quired tion (Replacing part) 8h 50h 250h 500h 1,000h

*

(First)

Gear oil

Check/Adjust tension of rubber/steel shoe

4-18

Check crawlers and links of rubber/steel shoe

4-32

Check Roller Idler

Change

4-37 Gear oil

Check oil leakage and wear of sprocket/travel reduction motor

ATTACHMENT

4-38 Grease

Grease for pins

ELECTRICAL EQUIPMENT

4-58 4-37

Bucket

OTHERS

4-57

Boom&Arm cylinder

4-42

Change

4-29

Adjust mount gap

4-30

Bucket

Check wear and damage of tooth and side cutters

4-26

Check damage of electrical wirings

4-34

Check electrolyte Battery level Measure specific gravity

4-41 Distilled water

4-41

Check function of warning lamps

3-8

Check switches / levers

3-15

Change working light(Lamp)

4-25

Check abnormal deformation and damage of machine exterior Check looseness and missing of capscrews and nuts

4-36 4-36

Check

3-15

Operating lever Lubricate

Grease

4-34

4-23

SECTION 4 - MAINTENANCE 4.14 WHEN REQUIRED Thoroughly read and understand the section SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

A. CLEANING RADIATOR CORES

Direct contact of yourself with compressed air, steam and high pressure water causes injury. Make sure to wear the protective glasses, mask, safety cap, safety shoes, etc.

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

[1] Open the left side cover and the cover under the seat, referring to page 2-12 "Open/Close Guard Cover."

[2] Check the radiator fins for clogging with dust and mud.

[3] Remove the dust and mud on the radiator cores and fins with compressed air.

PW-5-5

NOTE : To avoid damages on the fins, take some distance between the spray nozzle of compressed air and the fins. If the fins gets some damages, it causes water leakage resulting in overheating.

B. CLEANING OR REPLACEMENT OF RADIA-TOR CAP

USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP. THE COOLANT IS UNDER HIGH PRESSURE WHEN HOT. NEVER REMOVE THE RADIATOR CAP WHEN THE SYSTEM IS HOT. ALLOW SUFFICIENT TIME FOR THE MACHINE TO COOL DOWN BEFORE REMOVING THE RADIATOR CAP. [1] Remove the radiator cap after the engine has cooled down to touchable with a bare hand.Slowly loosen the cap to release the inside pressure.

Remove the radiator cap after all pressure is released.

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

Clean it and/or replace it if needed.

[3] Securely tighten the cap.

4-24

PA-1-21

Z2-303P

If the tightness of cap is insufficient, it may cause danger of getting burned due to spouting out of hot water or steam during operation.

SECTION 4 - MAINTENANCE C. REPLACEMENT OF WORKING LIGHT A light bulb of 23 W is used for the working light.

Since the light bulb develops high temperature while working, the service life of the light bulb becomes shorter if oil or grease is adhered on it.

When replacing the light bulb, hold it at the flange portion not touching with its glass portion.

When the working light is not lightened even though the switch for working light is turned on, the light bulb or fuse may be burned out.

If there is no trouble on the light bulb, check the fuse referring to page 2-13 .

The following is the description for the changing procedures of light bulb.

[1] Place the attachment on the ground, and set the safety lock lever to "LOCKED" position, then stop the engine.

[2] Remove four screws (8) to remove the rim (9) and the lens part (10) from the housing.

[3] Remove the spring (13) fixing the socket (12).

[4] Remove the light bulb (14) from the socket (12), and install a new bulb.

[5] Assemble the working light in reverse order of the above.

8

11 10

9

12

13

14

PR-4-31

NOTE : Pay attention not to break the light bulb at the replacement. Hold the lens at removing the screw (1), otherwise, the lens falls off.

4-25

SECTION 4 - MAINTENANCE D. RECONDITIONING BUCKET 1. CHECK FOR ABRASION/DAMAGES ON TOOTH POINT & SIDE CUTTER

When replacing the tooth point and side cutter, apply a safety block to the bottom face of the bucket.

Check the tooth point and side cutter for their wornout condition. The tooth point holed or cracked must be replaced before the abrasion on the adapter. And the worn-out side cutter is also to be replaced earlier.

If the replacement is too late, the bucket body will be damaged.

PV-4-47

4 3

NAME OF PARTS: (1)Adapter nose (2)Tooth point (3)Rubber lock pin (4)Locking pin 2

1

WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

REPLACEMENT OF TOOTH POINT & SIDE CUTTER Consult with an authorized dealer for the replacement of tooth point and side cutter.

4-26

PV-4-48

SECTION 4 - MAINTENANCE 2. REPLACING THE TOOTH POINTS Replace the bucket tooth in the following cases.

HAMMER

When little holes appear on the tooth point.

When the edge lines of the tooth point are worn.

PUNCHING TOOL

Wear, goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

SUPPORT (SAFETY BLOCK)

TOOTH POINT

PV4-49

[1] Using a hammer and punching tool, hammer out the locking pin. Be careful not to damage the rubber lock pin (3).

[2] Inspect the locking pin (4) and rubber lock pin (3).

Replace them if the locking pin (4) is too short or the rubber lock pin (3) is in poor condition.

PV4-50

[3] Clean the surface of the adapter nose (1) with a putty knife to remove the adhered soil.

[4] Fit the tooth point (2) onto the adapter nose (1).

!

[5] Push the rubber lock pin (3) in the hole of the adapter nose (1).

[6] Drive the locking pin (4) until it is aligned with the point face.

"

PV4-51

4-27

SECTION 4 - MAINTENANCE 3. REPLACING THE SIDE CUTTERS

Wear, goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

[1] Completely remove all sand and soil adhering around the capscrews completely. Use an acetylene torch to cut off the capscrews, then remove the side cutter.

PV4-52

[2] Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the capscrews and nuts with new ones.

Tightening torque : 11.7 ± 1.2 kgf m {84.6 ± 8.7 lbf·ft} [3] After tightening the nuts, spot-weld them.

PV4-53

4-28

SECTION 4 - MAINTENANCE E. REPLACEMENT OF BUCKET

Replace the bucket on firm flat ground. Pay close attention to safety.

When aligning the pin bores, do not insert your finger into the bores. It may cause severe injury.

Never insert your finger into the pin bores. Make sure to align them visually.

7 A 8 1. REMOVAL OF BUCKET [1] Slightly operate the boom and the arm to remove load from the pins.

[2] Roll O-rings (1) onto the bucket boss.

After installing the pins, get them back to the original position.

[3] Remove the spring lock ring (2) and lock pin (3), then remove the pins (4) and (5) to remove the bucket (6).

NOTE : Pay attention not to adhere any sand or dust to the pins removed.

Pay attention not to damage the dust seals (9) which are installed in both ends of the arm (7) and bucket link (8).

A

6 2

9

5

9 SECTION A-A

4

3

1

3 2

PW-4-26

4-29

SECTION 4 - MAINTENANCE 2. INSTALLING BUCKET [1] Clean each pin and pin hole and grease sufficiently.

[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] Fit the O-ring (1) into the normal position as shown in the right Figure (PME-4-36).

Apply grease to the bucket link from the grease nipples sufficiently.

NOTE : Replace the O-ring (1) showing cracks or losing elasticity with a new one.

PMJ-4-34

PWJ-4-27

PME-4-36

3. ADJUSTING BUCKET MOUNT GAP

Unexpected movement of attachment, while adjusting the bucket mounting gap is quite dangerous.

Place the bucket on the ground in a stable condition, and set the safety lock lever to "LOCKED" position, then stop the engine.

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.

If the clearance of the bucket is not properly adjusted, galling may occur on the contact faces of the bucket and arm, resulting in abnormal noise and damage of the shaft and O-ring.

Standard clearance of the bucket in total of both clearances Normal

0.5mm (0.02 in)

[1] Lower the bucket to the ground to stabilize, as shown in the Figure (PME-4-37).

Slightly lift boom to remove load from bucket pin connections to properly adjust bucket clearance.

4-30

PME-4-37

SECTION 4 - MAINTENANCE [2] Roll the O-ring (1) from its normal position to the bucket boss to avoid damage.

2 4

[3] 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).

By contacting the arm and bucket, total clearance is obtained on one place.

[4] Set the safety lock lever to the "LOCKED" position; then stop the engine.

[5] Measure the total clearance "X" between the arm and bucket boss. The clearance is the existing total clearance. Exact clearance is gotten easily by using a thickness gauge.

[6] If the measurement value is 1.0 mm (0.04 in) or more, decrease the clearance.

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.

3 5 1 BUCKT BOSS

SECTION C-C

ARM BOSS

PMJ-4-38

BUCKET CLEARANCE ADJUSTING MECHANISM

X

PMJ-4-39

NOTE : Thickness of shim is 0.6 mm (0.02 in). 8shims on the average are provided on one capscrew (2).

PWE-2-7

[7] Tighten the 3-capscrew (2) with washer (4) equally to the specified tightening torque.

[8] Return the O-ring (1) to the normal position.

(Groove between the arm and bucket bosses.)

PME-4-40

4-31

SECTION 4 - MAINTENANCE F. INSPECTING RUBBER CRAWLER SHOE Repair or replace rubber crawler shoe if it falls into the following condition.

(Contact an authorized dealer for repair or replacement of rubber crawler shoes)

1. Height of lug [1] If the lug of height (A) wears off, traction force decreases. Replace the shoe with a new one if (A) decreases below 5 mm (0.2 in).

LOWER ROLLER

METAL CORE

RUBBER CRAWLER SHOE

LUG

STEEL CORD PM5-76

[2] If the lug wears out at an extent that the steel cord in the shoe is exposed over two links, replace the shoe with a new one.

PME-4-42

2. Breakage of steel cord If the steel cords of the rubber crawler shoe are broken by more than one half of one side row, replace the shoe with a new one.

PME-4-43

3. Crack of rubber crawler shoe If a crack which has developed to about 60 mm (2.4 in) length is seen between the lug of rubber shoe, repair the shoe.

However, repair the shoe immediately if the steel cord inside is exposed even though a crack is small and short.

NOTE : For repairs or replacement of rubber crawler shoes, contact an authorized dealer.

PRE-4-54

4-32

SECTION 4 - MAINTENANCE 4. PEELING OFF OF METAL CORE ON RUBBER CRAWLER SHOE Depending on the usage of rubber crawler shoes, there may occasionally happen a peeling off of metal core on the rubber shoes (inner side) due to contact with the rollers and idler/sprocket or abrasion, even though there are no external damages or abrasion on the lug side (outer side) of it.

PME-4-44

NOTE : 1. THE METAL CORE STARTS PEELING WITH THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE. 2. FULLY UNDERSTAND THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE REFERRING TO PAGE3-36 "USING RUBBER CRAWLER SHOES." 3. NOTE THAT THE WARRANTY IS NOT APPLICABLE FOR ANY DAMAGES DUE TO THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE OR THE USE OF IT WITH IMPROPER TENSION ON IT.

PME-4-45

[1] The rubber crawler shoe on which the peeling off of metal core shows even at one place, must be replaced with a new one.

[2] The cracked rubber crawler shoe by which the metal core comes to the surface must be replaced with a new one.

PME-4-46

[3] The cracked rubber crawler shoe on the contacting portion of the metal core with the roller is not required to repair.

PME-4-47

4-33

SECTION 4 - MAINTENANCE G. LUBRICATION FOR OPERATING LEVERS When any operating levers become heavy to operate or do not move smoothly, apply grease to the sliding and rotating portion (A) and the top portion (B) of the universal joint.

[1] Move the machine to firm and level ground. Set the attachment on the ground. Place the safety control lever to LOCKED positon, then stop the engine.

[2] Carefully raise up the rubber boot on the troubled operating lever with hand paying attention not to give any damages to it.

PRE-4-81

[3] Apply grease to the sliding and 4 places of rotating portion (A) and the top portion (B) of the universal joint.

[4] Set back the rubber boot to the original position.

[5] Check the pilot valve for any looseness, and if loosened, retighten the socket bolt.

PRE-4-82

H. CHECKING ELECTRICAL WIRING AND FUSES

When a frequent replacement is required for the fuses or there are any traces of short circuiting on the electrical wiring, consult with an authorized dealer.

Before checking the electrical system, make sure to disconnect the battery cable of negative (-) side.

Erroneous short circuiting may cause fire.

UZ2-070

4-34

SECTION 4 - MAINTENANCE

*REPLACING PROCEDURES When a new fuse is blown within a short time of service or frequent replacement for fuses are required, it may be caused by troubles in electric sequence.

Consult with an authorized dealer for repairs.

PM2-63-1

The main fuse box, covered by the fuse box cover, is provided under the seat.

[1] Place the bucket to the ground.

[2] Set the safety control lever to the lock position.

[3] Turn the starter switch to OFF to stop the engine.

[4] Open the cover under the seat.

[5] The fuse box cover is locked on one side. Release the lock and remove the cover.

[6] When any fuse is blown as shown in the right, replace it with the spare fuse stored in the fuse box.

[7] After replacing the fuse, make sure to set the cover with a click.

PM2-64-1

NEVER REPLACE A FAULTY FUSE WITH HIGHER AMPERAGE FUSE. NEVER USE A JUMPER IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS.

PRE-2-53

Link (For starter) *Fusible In case power does not come when the starter switch

FUSIBLE LINK (RED)

is turned ON , a disconnection of the fusible link is suspected.

Inspect wires and fuse link. Replace the fusible link if needed.

NOTE : The fusible link is of a fuse wiring of big size provided in the electric wiring for large current.

It protects the electrical equipment and wiring from abnormal current just like an ordinary fuse.

FILLER PORT CAP (ENGINE OIL)

PW2-66

4-35

SECTION 4 - MAINTENANCE — 8Hr 4.15 8-HOUR (DAILY) INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

The following inspection and maintenance shall be carried out before starting / after starting and after work.

REFER TO SECTION 3 "BASIC MACHINE OPERATION" IN THE FOLLOWING ITEMS FOR INSPECTION AND MAINTENANCE Page 3-3 for checking and refilling of coolant.

Page 3-4 for checking of coolant leakage.

Page 3-6 for checking of fuel level and refilling.

Page 3-6 for checking of fuel leakage.

Page 3-7 for checking of fan belt.

Page 3-5 for checking of hydraulic oil level and refilling.

Page 3-4 for checking of engine oil level and refilling.

Page 3-8 for checking of warning lamps lightening.

Page 3-8 for checking of working light lightening.

Page 3-14 for checking of exhaust gas color, abnormal sound and smell.

Page 3-15 for checking of operating conditions of each switch and lever, A. CHECK EXTERNAL CONDITIONS OF MACHINE A dent or distortion which apparently seems not to be severe damage, may be abnormal contact on internal parts or hoses.

Consult with an authorized dealer for advise and/or for repairs.

B. CHECK CAPSCREWS AND NUTS FOR LOOSENESS AND/OR MISSING Check for missing capscrews and nuts and replace as needed. Check and make sure all capscrews and nuts are properly tighten. Likewise, check and make sure all hose clamps are properly tighten.

The abnormal sound during operation may cause leakage or fire. Use torque values from pages 4-10 and 411.

NOTE : Use the tools suitable for the work referring to page 4-9 , ACCESSORY TOOLS.

4-36

PMJ-1-6

SECTION 4 - MAINTENANCE — 50Hr C. CHECK EACH CYLINDER, PIPING AND HOSE FOR LEAKAGES AND DAMAGES BE CAUTIOUS OF HOT FLUIDS AND SURFACES, WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

HYDRAULIC LINE IS ALWAYS HIGHLY PRESSURIZED. MAKE SURE TO RELEASE THE PRESSURE IN THE LINE BEFORE STARTING SERVICE AND/ OR MAINTENANCE, OR REFILLING. NEVER USE HANDS TO CHECK FOR LEAKS. HIGH PRESSURE FLUID LEAKS WILL PENETRATE THE SKIN AND CAUSE SEVERE INJURY. Hydraulic oil leakage will slow down a machine. Move the machine to firm level ground and place the attachment in the oil check position and stop the engine.

[1] Set the safety lock lever to "LOCKED" position, then stop the engine.

[2] To check the location of leakage, take a time to allow getting the temperature on each portion of the machine down to around 40° C (104° F). Make sure to wear the protective glasses and gloves for the check.

[3] Press the rubber cap of the air breather on the top of the hydraulic oil tank several (five to seven) times to release the internal pressure of the tank.

Consult with an authorized dealer for advise and repairs.

PJE4-22

NOTE : When any abnormalities happen on the machine, immediately stop operation, and ask for repairs as needed.

When the volume becomes insufficient for the engine coolant or oil due to leakage, a warning lamp is illuminated.

D. CHECK TRAVEL SYSTEM FOR LEAKAGE AND ABRASION [1] Check the lower roller, idler and travel motor for any leakages.

[2] Check the lower roller, idler, and sprocket for abnormal wear and loosened fixing bolts.

[3] Slowly travel the machine and check for any abnormal sound.

NOTE : Consult with an authorized dealer for advise and/or repairs as needed.

PR-4-61

A B C

TRAVEL MOTOR SPROCKET LOWER ROLLER

D E F

CRAWLER SHOE SHOE SLIDE IDLER

4-37

SECTION 4 - MAINTENANCE — 50Hr 4.16 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

Perform together with 8-hour (daily) inspection and maintenance.

A. ADJUSTING CRAWLER TENSION Proper adjustment of the rubber crawler tension is essential for extending service life of the crawler and the travel system, and prevention of coming off of crawler due to insufficient tension.

THE INSPECTION OF THE CRAWLER SHOE TENSION IS CARRIED OUT WITH ONE SIDE OF MACHINE LIFTED. IT IS QUITE DANGEROUS IF THE MACHINE IS ERRONEOUSLY DROPPED. NEVER OPERATE THE MACHINE DURING THE INSPECTION. MAKE SURE TO CARRY OUT THE WORK WITH THE HELP OF ANOTHER PERSON. THE OPERATOR OPERATES THE MACHINE IN ACCORDANCE WITH THE SIGNAL OF THE PARTNER. Refer to page 4-18 for the check and adjustment of rubber crawler shoe tension.

B. GREASING PINS AROUND BUCKET Request for Greasing Generally the greasing is required at every 50 hours operation or weekly. Refer to page 4-42 for greasing under special conditions.

[1] Move the machine to firm level ground and place the attachment on the ground in the oil check position, as indicated in (PAE-4-25).

[2] Clean the grease fittings before greasing. Replace the grease nipple with a new one, if damaged.

[3] Lubricate with a grease gun through the grease fittings shown (PMJ-4-17) with arrows and the table below.

Q TY NO. GREASING POINTS 1 1 BUCKET CYLINDER ROD PIN 1 2 IDLER LINK/ARM CONNECTING PIN 1 3 BUCKET LINK PIN 1 4 ARM/BUCKET CONNECTING PIN [4] Properly wipe off any grease squirted out around the pin connection

4-38

PME-4-56

PAE-4-25

PMJ-4-17

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS.

SECTION 4 - MAINTENANCE — 50Hr C. DRAINING WATER FROM WATER SEPARATOR AND CLEANING If the red ring (D) in the water separator sinks down to 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.

WATER SEPARATOR

FUEL OIL ADHERED PERIPHERY MAY CAUSE FIRE. WIPE IT OFF THOROUGHLY.

A [1] Set the safety lock lever to "LOCKED" position, then stop the engine.

[2] Open the engine guard. After cooling down each portion, push the handle (A) of the water separator upward to the "CLOSE" position.

[3] Loosen the ring (H) to remove the case (F), and drain the water out.

NOTE : Pay attention not to lose the red float (D) and spring (C).

Check the water drained for its contamination and when it is dirty, clean up the element (B) and inside of the case (F).

[4] Remove the element (B), and clean it with diesel fuel.

[5] Replace the O-ring (E) with a new one.

[6] Install the element (B) to the water separator body.

[7] Set the O-ring (E) to the case (F), then tighten it up with ring (H).

[8] Push the handle downward to set at "OPEN" position.

[9] After draining water, make sure to bleed out the air releasing for the fuel system referring to page 4-15 .

NOTE : Do not clean up the element with gasoline.

CLOSE

B

H

D OPEN

WATER

C F

PJE4-82

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS.

PMJ-4-49

PV-4-71

4-39

SECTION 4 - MAINTENANCE — 50Hr D. DRAINING WATER AND DEPOSITS FROM FUEL TANK

MAKE SURE TO STOP THE ENGINE WHEN DISCHARGING FUEL FROM THE FUEL TANK. THOROUGHLY WIPE UP THE SPILLED FUEL. Loosen the drain plug to drain the water and deposits in an empty container.

Since the water is deposited during the night, it is effective to drain before starting up the engine in the morning.

[1] Swing the upper structure of the machine so that the drain plug (A) under the fuel tank comes midway between the crawler shoes of left and right.

[2] Remove the under cover under the fuel tank.

[3] Place an empty container under the drain plug to catch the fuel discharged.

[4] Slowly loosen the drain plug to drain water mixed in and deposits together with the fuel.

[5] When pure fuel begins to discharge, tighten up the drain plug (A).

[6] Install the under cover at the regular position.

NOTE : Check for fuel leakage after tightening up the drain plug.

Consult it with an authorized dealer for advise and repairs if needed.

Make sure to contain any fuel spillage.

FUEL TANK

PW-5-6

(A)

PW-5-7

4-40

SECTION 4 - MAINTENANCE — 50Hr E. CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY The battery fluid easily decreases with high ambient temperature in summer season. Check the battery fluid level in the morning before starting operation.

Continuous use of the battery with low fluid lowers battery performance.

Check the battery fluid level periodically, and if insufficient, refill the battery with distilled water before starting the engine (before charging battery).

FLAMMABLE GAS (HYDROGEN GAS) IS GENERATED IN THE BATTERY. DO NOT ALLOW SPARKS OR FLAMES TO COME IN CONTACT WITH BATTERIES TO AVOID TRIGGERING AN EXPLOSION. BATTERY FLUID HAS STRONG ACIDITY. IT CORRODES METAL VERY RAPIDLY. IF IT ADHERES ON SKIN OR ENTERS INTO EYES, IT CAUSES A BURN OR BLINDNESS. AT SUCH CASES, IMMEDIATELY WASH SKIN OR EYES WITH LOTS OF WATER, AND ASK A DOCTOR TO TREAT IT AS SOON AS POSSIBLE.

PME-4-66

Check the indicator (A) on the battery, and always keep it at green color. Red color means insufficient battery fluid or charging.

[1] Set the safety lock lever to "LOCKED" position, then stop the engine.

[2] Put down the seat stand forward, and remove the battery cover of the left.

[3] Remove the caps (1) of each cell to check the fluid level.

[4] If battery fluid level is low, refill the cell with distilled water up to the specified level (10-15 mm (0.4-0.6in) above the plate).

[5] Make sure the air vent holes on the caps (1) are clean and securely tighten caps (1).

[6] If the terminal (2) are dirty, wash it 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 sand paper.

PVE-4-40

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 (20° C or 68° F) For the specific gravity of battery fluid at cold climate or other specific conditions, refer to page 3-38, and make the charging rate around 100%.

If it is difficult even after re-charging is carried out, replacement of the battery with a new one is required.

NOTE : Measure the specific gravity of battery fluid with a gravimeter. The measured value varies depending on the ambient temperature. Consult with an authorized dealer for advise and/or repairs as needed.

4-41

SECTION 4 - MAINTENANCE — 250Hr 4.17 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

Perform together with 8-hour and 50-hour inspection and maintenance.

A. GREASING ATTACHMENT AND DOZER PINS

NOTE : In ordinary operation, apply grease every 250 hours of operation or every six months, but under special conditions, observe the following lubrication intervals 1) When operating the machine with a special attachment, apply grease every day before starting work.

2) For underwater digging operation, apply grease to the areas to be immersed in water every day before and after work.

3) Where the machine is stored for more than one month, apply grease before working.

PAE-4-25

[1] Move the machine to a firm level area and place the attachment in the oil check position.

[2] Make sure to clean the grease fittings before the greasing. Replace the grease fittings with a new one, if damaged.

[3] Use table below to lubricate all connections through grease fittings as shown in (PME-4-68) and (PME4-69) unil grease purges out.

[4] Properly wipe off any grease oozed out around the pin connection.

PME-4-68

NOTE : Since the dozer foot pin (3) is supported by an iron bushing, frequent greasing is required for it when the dozer is frequently used at the work.

And when greasing the attachment, make sure to grease to dozer foot pin (3), too.

NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4-42

GREASING POINTS Dozer cylinder rod pin Dozer cylinder foot pin Dozer foot pins Boom foot pin Boom cylinder foot pin Boom cylinder rod pin Arm cylinder foot pin Arm cylinder rod pin Boom/Arm connecting pin Bucket cylinder foot pin Bucket cylinder rod pin Swing cylinder foot pin Swing cylinder rod pin Swing bracket/frame connecting pin

Q TY 1 1 2 1 1 1 1 1 1 1 1 1 1 2

PME-4-69

14

12

13

PW-5-9

SECTION 4 - MAINTENANCE — 250Hr B. OIL CHANGE FOR ENGINE BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

DO NOT CARRY OUT THE OIL CHANGE JUST AFTER STOPPING THE ENGINE WHICH IS KEPT AT HIGH TEMPERATURE AT EVERY PORTION. ALLOW SUFFICIENT TIME FOR THE ENGINE TO COOL DOWN BEFORE MAINTENANCE. THE FIRST OIL CHANGE MUST BE CARRIED OUT AT 50 HOURS OPERATION FOR A NEW MACHINE ENGINE. Container to receive drained oil : 4 liter (1.1 gal) or more capacity Oil volume to be refilled : 3.9 liter (1.06 gal) (Upper limit of standard volume.)

[1] Place an empty container to receive the drain oil under the drain plug (1) located at the bottom of engine.

[2] Remove the bottom cover (4) under the drain plug.

[3] Slowly loosen the drain plug (1) so that the oil does not splash over yourself.

Make sure to contain any oil spillage.

[4] Check drained oil. In case that lots of metal particles and/or foreign materials are contained in it, consult with an authorized dealer for advise and/ or repairs.

[5] Securely tighten the drain plug (1).

[6] Open the engine guard, and remove the filler port cap (Yellow) (2) . Refill the engine with the specified oil.

Refer to page 4-7 for the recommended oil.

[7] Start the engine, operate it for several minutes at idling, and shut it down.

Check the oil level and make sure it is between the "H" and "L" marks on the dipstick (3) referring to page 3-4, the section for "CHECK & REFILL-UP OF ENGINE OIL".

1 4

PM5-108

H L

2

3

PM5-109

C. GREASING TO SLEWING BEARING

NEVER SLEWING THE MACHINE, WHILE FEEDING GREASE TO THE SLEWING BEARING. Feed grease to the swing bearing, slewing the machine and place it in 4 different positions (90° apart), until grease oozes out. Only one grease nipple is provided for the slewing bearing. Properly wipe off any grease oozed out around the swing bearing seal.

PWJ-4-37

4-43

SECTION 4 - MAINTENANCE — 250Hr D. ADJUSTMENT FOR BELT TENSION

MAKE SURE TO STOP THE ENGINE WHILE INSPECTION AND MAINTENANCE. OTHERWISE, YOUR FINGER OR HAND MAY BE CAUGHT BY THE FAN OR FAN BELT RESULTING IN INJURY. Check the fan belt for proper tension, wear conditions and damages. Make sure to adjust tension properly.

Provide a lever (such as bar, wrench or handle) and a wooden piece.

STOP

NOTE : There may be big differences among individuals on the adjustment for the belt tension with a lever causing too much or too little belt tension. Make sure to check for deflection and tensile force after the adjustment.

Use the lever with the length of 300-400 mm (12-16 in) suitable for the adjustment work.

E. ADJUSTMENT FOR FAN BELT [1] Loosen the mounting screw (1) and the adjusting screw (2) slightly before adjusting the fan belt tension.

[2] Loosen the adjusting bolt (3) to adjust the fan belt to the specified tension, and tighten the mounting screw (1) and the adjusting screw (2).

[3] After the adjustment, start up the engine and operate it at low idling for around 5 minutes, then stop the engine. And confirm the belt tension (deflection and tensile force). Refer to page 3-7 .

4-44

PM5-111

SECTION 4 - MAINTENANCE — 250Hr F. REPLACEMENT OF ENGINE OIL FILTER

EVERY PORTION OF THE ENGINE IS KEPT AT HIGH TEMPERATURE JUST AFTER STOPPING THE ENGINE. TAKE TIME TO ALLOW COOLING DOWN THE ENGINE FOR INSPECTION AND MAINTENANCE. NOTE : The oil filter is of a cartridge type which can not be reused nor cleaned with the filter disassembling. Replace it as a unit.

Replace it at 50 hours operation for the first use of new machine.

The filter wrench provided on the machine is used for removing.

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

The filter cartridge must be replaced with a new one at 50 hours operation for the first use of new machine.

[1] Stop the engine, open the engine guard, and remove the under cover.

PAE-4-27

[2] Apply the filter wrench (B) to the filter cartridge (A), and turn the wrench with spanner to counterclockwise to remove it.

[3] Wipe off any dust on the seal face of filter base, and avoid contamination.

[4] Thinly apply clean engine oil to the packing of new filter cartridge, and install and tighten it up with hand. Then retighten it by about 2/3 turns.

PME-4-74

[5] Start the engine, and operate it at idling for several minutes to check for any leakage at the installing face.

[6] Close the engine guard and install the under cover.

NOTE : When the machine is operated in dusty circumstances, a shorter interval is required for the replacement.

When some metal particles are adhered on the element removed, consult it with an authorized dealer.

PVE-4-47

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS. 4-45

SECTION 4 - MAINTENANCE — 250Hr G. CLEANING ENGINE FUEL FILTER BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

EACH UNIT IS HOT IMMEDIATELY AFTER THE MACHINE HAS BEEN OPERATED. CHANGE THE FILTER AFTER THE TEMPERATURE HAS COOLED DOWN. CLEAN UP ALL SPILLED FUEL TO AVOID A FIRE. Prepare empty container.

[1] Stop the engine, and open the engine guard.

[2] Set the handle (A) of fuel filter at "CLOSE" position. And remove the retaining ring (B), and take out the cup case (D) and element (C).

(WATER SEPARATOR)

[3] Drain dust and water accumulated on the bottom of cup case (D) of fuel filter in the empty container, and clean the fuel filter.

[4] Wash and clean the element (C) with diesel fuel, and use compressed air, 2~3 kgf/cm2 (28~43 psi) from the inside to remove dust.

HANDLE A CLOSE

B

NOTE : It is strictly prohibited to wash and clean element with gasoline.

OPEN

[5] Replace O-rings (E) and install the fuel filter in reverse order shown in the item [2].

D FUEL FILTER

PJE4-103

[6] Bleed air referring to the item "BLEEDING AIR IN FUEL SYSTEM" in page 4-15 .

[7] Ensure that the filter installing face is free from possible fuel leakage, after running engine at idling for several minutes.

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS.

PV-4-71

4-46

SECTION 4 - MAINTENANCE — 250Hr H. CHECKING RADIATOR HOSE Replacing the hoses before any problems occur is both economical and good maintenance practice.

This will reduce costs and minimize unexpected interruption of working.

Immediately replace the hose if it is cracked, worn, or if water is leaking from it. This will prevent serious problems, such as the engine overheating.

[1] Check the hoses for water leakage due to loose clamps or cracked and worn hoses.

[2] Tighten any loose clamps and replace any cracked or worn hoses following the procedures below.

RADIATOR

FULL LOW

RESERVE TANK

PW-5-13

I. REPLACING RADIATOR HOSE

DANGER OF HIGHLY PRESSURIZED STEAM IS GENERATED IN THE RADIATOR. WHILE THE COOLANT IS KEPT AT HIGH TEMPERATURE AND PRESSURE, DO NOT LOOSEN NOR OPEN THE RADIATOR CAP. WHEN OPENING THE RADIATOR CAP, STOP THE ENGINE. TAKE A GOOD ENOUGH TIME TO ALLOW COOLING DOWN THE COOLANT TEMPERATURE. [1] Loosen the radiator cap slowly. Ensure that pressure has been released. Push the cap down and hold it down while turning to remove.

RADIATOR CAP

[2] Remove the under cover under the radiator and the drain cock.

[3] Drain the coolant from the drain cock until the coolant level becomes below the hose to be replaced.

[4] Loosen the hose clamp and disconnect the damaged hose; then replace it with a new one.

DRAIN HOSE

DRAIN COCK PW-5-14

[5] Install the drain cock.

[6] Fill the radiator with coolant, then fill the reserve tank with coolant, too. Refer to page 3-3 .

[7] After the fill-in, tighten securely the radiator cap.

[8] Install the under cover.

4-47

SECTION 4 - MAINTENANCE — 250Hr J. CHECKING/CLEANING/REPLACING AIR CLEANER ELEMENT

WEAR PROTECTIVE GLASSES OR GOGGLES WHEN USING COMPRESSED AIR.

NOTE : Stop the engine before inspecting or cleaning the air cleaner element. This will prevent the engine from getting damaged due to dust.

STOP

1. CHECK ELEMENT When black smoke is discharged from the exhaust outlet, check the air cleaner element, and clean or replace if needed.

2

2. CLEANING ELEMENT NOTE : Do not reuse the element with damaged folds, gasket and/or seal.

Do not heavily tap the element nor hit it to anything else for cleaning.

AIR CLEANER

PJE4-107

[1] Unlock the two clamps (2) and pull out the air cleaner element (1).

[2] Clean the inside of the element body.

[3] Blow compressed air 3 kgf/cm2 (43 psi) along the folds of the element from the inside of the element.

[4] After cleaning, check the air cleaner element for possible damage, when small holes and partially thin parts are found, replace it with new one.

1

PJE4-108

REPLACEMENT OF ELEMENT [1] Insert new air element (1) in the housing.

[2] Install the cover on two clamp (2) positions, directing the mark TOP on the cover to the inlet side.

NOTE : The element is reusable up to 6 times of cleaning or for one year, after that it must be replaced to new one.

PM5-118

4-48

SECTION 4 - MAINTENANCE — 500Hr 4.18 500 HOUR (6-MONTH) INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

Perform together with 8 to 250-hour inspection and maintenance.

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

B. REPLACEMENT OF HYDRAULIC RETURN FILTER The return filter keeps the hydraulic oil clean by removing any foreign matter that may be in the oil. This will prevent the hydraulic equipment from becoming damaged and prolong the equipment's life. Thus, since the return filter is a very important part, treat it with care.

• NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. • RELEASE HYDRAULIC TANK PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. • WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

[1] Move the machine to firm level ground, place the attachment in the oil check position, and stop the engine.

See Fig. PAE-1-22.

[2] Open the cover on the top of the hydraulic oil tank with the stator key, and support the cover with the stay.

[3] Make the filter fixing portion clean in order not to enter any dust or foreign material.

[4] Press the rubber cap of the air breather several (five to seven) times to release the internal pressure of the hydraulic oil tank.

[5] Remove the capscrews (1), the spring washers (2) and the cover (3) on the top of the hydraulic oil tank.

[6] Take the spring (4), the valve (5) and the element (6) out of the tank.

[7] Exchange the O-ring (7) of the mounting face of the cover (3).

[8] Clean the parts taken out with light oil.

[9] Install the element in reverse order of the above [5] and [6].

PAE-1-22

PJE4-22

6

1 2 3 7 4 5 PW-5-16

4-49

SECTION 4 - MAINTENANCE — 500Hr [10] Install the cover (3).

Tightening torque: 2.4 ± 0.2 kgf.m (17 ± 1 lbf.ft) [11] Start the engine, operate each work lever to make the machine in a posture of hydraulic oil level inspection, and check the oil level.

[12] Remove the stay, return the cover on the top of the hydraulic oil tank to the normal position and lock.

NOTE : For the machine with the breaker, the deterioration of hydraulic oil is increased by the breaker work compared with the standard digging with bucket.

Earlier replacement for the line filter and hydraulic oil is required. Follow the replacement intervals for them to page 8-8.

C. REPLACEMENT OF FUEL FILTER

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

EACH PORTION OF THE ENGINE IS KEPT AT HIGH TEMPERATURE JUST AFTER THE OPERATION. START THE SERVICING AFTER COOLING DOWN EACH PORTION. THOROUGHLY WIPE UP THE FUEL SPILLED OVER, OTHERWISE IT MAY CAUSE FIRE. Provide an empty container to receive the fuel.

[1] Stop the engine and open the engine guard.

[2] Put fuel container under the fuel filter.

[3] Set the handle (A) of fuel filter at "CLOSE" position. And remove the retaining ring (B), and take the element (C) out of the cup case (D). At this time, care must be exercised not to miss the spring which is placed in the cup case.

For the sake of safety and in order not to make the ground dirty, make sure to discharge the fuel into the container and make the around clean.

[4] Replace element (C) and O-ring (E) with new ones.

(WATER SEPARATOR)

HANDLE A CLOSE

B

[5] Install them in reverse order shown in the item [3].

OPEN

[6] Bleed air referring to item "BLEEDING AIR IN FUEL SYSTEM" in page 4-15 .

D FUEL FILTER

PJE4-103

[7] Run the engine in low idle for several minutes to ensure that the filter fitting section is free from possible fuel leakage.

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS. 4-50

PAE-4-41

SECTION 4 - MAINTENANCE — 1000Hr 4.19 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

Perform together with 8 to 500-hour inspection and maintenance.

A. REPLACEMENT OF COOLANT Use of soft water with less impurities as base coolant. Use the "Long Life Coolant" mixing it in the coolant more than 30% of density to prevent the cooling line from corroding and freezing. The density of "Long Life Coolant" must correspond to the expected lowest ambient temperature.

Refer to page 4-7 for the required density of "Long Life Coolant."

Provide an empty container to receive the coolant drained.

[1] Stop the engine. Open the engine guard. Start the servicing with the coolant cooled down enough.

DANGER OF HIGHLY PRESSURIZED STEAM IS GENERATED IN THE RADIATOR. WHILE THE COOLANT IS KEPT AT HIGH TEMPERATURE, DO NOT LOOSEN NOR OPEN THE RADIATOR CAP. WHEN OPENING THE RADIATOR CAP, STOP THE ENGINE. ALLOW SUFFICIENT TIME TO COOL DOWN THE ENGINE BEFORE SERVICING.

THE ANTI-FREEZE AGENT IS INFLAMMABLE AND DETRIMENTAL TO HUMAN BODY. KEEP AWAY FROM FLAMES AND SPARKS. PAY ATTENTION NOT TO ADHERE THE ANTIFREEZE AGENT ON SKIN OR ENTER INTO EYE. IF IT ADHERES ON SKIN OR ENTERS INTO EYE, IMMEDIATELY WASH SKIN OR EYE WITH LOTS OF CLEAN WATER, AND ASK A DOCTOR TO TREAT IT.

[2] Loosen the radiator cap slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove.

[3] Discharge the coolant through the drain hose into the empty container.

[4] After discharging, close the drain cock. Then fill the cooling line with the mixture of water and cleaning solvent (radiator cleaner).

[5] Operate the engine at a speed slightly faster than idling to raise the coolant temperature to 80° C (176° F) or more within white range on the thermometer for coolant temperature. Then, operate the engine for approximately 10 minutes.

[6] Stop the engine and open the radiator drain cock.

Flush the radiator with tap water until the water draining becomes clean.

RADIATOR CAP

DRAIN HOSE

DRAIN COCK PW-5-14

ACCELERATION LEVER

PM5-124

4-51

SECTION 4 - MAINTENANCE — 1000Hr [7] Close the radiator drain cock. Fill the radiator with tap water in which LONG LIFE COOLANT has been mixed (30% or more) up to the radiator cap. Rotate the engine for a while to fully release air from the cooling system.

DISPOSE OF ALL HAZARDOUS WASTE IN ACCORDANCE WITH GOVERNMENT ENVIRONMENTAL REGULATIONS.

[8] Stop the engine. Check the coolant level (the reserve tank water level should be between FULL and LOW). Refer to page 3-3 . Make sure level is to specifications.

[9] After checking for leakage, close the engine guard.

RADIATOR

NOTE : When the Long Life Coolant is not used, replace the coolant two times a year in spring and autumn.

NOTE : The following works require a professional skill because they are the inspection and maintenance inside the engine. Since the adjustment also requires special knowledge and skill, consult them with an authorized dealer.

FULL LOW

RESERVE TANK

PW-5-13

B. CHECK AND ADJUSTMENT FOR VALVE CLEARANCE This is to correct the time lag on the operating timing of exhaust and intake valves. Negligence for this service causes faults such as output shortage, improper exhaust gas color, noise and so on.

C. CHECK AND ADJUSTMENT FOR STARTER AND GENERATOR There is a possibility of warn-out brush and/or lack of grease lubrication on bearing.

This is of the adjustment to get good start ability and power generation.

PW-5-17

4-52

SECTION 4 - MAINTENANCE — 2000Hr 4.20 2000-HOUR INSPECTION AND MAINTENANCE Thoroughly read and understand the section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing the machine.

Perform together with 8 to 1000-hour inspection and maintenance.

A. OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION STRAINER

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

DANGER OF HIGHLY PRESSURIZED FLUID WITH HIGH TEMPERATURE EXISTS IN THE HYDRAULIC OIL TANK JUST AFTER THE MACHINE OPERATION. DO NOT START THE FLUID CHANGE IMMEDIATELY. START IT AFTER THE FLUID COOLED DOWN. WHEN LOOSENING THE AIR PLUG, LOOSEN IT SLOWLY TO RELEASE INSIDE PRESSURE.

PME-4-58

Container to receive discharged fluid : 40 liter (10.6 gal) or more capacity Volume to be filled in : 37 liter (9.8 gal) [1] Slew the machine so that the drain plug on the hydraulic oil tank comes to midway between the both crawlers.

[2] Remove the under cover under the hydraulic oil tank.

[3] Referring to page 4-50 Items [2] through [4], proceed the work in accordance with the same procedures.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

PJE4-114

[4] After releasing inside pressure from hydraulic oil tank, remove the plug (4) of oil filling port with a wrench.

2

[5] Using an oil suction pump, discharge the oil from the oil filling port (F) into a container to receive the drained oil.

3 4

[6] The remaining oil in the tank is drained from the drain plug (1). Set up a container to receive the drained oil under the drain plug on the bottom of hydraulic oil tank. Then remove the drain plug with a spanner (27 mm) to drain up the remaining oil.

[7] Check the O-ring (5) for any scores or other damages and replace it with a new one, if necessary.

5 F

PJE4-115

NOTE : When loosening the drain plug (1), pay attention not to pour the fluid over yourself.

4-53

SECTION 4 - MAINTENANCE — 2000Hr [8] After draining oil, screw the drain plug (1) into the hydraulic oil tank.

Tightening torque: 7.5 ± 0.5 kgf.m (54.2 ± 1.1 lbf.ft) Then remove the suction strainer built in the hydraulic oil tank for checking.

7

[9] Remove dirt adhered on the suction strainer (6) and wash it with clean light oil or wash oil. If damage of the suction strainer (6) is found, exchange it with a new one.

[10] Check the bottom of the strainer (6) and the Oring (7). If wear or damage is found, exchange it.

PW-5-18

[11] Insert the suction strainer (6) for installation.

[12] Supply the specified amount of hydraulic fluid to the hydraulic oil tank according to the item "Recommended Oil Viscosity and Oil Change Volume."

[13] Install the cover (4) with the capscrews (2) and the lock washers (3).

Tightening torque: 2.4 ± 0.20 kgf.m (5.3 ± 0.4 lbf.ft)

m

m

0 46

4

2 3

6

[14] Install the under cover in the normal position.

[15] After starting the engine to continue running for several (five to seven) minutes, actuate each cylinder and perform slewing operation. Then return the machine to the posture of the hydraulic oil level inspection, stop the engine and check the oil level.

If the amount of oil is insufficient, replenish the oil.

PW5-132

4-54

SECTION 4 - MAINTENANCE — 2000Hr B. CLEANING LINE FILTER OF PILOT VALVE AND INLINE FILTER OF SOLENOID VALVE

THE HYDRAULIC LINE IS ALWAYS PRESSURIZED. DO NOT CARRY OUT ANY CHECK AND SERVICING BEFORE RELEASING THE INSIDE PRESSURE. TO RELEASE INSIDE PRESSURE IN THE HYDRAULIC OIL TANK, LOOSEN THE AIR PLUG SLOWLY WITH CARE. MAKE SURE TO CLEAN ANY SPILLAGE TO AVOID FIRE. The (P) ports of right and left pilot valves and solenoid valve are equipped with connector with filter. Dust, etc. that adheres on the filter will decrease oil flow. If dust, etc enter in the valve it may cause trouble.

Take out and clean filter, periodically.

PILOT VALVE

(P) port O - RING

(A)

(B)

[1] Move the machine to firm level ground, place the attachment in the oil check position, and stop the engine.

[2] Carry out the air releasing for the hydraulic line referring to page 4-13 .

[3] Loosen 2 bolts (C) on the operating box to remove the cover.

[4] Disconnect the hose (A) connected to "P port" on the pilot valve at first, then remove the elbow (B).

After the removal, put a blinding plug to the bore to prevent it from invasion of foreign matter.

[5] Dust tends to accumulate on the inside elbow (B) (dented portion). Make sure to properly clean parts to avoid contamination (projected portion).

[6] Check the O-ring for damages, and replace it with a new one, if damaged.

(C) (C) PAE-4-49

O - RING FILTER (B)

PAE-4-50

[7] After cleaning, install it to the original position in reverse order of the above [3] and [4]. Refer to page 4-11 for the tightening torque for the adapter hose.

Then the in-line filter of solenoid valve is removed for cleaning.

[8] Remove the floor mat and floor plate.

PAE-4-51

4-55

SECTION 4 - MAINTENANCE — 2000Hr [9] After disconnecting the hose, remove the inline filter assembly from the tee connected to the solenoid valve. Plug the oil holes of the tee and the hose after the removal.

[10] After removing the case and the nipple, remove the strainer with a flat screwdriver.

[11] Blow off the strainer for cleaning with light oil or compressed air. Also clean inside the case. Check the O-ring, and exchange it if damage is found.

[12] After installing the strainer to the nipple with a flat screwdriver, assemble the strainer in the inline filter case.

Tightening torque: 6 - 8 kgf.m (43 - 58 lbf.ft) [13] Remove the plug, install the inline filter assembly to the tee of the solenoid valve, and connect the hose.

4-56

1 1 2 3

CASE STRAINER LABEL

2

3

4 4 5 6

5

O-RING NIPPLE O-RING

6

PM5-137

SECTION 4 - MAINTENANCE — 2000Hr C. OIL CHANGE FOR TRAVEL SPEED REDUCTION UNIT

The oil is very hot just after the machine operation.

Start the servicing after getting down the oil temperature.

Remaining some residual pressure in the travel motor may cause flying out of plug or spouting out of oil at loosening the plug.

Slowly loosen the plug with care.

Container to receive discharged oil : 1000 cc (61 cu in) or more capacity Oil volume to fill in : 750 cc (46 cu in) ---LH/RH each

2

Change the oil at 500 hours operation for the first use of new machine.

[1] Set the machine on a level ground so that the DRAIN (discharge) port (1) comes just to the bottom.

[2] Provide a container under the DRAIN port (1) to receive the discharged oil.

GL 3

1

90 PW-5-10

[3] Slowly remove the plug of the SUPPLY port (2) and the LEVEL port (3) with an allen wrench.

Then remove the plug of the DRAIN port (1) to discharge oil into the container.

[4] Apply sealing tape on the thread of plug of the DRAIN port (1), and securely tighten it.

[5] Slowly fill in oil through the SUPPLY port (2), up to overflowing of oil from the LEVEL port (3).

See page 4-7 LUBRICANT, FUEL & COOLANT SPECIFICATIONS for the applied gear oil.

PW-5-11

[6] Apply sealing tape on the thread of plug of the LEVEL port (3), and securely tighten it.

Thoroughly wipe off oil spilled over.

[7] Ensure no oil leakages traveling the machine slowly.

NOTE : Check the waste oil. If any metal particles are mixed in it, consult it with an authorized dealer.

PW-5-12

4-57

SECTION 4 - MAINTENANCE — 2000Hr D. GEAR OIL CHANGE FOR LOWER ROLLER AND IDLER

Highly pressurized grease is contained in the grease cylinder of truck spring. When loosening the grease nipple for the tension adjustment of crawler shoes or disassembling, gradually loosen the grease nipple within one turn to slowly release the pressurized grease.

PA-4-57

The lower roller and idler have to be removed from the crawler frame to change the gear oil for each of them.

The following is to describe the procedures to remove/ reinstall, and the gear oil change for each of them.

Refer to page 4-7 for the oil and grease to be used and required volume.

A B C

Idler Idler Adjuster Shoe slide

D E F

Rubber crawler shoe Lower roller Crawler frame

1. LOWER ROLLER [1] Loosen the rubber crawler shoe of the side to change the gear oil referring to page 4-20 .

[2] The fixing capscrews (1) of lower roller is a bit loosened in advance. (around one turn) [3] Start up the engine, and lift up the oil filling side of the machine, with boom and arm getting down the back side of bucket to the ground.

[4] Support the machine with a safety support, etc., then stop the engine.

[5] Remove the capscrews (1) with washers (2) which are provided to install the lower roller to the crawler frame at two positions of inside and outside. Then remove the lower roller (3) .

PMJ-1-31

[6] Remove the feeding port plug (4) with an allen wrench, and discharge the old gear oil.

[7] Fill in the prescribed volume (60cc or 3.7cu in) of gear oil through the feeding port.

[8] Apply sealing tape to thread on the plug (4), and securely tighten it. Throughly wipe off oil adhered to periphery.

4-58

PMJ-4-90

SECTION 4 - MAINTENANCE — 2000Hr [9] Apply Locktite # 262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

[10] Remove the safety support which supports the machine to get down the machine to the ground, then tighten up the capscrew (1). + 0.2 kgf m (134 +1 Tightening torque : 18.5 lbf ft) [11] Again lift up the machine to adjust the crawler shoe tension referring to page 4-18.

NOTE : The collars (5) are available for the rubber and iron crawler shoes by changing the installing direction.

(R) ; Rubber crawler shoe Fit the collar (5) to the frame directing the groove to lower side.

(S) ; Iron crawler shoe Fit the collar (5) to the frame directing the groove to upper side.

(5)

(R)

(S)

23.5mm (0.93in)

31.5mm (1.24in)

PME-4-102

4-59

SECTION 4 - MAINTENANCE — 2000Hr 2. IDLER For the gear oil change of idler, the rubber crawler shoe of the changing side has to be removed.

The removal and installation of the rubber crawler shoe require to lift up one side of the machine. It is quite dangerous if the machine is erroneously fallen down.

Never operate the machine except the work for rubber crawler shoe.

[1] Remove the rubber crawler shoe referring to page 4-16 . Make sure to apply the safety support, etc.

Stop the engine.

[2] Pull off the idler (1) and idler adjuster (2) from the crawler frame.

Weight of Idler + Idler Adjuster = approx. 22 kg (49 lb) [3] Remove the feeding port plug (3) with an allen wrench to discharge the old gear oil.

PAE-4-59

[4] Fill in prescribed volume (30 cc or 1.8 cu in) of gear oil through feeding port.

[5] Apply sealing tape to thread on the plug (3), and securely tighten it. Throughly wipe off oil adhered to periphery.

[6] Apply grease to the sliding face on the piston (4) and cylinder (5) of the idler adjuster (2).

[7] Install the idler so that the feeding port plug (3) of idler and the grease nipple (6) of idler adjuster are facing to outside.

[8] Install the rubber crawler shoe referring to page 417 .

PAE-4-60

[9] Adjust the tension on the rubber crawler shoe referring to page 4-18 .

After confirming the engagement of rubber crawler shoe with the idler and the conditions for tension, get down the machine to the ground removing the safety support, etc.

4-60

SECTION 4 - MAINTENANCE — 2000Hr 3. UPPER ROLLER For the gear oil change of idler, the rubber crawler shoe of the changing side has to be removed.

[1] After stopping the engine, ensure that the machine is in a parking posture.

[2] Loosen the rubber crawler shoe of the side where gear oil to be changed according to page 4-20.

[3] Raise the shoe with a hydraulic jack.

[4] Remove the nuts (2) and the capscrews (3) of the support part fixing the shaft of the upper roller (1), and remove this roller.

PR-4-117

[5] Remove the oil supply port plug (4) with an Allen wrench, and drain old gear oil.

[6] Supply the specified amount (45 cc) of gear oil through the oil supply port.

[7] Wind seal tape on the plug (4) and tighten it securely. Wipe off oil adhered around the plug.

[8] Install the roller in reverse order of the removal.

After applying thread lock paste (Three Bond #1324) on thread of the capscrews (3), tighten the screws.

Tightening torque: 6.7 ± 0.7 kgf.m (48 ± 5 lbf.ft)

PR-4-118

4-61

SECTION 4 - MAINTENANCE — 2000Hr E. REPLACEMENT OF GREASE IN SLEWING GREASE BATH If a bit water is mixed in grease, it may become muddy into white color. When such machine work as immersing in water closely to the slewing bearing is repeated, grease in the slewing bearing as well as in the grease bath may be deteriorated.

The deteriorated grease may cause damages on the pinion gear of slewing motor and internal gears of slewing bearing. Consult with an authorized dealer for the judgement for the replacement of grease.

PWJ-3-28

CLEAN & FILL WITH MoS2 GREASE

If the slewing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

Grease Type - N.L.G.I. Lithium Base W/Mos2 Quanity - 4.8 kg (11 lb)

PJE4-130

NOTE : The following works require a professional skill because they are the inspection and maintenance for inside the engine. Since the adjustment also requires special knowledge and skill, consult them with an authorized dealer.

F. CHECK AND ADJUSTMENT FOR FUEL INJECTION TIMING This is to adjust the fuel injection timing to optimize the engine performance.

G. CHECK AND ADJUSTMENT FOR CONTACT SURFACE OF INTAKE AND EXHAUST VALVE This is to ensure the gas-tightness on the exhaust and intake valves to optimize the engine performance.

4-62

SECTION 4 - MAINTENANCE INSPECTION MAINTENANCE CHECK LIST Machine Model: ITEM

Serial NO.: OK

Machine Hours:

MAINT. PERFORMED

ITEM

ENGINE OIL LEVEL

SLEWING REDUCTION OIL

ENGINE COOLANT LEVEL

SLEWING RING GEAR

CHECK FOR FLUID LEAKS

GREASE BATH LEVEL

CHECK BELT TENSION

SLEWING RING PINION

CHECK FUEL LEVEL

SLEWING RING SEAL

DRAIN WATER SEPARATOR

SWIVEL JOINT SEALS

CHECK AIR CLEANER

DRAIN WATER FROM BATH

CHECK ENGINE ELECTRICAL

GREASE SLEWING RING

DRAIN WATER FROM FUEL

CHANGE GREASE BATH

CHANGE ENGINE OIL

CHECK BOLTS/HARDWARE

CHANGE OIL FILTER

CHECK LINES FOR DAMAGE

CHANGE FUEL FILTER

CHECK STEPS

CHANGE WATER SEPARATOR

CHECK FRAME STRUCTURE

CHECK AIR INTAKE INDICATOR

CHECK CRAWLERS

CHECK FAN ASSEMBLY

CHECK SPROCKET WEAR

CHECK BELT TENSIONER

CHECK IDLER WEAR

CLEAN RADIATOR

CHECK ROLLER WEAR

CHANGE ENGINE COOLANT

CHECK CRAWLER TENSION

AIR CLEANER ELEMENTS

ADJUST CRAWLER TENSION

ADJUST VALVE CLEARANCE

TRAVEL REDUCTION

HYDRAULIC OIL LEVEL

CHECK BOOM & ARM

CHECK HYD FUNCTIONS

BUCKET TEETH

CHECK FOR OIL LEAKS

SIDE CUTTERS

CHECK HOSES/PIPINGS

GREASE BOOM PINS

CLEAN SUCTION SCREEN

GREASE ARM PINS

CHANGE RETURN FILTER

GREASE BUCKET PINS

PILOT MANIFOLD FILTER

GREASE SWING PIN

CHANGE HYDRAULIC OIL

GREASE DOZER PIN

CLEAN HYDRAULIC TANK

CHECK COOLANT ADDITIVE

INSPECT ALL WIRING

CHECK CRAWLER SHOE

.

OK

MAINT. PERFORMED

BATTERY ELECTROLYTE BATTERY SERVICE HYD. FUNCTION OPERATION CHECK SWITCHES CHECK WARNING LIGHTS CHECK HORN CHECK DISPLAY MONITOR These item include non-equipped parts by the machine specification.

MECHANIC : SIGNATURE :

DATE :

4-63

SECTION 4 - MAINTENANCE NOTES

4-64

SECTION 5

TRANSPORTATION TABLE OF CONTENTS 5.0 TRANSPORTATION .................................................................................................................................

A. When Preparing Transportation Plans .............................................................................................

B. Loading And Unloading the Machine ...............................................................................................

C. Securing the Machine .....................................................................................................................

D. Lifting Procedures For the Machine Complete .................................................................................

5-2 5-2 5-2 5-3 5-4

5-1

SECTION 5 - TRANSPORTATION 5.0 TRANSPORTATION A. WHEN PREPARING TRANSPORTATION PLANS Before preparing to transport the machine, refer to Section 6, SPECIFICATIONS and check the total weight, height, width, length, traveling speed, ground pressure, etc.

Survey the width of roads, bridges, road surface conditions and traffic conditions for transportation.

Obtain any permits required from proper government agencies for the machine transportation.

B. LOADING / UNLOADING THE MACHINE

Slow speed traveling is necessary to load and unload the machine.

It is dangerous to use the attachment for loading and unloading the machine. Do not take such manner.

Do not operate other operating levers than the traveling lever on the ramps.

Pay attention for the sudden transferring of the center of gravity of the machine on the border between the truck/trailer and the ramps.

USE OF RAMPS

Refer to page 1-38 for cautions at loading/unloading the machine.

USE OF PLATFORM OR EARTH BANKING [1] Make the width of the earth banking (raising the ground level) enough to the machine width.

[2] Make the earth banking strong enough in order not to turn over the machine during loading/unloading due to broken side slope of the earth banking.

If necessary, provide some supporting posts to reinforce both side of the banking.

[3] The height of the platform or banking must correspond to that of the base of truck/trailer.

[4] At loading the machine, climb up to the truck/ trailer from front end of the machine for the case of the machine with attachment, and from back end for the machine without attachment.

[5] Set the machine at the center position on the truck/trailer.

5-2

15û OR LESS

PV5-01

SECTION 5 - TRANSPORTATION C. SECURING THE MACHINE After the machine is loaded and positioned, fix the machine by the following procedures.

[1] Get down the dozer.

82 °

[2] Fully extend the bucket and arm cylinders, then slowly lower the boom.

[3] Pull up on the safety lock lever and set to the LOCKED position.

OVERALL LENGTH

OVERALL HEIGHT

[4] Turn OFF all switches and pull out the starter key.

Lock all the caps and the door (CAB SPEC.).

[5] Apply the blocks to both the front and rear of the crawler and fix them with a wire rope of sufficient strength. This will prevent the machine from moving forward/backward or rolling due to vibration from the truck/trailer.

PVK5-02

LOCKED (UP) POSITION

PAD FOR EDGE

PAD FOR EDGE

WIRE ROPE PV1-89

5-3

SECTION 5 - TRANSPORTATION

The wire ropes to be used for lifting the machine should have sufficient strength against the machine weight.

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

Do not impose a load suddenly on the wire ropes and slings.

When the lifting work is carried out in cooperation with plural persons, make sure to check every situations with exchanging signals with each other.

During the lifting work, keep any persons away from around the lifting machine, especially under the machine

SIZE

Q'TY

CABLE (A)

Ø 11.2 X 2,200 mm

1

CABLE (B)

Ø 11.2 X 4,100 mm

2

ITEM

PV5-03

Weight : 2,560 kg (5,640 lb)

Unit : mm

Lifting angle 16

.7 °

°

.6

16

(B)

(A)

(D)

4,700

D. LIFTING PROCEDURES FOR THE MACHINE COMPLETE

Carry out the lifting work at a level ground.

[1] Manipulate each operating lever to take the machine a position as shown in the figure.

(C)

[2] Operate the boom swing lever to face the boom direct front.

[3] Stop the engine, and make the safety lock lever to LOCKED position. Then take off the machine after ensuring for no abnormalities around the operators seat.

[4] Install shackles to both bores (C) provided at both ends of the dozer blade, and put the wire ropes on them.

PVK5-04

Weight : 2,440 kg (5,380 lb)

Lifting angle 16

[5] Put the wire ropes on the (D) portion of the boom.

.1 °

[6] If any portions of the wire ropes directly touch the machine when the wire ropes are put up, protect the machine from damages by means of applying a wooden piece or rag between them.

(A)

4,700

[7] lightly lift the machine to confirm the balance, then lift up the machine.

Unit : mm

°

.6

16

(B)

(D)

NOTE : This figure is calculated with Japanese standard bucket.

CX31 Bucket weight ...... 88 kg (194 lb) CX36 Bucket weight ...... 91 kg (201 lb)

(C)

PV5-05

5-4

SECTION 6

SPECIFICATIONS TABLE OF CONTENTS 6.1 GENERAL SPECIFICATIONS ...................................................................................................................

A. Machine Dimensions .................................................................................................................

B. Attachment Working Ranges ......................................................................................................

C. Boom With Arm Cylinder ............................................................................................................

D. Arm & Standard Bucket .............................................................................................................

E. Arm ...........................................................................................................................................

F. Standard Bucket (Reference Only) ............................................................................................

G. Dozer ........................................................................................................................................

H. Crawler Shoe .............................................................................................................................

I. Performance Specifications .......................................................................................................

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

2. Side Digging & Dozer .............................................................................................................

3. Engine ...................................................................................................................................

4. Hydraulic Components ...........................................................................................................

J. Machine & Components Weight .................................................................................................

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

6-1

SECTION 6 - SPECIFICATIONS 6.1 GENERAL SPECIFICATIONS A. MACHINE DIMENSIONS A-1 CX31 [CANOPY] Unit : mm (ft in)

PW-7-1

[CAB]

PW-7-2

6-2

SECTION 6 - SPECIFICATIONS A-2 CX36 [CANOPY] Unit : mm (ft in)

PX-7-1

[CAB]

PX-7-2

6-3

SECTION 6 - SPECIFICATIONS B. ATTACHMENT WORKING RANGES [CANOPY]

PW-7-3

6-4

SECTION 6 - SPECIFICATIONS [CAB]

PW-7-4

6-5

SECTION 6 - SPECIFICATIONS C. BOOM WITH ARM CYLINDER

PA-6-4

D. ARM & STANDARD BUCKET

PAE-6-5

E. ARM

PAE-6-6

F. STANDARD BUCKET (Reference Only)

PA-6-7

G. DOZER

PA-6-8

6-6

SECTION 6 - SPECIFICATIONS H. CRAWLER SHOE

6-7

SECTION 6 - SPECIFICATIONS I. PERFORMANCE SPECIFICATIONS

6-8

SECTION 6 - SPECIFICATIONS J. MACHINE & COMPONENTS WEIGHT

6-9

SECTION 6 - SPECIFICATIONS NOTES

6-10

SECTION 7

TROUBLESHOOTING TABLE OF CONTENTS 7.1 GENERAL TROUBLESHOOTING ............................................................................................................ 7-2 A. Operating ......................................................................................................................................... 7-2 B. Travel .........................................................................................................................................7-2, 7-3 C. Hydraulic ......................................................................................................................................... 7-3 D. Gauge Cluster Display ..................................................................................................................... 7-3 E. Engine ............................................................................................................................................. 7-4

7-1

SECTION 7 - TROUBLESHOOTING 7.1 GENERAL TROUBLESHOOTING This troubleshooting information covers the components and systems as described in this MANUAL. Should in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact an authorized dealer for assistance.

7-2

SECTION 7 - TROUBLESHOOTING

7-3

SECTION 7 - TROUBLESHOOTING

7-4

SECTION 8

OPTIONAL EQUIPMENT TABLE OF CONTENTS 8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER ........................................................................

A. Selection of Hydraulic Breaker And Nibbler ....................................................................................

B. Before Operating Breaker and Nibbler .............................................................................................

C. Precautions For Impurity and Hydraulic Oil .....................................................................................

D. Operation ........................................................................................................................................

E. Connection To Hydraulic Circuit For Attachment .............................................................................

F. Selector Valve Shifting Procedures .................................................................................................

8-2 8-2 8-2 8-2 8-3 8-3 8-4

8.2 SAFETY PRECAUTIONS .........................................................................................................................

A. Use for Intended Purpose ................................................................................................................

B. Passengers .....................................................................................................................................

C. Protective Equipment ......................................................................................................................

D. Cylinders .........................................................................................................................................

E. Avoid Continuous Operation ............................................................................................................

F. Hose Surge ......................................................................................................................................

G. Do Not Use Dropping Force .............................................................................................................

H. Do Not Use Slewing Force ...............................................................................................................

I. Do Not Lift ........................................................................................................................................

J. Working Ranges ...............................................................................................................................

K. To Pry and Break Forcibly ................................................................................................................

L. Arm in Vertical Position ....................................................................................................................

8-5 8-5 8-5 8-5 8-5 8-5 8-6 8-6 8-6 8-6 8-7 8-7 8-7

8.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL ..................................................................... 8-8 A. Replacement Interval ...................................................................................................................... 8-8 B. Maintenance Record Sheet (Example) ............................................................................................ 8-8

8-1

SECTION 8 - OPTIONAL EQUIPMENT 8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER A. SELECTION OF HYDRAULIC BREAKER AND NIBBLER When installing a hydraulic breaker or nibbler to the machine, select the optimal breaker or nibbler taking the matters into consideration such as stability, blowing force, grasping force, required hydraulic oil volume, etc.

B. BEFORE OPERATING BREAKER OR NIBBLER Consult with an authorized dealer for the additional piping work and reinforcement for the arm to install the breaker or nibbler to the machine.

When using the breaker or nibbler, fully understand and peruse the operation manual of its manufacturer and the SAFETY PRECAUTIONS for the work mentioned in this MANUAL, in order to get full performance of them paying attention to damages on the machine and hydraulic breaker or nibbler.

C. PRECAUTIONS FOR IMPURITY AND HYDRAULIC OIL When the hydraulic breaker or nibbler is removed after its installation, apply a blinding plug to the stop valves attached on the tip of arm and openings on the hydraulic pipings for the hydraulic breaker or nibbler to prevent them from invasion of dust, water, etc.

Before the operation, check the looseness on the clamps which are fixing the piping for attachment, and the leakage on connections of tubes and hoses.

D. OPERATION 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. An option pedal is provided at left front of the operator's seat to operate them.

1. Operating Pedal [1] Single Hydraulic Circuit for Breaker only Release the pedal lock for the operating pedal located at left front of driver's seat, and operate the pedal.

Pedal Depressing Direction Operation Left Side (A) Breaker is not operated.

Right Side (B)

Breaker is operated.

Breaker stops at releasing pedal.

PM8-06

[2] Combined Hydraulic Circuit for Breaker and Nibbler Release the pedal lock for the operating pedal located at left front of driver's seat, and operate the pedal.

Hydraulic Breaker Operation

* Pedal Depressing Direction Left Side (A) Right Side (B)

* Nibbler Operation

Operation Breaker is not operated.

Breaker is operated.

Breaker stops at releasing pedal.

Pedal Depressing Direction Operation Left Side (A) Grasping operation Right Side (B) Opening operation

8-2

Do not put foot on the pedal except during operation. If you put foot on the pedal and mistakenly step foot on it, the machine may move suddenly to cause a serious accident.

SECTION 8 - OPTIONAL EQUIPMENT 2. Pedal Lock Device This is a device to lock the pedal.

PEDAL LOCK PIN

Make sure to set the pedal lock to "LOCKED" position while the breaker or nibbler is not used.

Careless contact with UNLOCKED position of pedal may cause severe accident and injury.

(1) Position ................. LOCKED (2) Position ................. UNLOCKED

(1) LOCK

(2) UNLOCK

PM8-08

E. CONNECTION TO HYDRAULIC CIRCUIT FOR ATTACHMENT Connect the hydraulic circuit for the breaker and nibbler with the following procedures.

[1] Remove the PF 1/2 blinding plugs (A) on pipings for stop valves (2 points of left and right).

Pay attention not to give any damages on the blinding plugs removed, or lose them.

[2] Connect the hydraulic pipings for the breaker and nibbler to the positions where the blinding plugs are removed at the above [1].

NOTE : Stop valves are to stop the flow of hydraulic oil.

LOCK : The hydraulic oil flow is stopped.

FREE : The hydraulic oil flows.

When installing or removing the hydraulic breaker or nibbler, make sure to set the stop valve at "LOCKED" position and attach the blinding plugs.

NOTE : The engine must be operated at 85% of rated speed while the work for breaker or nibbler.

From time to time, stop the work for a while, and make the engine speed at idling to cool the hydraulic oil.

PAE-8-3

PAE-8-4

PAE-8-5

8-3

SECTION 8 - OPTIONAL EQUIPMENT F. SELECTOR VALVE SHIFTING PROCEDURES When installing the hydraulic beaker or nibbler, the selector valve (1) must be installed to the main circuit. It is necessary to shift the selector valve to either of proper position.

1

NOTE : Improper shifting of the selector valve may cause deterioration of working efficiency and lowering the working speed as well as damages on the machine occasionally. Make sure to shift the selector valve to the proper position.

The selector valve needs to be periodically shifted every one or two times a month.

PM8-11

* SHIFTING PROCEDURES

NOTE : To shift the selector valve, make sure to stop the engine and lower the attachment to the ground making the machine at stable conditions.

(1)

4

3

TOOLS NEEDED Selector Valve Mark Position

1

Tool

2

Main circuit Wrench(width across flats 24mm)

PM8-12

Allen wrench (5 mm) Selector Valve Shifting Procedure

[1] Open the cover of the right of the machine to identify the selector valve (1).

[2] Remove the capscrews with an Allen wrench (2).

[3] Turn the valve to the specified position with the wrench (4).

Install the capscrews (3) at the specified position.

Selector valve engraving description B: Breaker; N: Nibbler (Crusher) [4] Close the cover

8-4

To tank

To tank Perform engraving To attachment To control valve

When breaker used

To attachment To control valve

When nibbler used PM8-13

SECTION 8 - OPTIONAL EQUIPMENT 8.2 SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with all other safety precautions found in this MANUAL.

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. A. USE FOR INTENDED PURPOSE Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

PMJ-8-6

B. PASSENGERS Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close all windows to protect the operator from flying debris. Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

PMJ-1-1

D. CYLINDERS Do not operate boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

PMJ-8-13

E. AVOID CONTINUOUS OPERATION Operate the nibbler/breaker in 30 sec. intervals. Operation for longer than 30 sec. at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

PMJ-8-7

8-5

SECTION 8 - OPTIONAL EQUIPMENT F. HOSE SURGE Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an authorized dealer for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

PMJ-8-8

G. DO NOT USE DROPPING FORCE Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

PMJ-8-9

H. DO NOT USE SLEW/SWING FORCE Never use the slew/swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

PMJ-8-10

I. DO NOT LIFT Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

PA-8-1

8-6

SECTION 8 - OPTIONAL EQUIPMENT J. WORKING RANGES

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the machine.

The balance on the machine becomes unstable at the position shown in the right figure involving a possibility of turning over the machine. Never carry out the breaker work with this position.

NOTE : Refer to this SECTION for the work with the other attachment than the hydraulic breaker, too.

Use the reinforced arm for the work with the hydraulic breaker, etc. The use of standard arm for such work may cause damages on the arm.

PMJ-8-17

K. TO PRY AND BREAK FORCIBLY Do not use the breaker to pry and break rock and concrete.

This may damage the hydraulic breaker, and also boom, arm and cylinder.

PMJ-8-11

L. ARM IN VERTICAL POSITION The arm should not be operated in the vertical position to prevent the arm cylinder from vertical shocks.

This may damage the rod packing and piston and cause oil to leak from those sections.

PMJ-8-12

8-7

SECTION 8 - OPTIONAL EQUIPMENT 8.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL A. REPLACEMENT INTERVAL Contamination and deterioration of hydraulic oil will cause malfunctioning of the control valves, early wear and seizure of the hydraulic pump and consequential failure of the entire hydraulic circuit. Operation of breaker hasten deterioration of hydraulic oil comparing with normal operation using bucket. Replace filters and hydraulic oil, referring to the following table : Inspection / maintenance

Location

Hydraulic oil

Hydraulic tank

Return filter

Hydraulic tank

Replacement interval First

2nd replacement

Regular

100 hours

Every 600 hours Every 200 hours

25 hours

B. MAINTENANCE RECORD SHEET (EXAMPLE) DATE

8-8

HRS

FILTER REPLACEMENT

HYD. OIL CHANGE

SECTION 9

SPECIFICATIONS (EPA ENGINE) TABLE OF CONTENTS

THE EPA REGULATIONS 1. Engine Identification .........................................................................................................................

2. Requirements on Engine Installation Condition .................................................................................

3. Emissions-Related Parts ..................................................................................................................

4. Maintenance Schedule .....................................................................................................................

5. Emission System Warranty Statement .............................................................................................

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

9-1

SECTION 9 - SPECIFICATIONS (EPA ENGINE)

Technical Bulletin To : All customers

TNE ISB-99-017-1 Nov. 16, 1999

THE EPA REGULATIONS The EPA regulations For non-road engines.

(Engines which will be used in the North American market.)

The information on engines to comply with the EPA Regulations for Non-road Engines are released and you are kindly requested to make every effort to comply with them.

The regulations covered Yanmar Engines of all TNE ENGINE MODELS. 1. ENGINE IDENTIFICATION With the regulations on engine emission worldwide, it has become necessary to identity engines in a manner to determine which regulations they comply with, hence. a) Emission control label as shown below which will contain:

* Emission Control is accomplished through Engine Modification (EM-Design) Engine family name as assigned by EPA identifying engine family group YYDXL2.78P4N and this identifies

Method of air aspiration Number of cylinders Combustion chamber design Displacement (liter) Non-road large Diesel Yanmar Diesel *2000 Model Year

X*: 1999 Y : 2000 1 : 2001 2 : 2002 3 : 2003

b) Label location : The typical location of this label for each engine is on the exhaust side or intake side of rocker arm cover or the top of rocker arm cover . A supplement label may be used in certain applications for improved visibility.

9-2

SECTION 9 - SPECIFICATIONS (EPA ENGINE) 2. REQUIREMENTS ON ENGINE INSTALLATION CONDITION The followings are required from the point of view of engine installation in order to comply with the EPA regulations. Unless otherwise satisfying these, engines exhaust gas emission will not be within the regulated value of the EPA Regulations for Non-road Engines.

2-1) Maximum Exhaust Gas Restriction shall be 600 mm H2O or less for 2TNE68 1200 mm H2O or less for 3TNE68 and 3TNE74 1560 mm H2O or less for 3TNE78A, 3TNE82A, 3TNE84, 3TNE88 4TNE84, 4TNE88, 4TNE94, 4TNE98 and 4TNE106 600 mm H2O or less for 3TNE84T, 4TNE84T and 4TNE106T 2-2) Maximum air intake restriction shall be 635 mm H2O or less and clean air cleaner element each time when air intake restriction exceeds 300 mm H2O at rated power condition.

3. EMISSIONS-RELATED PARTS The EPA regulates specific emissions-related parts are warranted for the period in the following table. However, ultimate purchasers are obligated to use and maintain the engine correctly.

Warranty Periods

Power Range kW (Gross Power)

Other Than Constant-Speed

Constant-Speed Under 3,000 rpm

Greater than or equal to 3,000 rpm

1,500 hours or 2 years 3,000 hours or 5 years

1,500 hours or 2 years

3,000 hours or 5 years * Actual hours or years of operation whichever occurs first is applied.

The specific emissions-related parts are 1) Fuel injection nozzle, 2) Fuel injection pump, 3) Turbocharger.

4. MAINTENANCE SCHEDULE To maintain optimum engine performance and compliance with the EPA Regulations Non-road Engines, it is necessary that the maintenance schedule be adhered to. Regular scheduled maintenance is a major key to engine service life and emissions regulations compliance. It is of utmost importance that scheduled maintenance, requirements are performed on a timely basis.

9-3

SECTION 9 - SPECIFICATIONS (EPA ENGINE) 5. EMISSION SYSTEM WARRANTY STATEMENT U.S. EMISSIONS CONTROL WARRANTY STATEMENT Yanmar Diesel Engine Co., Ltd. (Hereinafter referred to as Yanmar) warrants initial owner and each subsequent owner that the engine is designed, built and equipped so as to conform with applicable regulations for its warranty period.

Specific emissions-related parts and components are warranted for the period specified in 3 Emissionsrelated parts whichever comes first, after the date of delivery to the initial owner. If any emission-related part is defective during the warranty period, the part will be repaired or replaced by Yanmar.

To maintain engine performance and compliance with the regulations, the owner is responsible for the performance of the required maintenance listed in the owner s manual during the warranty period.

This emission warranty does not cover : 1. Failure caused by any of the following : Abuse, neglect, improper maintenance or use of non-genuine parts.

Use of fuel oil and lubricating oil not recommended for the engine.

Improper application and installation.

2. Add-on or modification affecting engine emissions.

3. Incidental or consequential damage.

9-4

CASE, LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

Part Number North American English Printed in U.S.A.

6-37920NA January 03 Bur