Case CX31B Compact Hydraulic Excavator Operator's Manual S2PW00040ZE02 - PDF DOWNLOAD

CX31B Compact Hydraulic Excavator PIN number PW14-46519 and higher

OPERATOR’S MANUAL

Part number S2PW00040ZE02 1st edition English August 2010

CX31B COMPACT HYDRAULIC EXCAVATOR OPERATOR’S MANUAL

Part Number: S2PW00040ZE02

Applicable Pin Number: PW14-46519 and higher

CASE CONSTRUCTION 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, Repair Manuals, and Maintenance records.

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

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

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

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

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

●

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

●

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

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

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

Is instructed in safe and proper use of the machine.

●

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

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

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

It is your responsibility to observe pertinent laws and regulations and follow Case Construction, LLC instructions on machine operation and maintenance.

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2010 CNh America LLC All Rights Reserved CASE is a registered trademark of CNH America LLC

CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIN (Product Identification Numbers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety Rules and Signal Word Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 CHAPTER 3 INSTRUMENTS AND CONTROLS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-3 3-7 3-8

CHAPTER 4 OPERATING INSTRUCTIONS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Starting and Stopping Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 CHAPTER 5 TRANSPORTATION Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHAPTER 6 LUBRICATION, FILTERS, AND FLUIDS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Bio-diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 CHAPTER 7 MAINTENANCE AND ADJUSTMENTS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 I

Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 Hour Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 8 ELECTRICAL Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10 7-17 7-25 7-31 7-34 7-37 7-38 7-47 7-48

8-1 8-3 8-4 8-8

CHAPTER 9 SPECIFICATIONS Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Lift Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11 CHAPTER 10 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER CX31B COMPACT HYDRAULIC EXCAVATOR

This excavator, with standard equipment and authorized attachments, is intended to be used for below ground level digging and general earth moving purposes such as trenching, truck loading, material rehandling, and ditch cleaning. If the machine is to be used for lifting objects, make certain the machine is properly equipped and follow the instructions and safety precautions in this manual.

DO NOT use this machine for any purpose or in any manner other than as described in the manual, decals, or other product safety information provided with the machine. These materials define the machine’s intended use.

If this machine is to handle a load (pipes, culverts, formwork, etc.), make sure that it is equipped to carry out this kind of work. For this type of application, the machine must be equipped with safety valves, 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 Construction 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.

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

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

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permit.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is 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 authorized Case Construction Dealer. Your Case Construction Dealer is available for any further information. They will also provide any after sales service you may need, and genuine Case spare parts, your guarantee of quality and match. Contact your dealer for operator manuals translated into Spanish or French Canadian.

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

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and current information from your dealer before you start any machine operation.

ATTENTION: The engine and fuel system on your machine is designed and built to government emissions standards. Tampering by dealer, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only.

1-1

CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

5. TRAVEL REDUCTION GEARS (TRAVEL MOTORS) 6. IDLER WHEELS

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

33

32

30 31 36

15 16 17

34

8 18 12

35 37

19

13

3 5 4 6 1

14 11 29 20 7 28 27 24 25

2

26 23

10 21 22

9 Figure 2

BS07M601

MACHINE COMPONENTS

1.

2.

3.

4.

5.

6.

7.

MITSUBISHI ENGINE OIL FILTER RADIATOR RESERVOIR TANK AIR CLEANER MUFFLER FUEL TANK

11.

12.

13.

14.

15.

16.

17.

SWING CYLINDER CONTROL VALVE TRAVEL LEVER SAFETY LOCK LEVER CANOPY CONTROL LEVER DOZER CONTROL LEVER

21.

22.

23.

24.

25.

26.

27.

SWIVEL JOINT TRAVEL MOTOR SWING BEARING IDLER ASSEMBLY LOWER ROLLER UPPER ROLLER RUBBER CRAWLER BELT

8. HYDRAULIC TANK

18. THROTTLE LEVER

28. DOZER BLADE

9. HYDRAULIC PUMP

19. MONITOR PANEL

29. DOZER CYLINDER

20. BATTERY

30. BOOM

10. SWING MOTOR

31.

32.

33.

34.

35.

36.

37.

BOOM CYLINDER ARM CYLINDER WORK LAMP ARM LINK BUCKET CYLINDER BUCKET

1-3

CHAPTER 1 - GENERAL INFORMATION

PIN (PRODUCT IDENTIFICATION NUMBERS) MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

When ordering par ts, obtaining infor mation or assistance, always supply your Case Construction Dealer with the type PIN and serial number of your machine or accessories.

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

Figure 4

BS07M603

ENGINE ➤ Make and Model ➤ Serial Number

Figure 3

BS07N400

PRODUCT IDENTIFICATION PLATE

COMPONENT SERIAL NUMBERS

➤

COMPONENT SERIAL NUMBERS Model

➤

➤

Hydraulic Pump PIN Number

➤

➤

Swing Reduction Gear Manufacturing Year

➤ Travel Reduction Gears ➤ Travel Control Valve ➤ Attachment Control Valve ➤ Swing Control Valve

1-4

CHAPTER 1 - GENERAL INFORMATION FOPS, ROPS CERTIFICATION

Figure 5

BS07M603

FOPS (Falling Object Protection) ➤ Make and Model ➤ Serial Number

ROPS (Roll Over Protection) ➤ Make and Model ➤ Serial Number

1-5

CHAPTER 1 - GENERAL INFORMATION ELECTRO-MAGNETIC INTERFERENCE (EMC) Electro-magnetic Interference (EMC) Interference may arise as a result of add-on equipment which may not necessarily meet the required standards.

As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following:

• The maximum power of emission equipment (radio,telephones, etc.) must not exceed the limits imposed by the national authorities of the country.

• The electro-magnetic field generated by the add-on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

• The add-on equipment must not interfere with the functioning of the on board electronics.

Failure to comply with these rules will render the warranty null and void.

1-6

CHAPTER 2 - SAFETY INFORMATION

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

2-3 2-3 2-3 2-4

OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 ROPS/FOPS (Roll Over Protection - Falling Object Protections Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY RULES AND SIGNAL WORD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11 2-11 2-11 2-11

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom and Arm Movement - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Controls - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Surfaces - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressurized Fluids and Lubricants - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Swing Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Stop - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Tension Adjuster - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keep Clear of Working Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Lock Lever - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Falling Front Window - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Check Position - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Engine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Confirm Attachment Movement- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate This Machine- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use Specified Diesel Oil for Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-19 2-20 2-20 2-21 2-22 2-23 2-24 2-24 2-25 2-25 2-26 2-26

2-1

CHAPTER 2 - SAFETY INFORMATION HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-2

CHAPTER 2 - SAFETY INFORMATION

SAFETY RULES WARNING Avoid injury!

The safety alert symbol is used to alert you to potential personal injury hazards. Carefully read and observe all the precautionary advice contained in this manual. Failure to comply could result in death or serious injury.

W0044A

NOTICE: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

PERSONAL SAFETY 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.

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

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

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

and

STOP

if

SAFETY AREA

1 1

Figure 1

BS06H091

1. OPERATOR’S MANUAL STORAGE SPACE

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

2 Figure 2

BC02N198

1. WORKING AREA 2. SAFETY AREA

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

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

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

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

2-3

CHAPTER 2 - SAFETY INFORMATION UTILITY SAFETY Safety precautions MUST be followed when working near buried and overhead Utility Lines.

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

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

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

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

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

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

RH99G001

Figure 3

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a h o l e by h a n d a n d / o r w i t h a u t o m a t i c va c u u m equipment to the utility line to verify the location and depth of the line.

2-4

CHAPTER 2 - SAFETY INFORMATION

OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

aid kit and a working fire extinguisher with you and know how to use each.

points of support when getting on and off the machine. Keep steps and platform clean. Face the machine when climbing up and down.

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

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

• Certain protective equipment should be replaced and renewed upon age and wear. Old or damaged hard hats may not provide the same level of protection as a new hard hat. Faded and soiled vest are no longer as highly visible as new vests.

See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

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

who

has

the

GENERAL

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

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

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

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

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

• DO NOT use the bucket or attachment to lift persons or carry riders on the machine.

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

• Remove all loose object stored in the machine.

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

STARTING AND STOPPING PRECAUTIONS

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

Sound the horn, if equipped, before starting.

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

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

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

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

• Do not bypass the machine’s neutral-start system. The neutral-start repaired if it malfunctions.

system

must

be

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

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

• DO NOT OPERATE the engine in an enclosed area without adequate ventilation.

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

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

2-5

CHAPTER 2 - SAFETY INFORMATION

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

OPERATING PRECAUTIONS

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

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a DO NOT OPERATE tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

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

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

Provide an escort for roading where required.

• On machines with independently operated wheel brakes, lock the brake pedals together when roading to provide equalized brake application.

• Use the recommended transport devices when roading the machine.

• Use the approved drawbar and / or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Before you operate at night, check that all lamps illuminate.

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

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

• Operate and drive the machine with care and at

• Check all controls in a clear area and make sure

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Dust, fog, smoke, etc., can decrease your vision

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

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

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

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

2-6

the machine is operating correctly. and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

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

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

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

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

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

CHAPTER 2 - SAFETY INFORMATION

• If you have extreme conditions, such as a fire,

• Disconnect the battery before working on the

etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

electrical system. Know the consequences of disconnecting any electronic or computer devices.

• DO NOT OPERATE the machine if you do not feel well. This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

MAINTENANCE PRECAUTIONS

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

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

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

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

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

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

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

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

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a tow bar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake. Avoid towing over long distances.

DC04E084

Figure 4

• 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 prevent accidental starting of the machine.

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Observe proper maintenance procedures.

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

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

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

• Wear gloves to protect hands when handling cable.

2-7

CHAPTER 2 - SAFETY INFORMATION

• When the battery electrolyte is frozen, the

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to contaminate the environment.

• To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top.

Allow room for expansion.

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

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

BURN PREVENTION

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

M111A

WARNING

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

• Check with your local environmental or recycling center or your dealer for correct disposal information.

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

ROLL-OVER PROTECTIVE STRUCTURE (IF EQUIPPED)

Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W005A

2-8

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

D o N OT m o d i f y t h e R O P S i n a n y m a n n e r.

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

CHAPTER 2 - SAFETY INFORMATION ROPS/FOPS (ROLL OVER PROTECTION FALLING OBJECT PROTECTIONS SYSTEMS.

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT

BS07M603

Figure 5

T h e P r o t e c t i ve S t r u c t u r e i s a s p e c i a l s a fe t y component of your machine.

Always wear your seat belt when operating the machine in order to fully utilize the ROPS/FOPS Protection Systems.

A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury.

The mounting structure and fasteners forming the mounting connection with the machine are part of the protective structure.

DO NOT atta ch any device to th e Prote ctive Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it w ill provide the same protection as a new Protective Str ucture. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, service MUST be perfor med by a qualified technician before returning the machine to field or job site operation.

The protective structure MUST be replaced.

2-9

CHAPTER 2 - SAFETY INFORMATION SEAT BELT PRECAUTIONS

EMERGENCY EXIT HAMMER

1

2 Figure 6

BC02N375

DC04D572

Figure 7

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

An emergency exit hammer is provided on the right s i d e o f c a b. I n c a s e o f e m e r g e n c y, t a ke t h e emergency hammer, break the cab glass, and escape from the cab. In addition, the emergency hammer is equipped with a cutter on the lever side to cut seat belt, etc.

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

FIRE EXTINGUISHER

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

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

WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or tool as low as possible while moving the machine around the job site.

• Never smoke while refueling.

• Do not use tractive force of the machine for loading the bucket attachment nor to push or pull any objects.

• Do not use swinging force of the machine for operations.

• Do not perform “hammering” operation with the bucket.

• Do not use this machine for anything other than its intended purpose.

• DO NOT OPERATE bucket and arm cylinders to stroke end repeatedly.

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

• Do not use the long reach attachment for general construction work at any time.

2-10

CHAPTER 2 - SAFETY INFORMATION

SAFETY RULES AND SIGNAL WORD DEFINITIONS PERSONAL SAFETY This is the safety symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. MACHINE SAFETY NOTICE: Notice indicates a situation which if not avoided could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual, you will find the signal word NOTICE followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

INFORMATION NOTE: Note indicates additional information which clarifies steps or other information in this manual.

Throughout this manual you will find the word NOTE followed by additional information about a step, procedure, or other information. The word Note is not intended to address personal safety or property damage.

2-11

CHAPTER 2 - SAFETY INFORMATION

DECALS WARNING An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply could result in death or serious injury.

CE-NA000

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

CE-NA000

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

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

NOTICE: 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

2-12

and

STOP

if used are RED.

CHAPTER 2 - SAFETY INFORMATION BOOM AND ARM MOVEMENT - CAUTION Located on seat stand cover - Part Number YN20T01013P1

BS07M605/BS07M647

Figure 8

HYDRAULIC OIL - WARNING Located on hydraulic tank- Part Number PW20T01007P1

BS08A249/PW20T01007P1

Figure 9

2-13

CHAPTER 2 - SAFETY INFORMATION SAFETY CONTROLS - WARNING Located on seat stand cover - Part Number YN20T01016P1

BS07M605/YN20T01016P1

Figure 10

HOT SURFACES - CAUTION Located on engine door hinge- Part Number YN20T01220P1

BS07M640/YN20T01220P1

2-14

Figure 11

CHAPTER 2 - SAFETY INFORMATION PRESSURIZED FLUIDS AND LUBRICANTS - WARNING Located on radiator duct- Part Number PW20T01094P1

BS07M444/PW20T01094P1

Figure 12

ENGINE STOP - CAUTION Located on hood - Part Number YN20T01012P1

BS07M444/BS07M448

Figure 13

2-15

CHAPTER 2 - SAFETY INFORMATION COUNTERWEIGHT SWING AREA - DANGER Located on radiator cover- Part Number PE2T01014P1

BS07M646/BS06J055

Figure 14

ENGINE STOP - WARNING Located on engine radiator- Part Number YN20T01009P1

BS07M606BS07M649

2-16

Figure 15

CHAPTER 2 - SAFETY INFORMATION BOOSTER CABLE - WARNING Located on battery box cover- Part Number YN20T01338P1

BS07M641/BS07M650

Figure 16

TRACK TENSION ADJUSTER - WARNING Located on crawler frame - Part Number 243T6110

BS07M645/BS07M651

Figure 17

2-17

CHAPTER 2 - SAFETY INFORMATION KEEP CLEAR OF WORKING AREA - DANGER Located on both sides of arm- Part Number PE20T01012P1

BS07M652/PE20T01012P1

Figure 18

DOZER BLADE - CAUTION Located on seat stand cover- Part Number PY20T01077P1

BS07M607/BS07M653

2-18

Figure 19

CHAPTER 2 - SAFETY INFORMATION BATTERY - DANGER Located on battery box cover- Part Number PY20T01069P1

BS07M652/PY20T01069P1

Figure 20

ELECTRICAL LINE SAFETY - DANGER Located on seat stand cover- Part Number PY20T01006P1

BS07M607/BS07M654

Figure 21

2-19

CHAPTER 2 - SAFETY INFORMATION SELECTOR VALVE - CAUTION Located on seat stand cover- Part Number PE20T01016P1

BS07M607/UPX00100022E01

Figure 22

SAFETY LOCK LEVER - WARNING Located on seat stand cover- Part Number PY20T01073P1

BS07M605/UPX00100017E01

2-20

Figure 23

CHAPTER 2 - SAFETY INFORMATION SEAT BELT - WARNING Located on seat stand cover- Part Number PE20T01027P1

BS07M607/UPX00100019E01

Figure 24

WINDOW LOCK - CAUTION Located on inside front window- Part Number YN20T01416P1

BS07M655/UPX00100026E01

Figure 25

2-21

CHAPTER 2 - SAFETY INFORMATION FALLING FRONT WINDOW - CAUTION Located on front window - Part Number PM20T01035P1

BS07M655/UPX00100021E01

Figure 26

CAB DOOR - WARNING Located inside cab door - Part Number PV20T01008P1

BS07M657/UPX00100023

2-22

Figure 27

CHAPTER 2 - SAFETY INFORMATION HYDRAULIC OIL CHECK POSITION - NOTICE Located on seat stand cover- Part Number 2432P3379

BS07M605/UPX00100017E01

Figure 28

CAP AND KEY COVER - CAUTION Located near fuel filler cap - Part Number PW20T01090P1

BS07M657/UPX00100028E01

Figure 29

2-23

CHAPTER 2 - SAFETY INFORMATION STOP ENGINE - DANGER Located on inside of side cover- Part Number YN20T01214P1

BS07M605/UPX00100031E01

Figure 30

CONFIRM ATTACHMENT MOVEMENT- WARNING Located on inside of right window (cab) or ceiling (canopy) - Part Number YN20T01039P1

BS07M656/UPX00100032E01

2-24

Figure 31

CHAPTER 2 - SAFETY INFORMATION DO NOT OPERATE THIS MACHINE- WARNING Located on inside of right window (cab) ceiling (canopy) - Part Number PE20T01028P1

BS07M656/UPW00100075E01

Figure 32

CALIFORNIA PROPOSITION 65 - WARNING Located on inside of right window (cab) on the ceiling (canopy) - Part Number 2432T6457

BS07M656UPJ00010005E01

Figure 33

2-25

CHAPTER 2 - SAFETY INFORMATION CALIFORNIA PROPOSITION 65 - WARNING Located on inside of right window (cab) on the ceiling (canopy) - Part Number YN20T01495P1

BS07M656/UPJ00010006E01

Figure 34

USE SPECIFIED DIESEL OIL FOR FUEL Located on the fuel filler cap - Part Number PV20T01068P1

BS07M656UPJ00010005E01

2-26

Figure 35

CHAPTER 2 - SAFETY INFORMATION

HAND SIGNALS IMPORTANT: When operating the machine, never attempt to carry out tasks calling for the control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

MOVE LOAD IN HORIZONTALLY

The following is a compilation of the Hand Signals to be used when a flagman is required for Excavator Operation. All personnel associated with the operation of the excavator should know these signals and their meaning before attempting to operate this machine.

RAISE LOAD VERTICALLY

DC04E040

Figure 38

Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 36

Face machine operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

LOWER LOAD VERTICALLY

DC04E041

Figure 39

Face machine operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

RAISE BOOM

DC04E039

Figure 37

Face machine operator, extend right arm down, point index finger down and move hand in small circular motion.

DC04E042

Figure 40

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with thumb up.

2-27

CHAPTER 2 - SAFETY INFORMATION ARM IN

LOWER BOOM

DC04E043

Figure 41

DC04E046

Figure 44

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with thumb down.

Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

SWING LEFT

ARM OUT

DC04E044

Figure 42

DC04E047

Figure 45

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with index finger pointing in swing direction.

Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other.

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 43

Fa c e m a c h i n e o p e ra t o r, ex t e n d l e f t a r m o u t horizontally from shoulder, make a fist with index finger pointing in swing direction.

2-28

DC04E048

Figure 46

Face machine operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

CHAPTER 2 - SAFETY INFORMATION CLOSE BUCKET (BUCKET IN OR DIG)

COUNTER ROTATE RIGHT

DC04E049

Figure 47

DC04E052

Figure 50

Face machine operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

Face machine operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 48

Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion

DC04E053

Figure 51

Face machine operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion.

TRAVEL REVERSE TURN LEFT

DC04E051

Figure 49

Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

DC04E054

Figure 52

Face machine operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small reverse circular motion.

2-29

CHAPTER 2 - SAFETY INFORMATION STOP

TURN RIGHT

Figure 53

DE04E055

Face machine operator, raise left forearm up, make fist with left hand and hold stationary, bend right hand arm in, make fist with right hand and rotate right fist in a small forward circular motion.

DC04E058

Figure 56

Face machine operator, raise left arm out horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

EMERGENCY STOP

MOVE THIS MUCH

DC04E059

Figure 54

DC04E056

Figure 57

Face machine operator, raise both forearms up, hands open and facing each other, move hands in laterally indicating how far to go.

Fa c e m ac hi n e op e ra to r, ra i s e b ot h a r m s ou t horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY

STOP ENGINE

.

DC04E057

Figure 55

Face machine operator, raise left arm out horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

2-30

DC04E060

Figure 58

Face machine operator, right arm at side, draw left thumb or index finger across throat.

CHAPTER 3 - CONTROLS AND INSTRUMENTS

CHAPTER 3

INSTRUMENTS AND CONTROLS CONTENTS OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Opening Right Window Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine door Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Window Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Components & Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Right Hand Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Warning Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Hydraulic Function Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Operating Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Left Hand Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 BHL Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Right Hand Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Left Hand Operator Control Lever (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Right Hand Operator Control Lever (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Left and Right Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Throttle Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Dozer Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-1

CHAPTER 3 - CONTROLS AND INSTRUMENTS

NOTES

3-2

CHAPTER 3 - CONTROLS AND INSTRUMENTS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

CAB DOOR LATCH

1

2

1

2

3

3 Figure 1

BS07M259

1. DOOR CATCH 2. HANDLE 3. KEY

Use the ignition switch key to lock or unlock cab door.

Insert key fully into door lock and turn to lock and unlock cab door. Use this key to open other machine locking compartments.

Figure 2

BS07M259

1. The cab door can be latched in an open position by opening door until it is locked in place by the door latch (1) located on the cab.

WARNING Fall hazard!

Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders and handholds. Refer to “SAFETY INFORMATION - General recommendations”.

Failure to comply could result in minor or moderate injury. c007a

1

Figure 3

BS07M660

1. DOOR RELEASE LEVER

2. Release door latch by pulling the release lever backward to release door from latch.

3-3

CHAPTER 3 - CONTROLS AND INSTRUMENTS REMOVING AND STORING LOWER FRONT WINDOW

OPENING AND CLOSING WINDSHIELD Front window (upper) can be stored in ceiling.

NOTICE: Make sure to properly lock the window frame in place, or the wiper lock may not function properly, and the wiper may be damaged because the wiper moves when the wiper motor switch is turned on.

1

1

1

Figure 6

DC04D662

1. LOWER FRONT WINDOW

1. After placing upper front window in ceiling, and locking it in place, remove lower front window by hand, lifting it from the window frame.

Figure 4

UPW00200038J01

1. Pull lock lever down (1) on front window upper section to unlock the window.

1

2. Securely store the removed lower front window in the holder in the rear of cab behind the operator’s seat.

3. To store it, insert the right and left sides of glass in holder in front of the rear window. Make certain it is secure in front of the retaining tabs.

OPENING RIGHT WINDOW GLASS

1 Figure 5

BS07M661

1. LOCK LEVER

2. Hold handles on left and right sides of the front window. Lift the front window up and slide overhead all the way to the back. The window will automatically lock when in position.

1. LOCK

1. Open right window by releasing lock and sliding the window.

WARNING Falling Object!

A falling window can cause injury to you or others.

Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in death or serious injury.

M1709

3-4

Figure 7

BS07M663

2. Close the glass sliding it to LOCK position, then lock it.

CHAPTER 3 - CONTROLS AND INSTRUMENTS DOCUMENT POUCH

CAB DOME LIGHT

Figure 8

BS06H100

CAB DOME LIGHT

1. Turn cab dome light ON by pushing the dome light switch downward.

2. Turn OFF by pushing switch all the way up.

Figure 9

BS06H091

DOCUMENT POUCH

T h e O p e r a t o r a n d Pa r t s M a n u a l s t o r a g e compartment is a pouch located on the back of the operator’s seat. Keep the Operator and Parts Manual for this machine in this location at all times for quick, easy reference.

3-5

CHAPTER 3 - CONTROLS AND INSTRUMENTS OPERATOR SEAT ADJUSTMENTS

SEAT BELT

The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety.

SEAT FRONT AND REAR HEIGHT ADJUSTMENT

2 1 1

Figure 11

DC04D529

1. BUCKLE 2. RED BUTTON BS07666

Figure 10

SEAT FRONT AND REAR ADJUSTMENT LEVER

• Move the seat adjustment lever to the right.

Adjust the seat forward or backward to the desired position.

• Release lever to lock the seat in position.

1. Sit on the operator’s seat and adjust the seat position so that the operator’s back closely contacts with the seat back.

2. Draw out the right side seat belt and fasten it to the buckle located on the left side.

NOTICE: If the belt stops while you’re pulling it out, release the tension and continue pulling it out.

3. Pull the belt out moderately long and insert it in the buckle until it snaps securely in place.

Release hands, and the length will automatically adjust.

4. After locking, the belt can be adjusted about 25 mm (1 in) to fit comfortably.

5. Press the red button on the buckle, and the belt will release.

WARNING Avoid Injury!

Always wear seat belt while sitting in operator seat.

Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure. Failure to comply could result in death or serious injury.

M422B

NOTICE: Replace the seat belt every three years regardless of appearance. Note date of replacement on support mount for reference.

3-6

CHAPTER 3 - CONTROLS AND INSTRUMENTS

MACHINE ACCESS COMPARTMENTS AND DOORS ENGINE DOOR COVER

2

3 1

4 Figure 12

DC04D529

Figure 14

BS07M668

2. RIGHT HAND SIDE COVER 3. ENGINE DOOR 4. LEFT HAND SIDE COVER

1. LOCK 2. RELEASE

A lock is provided for the engine doors. Use the ignition key to open and lock the engine doors.

2. Secure the cover in open position with the strut.

3. To close, return the strut to the storage position, and close cover. Lock the compar tment by turning the key in a counter clockwise direction.

WARNING Secure the engine doors in open position with strut when servicing. Failure to comply could result in death or serious injury.

M1709

WINDOW WASHER TANK

1 2

Figure 13

BS07M668

1. KEY CYLINDER

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

3

1 Figure 15

BS07M670

1. WASHER TANK 2. CAP 3. MOTOR

The window washer tank is located on the left rear of the cab. When the washer fluid becomes low, remove the cap and fill with washer fluid. Do not operate the windshield washers when the tank is empty, as this may damage the washer tank motor.

3-7

CHAPTER 3 - CONTROLS AND INSTRUMENTS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

2

7

20

5

10

4

21 6

9 8

1 15

3

16 14 13 11 18 19 12 17

Figure 16

BS07M671

COMPONENTS 1. Right Operating Lever 2. Left Operating Lever 3. Safety Lock Lever 4. Right Travel Lever 5. Left Travel Lever 6. Boom Swing Operating Pedal 7. Horn Switch

3-8

8. Breaker Operating Switch 9. Option Switch (Nibbler And Breaker) 10. Travel Speed Select Switch 11. Monitor Panel 12. Work Light Switch 13. Throttle Lever 14. Starter Switch

15. Deceleration Switch (Option) 16. Dozer Blade Operating Lever 17. Operator’s Seat 18. Wiper And Washer Switch 19. Heater Switch (Option) 20. Left Travel Pedal 21. Right Travel Pedal

CHAPTER 3 - CONTROLS AND INSTRUMENTS OPERATOR CAB NOMENCLATURE

RIGHT HAND CONSOLE AND MONITOR

This chapter points out locations of operator controls of the machine. Study these areas and locate the components on the machine. Specific information regarding these components is explained on the following pages of this section.

KEY SWITCH

WARNING Avoid Injury!

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

Figure 18

BS07M672

KEY SWITCH

COMPONENTS & CONTROLS The following information provides a brief description and function of the components and controls of this machine.

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

The Key Switch is located on the right hand operator console and has 4 operating functions.

OFF - When key is turned to this position, the e n g i n e s t o p s a n d e l e c t r i c a l p owe r t o t h e machine’s electrical system is stopped after approximately 3 seconds.

ON - When key is in the “ON” position, electrical power is supplied to all the machine’s electrical systems.

HOUR METER

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.

HEAT - When engine start-up is difficult due to cold temperatures, turn the key to this position to activate the pre-heat feature. Hold the key in this position for approximately 15 seconds and then turn the key to the START position to start the engine. Release the key after the engine starts.

BS07M792

Figure 17

The hour meter indicates the total time that the engine has run. It meters the time continuously as long as the engine is running. Use the hour meter as reference for machine maintenance.

3-9

CHAPTER 3 - CONTROLS AND INSTRUMENTS MONITOR

Figure 19

BS07M673

1.

2.

3.

4.

ENGINE COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE ENGINE OIL PRESSURE LAMP (RED) COOLANT TEMPERATURE LAMP (RED)

5.

6.

7.

8.

BATTERY CHARGE LAMP (RED) LOW FUEL WARNING LAMP (RED) AIR CLEANER LAMP (RED) HIGH TRAVEL SPEED LAMP - 2ND (YELLOW)

GAUGES

BS07M674

Figure 20

1. BLUE: COLD CONDITION 2. WHITE: OPERATING CONDITION 3. RED: OVER HEATING

COOLANT TEMPERATURE GAUGE Indicates the temperature of the engine coolant and operates when the starter key switch is turned to the ON position. The temperature is normal in the white range. If the indicator enters the red range, let the engine low idle until the coolant temperature indicator moves back into the white range.

If the indicator is in the blue range, warm up engine and hydraulic oil.

3-10

BS07M675

Figure 21

1. WHITE: OPERATING CONDITION 2. RED: REFILL

FUEL GAUGE Indicates the amount of fuel in fuel tank. F: Indicates a full tank. Refuel when the indicator is approaching empty with diesel fuel only. Do not allow the machine to run out of fuel.

CHAPTER 3 - CONTROLS AND INSTRUMENTS WARNING LAMPS NOTICE: If warning lamps illuminate, change machine operating method immediately. If this lamp remains illuminated, stop the engine and determine the cause of the problem. See the Maintenance Section - Chapter 6 in this manual or contact your dealer.

WARNING Do not perform any maintenance on a hot engine.

Allow the engine to cool before inspection or maintenance. Failure to comply could result in death or serious injury.

M1393

WARNING Improper service or repair can cause injury or death.

If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine. Failure to comply could result in death or serious injury.

M84-102

BS07M776

Figure 22

ENGINE OIL PRESSURE LAMP (RED) The engine oil pressure lamp (3) will illuminate if the engine oil pressure drops abnormally while the engine is running. Stop the engine immediately and check engine oil.

See the Maintenance Section- Chapter 6 for checking oil level.

BS07M779

Figure 24

BATTERY CHARGE LAMP (RED) The battery charge lamp (5) will illuminate if the charging system is experiencing a malfunction. This lamp will illuminate briefly when the engine is turned on and should turn off once the engine is running.

Check the charging system if this indicator remains illuminated after the engine has started.

BS07M777

Figure 23

COOLANT TEMPERATURE LAMP (RED) If the coolant temperature rises abnormally, the coolant temperature lamp (4) will illuminate. Run the machine at low idle until the coolant temperature drops to a normal range.

Reduce engine RPM to idle, and stop operation until engine coolant temperature reaches a safe operating temperature range.

See the Maintenance Section - Chapter 6 for checking coolant level.

3-11

CHAPTER 3 - CONTROLS AND INSTRUMENTS

Figure 25

BS07M780

BS07M778

LOW FUEL WARNING LAMP (RED)

ENGINE AIR FILTER LAMP (RED)

If fuel is low, a warning lamp will illuminate. Stop the engine and add fuel. Do not allow the machine to run out of fuel.

The engine air filter lamp will illuminate if the air cleaner filter is restricted. If the lamp illuminates, stop the machine immediately and clean or replace the air filter.

See Maintenance Section for additional information.

2

9

8 4

3 1

7 6 5

8 BS08J525

SWITCHES 1. Ignition switch

6. Heater switch

2. Travel speed select switch

7. Wiper and washer switch

3. Horn switch

8. Breaker operating switch

4. Deceleration selector switch

9. Option switch (Nibbler and Breaker)

5. Work lamp switch

3-12

CHAPTER 3 - CONTROLS AND INSTRUMENTS

Figure 27

BS07M672

Figure 29

BS07M784

IGNITION KEY SWITCH

HORN SWITCH

Use the ignition key (1) to start and stop the engine.

See page 3-9 for additional information.

The horn switch (3) is located on the top of the right control. Always sound the horn before star ting engine or moving the machine.

Figure 28

BS07M783

Figure 30

BS07M785

TRAVEL SPEED SELECT SWITCH Use the travel speed select switch (2) to change travel speeds. When the machine is turned off, the travel speed is automatically set to low (1st).

WARNING Use low speed when operating on a slope or loading/unloading from a truck or trailer. Sudden changes in ground level can cause accidents.

Failure to comply could result in death or serious injury.

D E C E L E R AT I O N (OPTIONAL)

S E L E C TO R

SWITCH

Press the deceleration switch (4) during engine rotation to change the engine to low speed. Press again to release the deceleration function. Fuel efficiency and noise generation can be aided by using this switch. Turning the ignition switch off will automatically release the deceleration function.

SA130

Select low speed when travelling on rough or soft ground, in confined spaces, loading or unloading from a trailer, or when tractive force is required.

Select high when moving on flat, level ground.

3-13

CHAPTER 3 - CONTROLS AND INSTRUMENTS

BS07M786

Figure 31 Figure 33

BS07M778

WORK LAMP SWITCH

WIPER AND WASHER SWITCH

Use the work lamp switch (5) for turning the boom and machine work lights on and off.

Use the washer/wiper switch (7) to spray washer fluid or turn on the windshield wipers. The switch has four settings.

Wash: (left): Sprays washer fluid Off: Stop On: Operates wipers only Wash (right) Operates washer fluid and wipers NOTICE: Do not use the washer for more than 20 seconds continually or without washer fluid, as the washer tank motor may be damaged.

2 BS07M787

1

Figure 32

HEATER SWITCH (OPTIONAL) Use the heater switch (6) to turn the optional heater on or off. The switch has three settings: OFF, (L) low fan speed, and (H) high fan speed.

BS08J519

Figure 34

BREAKER OPERATING SWITCH The breaker operating switch (8) is used to operate the breaker. Use the button (1) and the grip of the right control lever.

Make cer tain the selector valve is switched to breaker mode. Working in the incorrect mode can cause a malfunction and/or machine damage.

The breaker can be operated by sliding the option switch (2) to the left.

3-14

CHAPTER 3 - CONTROLS AND INSTRUMENTS

2

1

BS08J524

Figure 35

OPTION SWITCH (BREAKER AND NIBBLER) The proportional option switch (9) for breaker and nibbler is on the grip of the right control lever. This switch is used for opening and closing the nibbler by sliding right and left.

Do not touch the breaker (1) operation switch (button) when using the nibbler.

Operation of option switch 2 Slide left - attachment turns to left Slide right - attachment turns to right

3-15

CHAPTER 3 - CONTROLS AND INSTRUMENTS LEVERS AND PEDALS

3

2

6

2

1 5

4

Figure 36

BS08J525

1. Hydraulic Safety Lock Lever

4. Throttle Levers

2. Right/Left Control Levers

5. Dozer Control Lever

3. Travel Levers with Pedals

6. Boom Swing Operating Pedal

HYDRAULIC FUNCTION SAFETY LOCK LEVER A hydraulic function safety lock lever is provided on the left control console to avoid activation of any unwanted hydraulic function. When the function safety lock lever is placed in the unlock (down) position, the alarm will sound intermittently for one (1) second and the hydraulic system becomes active.

Before leaving the cab, shut down the engine, and always place the function safety lock lever in the locked (up) position.

1

2

WARNING Figure 37

BS06H080

1. SAFETY LOCK LEVER IN LOCKED (UP) POSITION 2. SAFETY LOCK LEVER IN UNLOCK (DOWN) POSITION

3-16

Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab. Never leave the machine unattended with engine running.

Failure to comply could result in death or serious injury.

M1710

CHAPTER 3 - CONTROLS AND INSTRUMENTS OPERATING CONTROL LEVERS

Left Hand Operator Control Lever (ISO/SAE Pattern)

Figure 39

DC04D562

LH CONTROL LEVER 2

4

WARNING

Figure 38

BS07N561

E

Arm Out

F

Arm In

G

Swing Left

H

Swing Right

RH CONTROL LEVER 1

3

A

Boom Down

B

Boom Up

C

Bucket In

D

Bucket Out

If your machine is set to the operational BHL pattern control make sure to remove the ISO/SAE operation pattern control decal and use the decal supplied for the optional BHL pattern control. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Confirm that the operating pattern of the levers conforms to the machine lever decal.

Unexpected movement could result if decal and lever pattern do not match. Failure to comply could result in death or serious injury.

M1716

The Left Hand Operator Control Lever is located at the top front of the left hand operator console. Its purpose is to allow the operator to control operations of the swing and arm. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has the following basic operational functions.

• • • • •

FORWARD - Variable speed ARM out.

BACKWARD - Variable speed ARM in.

LEFT - Variable speed left SWING. RIGHT - Variable speed right SWING. CENTER - Neutral position.

3-17

CHAPTER 3 - CONTROLS AND INSTRUMENTS BHL PATTERN

Right Hand Operator Control Lever (ISO/SAE Pattern)

DC04D563

Figure 40

BS07N561

LH CONTROL LEVER 1

4

E

Boom Down

F

Boom Up

G

Swing Left

H

Swing Right

RH CONTROL LEVER 2

3

A

Arm Out

B

Arm In

C

Bucket In

D

Bucket Out

In the BHL multi control shifting the boom and arm functions are opposite the ISO system.

Figure 41

The Right Hand Operator Control Lever is located at the top front of the right hand operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has the following basic operational functions.

• • • • •

FORWARD - Variable Speed BOOM down.

BACKWARD - Variable speed BOOM up.

LEFT - Variable speed BUCKET in (Digging).

RIGHT - Variable speed BUCKET out (Dump).

CENTER - Neutral position.

NOTICE: An optional Pattern Control Change Valve is available. Contact your dealer for more information.

If your excavator already has this valve installed use the following instructions (BHL Pattern) regarding its operation.

3-18

CHAPTER 3 - CONTROLS AND INSTRUMENTS PATTERN CONTROL CHANGE (BHL PATTERN) To change the machine’s control pattern from ISO (SAE) to (BHL) pattern, proceed as follows:

2

1. Place the attachment on the ground, throttle control in low idle, and turn the key switch off.

1 1

Figure 43

BS07N621

1. PATTERN CHANGER VALVE

3. Open the right compartment door, locate the pattern changer lever (2).

Figure 42

DC04C344

3

1. HYDRAULIC FUNCTION SAFETY LOCK LEVER IN LOCKED (UP) POSITION

4

2. Place the hydraulic function safety lock lever in the lock (UP) position before leaving the cab.

WARNING If your machine is set to the operational BHL pattern control make sure to remove the ISO/SAE operation pattern control decal and use the decal supplied for the optional BHL pattern control. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Confirm that the operating pattern of the levers conforms to the machine lever decal.

Unexpected movement could result if decal and lever pattern do not match. Failure to comply could result in death or serious injury.

M1716

BS07N564

Figure 44

4. Loosen wing bolt (3), and change the lever position to the desired pattern.

5. Hand tighten the wing bolt (3) securely. Do not use tools to tighten.

6. Close compartment cover.

7. Carefully operate the control levers to make certain functions match the pattern selected.

Practice in an open area to become familiar with the new pattern.

3-19

CHAPTER 3 - CONTROLS AND INSTRUMENTS

Figure 45

DC04D565

ISO/SAE PATTERN DECAL CARD

Figure 46

DC04D566

BHL PATTERN DECAL CARD

3-20

CHAPTER 3 - CONTROLS AND INSTRUMENTS LEFT HAND OPERATOR CONTROL LEVER (BHL PATTERN)

DC04D567

Figure 47

Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

RIGHT HAND OPERATOR CONTROL LEVER (BHL PATTERN)

DC04D568

Figure 48

Slowly operate Right Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

3-21

CHAPTER 3 - CONTROLS AND INSTRUMENTS LEFT AND RIGHT TRAVEL LEVERS AND PEDALS

BS07N624

Figure 50

1. Push both levers forward (or press the front of the pedals) to travel forward.

2. Pull both levers towards you (or press the near side of pedals) to move in reverse.

3. Release both levers in the center position to stop movement and place the machine in neutral.

2 1 Figure 49

BS07N623

The travel levers and pedals are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward.

• FORWARD - Variable speed forward track movement.

• BACKWARD - Variable speed reverse track movement.

• CENTER - Neutral position.

The travel functions described are with the travel motor located behind the cab.

WARNING Always know the position of excavator travel motors to prevent unexpected movement of the machine.

Normal positioning for determining front, rear, forward, and reverse is with the travel motors located behind the operator's cab. Failure to comply could result in death or serious injury.

M1726

3-22

BS07N625

Figure 51

THROTTLE CONTROL LEVER The throttle control lever is located to the right of the operator’s seat and is used to control engine speed.

(A) LOW (low idling) - Push the throttle fully forward to set the engine in low idle.

(B) HIGH (high idling) - Pull the throttle fully backward to set the engine in high idle.

CHAPTER 3 - CONTROLS AND INSTRUMENTS DOZER CONTROL LEVER

BOOM SWING OPERATING PEDAL

1

1

Figure 53

BC08J113

Use this pedal to operate the swing motion of the boom.

BS07N626

Figure 52

Use the dozer control lever to move the dozer up or down.

(C) Dozer Up - Pull the lever back.

To use the pedal, lift the pedal locking cover (1) up.

Right swing: push down right side of pedal Left swing: push down left side of pedal.

(D) Dozer Down - Push the lever forward.

When traveling, raise the dozer blade to its maximum height.

WARNING Always lock the pedal if not using the boom swing operating function. Failure to comply could result in death or serious injury.

M1491

3-23

CHAPTER 3 - CONTROLS AND INSTRUMENTS

NOTES

3-24

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 STARTING AND STOPPING MACHINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping Machine Engine in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 BASIC OPERATION OF HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Function safety lock lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Turning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Operating in a narrow space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Machine Attachment and Swing - ISO/SAE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Offset Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16 4-16 4-17 4-17 4-17 4-18 4-18 4-18 4-18 4-18 4-18 4-19 4-19 4-19

OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Optional Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Accelerate Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Setting Machine Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury CE-NA000

Before operating this machine: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr ican ts ar e suita ble for p reva iling conditions. See Chapter 6 - Maintenance and Adjustments.

2. Carry out the daily maintenance operations.

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

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

5. Check the track assemblies.

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

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

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

10. Remove any obstructions which hinder visibility.

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

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

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

The operator must be alone on the machine.

15. Work out a convenient means of escape from the machine (be proa ctive and deter mine an emergency exit) in the event of the cab door being jammed or the machine turning over. Cab models are equipped with an emergency hammer.

16. Before undertaking any travel or work operations during hours of darkness, make cer tain the lighting and signaling equipment is fully operative.

OPERATING THE MACHINE WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in death or serious injury CE-NA000

When operating the machine, perform the following: 1. When starting the engine, use the correct procedure for the prevailing weather conditions.

See Starting The Engine in this chapter.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 6 - Maintenance and Adjustments.

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

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

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

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

13. Make sure nobody is standing in the machine working area.

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

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

8. Modify your driving to suit the type of work and working conditions.

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 10. Operate all controls gradually to ensure smooth machine operation.

STARTING AND STOPPING MACHINE ENGINE

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

STARTING ENGINE

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

1. Sit comfortably in the operator’s seat, making certain you can reach all the pedals and controls.

Fasten the seat belt.

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

2. Move throttle control to LOW position.

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

3. Insert key into key switch and turn to the ON position.

4. Sound horn to warn personnel that the machine is being started.

15. Never use the attachment for sweeping the ground to level out rubble or push objects (this creates transversal stress on the attachment).

5. Turn key to the START position and release as soon as engine starts. Key will automatically return to the ON position.

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

NOTICE: Release Key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

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

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

NOTICE: If engine fails to start after 3 attempts, inspect fuel system and correct any problem found.

When cranking engine, the absence of “blue” or “white” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

STOPPING THE MACHINE

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

20. See Parking the Machine when you park the machine.

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

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

BS07M794

Figure 1

1. Move machine to a firm, level area and place the attachment in the position illustrated.

2. Move throttle to LOW position. Allow engine to idle for 5 minutes.

3. Turn Key Switch to OFF position.

4. Set the safety lock lever in the LOCKED position.

4-4

CHAPTER 4 - OPERATING INSTRUCTIONS EMERGENCY ENGINE SHUT DOWN Use this emergency shut down measure ONLY when the key switch fails to shut down the engine.

STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES STARTING ENGINE 1. Move throttle control to LOW position.

2. Turn the key switch to ON and preheat for 20 seconds to make start-up easier. The Preheat Icon will display.

3. Sound horn to warn personnel that the machine is being started.

4. Turn key to the START position and release as soon as engine starts. Key will automatically return to the ON position.

Figure 2 1. ENGINE EMERGENCY STOP CONTROL

NOTICE: Release Key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

1. Pull out the engine emergency stop control located at the lower right hand side of the operator’s seat until engine stops.

NOTICE: After starting the engine, use the auto warm up system described in Machine Warm Up in this chapter, and warm the engine and hydraulic oil.

1 DC04C344

2. Before restarting engine, engine stop control in.

push

emergency

• If engine fails to start after 3 attempts, inspect fuel system and correct any problem.

• When cranking engine, the absence of “blue” or “white” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

MACHINE WARM UP

Stopping the Machine

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions. Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

1

Auto warm up should be utilized when ever machine is started in temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in death or serious injury.

2

M1715

MANUAL WARM UP WARMING UP ENGINE a. Allow the engine to run for 5 minutes under no load conditions with throttle control at LOW idle position. b. During warm up, visually and audibly inspect engine for abnor mal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises.

BS07M861

Figure 3

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

2. Move throttle control to LOW position. Allow engine to idle for 5 minutes.

3. Turn key switch to OFF position.

Should problem areas be noticed, stop engine, locate and repair problem areas before restating or operating the machine.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS CHECK MONITOR PANEL

1

3

2

4

Figure 4

BS07M798

Check all gauges and indicators on the monitor after starting the engine. Make certain the water temperature (1) is in the normal range, fuel (2) is adequate, and other indicator lamps are not illuminated or indicating any engine abnormalities.

WARMING HYDRAULIC OIL NOTICE: 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. a. Move throttle control to HI idle position.

Figure 6

DC04D474

DC04D473

Figure 5

b. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket dump and hold over relief for 10 to 15 seconds. Repeat the operations for 5 to 10 minutes. c. Move throttle control to mid position.

d. Operate the boom and arm controls for 5 to 10 minutes each.

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions. Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

Auto warm up should be utilized when ever machine is started in temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in death or serious injury.

M1715

4-6

CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL DECAL OPERATING PATTERN The operating and travel controls of this machine are factory set at ISO/SAE standard operating patterns.

OPERATING PATTERN DECAL The illustrations are a repres entation of the CONTROLS decal located inside the right side window of the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this chapter. Should this decal become damaged or missing, install a new decal.

WARNING

BS07M796

Figure 7

BS07M797

Figure 8

Check and make sure that operations pattern control matches the decal provided inside the right side window. Failure to comply could result in death or serious injury.

M1713

WARNING If your machine is set to the operational BHL pattern control, change, make sure to remove the ISO/SAE operation pattern control decal inside the right side window and use the decal supplied for the optional BHL pattern control. This decal should be placed inside the door below the handle. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Failure to comply could result in death or serious injury.

M1716

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS

BASIC OPERATION OF HYDRAULIC CONTROLS The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use these instructions, and practice with a machine in a safe, clear area in order to operate safely and efficiently.

WARNING

Locked Position Before leaving the operator cab, place the Function safety lock lever in the LOCKED (up) position by pulling lever up. With Function safety lock lever in the LOCKED (up) position, no hydraulic operation is possible and this allows easy access in and out of the operator seat.

Normal positioning of the machine for the purpose of determining front, rear, forward, reverse are with the travel motors located behind the operator’s cab.

Always have the travel motor positioned correctly.

Failure to comply could result in machine damage, injury or death.

M1726

WARNING Always know the location of travel motors before operating any hydraulic controls.Failure to comply could result in death or serious injury.

M1727

Figure 10

BC08J114

SAFETY LOCK LEVER FUNCTION MACHINES WITH BOOM SWING PEDAL CONTROL

FUNCTION SAFETY LOCK LEVER

With engine running, set the safety control lever to the LOCKED (up) position.

2

Move the following controls: Left control lever Right control lever

1

Boom swing pedal - left and right Travel control lever

Figure 9

BS06H080

1. UNLOCKED POSITION 2. LOCKED POSITION

Unlocked Position Before any hydraulic operation is possible the Function safety lock lever must be placed in the UNLOCKED (down) position. Placing the Function safety lock lever in the UNLOCKED (down) position also positions the left hand Operator’s Console in its operating and lock position.

The functions should not actuate when the safety control lever is in the LOCKED (up) position. If any operation is functional, contact your authorized dealer for repairs to prevent unexpected machine movement.

WARNING Always place the safety lock lever in the Locked (up) position before leaving cab to prevent any operation of hydraulic controls. Failure to comply could result in death or serious injury.

WARNING Dozer blade control function is live at all times, even with the safety lock lever in locked up position. Use care when operating a machine with a dozer blade.Failure to comply could result in death or serious injury.

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE TRAVEL CONTROLS

TRAVEL SPEED SELECT SWITCH

This machine incorporates several travel controls for the convenience of the operator. Each track can be operated independently to turn the machine or operated simultaneously to counter rotate the machine or to travel straight.

OPERATING BOTH TRAVEL LEVERS TOGETHER

1

BS07M800

Figure 13

For fast travel speed, depress and release the travel speed select switch once before operating the travel controls. This puts the travel motors in FAST (1) travel speed and the lamp for FAST on the gauge cluster display will illuminate.

DC04D477

Figure 11

With the travel motors positioned behind the cab: a. Push both travel levers or press the pedals toward front of machine and machine will travel FORWARD.

DC04D478

To return to SLOW travel speed, stop travel and depress and release travel speed select switch once.

NOTICE: Use FAST travel speed on firm, level surfaces only. Do not travel continuously for more than two hours. Stop for a period of 10 minutes at low idle speed before resuming travel.

Figure 12

b. Pull both travel levers or press the pedals toward operator seat and machine will travel in REVERSE. c. Return both travel levers to NEUTRAL (center) position and machine will stop travelling.

NOTICE: The distance the travel levers are pushed or pulled determines travel speed of the machine.

EXAMPLE: Travel levers are pulled or pushed to full stroke machine will travel at top speed.

Travel levers are pulled or pushed to mid position machine will travel at 1/2 speed.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS TURNING THE MACHINE

DC04D482 DC04D479

Figure 14

a. Push the left travel lever toward front of machine to turn machine to the RIGHT in forward motion.

COUNTER ROTATING MACHINE

DC04D483 DC04D480

Figure 15

b. Pull the left travel lever back toward operator seat to turn machine to the LEFT in reverse motion.

Figure 16

c. Push the right travel lever toward front of machine to turn machine to the LEFT in forward motion.

Figure 18

a. Pull left travel lever BACK and push right travel lever FORWARD to counter rotate machine to the LEFT.

DC04D484 DC04D481

Figure 17

d. Pull right travel lever toward operator seat to turn machine to the RIGHT in reverse motion

Figure 19

b. Pull right travel lever BACK and push left travel lever FORWARD to counter rotate machine to the RIGHT. NOTICE: All functions explained with use of travel levers can also be performed using the travel pedals.

4-10

CHAPTER 4 - OPERATING INSTRUCTIONS NOTICE: A. Climbing ability of a machine can change depending upon shoe type, engine lubrication, etc.

B. When approaching or descending a slope, operate the travel levers slowly.

C. For braking, slowly return travel levers or pedals to the neutral (center) position. Brakes are engaged automatically.

D. The travel operation for 2 hours or more may cause the failure of the travel motors due to the rise of the operating temperature. Don’t travel continuously for more than 2 hours.

S t o p fo r 1 0 m i nu t e s a t l ow i d l e b e fo r e resuming travel.

E. In extremely cold conditions, below -20°C (-4°F), the travel lever or pedal action may be “heavier” than normal. This is due to the viscosity of the hydraulic oil in frigid climates.

TRAVEL SAFETY a. Know the position of the travel motor before beginning travel. b. Travel on firm, level surfaces as much as possible. c. When traveling on rough terrain, travel in SLOW speed with engine at a low idle. d. Travel with the travel motors in the back of the machine for long distance travel. e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging. f. Keep a safe distance from stationary objects and electrical power lines. g. Be aware of load capacities of bridges and road shoulders. Reinforce if necessary. h. Use decking or planks to protect road surfaces as much as possible. Be careful when turning or counter rotating machine on asphalt pavement. i. Do not allow large or heavy objects to strike travel motors. j. Do not travel over large objects such as boulders, rock, etc. k. The machine can sink on soft ground or mud.

Avoid these areas.

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN A NARROW SPACE

OPERATING THE MACHINE IN WATER

3

2

4

1 BS07M851

Figure 20

BS07N682

BOOM IN FOLDED POSITION

T h e bo o m m ay b e fo l d e d i n a s s h ow n i n th e illustration. Folding the boom in will decrease the swing radius of the machine.

Canopy swing radius with folded boom: 1590 m (63 in.)

Canopy swing radius with boom forward 1920 m(76 in.)

Cab swing radius with folded boom: 2100 m (83 in.)

Cab swing radius with boom forward 2480 m(98 in.)

4-12

Figure 21

If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the illustration.

If the machine is operated while the swing bearing is submerged in water, then the swing bearing, swing pinion, and the swivel joint may wear out prematurely.

NOTICE: Immediate replacement of grease in grease bath and flushing of the swing bearing is required. See Maintenance Section.

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE ATTACHMENT AND SWING - ISO/SAE PATTERN The following operation instructions are to be used with hoe bucket attachment only. If other attachments are being used, consult the operator’s manual for the particular attachment.

2. Arm Operation Operation of the Arm is performed by pushing or pulling the Left Control Lever forward and backward.

Arm speed is determined by how far the lever is activated.

WARNING Before operating this machine, review and understand all Safety Precautions in the Safety Section of this manual. Failure to comply could result in death or serious injury.

M1416

1. Boom Operation Operation of the Boom is performed by pushing and p u l l i n g t h e R i g h t C o n t r o l L eve r fo r wa r d a n d backward. Boom speed is determined by how far the lever is activated.

DC04D487

Figure 24

a. Pushing the left control lever FORWARD moves the arm out.

DC04D485

Figure 22

a. Pulling right control lever BACK raises boom.

DC04D488

Figure 25

b. Pulling the left control lever BACK brings arm in.

F. Returning the left control lever to the Neutral (center) position, stops operation of the arm.

DC04D486

Figure 23

b. Pushing right control lever FORWARD lowers boom. c. Returning right control lever to the neutral (center) position stops operation of the boom.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS BOOM SWING OPERATING PEDAL The swing function can also be operated with the boom swing operating pedal. Practice with this pedal in an open area. If the pedal is not in use, close cover to prevent unintentional swing. Do not use this pedal as a foot rest.

1

Figure 26

BC08J113

Use this pedal to operate the swing motion of the boom.

To use the pedal, lift the pedal locking cover (1) up.

Right swing: push down right side of pedal - boom will swing right.

Left swing: push down left side of pedal - boom will swing left.

WARNING Always lock the pedal if not using the boom swing operating function. Failure to comply could result in death or serious injury.

M1918

4-14

CHAPTER 4 - OPERATING INSTRUCTIONS Bucket Operation

Swing Operation - Lever

NOTICE: 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.

Swing operation is performed by moving the Left Control Lever to the right and left. Swing speed is determined by the amount the lever is moved.

Operation of the Bucket is performed by moving the Right Control Lever to the right or left.

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death.

M1088

NOTICE: Use operations.

DC04D489

swing

flashers

during

swing

Figure 27

a. Moving the right control lever to the LEFT operates the bucket in (digging).

DC04D491

Figure 29

a. Moving the left control lever to the LEFT swing machine to the left.

DC04D490

Figure 28

b. Moving the right control lever to the RIGHT operates the bucket out (dumping). c. Returning the right control lever to Neutral (center) position, stops operation of the bucket.

DC04D492

Figure 30

b. Moving the left control lever to the RIGHT swings the machine to the right. c. Returning control to the Neutral (center) position stops swing.

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY USE ARM IN ACTION

BS07M852

CLEANING SAND & SOIL FROM BUCKET

Figure 31 BS07M854

Operate the bucket at shallow depths and use the arm in action to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency. Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and the possibility of bucket teeth damage.

OPERATE BOOM SMOOTHLY

DC04E075

NOTICE: Avoid shaking out soil using the stops at the end of the bucket cylinder stroke.

DITCH DIGGING

Figure 32 BS07M855

Always begin and end boom operation slowly with smooth careful movement of the control lever. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

The attachment will provide maximum digging force when the arm and boom are at 90° - 110° of each other.

4-16

Figure 33

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.

Figure 34

For efficient ditch digging, position the machine parallel to the ditch to be dug using smooth bucket and arm motions. For wide ditch digging, dig both sides first, then dig the center portion.

CHAPTER 4 - OPERATING INSTRUCTIONS OFFSET DIGGING

USING THE DOZER

BS07M856

Figure 35

For back filling and leveling work after digging, use the dozer to push the soil back into the ditch or to level ground.

Do not push or pull material with the bucket like a bulldozer when using the machine to level material.

1. Scrape the soil at its upper surface with the dozer.

2. Use the dozer to back fill a trench.

Figure 37

BS07M858

3. Adjust the height of dozer with the dozer control lever to avoid over loading the engine.

4. Never travel with front attachment touching the ground. Severe structural damage could occur.

To operate the boom swing function, press the button on the top of the left control lever. Operate the control lever to the left for left boom swing or right for right boom swing.

NOTICE: While the boom swing control function is engaged, the boom will continue to swing when the finger is removed from boom swing control button. To cancel the boom swing function, return the left control handle back to the neutral position.

LOADING

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death.

M1088

BS07M857

Figure 36

1. Operating efficiency can be improved by positioning the dump truck so the swing distance is kept to a minimum. Always have a good field of view.

2. Start at the front side of the dump body and work toward the back.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS

4. Make certain that the engine coolant mixture is sufficient to keep the machine safe.

OPERATION IN EXTREME COLD

5. If the machine becomes overheated, idle the machine to help cool the engine, turn engine OFF and check coolant level. If after filling to proper level the machine continues to overheat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

1. Follow procedures at the beginning of this chapter as starting the engine may be difficult due to extremely cold temperature.

2. Use an engine oil, hydraulic oil, and diesel fuel d e s i g n e d fo r u s e i n c o l d c l i m a t e s . S e e Maintenance Section for reference. Keep batteries fully charged.

3. Make certain to perform machine warm-up procedures as described at the beginning of this chapter to prevent premature wear or damage to pumps, motors, and other components.

NOTICE: In extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain operating temperature, cover the outer edges of the radiator, leaving an opening in the center part of the cover thus avoiding fan overloading. Keep a close watch on the gauge for warning icons during operation. It may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting.

WARNING Do not drain the cooling system when the engine is hot. Allow time to cool all engine parts. Failure to comply could result in death or serious injury B121

6. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water.

7. Keep a close watch on the gauges for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

OPERATION IN HIGH ALTITUDES

4. Make certain that the engine coolant mixture is sufficient to keep the machine safe. Take into consideration wind chill factors when mixing coolant ratios.

1. Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced. Be aware of this fact when placing machine under heavy load in high altitudes climates.

NOTICE: Mix coolant to a protection temperature of 5°C (9°F) lower than the machine may experience during operation, storage or transport.

2. Keep close watch on the engine temperature gauge to avoid overheating of the engine.

5. Keep battery terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine system. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, removing the batteries and storing in a warm area is recommended.

OPERATION IN EXTREME HEAT

OPERATION IN SANDY AND DUSTY AREAS 1. Check the engine air cleaner elements frequently in sandy or dusty conditions.

2. When air cleaner restriction lamp illuminates, change filters immediately regardless of time intervals.

3. Service fuel filter, water separator, engine oil and filters, and all hydraulic filters frequently.

4. Keep the radiator, oil cooler, inter-cooler, and air conditioning condenser clean.

1. Use an engine oil, hydraulic oil and fuel designed for use in hot climates. See Maintenance Section for reference. Also keep batteries fully charged.

OPERATION AT SEASHORE OR SALTY CLIMATE

2. Clean radiator, oil cooler and debris screen often t o p r eve n t d a m a g e o r ove r h e a ti n g o f t h e machine.

1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electr ical components and cylinder rods.

NOTICE: Do not allow dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen, as this may cause a fire.

2. Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

3. Keep all belts properly tensioned.

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION IN HUMID CLIMATE 1. In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

2. Operate the A/C with the cab doors and windows closed.

LONGER UNDERCARRIAGE LIFE

BUCKET SELECTION GUIDE Bucke t se lection is extremely impo r tant to a machine’s productivity, durability, and stability.

Choosing an excessively large bucket can reduce productivity due to slower than normal cycle times.

Using an oversized or overly wide bucket in severe conditions such as mining, will lead to durability problems for both the machine and bucket involved.

Undercarriage life varies upon the operation method.

Use the following guides to increase the life of the machine’s undercarriage.

Stability will be adversely affected using a bucket that is unnecessarily large.

1. Select the track shoe that best suits the machine’s application. If in doubt, consult with your dealer when selecting track shoes.

If the buckets used locally var y in weight from recommended buckets, it will be necessary to adjust the bucket capacity accordingly. A heavier bucket must correspond to a reduced capacity.

2. Do not allow the tracks to slip during operation. If this occurs, reduce load until slipping stops.

3. Avoid sudden starts, accelerations, abrupt speed changes, high speeds on rough terrains, sharp turns, and sudden stops.

4. Always operate machine in straight lines whenever possible. Avoid short radius when turning. Make turns with the largest possible radius.

5. Prior to operation, clear boulders and obstacles to prevent damage to track shoes.

6. Always operate machine parallel to the incline of the slope. Operating machine across the incline of the slope will not only shorten the machine’s undercarr iage life, but the machine could unexpectedly slide down hill, and/or roll over.

If the material density (weight) exceeds guideline specifications then the bucket capacity must be reduced.

If the machine is to continuously dig rock, wasted shale, river cobble or other severe applications the narrowest bucket possible should be utilized. This will allow the greatest possible penetration and minimal twisting of the attachment (boom and arm). Bucket capacity is not to be the prime consideration for severe applications.

If a machine is used in a spoil pile operation, which causes a large radius dump cycle, applicable loads may have to be adjusted down by 5% from the Lift Chart Values.

7. Do not force the machine to carry out work that exceeds its working capability.

8. It is very important that inspections and maintenance schedules be followed as indicated in the Maintenance Section. Work conditions may require these scheduled times to be significantly shorter.

9. DO NOT OPERATE machine with loose track shoes, and maintain proper track tension adjustment at all times during operation.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

OPTIONAL EQUIPMENT USE OF OPTIONAL ATTACHMENTS If a machine is equipped with optional attachments, applicable bucket sizes and suspended loads must be reduced in direct proportion to the weight or combined weight of these attachments. Failure to consider the added weight of such attachments will cause stability problems. Additionally the weights of such attachments must be considered when the Lift Chart is referred to before lifting a load.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine.

HYDRAULIC BREAKER 1. SELECTION OF THE HYDRAULIC BREAKER When mounting a breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each breaker. To select hydraulic breakers, contact your dealer.

2. BEFORE OPERATING BREAKER

THE

HYDRAULIC

Consult your dealer for the piping needed for the boom and arm when installing a hydraulic breaker.

Replace the hydraulic return filter according to the replacement schedule table listed on MAINTENANCE FOR NIBBLER/BREAKER in the MAINTENANCE AND ADJUSTMENT Section.

Thoroughly read the Hydraulic Breaker Operation Manual and SAFETY PRECAUTIONS from this Section, as well as the Safety Precaution’s Section in this manual to avoid damaging the machine or hydraulic breaker during operation. Select the appropriate hydraulic flow for the breaker by following the instruction detailed in the NIBBLER/BREAKER BASIC MACHINE OPERATION in this section.

3. HYDRAULIC OIL LEVEL CHECK CONTAMINATION PREVENTION

AND

When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm-bucket end and the hose end on the on the hydraulic breaker side to prevent dust and water from entering into piping.

Before starting operation, check the cap screws on the tube securing clamps for looseness, and the connection of the tubes and hoses for oil leakage.

4. Basic Operation

WARNING Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

1

Figure 38

BS06H080

1. FUNCTION SAFETY LOCK LEVER

a. Start machine and place the hydraulic function safety lock lever in UNLOCKED (down) position.

4-20

CHAPTER 4 - OPERATING INSTRUCTIONS BREAKER

NIBBLER

Figure 39

BC08J116

1. BREAKER OPERATING SWITCH (BUTTON) 2. OPTION SWITCH (NIBBLER AND BREAKER)

Buttons are provided on the grip of the right control lever handle. Check the function of the right control handle buttons before operating the machine.

Figure 40

BS07HM860

1. BREAKER OPERATING SWITCH (BUTTON) 2. OPTION SWITCH (NIBBLER AND BREAKER)

Buttons are provided on the grip of the right control lever handle. Check the function of the right control handle buttons before operating the machine.

a. Move throttle control to HI idle position.

a. Move throttle control to HI idle position.

b. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

b. Using boom, arm and bucket controls set the nibbler to desired position.

c. Release control pedal lock rod.

c. Release control pedal lock rod.

d. Make certain breaker is in desired position and against material to be broken.

d. Make certain nibbler is in desired position and against material.

e. To operate breaker, press the switch (1).

e. To operate nibbler, slide the switch (2) left or right.

f. Release to stop operation. g. Operate breaker in 30 second intervals.

NOTICE: The breaker can be operated by sliding the option switch (2) to the left. When operating the breaker, it is recommended that the breaker switch button (1) should be used as much as possible.

Nibbler Button section

Operation

Slide left

Nibbler closes

Slide right

Nibbler opens

Breaker Button section

Operation

OFF

Breaker stops operating

Depress button B

Breaker starts operating

NOTICE: Do not touch the breaker operation switch (button) when you operate the nibbler.

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS OPTIONAL HAND CONTROL

WARNING Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

NOTICE: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition breaker or nibbler and repeat operation in one (1) minute intervals.

ACCELERATE SERVICE INTERVALS

Figure 41

BS08J521

1. SLIDE (TURN ATTACHMENT) SWITCH 2. HORN

Buttons are provided on the grip of the left control lever handle as an optional feature. Check the function of the left control handle buttons before operating the machine. a. Move throttle control to HI idle position. b. Using boom, arm and bucket controls set the breaker or nibbler to desired position. c. Use the boom, arm, and bucket controls to position the attachment. d. Sliding switch (1) will turn the attachment right or left.

• Slide left - attachment turns to left • Slide right - attachment turns to right NOTICE: Hydraulic flow will increase depending upon the slide distance of the switch (1).

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B

4-22

Contamination and deterioration of hydraulic oil may cause function problems with control valves, early wear and possible seizure of the hydraulic pump. The operation of breakers and/or nibblers accelerates the deterioration of hydraulic oil compared to normal earth moving operations with a bucket. Replace filters and hydraulic oil more frequently.

CHAPTER 4 - OPERATING INSTRUCTIONS SETTING MACHINE SELECTOR VALVE

a. Use a 24 mm Allen wrench to loosen bolt (3). b. Use wrench (4) to turn the selector valve (1) to the desired position. c. After valve is in position, tighten socket bolt (3).

1

2

2 1

2

Figure 42

BS07N621

1. SELECTOR VALVE 2. COVER

Machines equipped with a nibbler breaker attachment must have the selector valve (1) set to the correct position for the breaker or nibbler operation.

NOTICE: Make sure to relieve hydraulic system and tank pressure as instructed in RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE in Chapter 6.

Lower the attachment to the ground and stop the engine. Set the safety lock lever in the locked position.

SELECTOR VALVE SHIFTING POSITION TO TANK

TO TANK

TO C/V

TO ATT TO C/V

B : USE BREAKER

TO ATT

1. EXCAVATOR ARM 2. PLUG ATTACHMENT HYDRAULIC OIL VALVE POSITIONS A. CLOSED B. OPEN

Attachment Hydraulic Oil Shut off valve NOTICE: Make sure to switch the position of the stop valves to the CLOSED position before removing the attachment.

The valve is used to shut off the flow of hydraulic oil when changing attachment. Use a 19 mm hex to open and close valves.

Figure 43

3

BS07M864

Figure 45

N : USE NIBBLER

UPM00700003ES1

4

BS07M865

2

1

Figure 44

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS GETTING THE MOST OUT OF YOUR BREAKER

WARNING Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

A. BREAKER PROPER POSITIONING

When the excavator boom is lowered, it normally follows a curved path, which changes the original perpendicular position of the breaker. It is very important to keep adjusting the operator’s controls to maintain constant perpendicularity between the breaker and the surface of the material being broken.

In addition, the applied pressure should be sufficient to avoid the breaker tool from bouncing on the rock rather than transmitting the shock wave into it. The applied pressure should not lift the machine high off the ground, since the excavator can drop suddenly, as the breaker breaks through the material, and harmful shock loads will be transmitted through the entire machine.

C. BREAKING OVERSIZE ROCKS

DC03M065

Figure 46

Always position the breaker perpendicular to the material you intend to break. The breaker can be vertical, horizontal, or anywhere in between, as long as the tool is perpendicular to the surface and the pressure applied is in the same direction of the tool.

B. APPLIED PRESSURE ON BREAKER The breaker must have sufficient pressure between the tool and the surface of the material intended to break in order to allow the shock wave to flow through the tool and to the material being broken.

The applied pressure has to be constantly adjusted by combining the boom, arm, and bucket functions so that the breaker follows the tool at all times during breaker operation.

4-24

DC03M066

Figure 47

Do not attempt breaking oversize boulders from the center. It is much more efficient to break these type of rocks from the edges. Also, do not break into smaller pieces than necessary. There is a direct relationship between the size of the boulders and the size of the breaker. It is inefficient to break large rocks with small breakers and vice versa.

CHAPTER 4 - OPERATING INSTRUCTIONS F. RULES TO REMEMBER

D. SURFACE ROCK DEMOLITION

Use the following rules for correct breaker operation: 1. Make sure to adjust the proper hydraulic flow according to the breaker specifications.

2. Place tool against material to be broken at 90° angle to work surface.

3. Use the boom, arm, and bucket controls to press firmly against surface, keeping perpendicularity while operating the breaker.

4. As material breaks, stop breaker quickly to prevent idle strokes.

DC03M067

Figure 48

Use the breaker just as if it were a hand held breaker, or a plain hammer and chisel. Adjust the breaker’s position according to the work to be done, and take small bites at a time. The only difference between a hand held breaker and the hydraulic excavator breaker is the size of the rocks that can be broken.

Do not try to break too much at one time.

5. Reposition breaker if material does not break after 15 seconds of operation.

6. Do not bend or pry with the breaker tool while operating.

7. DO NOT OPERATE breaker with attachment cylinders at full extension.

8. DO NOT OPERATE breaker submerged in water.

9. DO NOT OPERATE breaker for more than a minute at a time.

E. EXCAVATING AND TRENCHING

10. Lubricate breaker every 30 minutes. Keep tool lubricated at all times.

DC03M068

Figure 49

Lay back side walls a bit at the time so that they do not interfere with the breaker housing. To lessen the opportunity for side loading, approach each wall from the opposite side by positioning the excavator perpendicular to the trench.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS SAFETY PRECAUTIONS

D. CYLINDERS

The following safety precautions should be used in conjunction with other safety precautions found in this manual.

WARNING Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

A. USE FOR INTENDED PURPOSE DC04E063

Figure 52

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.

E. AVOID CONTINUOUS OPERATION

DC04E061

Figure 50

Use the attachment only for its intended purpose. If not used in accordance with the manufacturer’s instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS

DC04E064

Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT

DC04E062

Figure 51

When operating attachments that create flying debris, install protective guards on the machine.

Close all windows to protect the operator from flying debris. The operator and all personnel in the vicinity of the machine should wear protective gear.

4-26

Figure 53

Operate the nibbler/breaker in one (1) minute intervals. Operation for longer than one (1) minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and/or pump damage.

CHAPTER 4 - OPERATING INSTRUCTIONS I. DO NOT LIFT

F. HOSE SURGE

DC04E065

Figure 54 DC04E068

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.

Never use optional attachment to lift or transport objects or materials. 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.

J. WORKING RANGES

G. DO NOT USE DROPPING FORCE

DC04E066

Figure 57

Figure 55

Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

DC04E069

Figure 58

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

H. DO NOT USE SWING FORCE

DC04E067

Figure 56

Never use the swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-28

CHAPTER 5 - TRANSPORTATION

CHAPTER 5

TRANSPORTATION CONTENTS TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 PREPARE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-1

CHAPTER 5 - TRANSPORTATION

NOTES

5-2

CHAPTER 5 - TRANSPORTATION

TRANSPORTING THE MACHINE GROUND TRANSPORTATION 1. Machine Preparation a. Know the total weight, length, width and height of the machine being transported. b. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

c. Obtain any permits required from proper gover nment agencies for machine transportation. d. Use only a trailer with a rated capacity sufficient to transport the machine. e. Make certain trailer has ramps or a ramp is available for loading and unloading the machine

CANOPY MACHINE

Machine with Canopy

CAB MACHINE

BS07M866/867

Figure 1

5-3

CHAPTER 5 - TRANSPORTATION Securing Machine to Trailer

2. Loading the Machine

WARNING Never attempt to load or unload machine without ramps. Failure to comply could result in death or serious injury B121

a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower ramps of trailer. c. Start the machine. d. Set travel speed to LOW - 1st speed. e. Move throttle control to low idle position. f. Raise the attachment and slowly travel machine up trailer ramps and over rear axles of trailer. g. Slowly move machine completely onto trailer until in proper transport position. h. Slowly swing machine 180° until attachment is toward rear of trailer. i. Slowly lower boom until attachment rests on trailer bed. j. Do not have bucket and arm cylinder at full stroke during transport as this may cause damage to cylinders.

1 Figure 3

DC04D581

Figure 2

DC04C344

1. FUNCTION SAFETY LOCK LEVER

k. Place hydraulic function safety lock lever in the LOCKED (up) position. l. Turn machine OFF, remove key and lock all doors, filler caps and access panels.

NOTICE: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

a. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer. Also, make sure to secure front and rear of each track. b. Securely fasten all loose parts, as well as removed parts from the machine to the trailer or transporting platform.

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury.

CM113A

5-4

CHAPTER 5 - TRANSPORTATION LIFTING MACHINE The following procedures are for lifting the machine, as built by Case Construction. These procedures do not take into account modifications made to the machine that affect machine weight or center of gravity.

LIFTING MACHINE WITH ATTACHMENT INSTALLED a. Install lift eyes/shackles at holes provided at both ends of the dozer blade. Locate lift areas. b. Attach cables or wire ropes with a capacity rating sufficient to lift the machine, at lifting locations.

1 Figure 4

DC04D582

1. HARDWOOD OR STEEL BLOCK

NOTICE: Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting. c. \Slowly raise the lift apparatus to check with contact with machine, security, and balance.

Do not lift the machine over any personnel. d. Lift machine carefully, keeping sway to a minimum. Place machine in desired location.

5-5

CHAPTER 5 - TRANSPORTATION

WARNING This machine is heavy. Use a suitable lifting and/or supporting device when lifting, moving or supporting the machine/component. Do not lift the machine/component higher than necessary. Make sure all persons and pets are a safe distance from the machine/component when it is being lifted or moved. Failure to comply could result in death or serious injury.

CM113A

BS07N632

5-6

Figure 5

BS07N633

Figure 6

CHAPTER 5 - TRANSPORTATION

MACHINE STORAGE

Figure 7

BS07M870

MACHINE IN STORAGE POSITION

PREPARE MACHINE

CARE DURING STORAGE

Perform the following procedures to prepare the machine for long term storage.

Every 30 days during storage, it will be necessary to start and run the machine to circulate the fluids through the systems. Before starting, clean cylinder rods and after running, re-grease cylinder rods.

1. Perform all inspection and maintenance proce dure s as de scr ibed in Mainte nance Section. Make certain fluid levels are correct.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

NOTICE: Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank. Make sure to use an anti-algae additive in the fuel tank.

4. Move machine to an indoor location for storage.

5. Park the machine with belts/tracks on top of wood if possible with the exposed piston rods of the cylinders retracted as much as possible.

6. Rest the bucket on a stable wood block.

7. Coat cylinder rods with heavy coat of grease to prevent corrosion during storage.

NOTICE: Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in the Maintenance Section before bringing machine out of storage for normal operation.

2. Remove drain plugs from the travel motors and swing gear reduction units to drain off any moisture which may have accumulated during storage.

3. Carefully and closely inspect all hydraulic hoses after long per iods of stora ge for signs of deterioration. Replace all hoses showing signs of deterioration.

NOTICE: Refill fluids to proper levels and lubricate as required.

8. Remove batteries and store in a well ventilated, warm area.

5-7

CHAPTER 5 - TRANSPORTATION

NOTES

5-8

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 6

LUBRICATION, FILTERS, AND FLUIDS CONTENTS FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 USE OF BIO-DEGRADABLE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-1

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

6-2

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES

SWING BEARING

ENGINE Type of Oil . . . . . . . . . . . . . . Engine Oil SAE 15W30 Capacity: Engine Oil with filter change . . 6.7 liters (1.8 gal) NOTE: See ENGINE OIL LEVEL in Chapter 7 for proper oil filling and/or checking engine oil level.

HYDRAULIC Type of Oil . . . . . . . . . . . . . . . . . Hydraulic Oil AW 46 Capacity: Hydraulic Tank. . . . . . . . . . . . .38 liters (10.0 gal) Hydraulic System . . . . . . . . . .48 liters (12.7 gal) NOTE: See HYDRAULIC OIL LEVEL in Chapter 7 for proper filling and/or checking hydraulic oil level.

TRAVEL MOTOR REDUCTION UNIT Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil Capacity 0.7 liters (0.18 gal) Each x 2 NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL in Chapter 7 for proper filling and/or checking oil level.

Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . As required (1 place - swing 90° x 4) NOTE: See SWING BEARING LUBRICATION in Chapter 7 for proper lubrication.

TRACK TENSION ADJUSTMENT Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . . . As required (2 places) NOTE: See TRACK TENSION in Chapter 7 for proper procedures in injecting grease.

RADIATOR Coolant . . . . . . . . . Ethylene-glycol Coolant Solution

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

UPPER ROLLERS Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil Capacity . . . . . . . . . . . . .45 cc (2.7 cu. in.) Each

Capacity: Radiator . . . . . . . . . . . . . . . . . . . . 1.6 liters (0.42 gal) Cooling System . . . . . . . . . . . . . . 4.6 liters (1.22 gal)

IDLERS Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil Capacity . . . . . . . . . . . . 80 cc (4.8 cu. in.) Each

OPERATING LEVER JOINT Type of Oil . . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . As required in each joint NOTE: See CONTROL LEVER JOINT LUBRICATION in chapter 6 for proper lubrications.

NOTE: See ENGINE COOLANT CHANGE in Chapter 7 for proper coolant filling and/or coolant level check.

FUEL TANK Type of Fuel . . . . . . . . . . . . . Diesel Fuel grade No. 2 Capacity . . . . . . . . Fuel Tank - 38 liters (10 gal) NOTICE: See FUEL LEVEL in Chapter 7 for proper filling and/or checking the fuel level.

UPPER ATTACHMENT PINS Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . .As required in each pin NOTE: See ATTACHMENT LUBRICATION Chapter 7 for proper lubrications.

in

6-3

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS REQUIRED FILTERS

Engine

NOTICE: Refer to the Parts Manual for the correct part numbers to order.

• Engine Oil Filter

HYDRAULIC

• Air Cleaner Inner Element

• Return Filter Element for Standard Machine • Return Filter Element for Breaker and N&B • Tank Suction Strainer

• Air Cleaner Outer Element FUEL

• Engine Fuel Filter

• Tank Breather Filler Element • Pilot Line Filter

OPERATOR CAB

• A/C Fresh Air Filter • A/C Recirculate Air Filter NOTICE: Refer to MAINTENANCE - Chapter 7 in this manual for the locations and proper procedures in replacing filters.

6-4

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climate and certain conditions.

CLIMATE ZONE

LUBRICANT HYDRAULIC OIL (ANTI-WEAR, ANTIOXIDANT, AND NON-FOAMING)

FRIGID -30°C~15°C (-22°F~59°F)

FRIGID -20°C~30°C (-4°F~86°F)

FRIGID-WARM -25°C~40°C (-13°F~104°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 5°C~55°C (41°F~131°F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT

ENGINE OIL A.P.I. CLASSIFICATION FOR SERVICE CD

FRIGID -30°C~30°C (-22°F~86°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 30°C and Above (86°F and Above)

SAE10W30

SAE15W40*

SAE15W50

NOTICE: *All engines shipped from factory with SAE15W40 engine oil.

CLIMATE ZONE

LUBRICANT

FUEL

LUBRICANT

FRIGID -15°C ~ -25°C (5°F ~ -13°F)

WARM -5°C ~ -15°C (23°F ~ 5°F)

VERY HOT -5°C and Above (23°F and Above)

WINTERIZED ASTM D975 No.1

ASTM D975 No.2

ASTM D975 No.2

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL (For General Purpose Lubrication)

A.P.I. Classification for Service CD - SAE15W40

LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

Extreme Pressure Multi Purpose Grease No.2 EP Type Grease

N.L.G.I. No. 2 Lithium Base with MOS2 Grease

FLUID ENGINE COOLANT (50% MIXTURE)

ANTIFREEZE (LLC) -34°C (-29.2°F) Mixture ratio should protect to 5°C (9°F) lower than the coldest temperature the machine will experience. Take into consideration Wind Chill Factors.

6-5

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

6-6

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, it is required to flush the hydraulic system that was filled with mineral oil twice, before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

6-7

CHAPTER 6 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

6-8

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 7

MAINTENANCE AND ADJUSTMENTS CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-3 7-3 7-4 7-4 7-4 7-4 7-4 7-4 7-5 7-5 7-5

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 DAILY INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Alternator/Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10 7-10 7-12 7-12 7-13 7-13 7-13 7-14 7-15 7-15 7-16

50 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17 7-17 7-17 7-18 7-19 7-23 7-24

250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect and Adjust Fan/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolt and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dozer Pin Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greasing the Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom, Arm, and Attachment Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the inner element (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Return Filter (Breaker Use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-25 7-25 7-26 7-26 7-27 7-27 7-28 7-29 7-29 7-30

7-1

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Clean and Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31 Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Replacing Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 Repairing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 Check Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 Check Starter and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 1500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Check Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Hydraulic Suction Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 Pilot Valve and Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 Upper and Lower Roller - Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 Upper Roller Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 Change Swing Gear Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 Intake and Exhaust Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48 Replacing the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 Replacing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 Rubber Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51 Rubber Track Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51 Rubber Track Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53 Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55 Releasing Lock on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55 Removing Gears from Travel Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55 Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56 Lowering Bucket Attachment on a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57

7-2

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in death or serious injury.

M1087

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

3. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition.

DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters, and other hazardous waste properly.

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

KEEP MACHINE CLEAN

M1070

DC04B669

DC04B668

Figure 1

1. It is recommended 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.

Figure 2

Thoroughly clean machine before perfor ming inspection and maintenace procedures. It is easier and safer to locate problems, perform maintenance and also reduce r isk of hydraulic s ystem contamination when machine is clean.

HOT SURFACE & FLUIDS

2. 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 a guide. Also, refer to the inspection and maintenance charts for general service interval recommendations. If you doubt your ability to perform these tasks, contact your dealer for assistance.

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

DC04B670

Figure 3

Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool down before performing maintenance procedure.

7-3

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS PREVENT CONTAMINATION

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

TAG-OUT MACHINE

Figure 6

DC04B673

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

DC04B671

Figure 4

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.

INSPECT WASTE OILS AND FILTERS

NOTICE: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

SEALS AND O-RINGS Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

STOP ENGINE Do NOT attempt any maintenance with engine running. Always stop the engine and allow machine to cool.

WEAR SAFETY EQUIPMENT Wear hard hat, safety goggles or face shield, work gloves, safety shoes, and well fitting work clothes when perfor ming inspection and maintenance procedures on this machine.

CLEANING PARTS

DC04B672

Figure 5

Before disposal, inspect all waste oils, fluids, and filters for debris and foreign material. Cut open the oil filters to determine any abnormal wear.

Use only approved cleaning solvents and proper equipment to clean parts.

WARNING Never use gasoline, diesel fuel or other flammable solvents to clean parts. Always clean parts in a well ventilated area. Failure to comply could result in death or serious injury.

M138A

7-4

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY

STEPS AND HAND HOLDS

1. Turn key switch to OFF position.

2. Remove negative (-) cable from battery terminal.

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

1. Inspect daily all mounting steps and hand holds on the machine to make sure they are clean and in safe working condition.

2. Repair or replace all damaged parts components prior to operating the machine.

or

NOTICE: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition free of grease, oil, mud, ice, and snow.

WARNING Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 m (2 ft) from the part being welded. Do not connect the ground cable to the welder to the cooling plate for the engine control module (ECM) or the engine control module itself. Welding on the engine or engine mounted components is not recommended or damage to the engine or components can result. Failure to comply could result in death or serious injury.

M1067

FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

NOTICE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding is required, consult an authorized Dealer for proper procedures. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding. Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

7-5

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM NOTICE: Before performing any work on the hydraulic system, there should be no pressure in any of the circuits.

1 2

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

Figure 8

BS07M871

5. Make certain the hydraulic oil temperature is below 40° C (104° F).

6. Open the door to the hydraulic tank (1) and secure in place with strut.

1

2

7. Press the rubber cab (2) on the top of the hydraulic tank 5 to 7 times.

WARNING

Figure 7

BS07M861

2. Turn the ignition switch key to the ON position.

Pilot control switch must be on.

3. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the ignition key to the OFF position.

4. Set the safety lock lever to LOCKED position.

WARNING Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply could result in death or serious injury.

M149C

7-6

Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS GUIDELINES TO REPLACE GROUND TOOLS

GUIDELINES FOR ATTACHMENT LUBRICATION

It is very important to keep bucket teeth and side cutters properly tightened. Loose or missing bolts will increase loads and eventually cause tool failure.

Extended operation with loose hardware can cause the bolts to stretch and wear on the support mounting holes. Heating of hardware and support mounting holes will cause the same effect. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters.

Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubrication inter vals are based on a standard excavator (see Specifications Section for the definition of Standard Excavator) working in an average duty cycle. Average duty cycle is defined as “Most typical digging application, road construction in natural bed clay, digging 50% ~ 60% of the daily work schedule”.

• When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

• Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT.

• When installing end bits, start at the center and work toward the outside edges.

• Always torque bolts according to specifications.

• For best results, strike all head bolts with a heavy hammer to seat them properly before final torque.

WARNING Avoid eye injury when using a drill, hammer, saw, or other tools that may cause chips to fly. Always wear safety glasses when working. Failure to comply could result in death or serious injury.

M428B

• When new parts are used, the mating surfaces will seat more uniformly and the bolts torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

• Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

• When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mount hole if needed. Torque bolts according to specifications.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points.

Because of these high spots, it is recommended that the front attachment or the repaired area be lubricated a minimum of once every eight (8) hours for the first one hundred (100) hours for a standard machine working in an average duty cycle. All other machines should be lubricated every 4 hours for the first twenty (20) hours and every eight (8) hours for the next eighty (80) hours of operation. This lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand operated grease dispenser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standard lubr ication procedure is modified. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. Therefore, to avoid this situation, the front attachment has to be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

7-7

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

Every 500 hours

Every 1000 hours

Every 1500 hours

7-8

7-16

Fan and air conditioning drive belt

7-29

Air filter

7-32

Fuel tank filter

AR

9-11

Bolt and nut torque

AR

Rubber track (if equipped)

7-10

Grease bucket, boom, arm cylinder, dozer

7-12

Engine oil level

8

7-12

Coolant level

8

7-12

Radiator and oil cooler

8

7-13

Electrical connections

8

7-13

Water separator

8

7-13

Fuel Tank

8

7-14

Hydraulic reservoir level

8

7-14

Cylinders, hydraulic lines Fan/alternator belt tension

7-15

Rubber crawler belt

7-17

Attachment

7-17

Drain fuel tank sediment

8

8 50 50

Engine oil and filter

Run-in

Rubber track

Run-in

7-23

Fan/alternator belt tension

50

8-4

Battery check

50

Hydraulic return filter Engine oil and filter

7-26

Fan/alternator belt tension

7-27

Swing reduction gear

7-28

Boom, arm cylinder, dozer

7-29

Air Cleaner Element

7-30

Hydraulic return filter (Breaker attachment)

9-11

Bolt and nut torque

7-31

Fuel water separator

7-32

Fuel filter

7-32

Air cleaner elements

7-33

Travel reduction gear

Drain

AR

7-19

7-24

AR

Run-in

7-18

7-25

Lubricate

AR AR

7-19

7-16

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

50 50

Run-in

50 250 250

Run-in

250 250 250 250 250 500 500 500

Run-in

500

7-34

Radiator coolant

1000

7-36

Hydraulic return filters

1000

RM

Valve clearances

1000

RM

Starter/generator

1000

RM

Injector Timing

1500

Every 2000 hours

Every 5000 hours

7-38

Hydraulic suction strainer

2000

7-38

Pilot valve

2000

7-40

Solenoid in-line filter

2000

Drain

Lubricate

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

7-43

Travel reduction gears

2000

7-45

Idler oil change

2000

RM

Swing gear grease

RM

Intake and exhaust

7-47

Hydraulic oil

2000 2000 5000

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTICE: RM = See Repair Manual or contact authorized dealer

7-9

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

3

4

1

M110B.

2

GREASE MACHINE AND ATTACHMENTS Figure 10

BS07N028

1

1.

2.

3.

4.

BUCKET CYLINDER ROD PIN IDLER LINK/ARM CONNECTING PIN BUCKET LINK PIN ARM/BUCKET CONNECTING PIN

2 2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease the leaks out of the pin connection.

BS07M861

Figure 9

During the initial 50 hours of operation during the run-in period, grease bucket, boom, arm cylinder and dozer every 8 hours. After the initial run-in period, grease every 50 hours.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

7-10

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS B O O M , A R M , A N D AT TAC H M E N T G R E A S E POINTS

DOZER PIN GREASE POINTS

3 1

7

4 2

8 10

3

11 6 5 9 Figure 11

BS07N035

Figure 13

BS07N033

1. DOZER CYLINDER ROD PIN (1) 2. DOZER CYLINDER FOOT PIN (1) 3. DOZER FOOT PIN (2)

4.

5.

6.

7.

8.

9.

10.

11.

BOOM SWING GREASE POINTS

12

BOOM FOOT PIN (1) BOOM CYLINDER FOOT PIN (3) BOOM CYLINDER ROD PIN (1) ARM CYLINDER FOOT PIN (1) ARM CYLINDER ROD PIN (1) BOOM/ARM CONNECTING PIN (2) BUCKET CYLINDER FOOT PIN (1) BUCKET CYLINDER ROD PIN (1)

NOTICE: Dispose of all waste in accordance with environmental regulations.

5

14

13 BS07N634

(5) BOOM CYLINDER FOOT PIN

Figure 12

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

(12) SWING CYLINDER FOOT PIN (13) SWING CYLINDER ROD PIN (14) SWING BRACKET/FRAME CONNECTING PIN

7-11

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL LEVEL

ENGINE COOLANT LEVEL 1. Check coolant level every 8 hours. Coolant should be changed at 1000 hours. The coolant reservoir tank is located on the right side of the engine compartment.

2. Proper coolant level is between FULL and LOW marks.

2

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

2 3 1

1 4

Figure 15

BS07M872

1. RESERVOIR CAP 2. RADIATOR CAP Figure 14

BS07N039

1. OIL DIPSTICK 2. FILLER CAP

1. Check oil level every day or each 8 hour sift. Oil should be changed at 50 hour run-in period and at every 250 hours thereafter.

2. Raise the engine cover.

3. Pull engine dipstick out, clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again to visually inspect the engine oil level on dipstick.

4. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

NOTICE: After adding oil, check oil level again, replace filler cap and dipstick and close engine cover.

7-12

3. RADIATOR 4. RESERVOIR

4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Refill reservoir to proper level. Inspect hoses and connections for leaks

WARNING Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS FUEL LEVEL

ENGINE ELECTRICAL

Figure 16

DC04C292

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Failure to comply could result in death or serious injury.

Figure 17

BS07M675

1. FUEL LEVEL GAUGE

1. Turn ON the key from key switch and the fuel gauge in the cluster will indicate the fuel tank level.

2. To refuel the machine, remove the fuel tank cap.

Do not remove the fuel screen for fueling. Refill fuel tank 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.

DRAIN WATER SEPARATOR

M1725

1

2 BS07N030

Figure 18

1. Inspect water separator every 8 hours. Drain and clean at 500 hours.

2. Visually inspect separator. If red ring (1) sinks to bottom of case, no water is present.

3. When ring is floating, drain water and sediment.

4. Open valve (2) and drain until clean fuel is discharged.

5. Repair or replace damaged hoses and lines before any operation.

7-13

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL

A. Release all pressure from hydraulic tank.

Depress air release button several times to r e l e a s e hy d ra u l i c t a n k p r e s s u r e. ( S e e releasing hydraulic pressure for additional information.)

1

1

2

2 3

Figure 19

BS07M861

WARNING For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. DO NOT OPERATE machines on inclined surfaces with a slope greater than 35°.

Failure to comply could result in death or serious injury.

4

M1718

Figure 21

BS07M873

1. Place the machine in the hydraulic oil check position on a firm level surface.

2. Check the sight glass located on the side of the hydraulic tank. The oil level should be between H and L. NOTICE: Oil level will depend on oil temperature.

Cold: L level (oil temperature 10-30° C [50-80° F]) Operating: H level (oil temperature 50-80° C [122-176° F]) 3. Refill if oil level is below L. 4. To add hydraulic oil, open the right side cover and support with strut.

1

2

1.

2.

3.

4.

CAP SCREW & WASHER COVER PLATE O-RING SIGHT GAUGE

B. Slowly remove the mounting bolts (1) from the cover plate.

C. Add hydraulic oil, filling hydraulic tank to the proper level.

D. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic oil and install the O-ring.

E. Install cover plate, cap screws and washers.

Tighten the cap screws to torque specification.

Torque to: 21.7 - 25.5 Nm (16 - 18.8 lbf ft).

F. Check all hydraulic controls for proper functionality before operating the machine.

NOTICE: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

Figure 20

BS07871

1. COVER 2. AIR RELEASE BUTTON

7-14

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEAKS

DC04C300

Figure 22

DC04C287

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, seek medical attention immediately. Failure to comply could result in death or serious injury.

Figure 23

CHECK CRAWLER BELTS Keep crawler belts free of dirt and imbedded rock for maximum traction. Visually check for cracking, separating, exposed core or other damage. Check tension after the first 50 hours of initial operation.

M587A

1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure.

2. Check all hoses and lines for signs of damage.

3. Repair or replace damaged hoses and lines before any operation.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

7-15

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS INSPECT ALTERNATOR/FAN BELT CONDITION Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time, and every 250 hours thereafter.

3 2

1

Figure 24

BS07N031

1. ATTACHING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

WARNING Stay clear of rotating machine parts and keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing.

Failure to comply could result in death or serious injury.

M223A

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

7-16

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE: DRAIN FUEL TANK SEDIMENT

ATTACHMENT LUBRICATION

2 3

4

1 2

Figure 25

BS07N028

1.

2.

3.

4.

BUCKET CYLINDER ROD PIN (1) IDLER LINK/ARM CONNECTING PIN (1) BUCKET LINK PIN (1) ARM/BUCKET CONNECTING PIN (1)

During the first 50 hours of operation, grease attachment every 8 hours. After the initial run-in period, grease every 50 hours.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease the leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

WARNING

1

Figure 26

BS07N128

1. FUEL TANK 2. DRAIN PLUG

WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious bodily injury.

M1394

The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

1. Draining water and sediment is most effectively perfor med in the mor ning. Tur n the upper structure of the machine so the drain plug (2) is midway between the crawler belts.

2. Place a suitable container under the drain plug (2) to catch the discharged fuel.

3. Slowly loosen the drain plug (2) to drain water and sediment. When clean fuel begins to flow, tighten the drain plug.

4. Check for fuel leakage after tightening drain plug.

If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

7-17

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS CHANGE ENGINE OIL

3

4 2

1

Figure 28

BD07N032

1. OIL FILTER 2. FILTER WRENCH

6. Use the filter wrench provided with the machine, and turn counter clockwise to remove the oil filter.

1

2

3

5

BD07N040

Figure 27

BS07N029

1.

2.

3.

4.

5.

DRAIN CAP COVER DIPSTICK OIL FILL CAP DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a new machine, then at every 250 hours thereafter.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off. Raise the engine cover. Remove the dipstick to allow oil to run more freely.

2. Remove bolts and engine belly pan covers 3. Locate the engine oil drain plug and place an empty oil container [7 L (2 gal) capacity] under the plug. Attach the quick drain hose (5), and drain the oil into the container.

4. Remove engine oil drain plug and let the engine oil drain out completely.

5. After draining oil, remove drain hose, and tighten drain cap (1) securely. Remove any spilled oil.

Figure 29

7. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head.

NOTE: Check the waste oil. If there are metal flakes in the oil, contact your authorized dealer. Do not reuse the oil filter.

8. Clean oil drain plug and install it. Tighten securely.

9. Check drained oil for any metal shavings or particles. Contact your dealer if any debris is found.

10. Fill with the specified amount of oil through filler port (4) and install oil filler cap.

11. Before starting the engine, check oil level using the dipstick (3). The level should be between the L and H limits as shown. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

12. Install under cover (2) to its original position.

7-18

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS TRACKS AND COMPONENTS Check rubber track tension every 50 hours.

1

Figure 32

BS07N042

DC04C300

Figure 30

Abrasion on the rubber crawler belt varies depending on working conditions. Frequently check for wear and tension, particularly on a new crawler belt as there will be an initial stretch during the first 30 hours of operation.

3. Move the upper structure at 90° to the crawler frame. Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Support the lower travel structure with a safety support (1).

2

1

1. Visually inspect track shoes for signs of excessive wear or damage.

3

4

BS07N043

1.

2.

3.

4.

BS07N041

Figure 31

2. Move the rubber crawler belt so the joining ends (M mark) comes to the upper center position.

Figure 33

CRAWLER FRAME LOWER ROLLER RUBBER BELT IRON SHOE

4. Measure the clearance in the center of the track, between the bottom of the track frame and the track shoe surface.

Measure Clearance (A) Rubber belt 80 - 90 mm (3.15 - 3.54 in.)

Iron shoe: 115 - 130 mm (4.53 - 5.12 in.)

If track tension is not within the specifications, make adjustment to the track.

NOTICE: If working on firm, hard ground, more track tension is recommended. If working on loose gravel or stone, lower track tension is recommended.

7-19

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

1

Figure 34

DC04C307

2

WARNING 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 (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

BS07N045

1.

2.

A. B.

Figure 36

GREASE FITTING GREASE CYLINDER GREASE FILL PRESSURE

M1720

1 BS07N046

BS07N044

Figure 35

5. 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 (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance.

7-20

Figure 37

6. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting (1) with a grease gun until proper tension is reach.

NOTICE: If the adjustment to the track cannot be maintained, the grease cylinder may need repair.

Contact your authorized dealer.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS Adjusting for less tension

Removing Rubber Crawler Belt

1 1

BS07N046

Figure 38

1. Gradually loosen the grease fitting to release grease under pressure. Do not loosen the grease fitting (1) more than one turn.

2. If the grease does not release adequately, move the machine forward and backward.

Figure 40

BS07N042

1. Park the machine on a hard, level surface. Move the upper structure at a 90° to the crawler frame.

Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Support the lower travel structure with a safety support (1).

1

1

BS07N047

Figure 39

3. After grease has been released, tighten the grease fitting.

Torque to: 73.5 ± 14.7 Nm (54.2 ± 10.8 lbf ft).

Move the machine forward and backward to confirm the correct tension of the crawler belt. If necessary, adjust again.

BS07N046

Figure 41

2. Gradually loosen the grease fitting to release grease under pressure. Loosen the grease fitting (1) less than one turn. Grease will flow from the fitting (2).

7-21

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

1

1 Figure 42

BS07N049

3. Insert three steel pipes into the bottom front rubber crawler belt, then slowly rotate the sprocket backward by moving the track.

4. Stop the rotation when the rubber crawler belt separates from the idler wheel. Shut off the engine.

5. Slide the crawler belt over the steel pipes to remove.

REPLACING THE RUBBER CRAWLER BELT

1

BS07N042

Figure 43

1. Park the machine on a hard, level surface. Move the upper structure at a 90° to the crawler frame.

Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Shut off the engine.Support the lower travel structure with a safety support (1).

7-22

BS07N049

Figure 44

2. Engage the rubber crawler belt with the sprocket and hang it on the idler.

3. Insert three steel pipes into the bottom front r ubber crawler belt then slowly rotate the sprocket backward. When the rubber crawler belt separates from the idler wheel, stop the rotation.

Shut of the engine.

4. Slide the rubber crawler belt over the steel pipes to install it.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS INSPECT BELT CONDITION

1

2

Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time, and every 250 hours thereafter.

6

3

5 2 4 1

7

WARNING

3

BS07N050

1.

2.

3.

4.

5.

6.

7.

Figure 46

BS07N031

Figure 45

LOWER ROLLER RUBBER CRAWLER BELT SPROCKET IDLER LUG METAL CORE TRAVEL MOTOR

5. Stop the rotation of the sprocket to confirm the rubber crawler belt is securely engaged to the sprocket, idler, and lower rollers. See illustration.

6. Check the tension on the belt and make any adjustments necessary.

7. If tension is correct, lower the machine to the ground.

Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

M124B

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

ADJUSTING BELT 1. Slightly loosen attaching bolt (1) and adjusting bolt (2).

2. Loosen adjust bolt (3) adjust the fan belt to the correct tension, and tighten bolts (1) and (2).

3. After adjustment, run the engine at low idle for approximately 5 minutes, then recheck the tension of belt.

New Belt Tension

Used Belt Tension

8 - 12 mm (8/16 - 7/16 inch)

10 - 14 mm (3/8- 1/2 inch)

NOTICE: A used belt refers to a belt that has been run 5 minutes or more.

7-23

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

1 2 3 6 1

7

2

4 5

8

Figure 47

BS07M861

Replace the hydraulic return filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 1000 hours thereafter.

1. Place the machine in the hydraulic oil check position on a firm level surface.

2. Make certain to remove all hydraulic pressure from the system.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

BS07N636.

Figure 48

3. Open the cover to the hydraulic tank and secure with the strut.

5. Press the valve (several times: 5 to 7 times) together with the breather cap (8), and bleed the hydraulic oil tank of the remaining pressure.

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

6. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

M1295

7. Take the spring (4), valve (5) and element (6) out of the tank.

8. Replace O-ring (7) fitted on the face of cover (3).

9. Clean the parts taken out with light oil.

10. Install element by reversing the disassembly procedure.

11. Install cover (3).

Tightening torque: 21.5 - 25.5 Nm {15.6 - 18.4 lbf ft} 12. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in position to check the oil level.

Stop the engine and check the oil level adding oil, if need.

13. Close the cover on the hydraulic oil tank and lock.

7-24

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE CHANGE ENGINE OIL

3

4 2

1

Figure 51

BD07N032

1. OIL FILTER 2. FILTER WRENCH

7. Use the filter wrench provided with the machine, and turn counter clockwise to remove the oil filter.

1

2 3

5

Figure 49 Figure 50

BS07N029

1. DRAIN CAP 2. COVER 3. DIPSTICK

4. OIL FILL CAP 5. DRAIN HOSE

1. Change oil and oil filter at 50 hour run-in period for a new machine, then at every 250 hours thereafter.

2. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off. Raise the engine cover. Remove the dipstick to allow oil to run more freely.

BD07N040

Figure 52

8. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head.

NOTICE: Do not reuse the oil filter.

9. Clean oil drain plug and install it. Tighten securely.

3. Remove bolts and engine belly pan covers

10. Check drained oil for any metal shavings, flakes, or particles. Contact your dealer if any debris is found.

4. Locate the engine oil drain plug and place an empty oil container [7 L (2 gal) capacity] under the plug. Attach the quick drain hose (5), and drain the oil into the container.

11. Fill with the specified amount of oil through filler port (4) and install oil filler cap.

5. Remove engine oil drain plug and let the engine oil drain out completely.

6. After draining oil, remove drain hose, and tighten drain cap (1) securely. Remove any spilled oil.

12. Before starting the engine, check oil level using the dipstick (3). The level should be between the L and H limits as shown. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

13. Install cover (2) to its original position.

7-25

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS INSPECT AND ADJUST FAN/ALTERNATOR BELT Check and adjust the fan/alternator belt every 250 hours.

Adjusting Belt 1. Slightly loosen attaching bolt (1) and adjusting bolt (2).

2. Loosen adjusting bolt (3) adjust the fan belt to the correct tension, and tighten bolts (1) and (2).

3

3. After adjustment, run the engine at low idle for approximately 5 minutes, then recheck the tension of belt.

2

1

New Belt Tension

Used Belt Tension

8 - 12 mm (8/16 - 7/16 inch)

10 - 14 mm (3/8- 1/2 inch)

NOTE: A used belt refers to a belt that has been run 5 minutes or more.

Figure 53

BS07N031

BOLT AND NUT TORQUE

1. ATTACHING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

When the hour meter registers 250 hours, check all machine bolts and nuts for proper torque. See charts in Chapter 8 - Specifications.

WARNING Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

M124B

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

7-26

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS GREASING THE SWING BEARING

DOZER PIN GREASE POINTS

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

3 BS07N130

1

Figure 55

Grease the swing bearing by adding grease to each fitting (4 locations) until grease comes out fittings.

2 3

Figure 54

BS07N035

1. DOZER CYLINDER ROD PIN (1) 2. DOZER CYLINDER FOOT PIN (1) 3. DOZER FOOT PIN (2)

When machine is new, during the first 50 hours of operation, grease attachment, boom, arm, and boom swing every 8 hours. After the initial run-in period, grease every 250 hours.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

7-27

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS BOOM, ARM, AND ATTACHMENT GREASE POINTS

7

4

8 10 11

6 5 9

Figure 56

BS07N033

4.

5.

6.

7.

8.

9.

10.

11.

BOOM FOOT PIN (1) BOOM CYLINDER FOOT PIN (3) BOOM CYLINDER ROD PIN (1) ARM CYLINDER FOOT PIN (1) ARM CYLINDER ROD PIN (1) BOOM/ARM CONNECTING PIN (2) BUCKET CYLINDER FOOT PIN (1) BUCKET CYLINDER ROD PIN (1)

BOOM SWING GREASE POINTS

15 12 14

13 BS07N034

12.

13.

14.

15.

Figure 57 SWING CYLINDER FOOT PIN (1) SWING CYLINDER ROD PIN (1) SWING BRACKET/FRAME CONNECTING PIN (2 SLEWING GEAR (1)

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

7-28

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS CLEANING AND REPLACING ENGINE AIR FILTER Clean the air filter element every 250 hours. After cleaning six times or at six month intervals, the element should be replaced at 500 hours. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance.

2

7. Install the cover on two clamp (2) positions, directing the mark "TOP" on the cover to the inlet side 8. The TOP position mark should face up. Make certain to avoid interference with the intake hose.

Incline the air filter casing approximately 15° to the engine side.

REPLACING THE INNER ELEMENT (IF EQUIPPED)

1 3

2

BS07N637

Figure 58

NOTICE: When cleaning outer element, do not remove inner element to prevent dust from entering the air intake.

1. Release the two clamps (2) from the air cleaner cover.

2. Remove the air cleaner outer element (1) from the housing.

3. Clean the inside of air cleaner casing.

BS07N132

1 3

BS07N637

Figure 60

9. The inner element is an optional part. To replace, remove the inner element (3).

10. Install new inner element (3) and outer element (1). Replace cover. Make certain the O-ring seal is correctly positioned.

NOTICE: For machines equipped with double element, the inner element must be replaced together with the outer element. Do not clean inner element.

Replace only with a new element.

Figure 59

4. To clean the outer element (1), blow compressed air (less than 0.3 MPa {43 psi}) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

5. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing d a m a g e . R e p l a c e w i t h a n ew e l e m e n t i f necessary.

6. Set outer element (1) in the casing.

7-29

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER (BREAKER USE)

1 2 3 6 1

7

2

4 5

8

Figure 61

BS07M861

Replace the hydraulic return filter at 250 hours if you are using a breaker/nibbler attachment.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Place the cancellation lever in the locked position. Keep all unauthorized personnel clear of the area.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295 BS07871 -

2. Open the cover to the hydraulic tank and secure with the strut.

3. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

Figure 62

4. Press the valve (several times: 5 to 7 times) together with the breather cap (8), and bleed the hydraulic oil tank of the remaining pressure.

5. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

6. Take the spring (4), valve (5) and element (6) out of the tank.

7. Replace O-ring (7) fitted on the face of cover (3).

8. Clean the parts taken out with light oil.

9. Install element by reversing the disassembly procedure.

10. Install cover (3).

Tightening torque: 21.5 - 25.5 Nm {15.6 - 18.4 lbf ft} 11. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in position to check the oil level.

Stop the engine and check the oil level, adding oil if necessary.

12. Close the cover on the hydraulic oil tank and lock.

7-30

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE CLEAN AND DRAIN WATER SEPARATOR Check the water separator every 8 hours. Clean and Drain the engine water separator every 500 hours.

2 7 4 8

5 1 6

9 1

4

BS07N136

1.

2.

3.

4.

5.

6.

7.

8.

9.

A. B. C. D.

2

5 8 6 3 BS07N135

Figure 64

AIR BREATHER PLUG HANDLE (FUEL VALVE) DRAIN VALVE ELEMENT RING (RED) SPRING O-RING CASE RING IN OUT FUEL VALVE CLOSED FUEL VALVE OPEN

Figure 63

1. Visually inspect separator. If red ring (1) sinks to bottom of case, no water is present.

2. When ring is floating, drain water and sediment.

3. Open valve (2) and drain until clean fuel is discharged.

4. The components of the water separator must be removed to clean. Take care not to lose red ring and spring. Do not use gasoline to clean the filter elements. Wipe off any spilled fuel.

BS07N137

Figure 65

5. Set the safety lock lever to the locked position, then stop the engine.

6. Allow the machine to cool. Open the engine door, push the handle (2) of the water separator upward to the CLOSE position (C).

7. Loosen the ring (9) to remove the case (8) and drain water out.

8. When the water is drained, clean the element (4) inside and out. Replace the O-ring with a new one.

9. Install the element (4) to the water separator body. Set the O-ring 7 to the case (8), then tighten.

10. Push the handle (2) downward to set at OPEN. 11. After draining water and cleaning, bleed air from the fuel system.

7-31

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS REPLACING FUEL FILTER

CLEANING AND REPLACING ENGINE AIR FILTER The air filter element should be replaced at 500 hours. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance. Do not clean inner element. Replace only with a new element.

2

The fuel filter should be replaced at 500 hours. The fuel filter should not be reused. It must be replaced.

1

1 3

BS07N398

Figure 68

1. Stop the engine, and allow the machine to cool.

Open the engine door and remove the lower cover.

Figure 66

BS07N637

1. Release the two clamps (2) from the air cleaner cover.

2. Remove the air cleaner outer element (1) from the housing.

2. Place the filter wrench on the filter cartridge (1), and remove the filter.

3. Wipe off any dirt on the seal face of filter base to avoid contamination.

3. Clean the inside of air cleaner casing.

2

1 3

BD07N040

BS07N637

Figure 67

4. The inner element is an optional part. To replace, remove the inner element (3).

5. Install new inner element (3) and outer element (1). Do not clean inner element.

6. Install the cover on two clamp (2) positions, directing the mark "TOP" on the cover to the inlet side 7. The TOP position mark should face up. Make certain to avoid interference with the intake hose.

Incline the air filter casing approximately 15° to the engine side.

8. Make certain the O-ring seal is correctly positioned.

7-32

Figure 69

4. Apply a thin coating of grease to the seal of the new oil filter. Install and tighten by hand, turning about 2/3 of a turn after the seal contacts the engine.

5. Start and run the engine at idle for 5 minutes to check for leaks.

6. close the engine door and install the cover located under the engine.

NOTICE: Dispose of all hazardous waste properly according to local environmental regulations.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil every 2000 hours thereafter.

2 3

Figure 72

BS07N670

1 BS07N668

Figure 70

1. DRAIN PORT 2. FILL PORT

5. After oil has been drained out completely, clean drain plug. Use teflon tape on drain plug for additional sealing and install plug. Tighten securely.

6. Add engine oil through the oil FILL opening (2) until oil starts flowing out of the port (3).

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Place the cancellation lever in the locked position. Keep all unauthorized personnel clear of the area.

2. When parking the machine, make certain the drain port (1) is at the bottom.

7. Clean oil FILL plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

8. Check drained oil for any metal particles. If contaminant are present, contact your dealer.

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

BS07N669

Figure 71

3. Stop engine and place an empty container under the drain plug.

4. Remove oil FILL and DRAIN plugs to drain oil into the container.

7-33

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE REPLACING ENGINE COOLANT The engine coolant should be replaced every 1000 hours. Check the coolant level every 8 hours as part of daily maintenance.

11

4. Replace any hoses that are damaged. See replacing radiator hoses for further information.

5. To drain radiator, place a rag or paper towel on the radiator cap and slowly remove it to release the pressure.

6. Drain the radiator with drain hose.

7. After draining, install the drain plug (2). Fill the cooling system with system cleaner according to cleaner container instructions.

5

3 4 BS07N142

2 Figure 73

UPW00400091J01

1. RADIATOR HOSE CLAMP 2. RADIATOR CAP

3. RADIATOR HOSE

1. Stop the engine. Open the engine cover and secure it with strut.

2. Check the hoses for leakage due to loose clamps, or cracked and worn hoses.

3. Tighten any loose clamps.

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

7-34

Figure 74

8. Operate the engine at a speed slightly faster than low idling (5) to raise the coolant temperature to 80° C (176° F) or within white range on the temperature gauge for coolant temperature.

O pe rate th e e n gi n e fo r a p pr ox i ma te l y 10 minutes.

9. Stop the engine. Allow the system to cool.

Loosen the radiator cap slowly. After ensuring that the pressure has been released, push the cap down and hold while turning to remove.

Loosen the radiator drain plug (2). Flush the radiator (3) with clean water until the water runs clear.

10. Install the radiator drain plug (2). Fill the radiator with a mix of 50% clean water and 50% LONG LIFE COOLANT. Start and run the engine to fully release air from the cooling system.

11. Stop the engine. Allow the engine to cool. Check the coolant level. The reservoir tank (4) water level should be between FULL and LOW. Adjust level to specifications.

12. Check the system for leaks and repair. Close the engine door.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS REPAIRING HOSES 1. Drain coolant into clean container for reuse if not changing coolant.

2. Clean the areas where the new hose will be connected.

3. Remove the clamps (if reusing old clamps) from the old hose and install them to the new hose.

4. Coat the inside ends of the new radiator hose with grease and install it. Tighten clamps properly.

CHECK VALVE CLEARANCES Check and adjust the engine valve clearance every 1000 hours of engine operation. Contact your authorized dealer for assistance.

CHECK STARTER AND GENERATOR Have the starter and generator checked every 1000 hours of engine operation. Contact your authorized dealer for assistance.

5. Fill radiator with coolant.

6. Install radiator cap, start engine, and bring engine temperature to about 90°C (194°F).

7. Run engine at low idle, check for leaks and repair as needed.

8. Install radiator lower cover and close engine cover.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

9. Inspect radiator cap for proper fit and pressure, and replace if needed.

7-35

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

1 2 3 6 1

7

2

4 5

8

Figure 75

BS07M861

Replace the hydraulic return filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 1000 hours thereafter.

1. Place the machine in the hydraulic oil check position on a firm level surface.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

2. Release pressure in the hydraulic system. Open the cover to the hydraulic tank and secure with the strut.

3. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

Figure 76

BS07N637

4. Press the valve (several times: 5 to 7 times) together with the breather cap (8), and bleed the hydraulic oil tank of the remaining pressure.

5. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

6. Take the spring (4), valve (5) and element (6) out of the tank.

7. Replace O-ring (7) fitted on the face of cover (3).

8. Clean the parts taken out with light oil.

9. Install element procedure.

by

reversing

disassembly

10. Install cover (3).

Tightening torque: 21.5 - 25.5 Nm {15.6 - 18.4 lbf ft} 11. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in position to check the oil level.

Stop the engine and check the oil level adding oil, if necessary.

12. Close the cover on the hydraulic oil tank and lock.

7-36

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

1500 HOUR MAINTENANCE CHECK INJECTION TIMING Have the injection timing checked every 1500 hours of engine operation. Contact your authorized dealer for assistance

7-37

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE HYDRAULIC SUCTION STRAINER CLEANING

2

The hydraulic tank suction strainer should be cleaned when the engine hour meter registers 2000 hours and every 2000 hours there after.

3 4

6 1

2

Figure 77

BS07M861

1. Place the machine in the hydraulic oil check position on a firm level surface.

WARNING

Figure 79

BS07N665

Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

5. Loosen the four cap screws (2) and lock washers ( 3 ) . R e m ove c ove r ( 4 ) . B e c a r e f u l n o t t o accidently drop bolts or nuts into the tank during this procedure.

M1295

2. Open the cover to the hydraulic tank and secure with the strut.

7 1

BS07N144

Figure 80

6. Remove strainer (5) and clean with light oil or by washing. If damaged, replace.

BS07N146

Figure 78

3. Release all pressure from the hydraulic system.

Press the valve 5 to 7 times together with the breather cap (1).

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

7-38

7. Check O-rings (6) and (7) for wear or damage. If damaged, replace O-rings.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

2 3 4 5

6

BS07N665

Figure 81

8. Insert strainer (5) into suction tube. Install cover (4) with cap screws (2) and lock washers (3).

Torque to: 23.5±1.98 Nm (17±1.4 lbf ft).

9. Start the engine and operate at low idle for 5 to 7 minutes. Operate each cylinder and swing.

Retur n the machine to the hydraulic level checking position. Stop the engine and check the hydraulic oil. If level is low, add oil.

7-39

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS PILOT VALVE AND SOLENOID VALVE Clean the pilot valve filter and solenoid filter when the hour meter registers 2000 hours.

4

The P port of right and left pilot valves (for operation and travel) and the solenoid valve are equipped with a connector with a filter. Dirt that adheres on the filter will decrease oil flow.

5

2

1

1

2

3 3 BS07N147

Figure 83

3. Loosen 2 bolts (3) on the operating box to remove the cover.

Figure 82

BS07M861

1. Place the machine in the hydraulic oil check position on a firm level surface.

5. After removal, put a plug into the bore to prevent entry of foreign matter.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

2. Release all pressure to the hydraulic system.

7-40

4. Disconnect the hose (1) connected to P port on the pilot valve (4), then remove connector with filter (2).

6. Wear face protection, wash the filter with cleaning solvent. Use compressed air to remove any material.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

7a

7b 7c

7d 7e

8 7

BS07N149

Figure 85

7a.CASE 7b.STRAINER

6

7c.LABEL 7d.O-RING 7e.FITTING BS07N148

Figure 84

7. Check the O-ring (5) for damage, and replace if necessary.

8. After cleaning, install it to the original position in reverse order. See torque charts.

9. Remove the in-line filter (7) of solenoid valve (6) for cleaning.

10. Remove the right-hand guard (8).

11. After removal of the hose, remove the in-line filter assembly (7) from the tee installed on the solenoid valve (6). After removal, the oil holes of tee and hose should be plugged.

12. Remove the case (7a) and the fitting (7e), and then remove strainer (7b) with screwdriver.

13. Spray light oil or air on the strainer (7b) to clean.

Clean the inside of the case (7a). Check the O-ring (7d) for damage, if it is damaged, replace it with new one.

14. Install the strainer (7b) on the fitting (7e) with screwdriver, and fit in the in-line filter case (7a).

Tightening torque: 59 to 79 N•m {43 to 58 lbf•ft} 15. Remove the plug, install the in-line filter assembly (7) on the solenoid valve (6), and then install hose (1).

7-41

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

12 12 99 11

12

P

13

10 10

9 BS07N150

Figure 87

18. Dust tends to accumulate on the inside elbow (9) (dented por tion). Clean par ts to avoid contamination (projected portion).

19. Check the O-ring (12) for damage, and replace, if damaged.

UPW00400107J01

Figure 86

16. Remove the elbow with filter (9) of pilot valve (10) for cleaning.

17. Remove the floor mat and floor plate. Disconnect the hose (11) connected to P port on the pilot valve (10). Remove the elbow (9). After removal, put a plug into the bore to prevent entry of foreign matter.

7-42

20. After cleaning, install to the original position in the reverse order of disassembly. Refer to torque charts for tightening hose (11).

21. Install the floor mat and floor plate.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil every 2000 hours thereafter.

2 3

Figure 90

BS07N670

1 BS07N668

Figure 88

1. DRAIN PORT 2. FILL PORT

5. After oil has been drained out completely, clean drain plug. Use teflon tape on drain plug for additional sealing and install plug. Tighten securely.

6. Add engine oil through the oil FILL opening (2) until oil starts flowing out of the port (3).

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Place the cancellation lever in the locked position. Keep all unauthorized personnel clear of the area.

2. When parking the machine, make certain the drain port (1) is at the bottom.

7. Clean oil fill plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

8. Check drained oil for any metal particles. If contaminants are present, contact your dealer.

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

BS07N669

Figure 89

3. Stop engine and place an empty container under the drain plug.

4. Remove oil FILL and DRAIN plugs to drain oil into the container.

7-43

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS UPPER AND LOWER ROLLER - IDLER OIL CHANGE

5 1

6

5

4

3

2 1. Loosen the rubber crawler shoe. Loosen the cap screws (1) of the lower roller about one turn.

Figure 91

BS07N259

1.

2.

3.

4.

5.

6.

Figure 92

BS07N260

TRAVEL MOTOR SPROCKET LOWER ROLLER CRAWLER BELT UPPER ROLLER IDLER

2. Start up the engine and lift up the side of the machine with the boom and arm.

3. Support the machine with a safety support (5).

Stop the engine.

Idlers must be removed from the crawler frame to change the gear oil. Refer to the oil and grease specification for the required volume.

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

BS07N261

3

4

1

1

2

2

Figure 93

4. Remove the capscrews (1) with washers (2) which install the lower roller to the crawler frame at two positions. Remove the lower roller (3).

5. Remove the feeding port plug (4) with allen wrench, and discharge the old engine oil.

WARNING 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 (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

M1720

6. Fill with the specified volume (35 cc or 2.1 cu.in) of engine oil through the feeding port.

7. Apply sealing (teflon) tape to thread on the plug (4), and securely tighten it. Thoroughly wipe off oil adhered to periphery.

8. Apply Loctite #262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

9. Remove the safety support which supports the machine, then tighten the capscrew (1).

Tightening torque: 208 ± 21 Nm {153 ± 15 lbf•ft} 10. 11.Lift up the machine to adjust the crawler shoe tension referring to Adjusting Track Tension.

7-44

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS IDLER OIL CHANGE

3 2 1 6 5 3

4

Figure 94

BD07N262

BS07N263

WARNING Check and adjustment for track tension requires the machine to be lifted off the ground one track at a time. Unexpected lowering of the machine could result in injury or death. Do not operate the boom while adjusting the crawler belt. Failure to comply could result in injury or death.

M1720

1. This is a two person procedure. See procedure for removing and installing crawler belt in this section.

2. Remove the rubber crawler belt. Place a safety support under the machine.

3. Remove the idler (1) and adjuster (2) from the crawler frame.

Weight of idler + Idler Adjuster = approximately. 40 kg (88 lb)

Figure 95

NOTE: Check the drained waste oil. If there are metal flakes in the oil, contact your authorized dealer.

DO NOT reuse the oil filter.

6. Apply sealing (teflon) tape to the threads on the plug (3), and securely tighten it. Wipe off any remaining oil.

7. Apply grease to the sliding face (A) on the piston (4) and cylinder (5) of the idler adjuster (2).

8. Install the idler so that the fill - drain port plug (3) of idler and the grease fitting (6) of idler adjuster (2) are facing to outside.

9. Install the rubber crawler belt.

10. Adjust the tension on the rubber crawler belt.

Refer to procedure for adjusting belt tension.

Raise the machine off the safety support, remove the safety support and slowly lower the machine to the ground.

4. Remove the fill drain plug (3) with Allen wrench to drain old gear oil.

5. Fill the idler with (80 cc {4.8 cu.in.}) of the specified oil through the fill drain port.

7-45

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS UPPER ROLLER OIL CHANGE

CHANGE SWING GEAR GREASE If the machine is operated in a water depth close to the swing gear grease bearing, the water may become mixed with the grease and cause it to deteriorate. Continued operation with deteriorated grease will cause damage to the gears and bearing.

Contact your dealer for service and inspection.

6

This procedure should be completed by a qualified service professional.

1

2

3

INTAKE AND EXHAUST VALVE CHECK

5 Figure 96

BD07N264

1. The crawler belts must be removed to service the idlers. See procedure for removing and installing crawler belts in this section.

2. Place the machine in the parked position and stop the engine.

3. Loosen the rubber crawler belt (6).

4. Raise the rubber crawler belt with a hydraulic jack (5).

1

2 3

4

BS07N265

Figure 97

5. Loosen the nuts (2) and the bolts (3) used to assemble the upper roller (1) to the machine and remove it.

6. Remove the oil fill - drain port plug (4) with an Allen wrench, and drain old gear oil.

7. Fill the upper roller with 45 cc {2.7 cu.in} of the specified oil through the fill - drain port.

8. Apply sealing (teflon) tape to the threads on the plug (4) and securely tighten it. Thoroughly wipe off any remaining oil.

9. Install the roller in reverse order of disassembly.

Apply thread lock sealant (Three Bond #1324) on thread of the bolts (3), tighten the screws.

Tightening torque: 66±7 Nm {48±5 lbf ft}

7-46

To ensure the seal of the exhaust and intake valves, contact your dealer for service and inspection. this procedure should be completed by a qualified service professional.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL

2 3 4

6 6

1

BS07N269

Figure 98

BS07N268

6. Place a container (40 L {11 gal.}) beneath the drain plug (1). Remove the drain plug (1) with a 27 mm wrench and drain the remaining oil.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

1. Park the machine so the drain plug (1) on the hydraulic oil tank comes midway between both crawlers. Make certain all pressure is removed from the hydraulic system.

2. Remove the right side guard.

3. Open the cover on the hydraulic tank with the engine key, and hold it open with the strut.

4. Clean dirt from the filter to avoid contaminating the hydraulic system.

5. Press the valve 5 to 7 times together with the breather cap (8), and bleed the hydraulic oil tank of the remaining pressure.

7. Tighten the drain plug (1).

Tightening torque 73.5 ± 5 Nm (54.2 ± 3.7 lbf. ft.)

8. Loosen the four bolts (2) and lock washers (3).

Remove cover (4).

9. Check O-ring for damage, and replace if necessary.

NOTE: Use caution not to drop bolts or nuts inside hydraulic tank. Do not allow fluid to come in contact with skin.

10. Fill the hydraulic oil tank with hydraulic oil at filling por t (F) according to machine specifications.

11. Install cover (4) with bolts (2) and lock washers (3).

Tightening torque: 23.5 ± 2 Nm (17 ó1 1.4 lbf. ft.)

12. Install the right side guard.

13. After starting the engine, run at low idle. Perform several telescopic movements of each cylinder and the swing operation. Return the machine to the hydraulic oil level check position, and check the oil level.

7-47

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

SPECIAL PROCEDURES BUCKET

4

3 WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

1 2

M110B.

5

ABRASION OR DAMAGE ON TOOTH POINTS AND SIDE CUTTERS

Figure 100

BS07N271

Check for wear and/or looseness of bucket tooth points. Tooth point life cannot be determined only by the number of operating hours.

1.

2.

3.

4.

5.

ADAPTER TOOTH POINT RUBBER LOCK PIN LOCKING PIN ADAPTER NOSE

7

8

6 BS07N269

Figure 99

When replacing a bucket tooth or side cutters, securely block the bucket to avoid injury.

2 Figure 101

BS07N272

Replace the bucket tooth is small holes appear on the tooth point or when the edge lines of the tooth point are worn.

6. SAFETY BLOCK 7. HAMMER 8. PUNCHING TOOL

1. Using a hammer and punch, hammer out the locking pin. Take care not to damage the rubber lock pin (3).

BS07N273

Figure 102

2. Inspect the locking pin (4) and rubber lock pin (3). Replace them if the locking pin (4) is too shor t or the r ubber lock pin (3) is in poor condition.

3. Clean the surface of the adapter nose (1) with a putty knife to remove any adhered soil.

4. Fit the tooth point (2) onto the adapter nose (1).

2

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.

7-48

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS REPLACING THE SIDE CUTTERS

REPLACING BUCKET

7 8

6

1 Figure 103

BS07N274

1. Remove all sand and soil adhering around the bolts. Use an acetylene torch to cut off the bolts, then remove the side cutter.

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the bolts and nuts with new ones.

3. Tightening torque: 115±12 Nm {84.6±8.7 lbf•ft} 4. After tightening the nuts, spot-weld them.

2

3 2

9

4

5

Figure 105

BS07N276

2 WARNING 1

4 3

Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

Figure 104

DC04C362

1.

2.

3.

4.

NUTS SIDE CUTTER BOLT TOOTH POINT

1. Carefully operate the boom and the arm to remove load from the pins.

2. Roll O-rings (1) onto the bucket boss. After removing the pins, place them back in the original position.

3. Remove the lock ring (2) and lock pin (3), remove the pins (4) and (5) in order to remove the bucket (6).

NOTICE: Keep pins free of sand, dirt or other contaminants when removed. Do not damage the dust seals (9) on both ends of the arm.

7-49

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS INSTALLING BUCKET

7 8 5

4

6

6

Figure 106

BS07N277

1. Clean each pin and pin hole and grease sufficiently.

2. Move the bucket cylinder to match the pin bores or the bucket (6) and bucket link (8) with each other, then insert the pin (4).

3. Raise the boom and slightly raise the bucket from the ground.

9 2 3

9

4 5 BS07N278

4. Align bucket (6) with the pin hole of arm (7) moving arm (7), and insert pin (5).

5. Insert pin (3) and fit lock ring (2).

Fit O-ring (1) to the normal position.

6. Apply grease on the grease nipples for respective pin until the grease comes out through the gap between pins and bore.

7-50

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS RUBBER CRAWLER TRACK Rubber track offers many benefits over metal track, but must be used in accordance to the m a nu fa c t u r e r ’s s p e c i f i c a t i o n s. T h e m a c h i n e guarantee does not cover improper operation at job sites. Do not operate the machine over objects such as steel plate, steel pipes, concrete rod, stones and r o ck s w i t h s h a r p e d g e s. O b s e r ve o p e r a t i n g conditions and characteristics of rubber track to gain optimum performance.

RUBBER TRACK OPERATION BS07N287

Figure 109

DO NOT operate or travel over river beds with stones of different sizes. Rubber crawler belts may be damaged or come off the rollers. The service life of the rubber crawler belts will be reduced if the belt is not maintained with the correct tension.

Figure 107

BS07N292

TRACK COMPARISON

BS07N288

Figure 110

DO NOT operate on oil contaminated surfaces. Oil will damage the rubber crawler belts.

BS07N286

Figure 108

DO NOT operate in gravel mixed land, rugged and solid rock bed, over iron scraps, or edges of iron plates such as concrete rebar.

BS07N287

Figure 111

DO NOT operate near open fires, or on steel plates exposed to the sun or use in asphalt leveling. Heat will damage rubber crawler belts.

When storing the machine for long periods indoor storage is recommended. Rubber crawler belts can be damaged if exposed for long periods of time to harsh environments in a non-operational mode.

7-51

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

BS07N290

Figure 112

DO NOT operate the crawler belt on the ground if the other track has been lifted. The additional weight may damage the track or cause the track to come off.

BS07N291

I f m a c h i n e i s o p e ra t e d i n s a l t y o r c o r r o s i ve conditions, the bonding of the rubber to the metal core can be damaged. Clean the belts after use. The normal temperature operating range for rubber crawler belts is between -25° to 55° C (-13 to 131° F).

BS07N296

Figure 116

Avoid changing direction of the machine on ground with a difference in level of 20 cm (8 in.) or more.

Travel at right angles over ground when there is a significant difference in level.

Figure 114

Use care not to damage the track with the machine attachment.

Do not apply side load force or side impact on the bucket or attachment during operation.

If the machine is raised with the bucket, lower machine slowly.

7-52

Figure 115

Figure 113

Use caution when operating on ice or snow. Rubber belts can easily slip. Avoid making sudden turns on concrete. Avoid sudden direction changes, as this may cause premature wear on the crawler belts.

BS07N294

BS07N295

BS07N297

Figure 117

When moving up a slope, avoid changing direction of the machine when the machine is at a point between the level ground and the slope.

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK INSPECTION

1

5

2 3 BS07N298

4

Figure 118

Do not travel on a slope with one side of the machine lifted. Always travel with both sides level to avoid damage to the track.

Figure 120

BS07N280

1.

2.

3.

4.

5.

LOWER ROLLER RUBBER CRAWLER BELT LUG STEEL CORD METAL CORE

Repair or replace rubber crawler belt if it is damaged.

Contact your dealer for assistance in replacing belts or refer to the machine Repair Manual.

HEIGHT OF LUG

BS07N299

Figure 119

Do not change direction of the machine with the rubber crawler on high spots as illustrated. This can cause the rubber crawler belt to be damaged or come off.

4 BS07N281

Figure 121

Replace the belt with a new one if the height of the lug is below (A) 5 mm (0.2 in.). The low height of lug will decrease traction.

If the lug wears and the steel cord (4) in the belt is exposed over two links, replace the belt.

7-53

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK METAL CORE

STEEL CORD DAMAGE

1 2 4

5 3 Figure 122

BS07N282

If the steel cords (B) are over one half broken in one row, replace the crawler belt.

CRACKED CRAWLER BELT

Figure 124

BS07N284

1.

2.

3.

4.

A.

LOWER ROLLER METAL CORE RUBBER STEEL CORD INTERFERENCE WITH ROLLER

Depending on the usage of the rubber crawler belt, there occasionally may be peeling of the metal core (2). Peeling occurs on the inner side due to contact with the rollers (1), idlers, and sprockets. The lug side (outer side of belt) may appear undamaged.

NOTICE: Unapproved or prohibited operation of the machine can cause damage to the rubber crawler belt. The warranty is not applicable for any damage due to prohibited or unapproved usage of the rubber track or the use of it with improper tension.

4

BS07N283

Figure 123

2

Repair the belt if a crack approximately 60 mm (2.4 in) is seen between the lug of the rubber belt. Repair immediately if the steel cord (4) is exposed even though the crack is minimal.

BS07N285

Figure 125

Cracked rubber belts showing metal core (2) must be replaced with new belts.

Minute cracks will not effect performance, and it is not necessary to replace belt.

7-54

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS MOVING A DISABLED MACHINE

WARNING WARNING Read and understand all safety precautions and procedures before attempting any operation, inspection, maintenance, or repair of this machine, any attachment or any of its systems.Failure to comply could result in death or serious injury.

Make certain chock blocks are secure at front and rear of each track before attempting to release brakes. Never stand in the path of the tracks when releasing brakes. Failure to comply could result in death or serious injury.

M1723

M1087

NOTICE: The following procedures should only be performed by an experienced service technician familiar with this machine.

RELEASING LOCK ON TRAVEL MOTOR

Figure 128

BS07N669

3. Place a pan under the travel motor to drain oil.

Slowly remove upper plug, then remove drain plug to drain reduction unit oil.

4. Plug (1) Opposing flat 6 mm (0.24).

WARNING BS07N300

Figure 126

The travel motors of a disabled machine are locked by the hydraulic control valve and by the mechanical brake system. If the machine is locked and unable to run, it can be moved by releasing the travel motor lock by one of the following methods.

REMOVING GEARS FROM TRAVEL REDUCTION UNIT

BS07377

Travel reduction gear is under pressure. Keep your face and body clear of drains. Heat increases travel reduction gear oil pressure. Loosen plugs slowly and wear face protection. Never attempt to service a hot machine. allow machine to cool before performing any service. Failure to comply could result in death or serious injury.

M1721

Figure 127

1. Place blocks at front and rear of tracks to prevent machine from moving when brakes are released.

2. Lower attachment to the ground.

7-55

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS ASSEMBLING THE TRAVEL MOTOR

14

2

4

2

14 4

1 1 3 5. Remove the plug (2). Attach eyebolt (A) to the threaded hole of plug (1) and insert pry-bar (B) in the eye hole, and turn the bar until wire (3) can be seen through the threaded hole of plug (2).

Draw the wire outside when the wire end can be seen.

6. Remove the cover (4), sun gear assembly (5), holder (6), planetary gear (7), needle bearing (8), inner race (9), drive gear (10) and thrust plate (11).

NOTICE: The crawler belt is now free to rotate.

9

8 7

BS07N380

BS07N379

Figure 131

After all repairs are completed, assemble the travel motor units in reverse order.

To prevent the ball (5) from falling from sun gear (6), coat the ball (5) with a light coat of grease.

Lubricate the O-ring (14) with grease and fit into groove of cover (4). Install cover (4).

Use care not to damage O-ring.

Replace the O-ring at drain plug (1) with a new one.

Install the drain plug (1).

Add the specified gear oil through the oil fill plug until oil starts flowing out of the oil level plug.

5 6 10 11 Figure 130

7. Temporarily install the cover (4).

8. Repeat steps 3 through 6 on the opposite travel reduction unit to remove the inner parts.

9. Tow the machine to a safe place to proceed with the appropriate repairs.

NOTICE: Avoid spills. Dispose of all hazardous waste in accordance with government laws and regulations.

7-56

3

Figure 129

BS07N379

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS LOWERING BUCKET ATTACHMENT ON A DISABLED MACHINE

BS07N384

Figure 132

BS07N380

WARNING Make certain the area around the machine is clear of people and objects before attempting these procedures. Failure to comply could result in death or serious injury.

M103B

NOTICE: The weight of the bucket or attachment may cause unexpected movement of bucket/attachment, ar m and boom during the procedure.

Block the bucket/attachment to avoid unexpected movement. Release the pressure in the hydraulic lines slowly until pressure is completely released.

Figure 133

To lower the bucket position, proceed carefully as follows: When the bucket is in digging position (A) (bucket cylinder completely extended, (see figure) disconnect hose head (H) side. When the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose rod (R) side NOTICE: Do not allow the hydraulic line or components to become contaminated. This could cause severe system damage to the hydraulic system. Contact your dealer to obtain the proper caps and plugs to be used.

NOTICE: Clean up all spilled oil. Dispose of any hazardous waste in compliance with local environmental regulations.

Control the bucket/attachment movement by slowly removing the lock.

Do not enter the area under bucket/attachment while lowering.

The following procedure is to be used only in an emergency if the machine is disabled. Proceed with extreme caution. Keep people away from the bucket/attachment and excavator boom.

Block the bucket/attachment to avoid unexpected movement. Release the pressure in the hydraulic lines slowly until pressure is completely released.

Control the bucket/attachment movement by slowly removing the lock.

7-57

CHAPTER 7 - MAINTENANCE AND ADJUSTMENTS

BS07N385

Figure 134

LOWERING THE ARM Gradually loosen the hose of rod side connected to the arm (4).

BS07N386

Figure 135

LOWERING THE BOOM G ra d u a l l y l o o s e n t h e h o s e o f h e a d ( H ) s i d e connected to the boom cylinder.

Stop lowering the attachment at 30 - 40 cm (12 - 16 in.) above ground level to allow for moving the machine.

1. Tighten the hose fitting.

2. After moving the machine to the service area, slowly loosen the hose fitting to lower the attachment to the ground.

3. Contact your dealer for machine repairs.

7-58

CHAPTER 8 - ELECTRICAL

CHAPTER 8

ELECTRICAL CONTENTS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fusible Starter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Machine Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 8-3 8-3 8-4 8-6 8-6 8-6 8-6 8-7 8-7 8-7 8-8

8-1

CHAPTER 8 - ELECTRICAL

NOTES

8-2

CHAPTER 8 - ELECTRICAL FUSIBLE STARTER LINK

ELECTRICAL COMPONENTS

.

FUSES .

1

Figure 1

BS07N387

NOTICE: Make certain the starter switch is in the OFF position before replacing any fuse.

Fuses protect the electrical system from excess current. Replace a blown fuse or any fuse generating white powder on it.

Always replace fuses with a fuse of the same capacity. The spare fuses are stored in the back side of the fuse box cover.

Figure 2

BS07N388

If the electrical power does not come on when the starter key switch is in the on position, the fusible link may be the cause. Inspect and replace the red fusible link (1).

The fusible link protects the electrical system from current over load. The fusible link functions like a fuse.

WARNING AMPS

FUNCTION

1

30A

WIPER, HEATER

2

30A

RELAY, SOLENOID

3

30A

WORK LAMP

4

10A

HORN, CAB LIGHT

5

30A

ENGINE STOP SOLENOID

6

10A

BATTERY RELAY, CLUSTER GAUGE

NO.

Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

Failure to comply could result in death or serious injury.

M1728

8-3

CHAPTER 8 - ELECTRICAL BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours.

WARNING Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

Wear eye protection and protective clothing when handling or servicing batteries.

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention. Failure to comply could result in injury or death.

M4655

Figure 3

BS07N390

1.

2.

3.

A. B. C. D. E. F. G. H. I. J.

1. Stop the engine. Set the safety lock lever in the LOCKED position.

2. The batter is located under the floor plate.

Remove the floor mat and remove the battery cover.

CAP TERMINAL TERMINAL COVER INDICATOR AIR VENT HOLE BLUE RED WHITE UPPER LIMIT LOWER LIMIT GOOD CONDITION REFILLING REQUIRED CHARGING REQUIRED

.

2

BS07N391

1

Figure 4

3. Remove battery cell caps (1) and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

4. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 5. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

6. If cables are found to be in poor condition, replace with new parts immediately.

8-4

CHAPTER 8 - ELECTRICAL f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

M144C

NOTICE: Battery life can be shortened by over charging and over discharging of the battery. Replace any battery that will not hold charge or difficult to charge.

7. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTICE: Use hydrometer manufacturer’s instruction.

according

to

its

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

8. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

9. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

NOTICE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats.

8-5

CHAPTER 8 - ELECTRICAL STARTING MACHINE ENGINE WITH BOOSTER CABLES

3 CONNECTING BOOSTER CABLE

1

2

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable last. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

84-109

1. Move vehicle or machine to be used for boosting as close to the batter y box of the disabled machine as possible.

NOTICE: Do not allow the vehicle or machine used for boosting to touch metal to metal with the disabled machine. This could short circuit electrical systems and cause extensive damage to the CPU and other components.

NOTICE: Use only vehicles or machines with 24V DC electrical system to boost start this machine.

2. Make certain key switch of disabled machine is in the OFF position before proceeding with booster cable connection.

WARNING Improper booster cable connections can cause an explosion resulting in personal injury.

Always follow the correct procedures when connecting and disconnecting the booster cables.

Failure to comply could result in injury or death.

M146B

4 1

2

3

4

DC04D588

Figure 5

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY BEING USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY BEING USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

3. Locate and connect one end of the booster cable to the positive (+) terminal on the battery of the disabled machine.

4. Connect other end of positive booster cable to positive (+) terminal of battery being used for boosting.

5. Locate and connect second cable to the negative (-) te r minal of th e ba tte r y being used fo r boosting.

6. Connect other end of negative (-) cable to the upper frame of disabled machine as far away from battery as possible.

STARTING BOOSTING MACHINE ENGINE 1. Start engine boosting machine in normal manner according to climate conditions.

2. Allow 5 minutes or more to provide partial charge to the discharged batteries.

STARTING DISABLED MACHINE ENGINE

WARNING Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

Wear eye protection and protective clothing when handling or servicing batteries.

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention. Failure to comply could result in injury or death.

M4655

8-6

1. Start engine of disabled machine in normal manner according to climate conditions.

CHAPTER 8 - ELECTRICAL DISCONNECTING BOOSTER CABLES

3

1

2

4 4

3

2

1

DC04D588

Figure 6

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

After disabled machine engine is running, follow these steps to disconnect the cables.

1. Disconnect the negative (-) cable from disabled machine upper frame.

2. Disconnect negative (-) cable from battery used for boosting.

3. Disconnect positive (+) cable from battery used for boosting.

4. Disconnect positive (+) cable from terminal of disabled machine.

NOTICE: When disconnecting booster cables always disconnect negative (-) cable first from frame of disabled machine.

ALTERNATOR Ask your Dealer to check the Alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

8-7

CHAPTER 8 - ELECTRICAL WORK LAMPS

.

1

.

1

4 3

2

5

6

7

Figure 7

BS07N392

A 55W bulb is used for the work lamps.

BS07N393

Figure 8

1. To replace the bulb, place the attachment on the ground, and set the safety lock lever to the LOCKED position, then stop the engine.

WARNING Do not touch a lighted bulb. Shut off lamp and allow it to cool. Make certain work lamp switch is in the OFF position.Failure to comply could result in death or serious injury.

M1223

2. Disconnect the electrical connector, then remove the work lamp from the machine with a wrench.

3. Remove screw (1), then remove rim (2) and lens (3) from the casing (4).

4. Remove spring (6) that secures the socket (5).

5. Remove the bulb (7) from the socket (5) and replace the bulb with a new one.

NOTICE: The service life of a bulb is shortened if oil or grease is on the bulb at the time of installation.

When replacing the bulb, hold it at the flange area. Do not touch the bulb glass with your fingers. Wipe the bulb with a clean cloth after installation.

8-8

6. Assemble the work lamp using the reverse order.

NOTICE: If the replacement bulb does not light, check the fuse.

CHAPTER 9 - SPECIFICATIONS

CHAPTER 9

SPECIFICATIONS CONTENTS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cap screws & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nuts & Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3 9-3 9-3 9-4 9-4 9-4 9-4 9-5 9-5 9-5 9-6 9-7 9-9

9-11 9-11 9-11 9-12 9-12 9-13 9-13 9-13 9-14 9-15 9-15 9-15 9-15 9-15 9-15 9-15 9-15

9-1

CHAPTER 9 - SPECIFICATIONS

NOTES

9-2

CHAPTER 9 - SPECIFICATIONS

GENERAL SPECIFICATIONS CANOPY MACHINE DIMENSIONS

BS07N394

Figure 1

CAB MACHINE DIMENSIONS

BS07N395

Figure 2

9-3

CHAPTER 9 - SPECIFICATIONS SPEED AND GRADEABILITY Rubber Crawler Belt 8.7 min (8.7 RPM)

Swing Speed

Travel Speed

Steel Crawler Belt 1

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.5 km/h (1.6 mph)

4.5 km/h (2.8 mph)

2.5 km/h (1.6 mph)

4.5 km/h (2.8 mph)

Gradeability

58% (30°)

ENGINE Model Type Number of cylinders - Bore X Stroke Total Displacement Output Rating Maximum Torque Starting Motor Generator

YANMAR 3TNV88A-BPYB Water cooled, 4 cycle type swirl chamber type diesel engine 3 - 88 mm X 90 mm (3 - 3.46 in. X 3.54 inch) 1.642 liters (100.2 cubic inch) 21.2 kW (2400 min1) 29 PS (2400 RPM) 98.0 Nm (1440 min1) 72.6 lbf ft (1440 RPM) 12 V (1.7 kW) 12 V (55 A)

HYDRAULIC COMPONENTS Hydraulic Pump Hydraulic Motor

Tandem variable displacement axial piston pump Axial piston

Hydraulic Motor with Reducer (Travel)

2 - Axial piston, 2-speed motor

Control Valve

10- spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer) Return Filter

Double action cylinder Filter type with bypass valve (30 microns)

SIDE DIGGING AND DOZER Type

Boom swing by hydraulic cylinder

Boom Swing Angle Right

60°

Boom Swing Angle Left

70°

Dozer Blade Travel (Up/Down)

9-4

560/410 (22.0/16.1)

CHAPTER 9 - SPECIFICATIONS CRAWLER TYPE Length between center of idler and center of travel motor mm (ft - in)

Width mm (inch)

Type

Ground Pressure kPa (psi) Canopy - Cab

Rubber Belt

300 mm (11.8 in)

1700 mm (67 inch)

27 (4.0)

28 (4.1)

Steel Belt

300 mm (11.8 in)

1700 mm (67 inch)

28 (4.1)

29 (4.3)

BUCKET TYPE Heaped Capacity m3 (cubic yard)

Bucket

0.09 (0.105)

Outer Width with side cutter 500 (43.7)

Outer Width without side cutter

Number of teeth 4

454 (41.9)

Weight Kg (lbs.)

81 (179)

MACHINE WEIGHTS

Rubber Crawler Belt

Steel Crawler Belt

Canopy

Cab

Canopy

Cab

3030 kg (6680 lb)

3170 kg (6990 lb)

3140 kg (6920 lb)

3280 kg (7230 lb)

* With 165 lb (75 kg) operator, 137 lb (62 kg) bucket, full fuel and standard equipment

9-5

CHAPTER 9 - SPECIFICATIONS CANOPY TYPE MACHINE WORKING RANGES A A’

L

B

F J

K

Y

X

E

D

H

C

G

Figure 3

UPV00600003ES1

Units: m (ft-in) Machine equipped with 0.09 m3 (0.118 yd.3) Bucket WORKING RANGES

9-6

Standard Arm 1.18 m (46.5 in)

Long Arm 1.47 m (57.9 in)

Bucket 0.09 m3 (0.118 cu. yd.)

Bucket 0.09 m3 (0.118 cu. yd.)

A

Maximum digging reach

4930 mm (16 ft. 2 in.)

5200 mm (17 ft. 1 in.)

A’

Maximum digging reach at ground level

4780 mm (15 ft. 8 in.)

5060 mm (16 ft. 7in.)

B

Maximum digging depth

2810 mm (9 ft. 3 in.)

3100 mm (10 ft. 2 in.)

C

Maximum digging height

4770 mm (15 ft. 8 in.)

4960 mm (16 ft. 3 in.)

D

Maximum dumping clearance

3360 mm (11 ft. 0 in.)

3550 mm (11 ft. 8 in.)

E

Minimum dumping clearance

1380 mm (4 ft. 6 in.)

1110 mm (3 ft. 8 in.)

F

Maximum vertical wall digging depth

2160 mm (7 ft. 1 in.)

2430 mm (8 ft. 0 in.)

G

Minimum swing radius

1920 mm (6 ft. 4 in.)

2000 mm (6 ft. 7 in.)

H

Height at minimum swing radius

3580 mm (11 ft. 9 in.)

3590 mm (11 ft. 9 in.)

J

8-ft. level digging depth

2310 mm (7 ft. 7 in.)

2660 mm (8 ft. 9 in.)

K

Horizontal digging stroke at ground level -stroke

2110 mm (6 ft. 11 in.)

2510 mm (8 ft. 3 in.)

L

Horizontal digging stroke at ground level - minimum

1620 mm (5 ft. 4 in.)

1480 mm (4 ft. 10 in.)

X

Dozer blade - Above

560 mm (1 ft 10 in.)

560 mm (1 ft 10 in.)

Y

Dozer blade - Below

410 mm (1 ft 4 in.)

410 mm (1 ft 4 in.)

CHAPTER 9 - SPECIFICATIONS CAB TYPE MACHINE WORKING RANGES

A A’

L

B

J

F

K

Y

X

E

D

H

C

G

Figure 4

UPV00600004ES1

Units: m (ft-in) Machine equipped with 0.09 m3 (0.118 yd.3) Bucket WORKING RANGES

Standard Arm 1.18 m (46.5 in)

Long Arm 1.47 m (57.9 in)

Bucket 0.09 m3 (0.118 cu. yd.)

Bucket 0.09 m3 (0.118 cu. yd.)

A

Maximum digging reach

4930 mm (16 ft. 2 in.)

5200 mm (17 ft. 1 in.)

A’

Maximum digging reach at ground level

4780 mm (15 ft. 8 in.)

5060 mm (16 ft. 7in.)

B

Maximum digging depth

2810 mm (9 ft. 3 in.)

3100 mm (10 ft. 2 in.)

C

Maximum digging height

4180 mm (13 ft. 9 in.)

4300 mm (14 ft. 1 in.)

D

Maximum dumping clearance

2830 mm (9 ft. 3 in.)

2950 mm (9 ft. 8 in.)

E

Minimum dumping clearance

1100 mm (3 ft. 7 in.)

810 mm (2 ft. 8 in.)

F

Maximum vertical wall digging depth

2160 mm (7 ft. 1 in.)

2430 mm (8 ft. 0 in.)

G

Minimum swing radius

2480 mm (8 ft. 2 in.)

2480 mm (8 ft. 2 in.)

H

Height at minimum swing radius

3260 mm (10 ft. 8 in.)

3270 mm (10 ft. 9 in.)

J

8-ft. level digging depth

2310 mm (7 ft. 7 in.)

2660 mm (8 ft. 9 in.)

K

Horizontal digging stroke at ground level -stroke

2110 mm (6 ft. 11 in.)

2510 mm (8 ft. 3 in.)

L

Horizontal digging stroke at ground level - minimum

1620 mm (5 ft. 4 in.)

1480 mm (4 ft. 10 in.)

X

Dozer blade - Above

560 mm (1 ft 10 in.)

560 mm (1 ft 10 in.)

Y

Dozer blade - Below

410 mm (1 ft 4 in.)

410 mm (1 ft 4 in.)

9-7

CHAPTER 9 - SPECIFICATIONS

LIFT CAPACITIES LIFT CAPACITIES CANOPY MODEL 3 ft. 11 in (1.2 m) Arm Lift capacities calculated using 11.8 in (300 mm) shoes (179 lb (81 kg) bucket, blade down, 550 lb (250 kg) counterweight Load (Lift Point) Height

5 ft (1.5 m) END - SIDE

7.5 ft (2.3 m) END - SIDE

10 ft (3.0 m) END - SIDE

12.5 ft (3.8 m) END - SIDE

+ 10 ft (3.0 m)

*1210 lb *550 kg

*1210 lb *550 kg

+7.5 ft (2.3 m)

*1440 lb *650 kg

1330 lb 600 kg

*1410 lb *640 kg

900 lb 410 kg

+5 ft (1.52 m)

*2720 lb *1230 kg

1970 lb 890 kg

*1880 lb *850 kg

1260 lb 570 kg

*1580 lb *710 kg

870 lb 390 kg

+2.5 ft (0.8 m)

*3810 lb *1730 kg

1800 lb 820 kg

*2340 lb *1060 kg

1180 lb 530 kg

*1780 lb *810 kg

840 lb 380 kg

*1910 lb *860 kg

810 lb 370 kg

Ground Level

*2540 lb *1150 kg

*2540 lb *1150 kg

*4150 lb *1880 kg

1750 lb 790 kg

*2610 lb *1180 kg

1130 lb 510 kg

-2.5 ft (-0.8 m)

*4170 lb *1890 kg

3540 lb 1600 kg

*3960 lb *1790 kg

1750 lb 790 kg

*2590 lb *1170 kg

1120 lb 510 kg

-5.0 ft (-1.52 m)

*5820 lb *2640 kg

3620 lb 1640 kg

*3290 lb *1490 kg

1790 lb 810 kg

*2130 lb *960 kg

1150 lb 520 kg

* Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits. Reference important considerations on page 8-10 for machine operation and use of lifting charts.

LIFT CAPACITIES CANOPY MODEL 3 ft. 11 in (1.2 m) Arm Lift capacities calculated using 11.8 in (300 mm) shoes (179 lb (81 kg) bucket, blade down, Load (Lift Point) Height

5 ft (1.5 m) END - SIDE

7.5 ft (2.3 m) END - SIDE

10 ft (3.0 m) END - SIDE

12.5 ft (3.8 m) END - SIDE

+ 10 ft (3.0 m)

*1210 lb *550 kg

1130 lb 510 kg

+7.5 ft (2.3 m)

*1440 lb *650 kg

1090 lb 490 kg

*1410 lb *640 kg

720 lb 320 kg

+5 ft (1.52 m)

*2720 lb *1230 kg

1620 lb 730 kg

*1880 lb *850 kg

1020 lb 460 kg

*1580 lb *710 kg

690 lb 310 kg

+2.5 ft (0.8 m)

*3810 lb *1730 kg

1450 lb 660 kg

*2340 lb *1060 kg

940 lb 420 kg

*1780 lb *810 kg

650 lb 290 kg

*1910 lb *860 kg

630 lb 280 kg

Ground Level

*2540 lb *1150 kg

*2540 lb *1150 kg

*4150 lb *1880 kg

1390 lb 630 kg

*2610 lb *1180 kg

890 lb 400 kg

-2.5 ft (-0.8 m)

*4170 lb *1890 kg

2870 lb 1300 kg

*3960 lb *1790 kg

1390 lb 630 kg

*2590 lb *1170 kg

880 lb 400 kg

-5.0 ft (-1.52 m)

*5820 lb *2640 kg

2950 lb 1340 kg

*3290 lb *1490 kg

1430lb 650 kg

*2130 lb *960 kg

910 lb 410kg

* Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits. Reference important considerations on page 8-10 for machine operation and use of lifting charts.

9-8

CHAPTER 9 - SPECIFICATIONS LIFT CAPACITIES CAB MODEL 3 ft. 11 in (1.2 m) Arm Lift capacities calculated using 11.8 in (300 mm) shoes (179 lb (81 kg) bucket, blade down Load (Lift Point) Height

5 ft (1.5 m) END - SIDE

7.5 ft (2.3 m) END - SIDE

+7.5 ft (2.3 m)

10 ft (3.0 m) END - SIDE

12.5 ft (3.8 m) END - SIDE

*1430 lb *650 kg

1160 lb 630 kg

*1400 lb *630 kg

770 lb 350 kg

+5 ft (1.52 m)

*2720 lb *1220 kg

1710 lb 770 kg

*1870 lb *850 kg

1080 lb 490 kg

*1560 lb *710 kg

730 lb 330 kg

+2.5 ft (0.8 m)

*3780 lb *1710 kg

1530 lb 690 kg

*2320 lb *1050 kg

990 lb 450 kg

*1760 lb *800 kg

690 lb 310 kg

*1880 lb *850 kg

660 lb 300 kg

Ground Level

*2540 lb *1150 kg

*2540 lb 1150 kg

*4100 lb *1860 kg

1460 lb 660 kg

*2580 lb *1170 kg

470 lb 420 kg

-2.5 ft (-0.8 m)

*4170 lb *1890 kg

3000 lb 1360 kg

*3910 lb *1770 kg

1460 lb 660 kg

*2560 lb *1160 kg

930 lb 420 kg

-5.0 ft (-1.52 m)

*5720 lb *2590 kg

3080 lb 1390 kg

*3240 lb *1470 kg

1500 lb 680 kg

*2090 lb *950 kg

960 lb 430 kg

* Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits. Reference important considerations on page 8-10 for machine operation and use of lifting charts.

LIFT CAPACITIES CAB MODEL 3 ft. 11 in (1.2 m) Arm Lift capacities calculated using 11.8 in (300 mm) shoes (179 lb (81 kg) bucket, blade down 550 lb (250 kg) counterweight Load (Lift Point) Height

5 ft (1.5 m) END - SIDE

7.5 ft (2.3 m) END - SIDE

+7.5 ft (2.3 m)

10 ft (3.0 m) END - SIDE

12.5 ft (3.8 m) END - SIDE

*1430 lb *650 kg

1420 lb 640 kg

*1400 lb *630 kg

960 lb 430 kg

+5 ft (1.52 m)

*2710 lb *1220 kg

2090 lb 950 kg

*1870 lb *850 kg

1340 lb 600 kg

*1560 lb *710 kg

930 lb 420 kg

+2.5 ft (0.8 m)

*3780 lb *1710 kg

1910 lb 860 kg

*2320 lb *1050 kg

1250 lb 570 kg

*1760 lb *800 kg

890 lb 400 kg

*1880 lb *850 kg

860 lb 390 kg

Ground Level

*2540 lb *1150 kg

*2540 lb 1150 kg

*4100 lb *1860 kg

1840 lb 830 kg

*2580 lb *1170 kg

1200 lb 540 kg

-2.5 ft (-0.8 m)

*4170 lb *1890 kg

3720 lb 1680 kg

*3910 lb *1770 kg

1840 lb 830 kg

*2560 lb *1160 kg

1190 lb 540 kg

-5.0 ft (-1.52 m)

*5720 lb *2590 kg

3800 lb 1720 kg

*3240 lb *1470 kg

1880 lb 850 kg

*2090 lb *950 kg

1220 lb 550 kg

* Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits. Reference important considerations on page 8-10 for machine operation and use of lifting charts.

9-9

CHAPTER 9 - SPECIFICATIONS LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radius and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury CE-NA000

9-10

5. Capacities apply to the machine as originally manufactured and normally equipped by the manufacturer.

IMPORTANT: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. Example: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the Lifting Chart accordingly.

2. If a bucket is changed for a larger bucket, which weight is more than the bucket indicated in the Lifting Chart, then you have to subtract this additional weight from every value indicated in the Lifting Chart accordingly.

3. If a bucket is changed for a smaller bucket, which weight is less than the bucket indicated in the Lifting Chart, then you can add this additional weight to every value indicated in the Lifting Chart accordingly.

CHAPTER 9 - SPECIFICATIONS

TORQUE SPECIFICATIONS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

CAP SCREWS AND NUTS METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES Make certain to tighten all Capscrews & Nuts to proper torque values.

Metric Coarse Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

1.77 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1)

14.6 ± 1.5 (105 ± 10.8)

12.3 ± 1.2 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6)

12.8 ± 1.3 (92.5 ± 9.4)

10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50.5 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

TORQUE VALUE UNIT: kgf (ft-lbs)

9-11

CHAPTER 9 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES Tighten all Capscrews & Nuts to proper torque values.

Metric Fine Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M8

P=1

1.15 0.11 (8.3 ± 0.8)

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190)

212 ± 21 (1530 ± 150)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ±43 (3090 ± 310)

357 ± 36 (2580 ± 260)

TORQUE VALUE UNIT: kgf (ft-lbs)

ORS JOINT (O-RING SEALING TYPE) ORS Joint (O-ring Sealing Type)

Hose mouth ring and Coupling

9-12

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgfm (ft-lbs)

1 - 14 UNS

30 - 32

14 ± 1.4 (101 ± 10)

1 - 3/16 12 UN

36 - 41

18 ± 1.8 (130 ± 13)

1 - 7/16 12 UN

41 - 46

21 ± 2.1 (152 ± 15)

WORKING PRESSURE kgf/cm2 (psi) 350 (4980) 385 (5475) Power Boost

CHAPTER 9 - SPECIFICATIONS NUTS AND SLEEVES Nuts and Sleeves

MANUFACTURER’S NAME

WORKING PRESSURE kgf/cm2 (psi)

350 (4980) Travel line only

NIPPON A.M.C.

350 (4980) Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS Flare Type Fitting Joints

TUBE SIZE O.D. X THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE kgfm (ft-lbs)

10 X 1.5 (0.394 X 0.059)

19

4.5 ± 0.5 (33 ± 4)

15 X 2.0 (0.591 X 0.079)

27

15 ± 2 (108 ± 14)

18 X 2.5 (0.709 X 0.098)

32

18 ± 2 (130 ± 14)

22 X 3.0 (0.866 X 0.118)

36

22 ± 2 (159 ± 14)

28 X 4.0 (1.10 X 0.157)

41

28 ± 3 (203 ± 22)

35 X 5.0 (1.38 X 0.20)

55

35 ± 4.5 (253 ± 29)

N2 (NYLON) TUBE FITTING JOINTS N2 (Nylon) Tube Fitting Joints

Overtightening of flare type (Union Nut Type) metal joints may cause damage to nuts, seat surfaces, and prevent optimum sealing resulting in oil leaks.

NOMINAL SIZE (PIPE THREAD)

TORQUE VALUE

1/4”

2.5 ± 0.3 (18.1 ± 1.8)

3/8”

5 ± 0.5 (36.2 ± 3.6)

1/2”

6 ± 0.6 (43.4 ± 4.3)

3/4”

12 ± 1.2 (86.8 ± 8.7)

1”

14 ± 1.4 (101 ± 10)

1-1/4”

17 ± 1.7 (123 ± 12)

1-1/2”

21 ± 2.1 (152 ± 15)

2”

42 ± 4.2 (304 ± 30) Unit: kgfm (ft.-lbs)

1. Clean Tube and make sure certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

9-13

CHAPTER 9 - SPECIFICATIONS WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted & broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

Material (Loose Weight)

9-14

CHAPTER 9 - SPECIFICATIONS SOME CONVERSION UNITS

UNITS OF PRESSURE

UNITS OF WEIGHT

Units of Pressure Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

Bars

0.06895

kg/cm2

0.0703

Pa (Pascal)

6894.76

psi

145.04

From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

UNITS OF LENGTH psi Units of Length From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

MPa (MegaPascal)

UNITS OF VOLUME

UNITS OF POWER

Units of Volume From

Units of Power

Into

Multiply by

From

Into

Multiply by

Gal (US Liquid)

0.264

HP

kW

0.7457

in3

61.02

kW

HP

1.341

yard3

0.00131

quarts

1.0567

ounces (US)

33.81

m3

0.765

in3

46656

ft3

27

Liters

UNITS OF FLOW Units of Flow Into

From

Lit/min Gal/min (US liquid)

Liter/min

Lit/sec

Multiply by 3.79 0.0631

cm3/min

3785.4

ft3/min

0.1337

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

Yard3

cm

3

liters

764554.9 764.555

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgfm

0.1382552

N·m

1.35582

lbf-in

12

9-15

CHAPTER 9 - SPECIFICATIONS

NOTES

9-16

CHAPTER 10 - INDEX

Chapter 10

INDEX A Access Doors ....................................................... 3-7 Air Cleaner.......................................................... 7-29 Air Conditioner.................................................... 7-16 Alternator .................................................... 7-16, 8-7 Arm Operation ................................................... 4-13 Attachment Lubrication ...................................... 7-17 Attachment and Swing........................................ 4-13

B Back Filling and Leveling ................................... 4-17 Basic Operation of Hydraulic Controls ................. 4-8 Before Operating the Hydraulic Breaker ............ 4-20 Before Operating the Machine ............................. 4-3 Bio-diesel Fuel...................................................... 5-6 Bio Degradable Oil ............................................... 5-7 Bolt and Nut Torque ........................................... 9-11 Boom Operation ................................................ 4-13 Breaker BHL Pattern ............................................ 4-7 Bucket ................................................................ 4-15 Bucket Operation ............................................... 4-15 Bucket Selection Guide ..................................... 4-19 Burn Prevention ................................................... 2-8

C Cab Dome Light ................................................... 3-5 Cab Door Latch ................................................... 3-3 Cab Machine Dimensions .................................... 9-3 Canopy Machine Dimensions .............................. 9-3 Cleaning Parts ..................................................... 7-4 Cleaning Sand & Soil from Bucket .................... 4-16 Components & Controls Nomenclature ............... 3-9 Connecting Booster Cable ................................... 8-6 Control Decal ....................................................... 4-7 Coolant ...................................................... 7-12, 7-34 Counter Rotating Machine ................................. 4-10 Cylinders............................................................... 1-3

D Decals ................................................................ 2-12 Disposal of Hazardous Waste ............................. 7-3 Document Pouch ................................................. 3-5

E EMC (Electro-Magnetic Interference .................... 1-6 Emergency Engine Shut Down ............................ 4-5 Emergency Exit Hammer.................................... 2-10

Engine ..................................................................1-4 Engine Coolant Level .........................................7-12 Engine Door Cover................................................3-7 Engine Electrical .................................................7-13 Engine Oil Level ....................................... 7-18, 7-25

F Fan and air conditioner........................................7-16 Filters.....................................................................6-3 Fire Extinguisher ................................................2-10 Fire Prevention ...................................................2-10 Flare Type Fitting Joints .....................................9-13 Fluids.....................................................................6-3 FOPS (Falling Object Protection System) .............2-9 Frame Structure ...................................................7-5 Fuel Handling Precautions ...................................2-8 Fuel Bio-diesel.......................................................6-6 Fuel Level ...........................................................7-13 Fuel Tank Sediment ............................................7-17

G General Information ..............................................1-1 Guidelines for Attachment Lubrication .................7-7 Guidelines to Replace Ground Tools ...................7-7

H Hand Signals ......................................................2-27 Hazardous Chemical Precautions ........................2-8 Hazardous Waste..................................................7-3 Hot Surface and Fluids .........................................7-3 Hydraulic Breaker ...............................................4-20 Hydraulic Oil Leaks ............................................7-15 Hydraulic Oil Level ................................... 7-14, 7-47

I Identification Numbers ..........................................1-4 Ignition Switch .......................................................3-9 Inspect Waste Oils and Filters ..............................7-4 ISO/SAE Operating Pattern...................................4-7

K Keep Machine Clean ............................................7-3 Key Switch ............................................................3-9

L Lifting Capacities ..................................................9-8 Lifting Machine .....................................................5-5 10-1

CHAPTER 10 - INDEX Lifting Machine With Attachment Installed ........... 5-5 Locking/Unlocking Cab Door ............................... 3-3 Lubricants ............................................................. 6-5 Lubrication Quick Reference Chart ...................... 7-8

Operator Precautions ...........................................2-5 Operator Seat Adjustments ..................................3-6 Operator’s Compartment Controls .......................3-8 ORS Joint (O-ring Sealing Type .........................8-12

P M Machine Access Compartments and Doors ........ 3-7 Machine Attachment and Swing ........................ 4-13 Machine Components .......................................... 1-3 Machine Dimensions ........................................... 9-3 Machine Electrical ............................................... 8-3 Machine Operation in Adverse Weather ............ 4-18 Machine Storage ................................................. 5-7 Machine Travel Controls ...................................... 4-9 Machine Warm Up ............................................... 4-5 Maintenance Precautions .................................... 2-7 Manual Warm Up ................................................. 4-5 Metric Coarse Thread Standard Tightening Torque Values ......................................................... 9-11 Metric Fine Thread Standard Tightening Torque Values ......................................................... 9-12 Model, Serial Number, and Year of Manufacture 1-4 Monitor ............................................................... 3-10 Mounting and Dismounting Precautions .............. 2-5

Personal Safety ....................................................2-3 PIN Numbers.........................................................1-4 Practices to Improve Efficiency ..........................4-16 Prevent Contamination .........................................7-4

R Radiator...............................................................7-12 Releasing Hydraulic System Pressure .................7-6 Removing and Storing Lower Front Window ........3-4 Removing Machine from Storage .........................5-7 Removing the Bucket .........................................7-54 Required Filters ....................................................5-4 Required Fluids/Lubricants and Capacities ..........5-3 Return Filters.......................................................7-24 Right Hand Operator Console and Monitor ..........3-9 Right, Left, Front, and Rear of the Machine .........1-2 Roll-Over Protective Structure (If equipped) ........2-8 Rubber track........................................................7-15

S N N2 (Nylon) Tube Fitting Joints ........................... 9-13 Nuts & Sleeves .................................................. 9-13

O Oil, bio-degradable ............................................... 6-7 Oil capacities ........................................................ 6-3 Oil, changing....................................................... 7-18 Oil, checking ....................................................... 7-12 Opening and Closing Door .................................. 3-4 Opening and Closing Windshield ........................ 3-4 Operate Boom Smoothly ................................... 4-16 Operating Both Travel Levers .............................. 4-9 Operating Pattern ................................................ 4-7 Operating Pattern Decal ...................................... 4-7 Operating Precautions ......................................... 2-6 Operating the Machine ........................................ 4-3 Operating the Machine in Water ........................ 4-12 Operation at Seashore or Salty Climate ............ 4-18 Operation in Extreme Cold ................................ 4-18 Operation in Extreme Heat ................................ 4-18 Operation in High Altitudes ................................ 4-18 Operation in Humid Climate .............................. 4-19 Operation in Sandy and Dusty Areas ................ 4-18 Operator Cab Nomenclature ............................... 3-9 10-2

Safety Area ...........................................................2-3 Safety Rules .........................................................2-3 Seals and O-Rings ...............................................7-4 Seat Belt ...............................................................3-6 Seat Belt Precautions .........................................2-10 Seat Height Adjustment ........................................3-6 Securing Machine to Trailer .................................5-4 Selection of the Hydraulic Breaker .....................4-20 Specific Precautions to this Machine ..................2-10 Starter Motor ........................................................8-7 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) .....................4-4 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) ......................4-5 Starting and Stopping Precautions .......................2-5 Starting Boosting Machine Engine .......................8-6 Starting Disabled Machine Engine .......................8-6 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable .......8-6 Steps and Handrails ..................................... 2-5, 7-5 Stop Engine ..........................................................4-5 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Operation .................................................4-15 Swing Reduction Gear ........................................7-27

CHAPTER 10 - INDEX

T Torque Specifications ........................................ 9-11 Track Links ........................................................ 7-23 Tracks and Components ................................... 7-19 Transporting Precautions ............................. 2-8, 5-3 Travel Reduction Gear ....................................... 7-33 Travel Safety ..................................................... 4-11

U Units of Flow ...................................................... 9-15 Units of Length .................................................. 9-15 Units of Power ................................................... 9-15 Units of Pressure ............................................... 9-15 Units of Torque .................................................. 9-15 Units of Volume ................................................. 9-15 Units of Weight .................................................. 9-15 Use Arm in Action .............................................. 4-16 Use of Optional Attachment ............................... 4-20 Utility Safety ......................................................... 2-4

W Warm Engine Oil ................................................. 7-4 Water Separator ................................................. 7-31 Warming Hydraulic Oil ......................................... 4-6 Warm Up of Engine ............................................. 4-5 Wear Safety Equipment ....................................... 7-4 Weight of Materials Table .................................. 8-14 Welding Safety .................................................... 7-5 Windows ............................................................... 3-4 Windshield Washer Tank...................................... 3-7

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CHAPTER 10 - INDEX

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

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