Case CX31B TIER 4 COMPACT CRAWLER Excavator Operator's Manual - PDF DOWNLOAD

OPERATOR’S MANUAL COMPACT CRAWLER EXCAVATOR

CX31B TIER 4

APPLICABLE

PW14-45964~

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Nov 08 Printed in U.S.A. • Book/Form Number S2PW00035ZE01 NA Copyright © 2008. CNH America, LLC. All Rights Reserved.

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.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 11-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Nov 08

CX31B Tier 4 Compact Crawler Excavator

S2PW00035ZE01 NA

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. 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: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ 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 instructions on machine operation and maintenance.

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.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

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

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

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

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

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

Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of 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 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Starting and Stopping Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting and Stopping Machine Engine in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Angle Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-3 5-5 5-5

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 50 hour maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 S2PW00035ZE01 NA

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

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

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

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

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

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

6-30 6-34 6-37 6-38 6-47 6-48

CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER CX31B COMPACT CRAWLER EXCAVATOR

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

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

The standard attachments and tools of this machine are designed to carry out all kinds of earth moving and rehandling operations. If you want to use this machine 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 Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine's technical specifications and with prevailing safety requirements.

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

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

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

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

Contact your dealer for operator manuals translated into Spanish or French Canadian.

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, LLC 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.

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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

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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.

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

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31.

32.

33.

34.

35.

36.

37.

BOOM CYLINDER ARM CYLINDER WORK LAMP ARM LINK BUCKET CYLINDER BUCKET

1-3

CHAPTER 1 - GENERAL INFORMATION

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 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

BS07M602

PRODUCT IDENTIFICATION PLATE

COMPONENT SERIAL NUMBERS

➤

COMPONENT SERIAL NUMBERS Model

➤

➤

Hydraulic Pump Serial Number

➤

➤

Swing Reduction Gear Manufacturing Year

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

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

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

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

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

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

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

OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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 - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Parts (Optional Cab with Air Conditioning) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use Specified Diesel Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10 2-11 2-11 2-12 2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-17 2-18 2-18 2-19 2-20 2-21 2-22 2-22 2-23 2-23 2-24 2-24

HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-25 2-25 2-25 2-25 2-25 2-25

Issued 11-08

Bur

S2PW00035ZE01NA

2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-2

Issued 11-08

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S2PW00035ZE01 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

M171C

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

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

• The first panel indicates the nature of the hazard.

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

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

and

STOP

if

SAFETY AREA

1

1

2 Figure 1

BS06H091

Figure 2

BC02N198

1. OPERATOR’S MANUAL STORAGE SPACE

1. WORKING AREA 2. SAFETY AREA

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.

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.

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

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

S2PW00035ZE01 NA

Issued 11-08

Bur

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 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 IMPORTANT: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

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

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

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

Figure 3

RH99G001

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

Issued 11-08

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S2PW00035ZE01 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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 vests 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

• 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 before starting the machine.

GENERAL

• It is the responsibility of the operator to read and

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

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Start and operate the machine only from the

• DO NOT OPERATE this machine or perform

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

maintenance work if you have not had appropriate training and have 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 objects stored in the machine.

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

operator’s seat.

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

• 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 cancellation lever into the locked or up position.

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

S2PW00035ZE01 NA

Issued 11-08

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2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 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.

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

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

• Know and understand that job site conditions may

• 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.

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

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

• Contact

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.

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.

• If a part of the machine touches high voltage

• Watch for bystanders and never allow anyone to

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.

be under or to reach through the machine and its equipment while operating.

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

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

Provide an escort for roading where required.

2-6

power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

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

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• DO NOT OPERATE the machine if you do not feel

• Avoid lubrication or mechanical adjustments with

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

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.

• 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.

• 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.

• 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.

Figure 4

DC04E084

• 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.

• Wear gloves to protect hands when handling cable.

• 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 decals. Keep all decals and safety notice signs clean.

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

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2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Hot coolant can spray out if the radiator cap is

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 manufacturer’s 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.

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.

• 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.

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.

M144B

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

• When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured 2-8

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.

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

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

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

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system Issued 11-08

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SPECIFIC PRECAUTIONS TO THIS MACHINE

SEAT BELT PRECAUTIONS

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

1

• 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

2

bucket.

• Do not use this machine for anything other than its Figure 5

BC02N375

intended purpose.

• DO NOT OPERATE bucket and arm cylinders to

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

stroke end repeatedly.

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

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

• 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.

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

M422A

EMERGENCY EXIT HAMMER

Figure 6

DC04D572

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.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary.

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.

CE-NA000

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

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

NOTE: 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

2-10

and

STOP

if used are RED.

Issued 11-08

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOM AND ARM MOVEMENT - CAUTION Located on seat stand cover - Part Number YN20T01013P1

Figure 7

BS07M605/BS07M647

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

Figure 8

BS07M639/PW20T01007P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SAFETY CONTROLS - WARNING Located on seat stand cover - Part Number YN20T01016P1

Figure 9

BS07M605/BS07M647

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

Figure 10

BS07M640/YN20T01220P1

2-12

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS PRESSURIZED FLUIDS AND LUBRICANTS - WARNING Located on radiator duct - Part Number PW20T01094P1

Figure 11

BS07M444/PW20T01094P1

ENGINE STOP - CAUTION Located on hood support- Part Number YN20T01012P1

Figure 12

BS07M444/BS07M448

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT SWING AREA - DANGER Located on radiator cover- Part Number PE2T01014P1

Figure 13

BS07M646/BS06J055

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

Figure 14

BS07M606BS07M649

2-14

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOSTER CABLE - WARNING Located on battery box cover- Part Number YN20T01338P1

Figure 15

BS07M641/BS07M650

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

Figure 16

BS07M645/BS07M651

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS KEEP CLEAR OF WORKING AREA - DANGER Located on both sides of arm- Part Number PE20T01012P1

Figure 17

BS07M652/UPX00100013E01

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

Figure 18

BS07M607/BS07M653

2-16

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BATTERY - DANGER Located on battery box cover- Part Number PY20T01069P1

Figure 19

BS07M652/PY20T01069P1

ELECTRICAL LINE SAFETY - DANGER Located on seat stand cover- Part Number YN20T01006P1

Figure 20

BS07M607/BS07M654

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SELECTOR VALVE - CAUTION Located on seat stand cover- Part Number PE20T01016P1

Figure 21

BS07M607/UPX00100022E01

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

Figure 22

BS07M605/UPX00100017E01

2-18

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SEAT BELT - WARNING Located on seat stand cover- Part Number PE20T01027P1

Figure 23

BS07M607/UPX00100019E01

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

Figure 24

BS07M655/UPX00100026E01

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS FALLING FRONT WINDOW - CAUTION Located on inside front window - Part Number PM20T01035P1

Figure 25

BS07M655/UPX00100021E01

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

Figure 26

BS07M657/UPX00100023

2-20

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HYDRAULIC OIL CHECK POSITION - NOTICE Located on seat stand cover- Part Number 2432P3379

Figure 27

BS07M605/UPX00100017E01

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

Figure 28

BS07M610/UPX00100028E01

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP ENGINE - DANGER Located on inside of side cover- Part Number YN20T01214P1

Figure 29

BS07M605/UPX00100031E01

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

Figure 30

BS07M656/UPX00100032E01

2-22

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT OPERATE THIS MACHINE- WARNING Located on inside of right window (cab). Located on ceiling (canopy) - Part Number PE20T01028P1

Figure 31

BS07M656/UPW00100075E01

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

Figure 32

BS07M656UPJ00010005E01

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT PARTS (OPTIONAL CAB WITH AIR CONDITIONING) - CAUTION Located on compressor - Part Number PH20T01102P1

Figure 33

BS07M656/BS07N559

USE SPECIFIED DIESEL OIL - WARNING Located on fuel fill cap - Part Number PV20T01068P1

Figure 34

BS07M656UPJ00010005E01

2-24

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS IMPORTANT: When operating the machine, never attempt to carry out tasks calling for the control of or to work in areas where visibility is poor or impaired without seeking the assistance of a signal person. Make certain that you and the signal person 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 opera tion. 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 37

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

MOVE LOAD OUT HORIZONTALLY

Figure 35

DC04E038

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 38

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

RAISE BOOM

Figure 36

DC04E039

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

DC04E042

Figure 39

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb up.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LOWER BOOM

DC04E043

ARM IN

Figure 40

Figure 43

DC04E046

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 41

Figure 44

DC04E047

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 42

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

2-26

Figure 45

DC04E048

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.

Issued 11-08

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTER ROTATE RIGHT

CLOSE BUCKET (BUCKET IN OR DIG)

Figure 46

DC04E049

DC04E052

Figure 49

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)

Figure 47

DC04E050

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

DC04E053

Figure 50

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

Figure 48

DC04E051

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

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Issued 11-08

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DC04E054

Figure 51

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.

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS TURN RIGHT

DE04E055

STOP

Figure 52

Figure 55

DC04E058

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.

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

MOVE THIS MUCH

EMERGENCY STOP

DC04E056

Figure 53

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

Figure 56

DC04E059

Face Machine Operator, raise both ar ms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY STOP ENGINE

DC04E057

Figure 54

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t 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).

2-28

Figure 57

DC04E060

Face Machine Operator, right arm at side, draw left thumb or index finger across throat.

Issued 11-08

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Right Window Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 3-3 3-3 3-4 3-4 3-4 3-5 3-5 3-6 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 Cancellation 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Right Hand Operator Control Lever (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Left and Right Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Throttle Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Dozer Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

CAB DOOR LATCH

1

2

1

2

3

3 Figure 1

BS07M259

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.

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.

WARNING: Never use the lever for door latch release as a handle to mount and/or dismount from the machine. Failure to comply could result in injury or death.

1

Figure 3

BS07M660

1. DOOR RELEASE LEVER

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

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3-3

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

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

IMPORTANT: 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.

WARNING: Special attention must be paid not to injure hands and others when the front window is closed. Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in injury or death.

3-4

Figure 7

BS07M663

1. LOCK

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

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

Issued 11-08

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB DOME LIGHT

DOCUMENT POUCH

Figure 8

BS06H100

CAB DOME LIGHT

DOCUMENT POUCH

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

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

S2PW00035ZE01 NA

Issued 11-08

Figure 9

BS06H091

Bur

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 - INSTRUMENTS AND CONTROLS 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.

NOTE: 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: 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 injury or death.

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

3-6

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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 injury or machine damage.

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.

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Issued 11-08

Bur

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

2

7

20

5

10

4

21 6

9 1

8

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

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 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: DO NOT OPERATE this machine unless you have read and understand the instructions in this manual.

Improper machine operation is dangerous and could result in injury or death.

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.

Figure 18

BS07M672

KEY SWITCH

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.

HOUR METER

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

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.

Figure 17

BS07M792

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.

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Issued 11-08

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3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS 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.

Figure 21

BS07M675

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.

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

3-10

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING LAMPS WARNING: Do not perform any maintenance on a hot engine. Allow the engine to cool before inspection or maintenance. Failure to comply may result in death or injury.

IMPORTANT: 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: Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply may result in death or injury.

Figure 22

BS07M776

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.

Figure 23

BS07M777

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.

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3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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- Chapter 6 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

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

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 injury or death.

Figure 30

BS07M785

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.

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.

S2PW00035ZE01 NA

Issued 11-08

Bur

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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 NOTE: 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.

Figure 34

BS08J519

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

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

2

1

Figure 35

BS08J524

OPTION SWITCH (BREAKER AND NIBBLER) The 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

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Issued 11-08

Bur

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEVERS AND PEDALS

2

3

6

2

1 5

4

Figure 36

BS08J525

1. Cancellation Lever (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 CANCELLATION LEVER A hydraulic function cancellation lever is provided on the left control console to avoid activation of any unwanted hydraulic function. When the function cancellation 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 cancellation lever in the locked (up) position.

1

2

Figure 37

BS06H080

1. FUNCTION CANCELLATION LEVER IN LOCKED (UP) POSITION 2. FUNCTION CANCELLATION LEVER IN UNLOCK (DOWN) POSITION

3-16

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

Failure to comply could result in injury or death.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATING CONTROL LEVERS

Left Hand Operator Control Lever (ISO/SAE Pattern)

Figure 39

DC04D562

LH CONTROL LEVER 2

4

WARNING: Hydraulic controls are designed for and set to an ISO operating pattern.

Changing the control pattern will effect the operation of the machine controls. Make certain patterns match machine movement.

Failure to comply could result in injury or death.

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

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.

• • • • •

S2PW00035ZE01 NA

Issued 11-08

Bur

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 - INSTRUMENTS AND CONTROLS Right Hand Operator Control Lever (ISO/SAE Pattern)

BHL PATTERN

Figure 41

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.

3-18

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.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS NOTE: 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.

2

PATTERN CONTROL CHANGE (BHL PATTERN) To change the machine’s control pattern from ISO (SAE) to (BHL) pattern, proceed as follows:

1

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

1

Figure 43

BS07N621

1. PATTERN CHANGER VALVE

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

3 4 Figure 42

DC04C344

1. HYDRAULIC FUNCTION CANCELLATION LEVER IN LOCKED (UP) POSITION

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

Figure 44

BS07N564

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.

WARNING: Check machine’s control pattern for conformance to pattern on decal-card in cab. If pattern does not match decal-card on cab door holder, flip decal-card on holder to match the machine’s control pattern before operating machine. Failure to comply could result in injury or death.

S2PW00035ZE01 NA

Issued 11-08

Bur

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING: Whenever a change is made to the machine’s control pattern, also change the pattern decal card in the cab to match the new pattern. Failure to comply could result in injury or death.

LEFT HAND OPERATOR CONTROL LEVER (BHL PATTERN)

Figure 45

DC04D565

Figure 47

DC04D567

ISO/SAE PATTERN DECAL CARD

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)

Figure 46

DC04D566

BHL PATTERN DECAL CARD

Figure 48

DC04D568

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

3-20

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 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.

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.

• CENTER - Neutral position.

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

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

WARNING: Always know the position of the travel motors before starting movement.

Failure to comply could result in injury or death.

S2PW00035ZE01 NA

Issued 11-08

Bur

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS 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.

3-22

WARNING: Always lock the pedal if not using the boom swing operating function.

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

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 STARTING AND STOPPING MACHINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Machine Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Check Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 BASIC OPERATION OF HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function Cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in a narrow space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Attachment and Swing - ISO/SAE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10 4-10 4-10 4-11 4-11 4-11 4-12 4-12 4-13 4-13 4-13 4-14 4-14 4-14 4-15

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17 4-17 4-18 4-18 4-18 4-19 4-19 4-19 4-19 4-19 4-19 4-20 4-20 4-20

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Issued 11-08

Bur

S2PW00035ZE01 NA

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Optional Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 Accelerate Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 Setting Machine Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 ANGLE DOZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Dozer Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Lubricating Dozer Blades and Cylinder Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Machine Dimensions with Dozer Angle Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

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S2PW00035ZE01 NA

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.

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

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.

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

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.

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

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

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

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

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

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

15. Work out a convenient means of escape from the m ac h i ne ( be p ro a c t i ve an d d et er m i n e an emergency exit) in the event of the cab door being jammed or the machine turning over. Cab m odel s a re eq u i pp e d wi th a n em erge ncy hammer.

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

S2PW00035ZE01 NA

Issued 11-08

Bur

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

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 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.

STARTING AND STOPPING MACHINE ENGINE STARTING ENGINE

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

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

Fasten the seat belt.

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

2. Move throttle control to LOW position.

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.

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.

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

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

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

CAUTION: 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.

NOTE: 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

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.

Figure 1

BS07M794

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 cancellation lever in the LOCKED position.

4-4

Issued 11-08

Bur

S2PW00035ZE01 NA

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.

1 Figure 2

DC04C344

1. ENGINE EMERGENCY STOP CONTROL

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

2. Before restarting engine, engine stop control in.

push

emergency

IMPORTANT: 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.

NOTE:

• 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.

• 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.

Stopping the Machine

1

BS07M861

2

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.

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Bur

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING MACHINE ENGINE WITH BOOSTER CABLES

3 CONNECTING BOOSTER CABLE

1

2

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.

1. Move vehicle or machine to be used for boosting as close to the batter y box of the disabled machine as possible.

CAUTION: 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.

CAUTION: 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: Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries. Failure to comply could result in injury or death.

WARNING: AVOID ACID BURNS 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.

4 1

2

3

4 Figure 4

DC04D588

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 1. Start engine of disabled machine in normal manner according to climate conditions.

WARNING: The negative (-) cable, when connected to the upper frame of disabled machine may arc and create sparks. Sparks coming in contact with batteries could trigger an explosion. Never connect negative (-) terminal of disabled battery. Failure to comply could result in injury or death.

4-6

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 4 - OPERATING INSTRUCTIONS DISCONNECTING BOOSTER CABLES

3

MACHINE WARM UP

1

2

4 4

3

2

1 Figure 5

DC04D588

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.

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 climate temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in injury or death.

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

4. Disconnect positive (+) cable from terminal of disabled machine.

CAUTION: When disconnecting booster cables always disconnect negative (-) cable first from frame of disabled machine.

S2PW00035ZE01 NA

Issued 11-08

Bur

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS CHECK MONITOR PANEL

1

3

2

4

Figure 6

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 CAUTION: 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 8

DC04D474

DC04D473

Figure 7

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.

4-8

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 anytime machine is started in climate temperature below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in injury or death.

Issued 11-08

Bur

S2PW00035ZE01 NA

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

BS07M796

Figure 9

BS07M797

Figure 10

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 injury or death.

S2PW00035ZE01 NA

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4-9

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: 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. Failure to comply could result in injury or death.

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

Figure 12

BC08J114

SAFETY LOCK LEVER FUNCTION MACHINES WITH BOOM SWING PEDAL CONTROL With engine running, set the safety control lever to the LOCKED (up) position.

FUNCTION CANCELLATION LEVER

Move the following controls:

2

Left control lever Right control lever Boom swing pedal - left and right

1

Travel control lever 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.

Figure 11

BS06H080

1. UNLOCKED POSITION 2. LOCKED POSITION

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

1. Locked Position

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 injury or death.

WARNING: Always place the Function Cancellation Lever in the Locked (up) position before leaving cab to prevent any operation of hydraulic controls. Failure to comply could result in injury or death.

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

4-10

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 4 - OPERATING INSTRUCTIONS TRAVEL SPEED SELECT SWITCH

MACHINE TRAVEL CONTROLS 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 15

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.

Figure 13

DC04D477

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.

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

IMPORTANT: 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 14

DC04D478

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.

NOTE: 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.

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4-11

CHAPTER 4 - OPERATING INSTRUCTIONS TURNING THE MACHINE

Figure 19

DC04D482 DC04D479

Figure 16

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

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

Figure 20

DC04D483 DC04D480

Figure 17

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

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

Figure 21

DC04D484 DC04D481

Figure 18

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

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

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Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN A NARROW SPACE

IMPORTANT: 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.

Figure 22

BS07N682

BOOM IN FOLDED POSITION

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

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

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

OPERATING THE MACHINE IN WATER

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.

3

2

4

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.

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1 BS07M851

Figure 23

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.

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

4-13

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.

WARNING: Read, understand and follow all safety precautions during all operations of this machine and its attachment.

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.

DC04D485

Figure 24

a. Pulling right control lever BACK raises boom.

Figure 26

DC04D487

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

Figure 27

DC04D488

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 25

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

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.

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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 28

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 machine damage, injury or death.

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4-15

CHAPTER 4 - OPERATING INSTRUCTIONS Bucket Operation

Swing Operation - Lever

IMPORTANT: 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.

WARNING: Make certain area is clear of obstacles and persons before beginning swing operation of the machine. Sound horn before beginning swing operation. Failure to comply could result in injury or death.

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

NOTE: Use swing flashers during swing operations.

DC04D489

Figure 29

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

Figure 31

DC04D491

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

DC04D490

Figure 30

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.

Figure 32

DC04D492

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY CLEANING SAND & SOIL FROM BUCKET

USE ARM IN ACTION

Figure 33

BS07M852

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

Figure 35

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.

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

DITCH DIGGING

Figure 34

DC04E075

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.

Figure 36

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.

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

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4-17

CHAPTER 4 - OPERATING INSTRUCTIONS USING THE DOZER

BS07M856

OFFSET DIGGING

Figure 37

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 39

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.

IMPORTANT: 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: Make certain area is clear of obstacles and persons before beginning swing operation of the machine. Sound horn before beginning swing operation. Failure to comply could result in injury or death.

BS07M857

Figure 38

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.

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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.

NOTE: 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.

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.

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

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.

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 injury or death.

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 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.

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

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.

OPERATION IN EXTREME HEAT 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.

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 th e machine.

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

OPERATION AT SEASHORE OR SALTY CLIMATE 1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electr ical components and cylinder rods.

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.

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4-19

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION 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.

Machine with Canopy

Machine with Cab

Figure 40

BS07N629/BS07N630

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4-21

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Loading the Machine WARNING: Never attempt to load or unload machine without ramps. Failure to comply could result in injury or death. 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 move 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 41

DC04C344

1. FUNCTION CANCELLATION LEVER

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS Securing Machine to Trailer

Figure 42

BS07N631

Once the machine is loaded and secured to the t ra i l e r, m a ke c e r t a i n t h e t i e d ow n fa s t e n i n g cables/straps are of sufficient strength to hold the machine. Make certain height and weight regulations are met.

DC04D581

Figure 43

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.

Securely fasten all loose parts, as well as removed parts from the machine to the trailer or transporting platform.

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4-23

CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING MACHINE WARNING: Keep all unauthorized personnel clear of area. Do not lift machine over personnel or equipment. Failure to comply could result in machine damage, injury or death.

The following procedures are for lifting the machine, without modification. 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 WARNING: Always use proper lifting equipment and devices. Use of improper lifting equipment could allow the load to shift or fall causing severe damage, serious injury or death. 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.

BS07N632

Figure 45

BS07N633

Figure 46

1 Figure 44

DC04D582

1. HARDWOOD OR STEEL BLOCK

c. Place hardwood or steel block between cables and crawler frame. \

WARNING: Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting. Failure to comply could result in machine damage. d. Slowly raise the lift apparatus to check with contact with machine, security, and balance.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE

Figure 47

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.

IMPORTANT: 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.

NOTE: 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.

4. Move machine to an indoor location for storage.

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

3. Carefully inspect all hydraulic hoses after long periods of storage for signs of deterioration.

Replace all hoses showing signs of deterioration.

6. Rest the bucket on a stable wood block.

4. Refill fluids to proper levels and lubricate as required.

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

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

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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 with this warning could result in injury or death.

4-25

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.

IMPORTANT: 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 W h e n m o u n t i n g a b r e a ke r o n t h e hy d r a u l i c 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 appropr iate hydraulic flow for the breaker by fo l l o w i n g t h e i n s t r u c t i o n d e t a i l e d i n t h e NIBBLER/BREAKER BASIC M AC H I N E 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: Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment. Failure to comply could result in injury or death.

1

Figure 48

BS06H080

1. FUNCTION CANCELLATION LEVER

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

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CHAPTER 4 - OPERATING INSTRUCTIONS BREAKER

NIBBLER

Figure 49

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 50

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.

NOTE: 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

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

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS OPTIONAL HAND CONTROL WARNING: Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment. Failure to comply could result in injury or death.

IMPORTANT: 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 51

BS08J521

1. SLIDE (TURN ATTACHMENT) SWITCH 2. HORN

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 deter ioration of hydraulic oil compared to normal earth moving operations with a bucket. Replace filters and hydraulic oil more frequently.

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 NOTE: Hydraulic flow will increase depending upon the slide distance of the switch (1).

WARNING: Never leave the operator cab with engine running. Failure to comply could result in injury or death.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform any inspection or maintenance on this machine. Failure to comply could result in injury or death.

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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 52

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.

NOTE: 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 cancellation lever in the locked position.

SELECTOR VALVE SHIFTING POSITION TO TANK

TO C/V

TO TANK

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 NOTE: 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 53

3

2

1

Figure 54

BS07M864

S2PW00035ZE01 NA

Figure 55

N : USE NIBBLER

UPM00700003ES1

4

BS07M865

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4-29

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

C. BREAKING OVERSIZE ROCKS

WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment. Failure to comply could result in injury or death.

A. BREAKER PROPER POSITIONING

Figure 57

DC03M066

DC03M065

Figure 56

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

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.

D. SURFACE ROCK DEMOLITION

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.

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.

4-30

Figure 58

DC03M067

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS 4. As material breaks, stop breaker quickly to prevent idle strokes.

E. EXCAVATING AND TRENCHING

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.

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

Figure 59

DC03M068

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.

F. RULES TO REMEMBER 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.

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CHAPTER 4 - OPERATING INSTRUCTIONS D. CYLINDERS

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

WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.

A. USE FOR INTENDED PURPOSE

Figure 62

DC04E063

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 60

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 Never allow passengers on the attachment or machine.

Figure 63

DC04E064

C. PROTECTIVE EQUIPMENT

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.

DC04E062

Figure 61

When operating attachments that produce flying debris, installing protective guards on the machine is highly recommended. Close all windows to protect the operator from flying debris. Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

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CHAPTER 4 - OPERATING INSTRUCTIONS I. DO NOT LIFT

F. HOSE SURGE

Figure 64

DC04E065

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

Figure 65

DC04E066

Figure 67

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 68

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

Figure 66

DC04E067

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS

ANGLE DOZER USING THE ANGLE SWITCH

Figure 70

BC08J118

Turn angle switch (2) ON and the lever operation of RH or LH angle is available. Hold the switch in while angling the blade to the desired position.

DOZER INSPECTION AND MAINTENANCE Each day or at each eight hour shift:

• Tighten all dozer blade cap screws • Check hydraulic hose, control valve and cylinder for oil leakage.

Figure 69

BC08J117

The dozer angle blade feature allows for up and down movement as well as left and right angle positions of the dozer blade.

• Check dozer blade cutting edge for wear and damage

• Check tilt angle frame for wear or damage.

The dozer control lever is located on the right hand console. Moving the lever (1) allows the blade to move up or down. Switch (2) on the top of the lever turns the angle feature on and off. By turning the angle control on, the blade can be angled left or right.

Lever Direction Forward Backward

Variable speed for lowering blade Variable speed for raising blade

Press button and push lever right

Right side of blade will angle back

Press button and push lever left

Left side of blade will angle back

Center

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CHAPTER 4 - OPERATING INSTRUCTIONS LUBRICATING DOZER BLADES AND CYLINDER PINS Every 50 hours of engine operation, lubricate the dozer blade pins using extreme pressure multi purpose grease (No. 2 EP grease). Lubricate all grease points until grease overflows from fittings.

LUBRICATION 1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface.

Lower blade and attachments to the ground.

Turn the engine off.

2. Wipe all grease fittings clean. Replace nipples if damaged.

3. Apply grease on nipples with grease gun.

4. Apply grease until grease flows from fittings.

Wipe area clean of excess grease.

Operating machine in water If operating the machine in water, lubricate the m a c h i n e b e fo r e s t a r t i n g o p e ra t i o n a n d a f t e r operation.

Machine Storage If the machine has been out of use for one month or more, lubricate prior to starting operations.

Figure 71

BC08J119

1.

2.

3.

4.

DOZER CYLINDER DOZER FOOT PIN ANGLE CYLINDER BLADE AND FRAME CONNECTION

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CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE DIMENSIONS WITH DOZER ANGLE BLADE

Figure 72

BS08J522

Overall length with angle dozer ...................................................................................................5100 mm (16 ft 9 in) Overall width ..................................................................................................................................1500 mm (5 ft 1 in) Dozer blade height ...........................................................................................................................345 mm (13.5 in) Operating angle ............................................................................................................................................25° X 25° Dozer raise range .............................................................................................................................615 mm (24.2 in) Dozer lower range ............................................................................................................................485 mm (19.1 in)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 USE OF BIO-DEGRADABLE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS SWING BEARING

REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES 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 6 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)

Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . As required (1 place - swing 90° x 4) NOTE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

TRACK TENSION ADJUSTMENT Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . . . As required (2 places) NOTE: See TRACK TENSION in Chapter 6 for proper procedures in injecting grease.

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

NOTE: 1. See HYDRAULIC OIL LEVEL in Chapter 6 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

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

Capacity:

UPPER ROLLERS

Radiator . . . . . . . . . . . . . . . . . . . . 1.6 liters (0.42 gal)

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

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

NOTE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

FUEL TANK OPERATING LEVER JOINT Type of Oil . . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . As required in each joint

Type of Fuel . . . . . . . . . . . . . Diesel Fuel grade No. 2 Capacity . . . . . . . . Fuel Tank - 38 liters (10 gal) NOTE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

NOTE: See CONTROL LEVER JOINT LUBRICATION in chapter 6 for proper lubrications.

UPPER ATTACHMENT PINS Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . . . . . . . . . . .As required in each pin NOTE: See ATTACHMENT LUBRICATION Chapter 6 for proper lubrications.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REQUIRED FILTERS NOTE: Refer to the Parts Manual for the correct part numbers to order.

HYDRAULIC

• Return Filter Element for Standard Machine • Return Filter Element for Breaker and N&B • Tank Suction Strainer • Tank Breather Filler Element • Pilot Line Filter

Engine

• Engine Oil Filter • Air Cleaner Inner Element • Air Cleaner Outer Element FUEL

• Engine Fuel Filter OPERATOR CAB

• A/C Fresh Air Filter • A/C Recirculate Air Filter NOTE: Refer to Chapter 6 - MAINTENANCE AND ADJUSTMENT in this Manual for the Locations and proper procedures in replacing filters.

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CHAPTER 5 - 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

*Note: 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

ANTIFREEZE (LLC) -34°C (-29.2°F)

FLUID ENGINE COOLANT (50% MIXTURE)

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-3 6-3 6-4 6-4 6-4 6-4 6-4 6-4 6-5 6-5 6-5

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10 6-10 6-11 6-12 6-12 6-13 6-13 6-14 6-15 6-15 6-16

50 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-17 6-17 6-17 6-18 6-19 6-23 6-24

250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-25 6-25 6-26 6-26 6-27 6-27 6-27 6-28 6-28 6-29

500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Clean and Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Issued 11-08

Bur

S2PW00035ZE01 NA

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Replacing the Inner Element (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Replacing Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Repairing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Check Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Check Starter and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 1500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Check Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Hydraulic Suction Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Pilot Valve and Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Upper and Lower Roller - Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Upper Roller Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Change Swing Gear Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Intake and Exhaust Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Replacing the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Replacing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Rubber Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Rubber Track Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Rubber Track Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Releasing Lock on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Removing Gears from Travel Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Lowering Bucket Attachment on a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57

6-2

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION GENERAL SAFETY

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 injury or death.

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 injury or death.

DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters, and other hazardous waste properly.

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

KEEP MACHINE CLEAN

DC04B669

Figure 1

DC04B668

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.

NOTE: 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.

3. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition.

S2PW00035ZE01NA

Issued 11-08

Bur

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.

6-3

CHAPTER 6 - 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

IMPORTANT: 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.

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.

CLEANING PARTS 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 injury or death.

6-4

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - 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.

WARNING: Disconnect batteries before welding on this machine. Connect welder ground cable within 1 m (39 in.) of area to be welded. Failure to comply could result in machine damage, injury or death.

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 or components before allowing any operation of the machine.

IMPORTANT: 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.

FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

NOTE: 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 your 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.

S2PW00035ZE01NA

Issued 11-08

Bur

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before performing any work on the hydraulic system, there should be no pressure in any of the circuits.

1 2

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool until oils and fluids are warm, not hot. Release hydraulic tank pressure before working with any hydraulic components. Failure to comply could result in machine damage, injury or death.

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).

1

BS07M861

2

Figure 7

2. Turn the ignition switch key to the ON position.

Pilot control switch must be on.

6. Open the door to the hydraulic tank (1) and secure in place with strut.

7. Press the rubber cap (2) on the top of the hydraulic tank 5 to 7 times.

WARNING: When replacing any hose or seal, make sure the attachment is well secured to avoid sudden movement. Slowly remove bolts to release any remaining hydraulic pressure during disassembly.

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

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. If machine is equipped with a swing pedal, operate the pedal both left and right.

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 with this warning could result in injury or death.

WARNING: Before carrying out any service work on the hydraulic system, it is necessary to allow the system to cool (the temperature should not be more than 40°C (104° F).

Failure to comply with this warning could result in injury or death.

6-6

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - 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 intervals are based on 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: Wear safety glasses whenever striking metal objects with a hammer. Failure to comply could result in injury or death.

• When new parts are used, the mating surfaces will seat more uniformly and the bolt 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.

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 50 hours for a standard machine working in an average duty cycle. 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. To avoid this, 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.

• When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mounting hole if needed. Torque bolts according to specifications.

S2PW00035ZE01NA

Issued 11-08

Bur

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

Every 500 hours

Every 1000 hours

Every 1500 hours

6-8

6-16

Fan and air conditioning drive belt

6-28

Air filter

6-31

Fuel tank filter

AR

8-11

Bolt and nut torque

AR

AR AR

6-19

Rubber track (if equipped)

6-10

Grease bucket, boom, arm cylinder, dozer

6-11

Engine oil level

8

6-12

Coolant level

8

6-12

Radiator

8

6-12

Electrical connections

8

6-13

Water separator

8

6-13

Fuel tank level

8

6-14

Hydraulic reservoir level

8

6-15

Hydraulic lines

8

AR

AR Run-in

8

6-16

Fan/alternator belt tension

8

6-15

Rubber crawler belt

8

6-17

Attachment

50

4-35

Angle dozer blade

50

6-17

Drain fuel tank sediment

6-18

Engine oil and filter

Run-in

6-19

Rubber track

Run-in

6-23

Fan/alternator belt tension

7-4

Battery check

6-24

Hydraulic return filter

6-25

Engine oil and filter

6-26

Fan/alternator belt tension

6-27

Swing reduction gear

6-27

Boom, arm cylinder, dozer

6-28

Engine air cleaner element

6-29

Hydraulic return filter (Breaker attachment)

Drain

Lubricate

Replace

Check

Page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

50 50 50 50 50 Run-in

50 250 250

Run-in

250 250 250 250

8-11

Bolt and nut torque

6-30

Fuel water separator

250

6-31

Fuel filter

500

6-32

Engine air cleaner elements

500

6-33

Travel reduction gear

6-34

Radiator coolant

6-36

Hydraulic return filters

RM

Valve clearances

1000

RM

Starter/generator

1000

RM

Injector Timing

1500

500

Run-in

500 1000 1000

Issued 11-08

Bur

S2PW00035ZE01 NA

Every 2000 hours

Every 5000 hours

6-38

Hydraulic suction strainer

2000

6-40

Pilot valve

2000

6-41

Solenoid in-line filter

2000

Drain

Lubricate

Replace

Check

Page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-43

Travel reduction gears

2000

6-44

Idler oil change

2000

RM

Swing gear grease

RM

Intake and exhaust

6-47

Hydraulic oil

2000 2000 5000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTE: RM = See Repair Manual or contact Authorized Dealer

S2PW00035ZE01NA

Issued 11-08

Bur

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

DOZER PIN GREASE POINTS WARNING: Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

3 1 2 3

GREASE MACHINE AND ATTACHMENTS

1

2

Figure 11

BS07N035

1. DOZER CYLINDER ROD PIN (1) 2. DOZER CYLINDER FOOT PIN (1) 3. DOZER FOOT PIN (2)

B O O M , A R M , A N D AT TAC H M E N T G R E A S E POINTS Figure 9

BS07M861

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.

7

4

8 10

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.

11 6 5 9

Figure 12

BS07N033

3

4

1 2

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)

Figure 10

BS07N028

1.

2.

3.

4.

BUCKET CYLINDER ROD PIN IDLER LINK/ARM CONNECTING PIN BUCKET LINK PIN ARM/BUCKET CONNECTING PIN

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.

6-10

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL LEVEL

12

5

14

2 13 Figure 13

BS07N634

(5) BOOM CYLINDER FOOT PIN (12) SWING CYLINDER FOOT PIN (13) SWING CYLINDER ROD PIN

1

(14) SWING BRACKET/FRAME CONNECTING PIN

IMPORTANT: Dispose of all waste in accordance with environmental regulations.

WARNING: The machine and attachment should not be moved when greasing.

Personal injury may result. Move attachment to a different position, stop the engine and lubricate the attachment again. Repeat this procedure until the front attachment is completely lubricated.

Figure 14

BS07N039

1. OIL DIPSTICK 2. FILLER CAP

1. Check oil level every day or each 8 hour shift. 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.

NOTE: After adding oil, check oil level again, replace filler cap and dipstick and close engine cover.

S2PW00035ZE01NA

Issued 11-08

Bur

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE ELECTRICAL

ENGINE COOLANT LEVEL

1

Figure 15

BS07M477

1. ENGINE COOLANT RESERVOIR

Figure 17

DC04C292

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.

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

2 3

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.

Repair or replace faulty components immediately.

1 4

Figure 16

BS07M872

1.

2.

3.

4.

RESERVOIR CAP RADIATOR CAP RADIATOR RESERVOIR

4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then refill reservoir to proper level. Inspect hoses and connections for leaks.

WARNING: Never remove radiator cap when engine is hot. Allow engine to cool before removing radiator cap.

6-12

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL LEVEL

DRAIN WATER SEPARATOR

1

2 Figure 18

BS07M675

1. FUEL LEVEL GAUGE

1. Turn the ignition switch key ON 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 (if equipped) for fueling. Refill fuel tank to full mark to reduce air volume (condensation). Failure to do so could create problems such as r usting and fuel freezing, as well as other associated problems.

S2PW00035ZE01NA

Issued 11-08

Bur

BS07N030

Figure 19

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.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL WARNING: Gasses from hydraulic tank may be hot. Wear personal safety equipment.

Failure to comply could result in injury or death.

1

1

2

2 3

Figure 20

BS07M861

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. Check the sight glass located on the side of the hydraulic tank. The oil level should be between H and L. NOTE: 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

4 Figure 22

BS07N635

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.

2

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.

Refer to Torque Specification Table in the Specifications Section.

F. Check all hydraulic controls for proper functionality before operating the machine.

Figure 21

BS07871

1. COVER 2. AIR RELEASE BUTTON

A. Release all pressure from hydraulic tank. (See releasing hydraulic pressure for additional infor mation.)Depress air release button several times to release hydraulic tank pressure.

6-14

WARNING: Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

IMPORTANT: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEAKS

DC04C300

Figure 23

DC04C287

WARNING: Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

Failure to comply could result in injury or death.

Figure 24

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.

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: Release all hydraulic pressure before performing any work on the hydraulic system. Hydraulic fluids are under extreme pressure. Failure to comply could result in injury or death.

S2PW00035ZE01NA

Issued 11-08

Bur

6-15

CHAPTER 6 - 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 25

BS07N031

1. ATTACHING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

WARNING: Rotating parts can cause extreme injury. Stop engine before servicing.

Keep away from fan and belt when engine is running. Failure to comply could result in injury or death.

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.

A belt is considered used when it has been on a running engine for 5 minutes or more.

To check tension apply a force of 98 N (22 lb) to the center of the belt and measure the deflection.

6-16

New belt tension

Used belt tension

8 - 12 mm (8/16 - 7/16 in)

10-14 mm (3/8 - 1/2 in)

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE: DRAIN FUEL TANK SEDIMENT

ATTACHMENT LUBRICATION

2 3

4

1 2

Figure 26

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. 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. 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.

IMPORTANT: Dispose of all waste in accordance with environmental regulations.

WARNING: The machine and attachment should not be moved when greasing.

Personal injury may result. Move attachment to a different position, stop the engine and lubricate the attachment again. Repeat this procedure until the front attachment is completely lubricated.

ANGLE BLADE DOZER LUBRICATION T h e a n g l e bl a d e d o ze r ( o p t i o n a l ) s h o u l d b e lubricated every 50 hours. See Optional Equipment i n C h a p t e r 4 o f t h i s m a nu a l fo r a n g l e bl a d e information and specifications regarding lubrication.

S2PW00035ZE01NA

Issued 11-08

Bur

1

Figure 27

BS07N128

1. FUEL TANK 2. DRAIN PLUG

WARNING: Do not smoke or allow any open flame near by when draining fuel. Stop engine. Thoroughly clean up any spilled fuel.

Failure to comply could result in injury or death.

Draining water and sediment is most effectively performed in the morning. Turn the upper structure of the machine so the drain plug (2) is midway between the crawler belts.

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. 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.

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. After draining oil, remove drain hose, and tighten drain cap (1) securely. Remove any spilled oil.

ENGINE OIL LEVEL

3

4

2

1

Figure 29

BD07N032

1. OIL FILTER 2. FILTER WRENCH

1

7. Use the filter wrench provided with the machine, and turn counter clockwise to remove the oil filter.

2

3

5

Figure 28

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. 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. Raise the engine cover. Remove the dipstick to allow oil to run more freely.

3. Remove bolts and engine belly pan covers 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.

5. Remove engine oil drain plug, and let the engine oil drain out completely.

6-18

Figure 30

BD07N040

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. Do not use filter wrench to tighten.

NOTE: Check the waste oil. If there are metal flakes in the oil, contact your dealer. DO NOT reuse the oil filter.

9. Clean oil drain plug and install it. Tighten securely.

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.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACKS AND COMPONENTS Check rubber track tension every 50 hours.

1

Figure 33

BS07N042

Figure 31

DC04C300

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.

Figure 32

BS07N041

2. Keep all unauthorized personnel clear of the area. Move the rubber crawler belt so the joining ends (M mark) comes to the upper center position.

Figure 34

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 70 - 80 mm (2.76 - 3.15 in.)

Steel belt: 115 - 130 mm (4.53 - 5.12 in.)

If track tension is not within the specifications, make adjustments to the track.

NOTE: If working on firm, hard ground, more track tension is recommended. If working on loose gravel or stone, lower track tension is recommended.

S2PW00035ZE01NA

Issued 11-08

Bur

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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 injury or death.

2

1

Figure 35

DC04C307

Figure 37

BS07N045

1.

2.

A. B.

GREASE FITTING GREASE CYLINDER GREASE FILL PRESSURE

INCREASING TRACK TENSION

1

BS07N044

Figure 36

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.

6-20

Figure 38

BS07N046

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 reached.

IMPORTANT: If the adjustment to the track cannot be maintained, the grease cylinder may need repair.

Contact your authorized dealer.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REMOVING RUBBER CRAWLER BELT

ADJUSTING FOR LESS TENSION

1 1

Figure 39

BS07N046

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.

1

Figure 41

BS07N042

1. Keep all unauthorized personnel clear of the area. 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 Figure 40

BS07N047

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.

S2PW00035ZE01NA

Issued 11-08

Bur

BS07N046

Figure 42

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).

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Replacing the Rubber Crawler Belt

1 1 BS07N049

Figure 43

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.

Figure 44

BS07N042

1. Keep all unauthorized personnel clear of the area. 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).

1 Figure 45

BS07N049

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 off the engine.

4. Slide the rubber crawler belt over the steel pipes to install it.

6-22

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECT FAN 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 3

Figure 46

BS07N050

1.

2.

3.

4.

5.

6.

7.

Figure 47

BS07N031

LOWER ROLLER RUBBER CRAWLER BELT SPROCKET IDLER LUG METAL CORE TRAVEL MOTOR

WARNING: Rotating parts can cause extreme injury. Stop engine before servicing.

Keep away from fan and belt when engine is running. Failure to comply could result in injury or death.

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.

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.

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. 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)

NOTE: A used belt refers to a belt that has been run 5 minutes or more.

S2PW00035ZE01NA

Issued 11-08

Bur

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

1 2 3 6 1

7

2

4 5

BS07M861

8

Figure 48

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. 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. 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 injury or death.

3. Open the cover to the hydraulic tank and secure with the strut.

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

Figure 49

BS07N636

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.

6. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

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: 23.5±2 N•m {17±1.4 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.

6-24

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE 6. After draining oil, remove drain hose, and tighten drain cap (1) securely. Remove any spilled oil.

ENGINE OIL LEVEL

3

4 2

1

Figure 51

BD07N032

1. OIL FILTER 2. FILTER WRENCH

1 7. Use the filter wrench provided with the machine, and turn counter clockwise to remove the oil filter.

2 3

5

Figure 50

BS07N029

1. DRAIN CAP 2. COVER 3. DIPSTICK

4. OIL FILL CAP 5. DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a new machine, then at every 250 hours thereafter.

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. Raise the engine cover. Remove the dipstick to allow oil to run more freely.

3. Remove bolts and engine belly pan covers 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.

5. Remove engine oil drain plug and let the engine oil drain out completely.

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 secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the filter head.

NOTE: Do not reuse the oil filter.

9. Clean oil drain plug and install it. Tighten securely.

10. Check drained oil for any metal shavings, flakes, or particles. Contact your dealer if any debris is found.

11. Fill with the specified amount of oil through filler port (4) and install oil filler cap.

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.

S2PW00035ZE01NA

Issued 11-08

Bur

6-25

CHAPTER 6 - 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

1. ATTACHING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

BOLT AND NUT TORQUE When the hour meter registers 250 hours, check all machine bolts and nuts for proper torque. See charts in Chapter 8 - Specifications.

WARNING: Rotating parts can cause extreme injury. Stop engine before servicing.

Keep away from fan and belt when engine is running. Failure to comply could result in injury or death.

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.

6-26

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DOZER PIN GREASE POINTS

BOOM, ARM, AND ATTACHMENT GREASE POINTS

3 7

4

1

8

2

10

3

11 6 5 9 Figure 54

BS07N035

1. DOZER CYLINDER ROD PIN (1) 2. DOZER CYLINDER FOOT PIN (1) 3. DOZER FOOT PIN (2)

Figure 56

BS07N033

4.

5.

6.

7.

8.

9.

10.

11.

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. 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.

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

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

12

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

14

IMPORTANT: Dispose of all waste in accordance with environmental regulations.

GREASING THE SWING BEARING

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. 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.

Figure 55

BS07N130

Grease the swing bearing by adding grease to each fitting (4 locations) until grease comes out fittings.

WARNING: Do not swing the machine while greasing the swing bearing.

S2PW00035ZE01NA

Issued 11-08

Bur

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.

6-27

CHAPTER 6 - 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

BS07N637

6. 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.

7. Set outer element (1) in the housing.

8. Install the cover on two clamp (2) positions, directing the mark "TOP" on the cover to the inlet side

1 3

Figure 58 Figure 60

BS07N664

IMPORTANT: When cleaning outer element, do not remove inner element to prevent dust from entering the air intake.

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.

9. 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)

2

2. Release the two clamps (2) from the air cleaner cover.

1 3

3. Remove the air cleaner outer element (1) from the housing.

4. Wipe the inside of air cleaner housing clean with a dry, lint free cloth.

Figure 61

BS07N637

10. The inner element is an optional part. To replace, remove the inner element (3).

11. Install new inner element (3) and outer element (1). Replace cover. Make certain the O-ring seal is correctly positioned.

BS07N132

Figure 59

5. 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.

6-28

IMPORTANT: For machines equipped with double elements, the inner element must be replaced together with the outer element. Do not clean inner element. Replace only with a new element.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER (BREAKER USE)

1 2 3 1

2

6 8

7 4 5

Figure 62

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 injury or death.

2. Remove all pressure from the hydraulic system.

3. Open the cover to the hydraulic tank and secure with the strut.

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

BS07871

Figure 63

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.

6. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

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: 23.5±2 N•m {17±1.4 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 a level position to check the oil level. Stop the engine and check the oil level, adding oil if necessary.

13. Close the cover on the hydraulic oil tank and lock.

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6-29

CHAPTER 6 - 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

1.

2.

3.

4.

5.

6.

7.

8.

9.

A. B. C. D.

2

5 8 6 3 BS07N135

Figure 65

BS07N136

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 64

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. 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. 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.

Figure 66

BS07N137

6. 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. Place the O-r ing 7 on the case (8), reassemble, then tighten.

10. Push the handle (2) downward to set at OPEN. 11. After draining water and cleaning, bleed air from the fuel system.

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S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING FUEL FILTER The fuel filter should be replaced at 500 hours. The fuel filter should not be reused. It must be replaced.

1

BD07N040

Figure 67

BS07N398

WARNING: Engine and components stay hot after operating. Allow machine to cool before servicing. Failure to comply could result in injury or death.

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.

Figure 68

5. 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.

6. Start and run the engine at idle for 5 minutes to check for leaks.

7. Close the engine door and install the cover located under the engine.

IMPORTANT: Dispose of all hazardous waste properly according to local environmental regulations.

2. Allow the machine to cool. Open the engine door and remove the lower cover.

3. Place the filter wrench on the filter cartridge (1), and remove the filter.

4. Wipe off any dirt on the seal face of filter base to avoid contamination.

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CHAPTER 6 - 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

1 3

Figure 71

BS07N664

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.

REPLACING THE INNER ELEMENT (IF EQUIPPED) BS07N637

Figure 69

IMPORTANT: When cleaning outer element, do not remove inner element to prevent dust from entering the air intake.

2

1 3

1. Release the two clamps (2) from the air cleaner cover. Remove the air cleaner outer element (1) from the housing.

2. Clean the inside of air cleaner housing.

Figure 72

BS07N131

8. The inner element is an optional part. To replace, remove the inner element (3).

9. Install new inner element (3) and outer element (1). Replace cover. Make certain the O-ring seal is correctly positioned.

BS07N132

Figure 70

3. 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.

IMPORTANT: For machines equipped with double elements, the inner element must be replaced together with the outer element. Do not clean inner element. Replace only with a new element.

4. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing damage. Replace with a new element every 500 hours or anytime damage is evident.

5. Set outer element (1) in the housing.

6. Install the cover on two clamp (2) positions, directing the mark "TOP" on the cover to the inlet side 6-32

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S2PW00035ZE01 NA

CHAPTER 6 - 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

BS07N670

1 Figure 73

BS07N668

1. DRAIN PORT 2. FILL PORT

Figure 75

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 injury or death.

Figure 74

BS07N669

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.

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6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE REPLACING ENGINE COOLANT WARNING: Use extreme caution when removing the radiator cap. The coolant is under high pressure when hot. Never remove the radiator cap when system is hot. Allow sufficient time for machine to cool down.

Failure to comply could result in injury or death.

The engine coolant should be replaced every 1000 hours. Check the coolant level every 8 hours as part of daily maintenance.

11

6. To drain radiator, place a rag or paper towel on the radiator cap and slowly remove it to release the pressure.

7. Drain the radiator with drain hose.

8. After draining, install the drain plug (2). Fill the cooling system with system cleaner according to cleaner container instructions.

5 3 4

2 UPW00400091J01

1. RADIATOR HOSE CLAMP 2. RADIATOR CAP

Figure 77

BS07N142

Figure 76 3. RADIATOR HOSE

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. Open the engine cover and secure it with strut.

3. Check the hoses for leakage due to loose clamps, or cracked and worn hoses.

4. Tighten any loose clamps.

5. Replace any hoses that are damaged. See replacing radiator hoses for further information.

9. 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 t e m p e r a t u r e . O p e r a t e t h e e n g i n e fo r approximately 10 minutes.

10. 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.

11. Install the radiator drain plug (2). Fill the radiator w i t h a m i x o f 5 0 % c l e a n wa t e r a n d 5 0 % COOLANT. Start and run the engine to fully release air from the cooling system.

12. 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.

13. Check the system for leaks and repair. Close the engine door.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPAIRING HOSES

CHECK VALVE CLEARANCES

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. Tighten clamps securely.

Check and adjust the engine valve clearance every 1000 hours of engine operation. Contact your a u t h o r ize d D e a le r ’s S e r v i c e D e p a r t m e n t fo r assistance.

CHECK STARTER AND GENERATOR Have the starter and generator checked every 1000 hours of engine operation. Contact your authorized Dealer’s Service Department 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.

NOTE: 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.

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6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

1 2 3 1

2

7

6

4

8

5 BS07M861

Figure 78

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 injury or death.

2. Release all pressure from the hydraulic system.

3. Open the cover to the hydraulic tank and secure with the strut.

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

Figure 79

BS07871

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.

6. Remove bolt (1), spring washer (2) and cover (3) from the upper surface of the tank.

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: 23.5±2 N•m {17±1.4 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 level position to check the oil level. Stop the engine and check the oil level, adding oil, if necessary.

13. Close the cover on the hydraulic oil tank and lock.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1500 HOUR MAINTENANCE CHECK INJECTION TIMING Have the injection timing checked every 1500 hours of engine operation. Contact your authorized Dealer’s Service Department for assistance

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6-37

CHAPTER 6 - 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 80

BS07M861

WARNING: Do not perform any service work on a machine that is hot. Allow the machine and components to cool before performing any work on fluids and oils. Failure to comply could result in injury or death.

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.

Figure 82

BS07N665

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.

WARNING: Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in injury or death.

7

2. Open the cover to the hydraulic tank and secure with the strut.

1 Figure 83

BS07N667

6. Remove strainer (5) and clean with light oil or by washing. If damaged, replace.

7. Check O-rings (6) and (7) for wear or damage. If damaged, replace O-rings.

BS07N146

Figure 81

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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2 3 4 5

6

Figure 84

BS07N667

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.

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6-39

CHAPTER 6 - 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 Figure 86

BS07N147

3. Loosen 2 bolts (3) on the operating box to remove the cover.

BS07M861

Figure 85

WARNING: Do not perform any service work on a machine that is hot. Allow the machine and components to cool before performing any work on fluids and oils. Failure to comply could result in injury or death.

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.

4. Disconnect the hose (1) connected to P port on the pilot valve (4), then remove connector with filter (2).

5. After removal, put a plug into the bore to prevent entry of foreign matter.

6. Wear face protection, wash the filter with cleaning solvent. Use compressed air to remove any material.

WARNING: Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in injury or death.

2. Release all pressure to the hydraulic system.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

7a

7b 7c

7d 7e

8 7

BS07N149

Figure 88

7a.CASE 7b.STRAINER

6

7c.LABEL 7d.O-RING 7e.FITTING Figure 87

BS07N148

7. Check the O-ring (5) for damage, and replace if necessary.

8. After cleaning, install 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.

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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).

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

12 12 99 11

12

P

13

10 9 Figure 90

BS07N150

18. Dust tends to accumulate on the inside elbow (9) (cur ved area). Clean par ts to avoid contamination (projected portion).

19. Check the O-ring (12) for damage, and replace, if damaged.

UPW00400107J01

Figure 89

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.

6-42

20. After cleaning, install to the original position in the reverse order of disassembly. Refer to torque charts for tightening hose (11).

21. Reinstall the floor mat and floor plate.

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S2PW00035ZE01 NA

CHAPTER 6 - 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

BS07N670

1 Figure 91

BS07N668

1. DRAIN PORT 2. FILL PORT

Figure 93

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 injury or death.

Figure 92

BS07N669

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.

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6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS UPPER AND LOWER ROLLER - IDLER OIL CHANGE

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

2. Loosen the rubber crawler shoe. Loosen the cap screws (1) of the lower roller about one turn.

3. Start up the engine and lift up the side of the machine with the boom and arm.

1

6

4

5

3

4. Support the machine with a safety support (5).

Stop the engine.

2

Figure 94

BS07N259

1.

2.

3.

4.

5.

6.

TRAVEL MOTOR SPROCKET LOWER ROLLER CRAWLER BELT UPPER ROLLER IDLER

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: Do not perform any service work on a machine that is hot. Allow the machine and components to cool before performing any work on fluids and oils. Failure to comply could result in injury or death.

WARNING: Grease in track tensioning mechanism is under extreme pressure and can penetrate skin. Keep face and body away from grease fitting area. Do not loosen grease fitting more than one turn. Failure to comply could result in injury or death.

3

4

1

1

2

2

Figure 96

BS07N261

5. Remove the capscrews (1) with washers (2) which install the lower roller to the crawler frame at two positions. Remove the lower roller (3).

6. Remove the feeding port plug (4) with allen wrench, and discharge the old engine oil.

7. Fill with the specified volume (35 cc or 2.1 cu.in) of engine oil through the feeding port.

8. Apply sealing (teflon) tape to thread on the plug (4), and securely tighten it. Thoroughly wipe off oil adhered to periphery.

9. Apply Loctite #262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

10. Remove the safety support which supports the machine, then tighten the capscrew (1).

Tightening torque: 208 ± 21 Nm {153 ± 15 lbf•ft} 11. 11.Lift up the machine to adjust the crawler shoe tension referring to Adjusting Track Tension.

5

BS07N260

Figure 95

1.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS IDLER OIL CHANGE

3 2 1 6 5 3

4

Figure 97

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.

1. This is a two person procedure. If you doubt your ability to perfor m this procedure, call your authorized dealer. 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 98

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.

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6-45

CHAPTER 6 - 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 99

BD07N264

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.

The crawler belts must be removed to service the idlers. See procedure for removing and installing crawler belts in this section.

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. Loosen the rubber crawler belt (6).

3. Raise the rubber crawler belt with a hydraulic jack (5).

1

2 3

4

BS07N265

Figure 100

4. Loosen the nuts (2) and the bolts (3) used to assemble the upper roller (1) to the machine and remove it.

5. Remove the oil fill - drain port plug (4) with an Allen wrench, and drain old gear oil.

6. Fill the upper roller with 45 cc {2.7 cu.in} of the specified oil through the fill - drain port.

7. Apply sealing (teflon) tape to the threads on the plug (4) and securely tighten it. Thoroughly wipe off any remaining oil.

8. 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 N•m {48±5 lbf•ft} 6-46

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL

2 3 4

6 6

1

BS07N269

Figure 101

BS07N268

WARNING: Allow machine to cool. Release hydraulic pressure before servicing any hydraulic component. Hydraulic fluid is under extreme pressure and can cause severe injury. Failure to comply could result in injury or death.

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. 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.

3. Remove the right side guard.

4. Open the cover on the hydraulic tank with the engine key, and secure open with the strut.

5. Clean dirt from the filter to avoid contaminating the hydraulic system.

6. Press the valve 5 to 7 times together with the breather cap (8), and bleed the remaining pressure from the hydraulic oil tank.

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7. 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.

8. Tighten the drain plug (1).

Tightening torque 73.5 ± 5 Nm (54.2 ± 3.7 lbf. ft.)

9. Loosen the four bolts (2) and lock washers (3).

Remove cover (4).

10. 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.

11. Fill the hydraulic oil tank with hydraulic oil at filling por t (F) according to machine specifications.

12. Install cover (4) with bolts (2) and lock washers (3).

Tightening torque: 23.5 ± 2 Nm (17 ± 1.4 lbf. ft.)

13. Install the right side guard.

14. 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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL PROCEDURES BUCKET 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 injury or death.

ABRASION OR DAMAGE ON TOOTH POINTS AND SIDE CUTTERS

7

8

6

Check for wear and/or looseness of bucket tooth points. Tooth point life cannot be determined only by the number of operating hours.

2 Figure 104

BS07N272

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).

Figure 102

BS07N269

WARNING: When replacing a bucket tooth or side cutters, securely block the bucket to avoid injury.

Replace the bucket tooth if small holes appear on the tooth point or when the edge lines of the tooth point are worn.

1 2

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).

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.

5 Figure 103

BS07N271

1.

2.

3.

4.

5.

6-48

Figure 105

BS07N273

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.

4

3

2

ADAPTER TOOTH POINT RUBBER LOCK PIN LOCKING PIN ADAPTER NOSE

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE SIDE CUTTERS

REPLACING BUCKET

7 8

6

1 Figure 106

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 BS07N276

9

4

5

Figure 108

2

1

4 3 Figure 107

DC04C362

1.

2.

3.

4.

WARNING: When replacing a bucket tooth or side cutters, securely block the bucket to avoid injury. Do not insert fingers to align pin bores. Align visually or with a tool. Failure to comply could result in injury or death.

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.

NUTS SIDE CUTTER BOLT TOOTH POINT

3. Remove the lock ring (2) and lock pin (3), remove the pins (4) and (5) in order to remove the bucket (6).

IMPORTANT: Keep pins free of sand, dirt or other contaminants when removed. Do not damage the dust seals (9) on both ends of the arm.

S2PW00035ZE01NA

Issued 11-08

Bur

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING BUCKET

9 2

7 8

3 5

9

4 4 5 6

BS07N277

6 Figure 109

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.

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.

WARNING: When replacing a bucket tooth or side cutters, securely block the bucket to avoid injury. Do not insert fingers to align pin bores. Align visually or with a tool. Failure to comply could result in injury or death.

6-50

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - 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 plates, 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 112

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 110

BS07N292

TRACK COMPARISON

BS07N288

Figure 113

DO NOT operate on oil contaminated surfaces. Oil will damage the rubber crawler belts.

Figure 111

BS07N286

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 114

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.

S2PW00035ZE01NA

Issued 11-08

Bur

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BS07N290

Figure 115

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

Figure 119

BS07N296

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 117

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.

6-52

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).

Figure 116

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

Figure 118

BS07N295

Figure 120

BS07N297

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.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK INSPECTION

1

5

2 3 4

Figure 121

BS07N298

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 123

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

Figure 122

BS07N299

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 124

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.

S2PW00035ZE01NA

Issued 11-08

Bur

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK METAL CORE

STEEL CORD DAMAGE

1 2 4

5 3 Figure 125

BS07N282

If the steel cords (B) are over one half broken in one row, replace the crawler belt.

CRACKED CRAWL ER BELT

Figure 127

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.

IMPORTANT: 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 126

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.

Figure 128

BS07N285

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.

6-54

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOVING A DISABLED MACHINE WARNING: Block front and rear tracks to prevent movement. Support the attachment securely. Failure to comply could result in injury or death.

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 injury or death.

WARNING: The following procedures should only be performed by an experienced service technician familiar with this machine.

Failure to comply could result in injury or death.

RELEASING LOCK ON TRAVEL MOTOR

Figure 131

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.

Plug Opposing flat - 6 mm (0.24).

Figure 129

BS07N300

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.

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.

5

2 1

REMOVING GEARS FROM TRAVEL REDUCTION UNIT

3

1

6

5 6 2 4 14 3

BXPX00900004E01

Figure 132

4. Insert a flat blade screwdriver into gap between the body (1) and snap ring (3), and remove the snap ring.

5. Remove the cover (2).

6. Use care when removing cover, as ball (5) will fall. Clean ball if contaminated.

Figure 130

BS07N674

1. Place blocks at front and rear of tracks to prevent machine from moving when brakes are released.

2. Lower attachment to the ground.

S2PW00035ZE01NA

Issued 11-08

Bur

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ASSEMBLING THE TRAVEL MOTOR

1

2 5

5 3

6 6

2 4 14 3 Figure 133

BS07N674

NOTE: The crawler belt is now free to rotate.

7. Install drain plug (4) and refill unit with the previously drained oil. Make certain there are no contaminants in the drained oil prior to refilling.

Tow the machine to desired location for further service.

IMPORTANT: Avoid spills. Dispose of all hazardous waste in accordance with government laws and regulations.

Figure 135

XPX00900005E01

2. To prevent the ball (5) from falling from sun gear (6), coat the ball (5) with a light coat of grease.

3. Lubricate the O-ring (14) with grease and fit into groove of cover (2). Install cover (2).

4. Use care not to damage O-ring.

5. Replace the O-ring at drain plug (4) with a new one. Install the drain plug (4).

6. Add the specified gear oil through the oil fill plug until oil starts flowing out of the oil level plug.

ASSEMBLING THE TRAVEL MOTOR

1

5 6 2 4 14 3 BS07N674

Figure 134

1. After all repairs are compete, assemble the travel motor units.

6-56

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOWERING BUCKET ATTACHMENT ON A DISABLED MACHINE

BS07N384

Figure 136

BS07N380

WARNING: Keep all unauthorized personnel away from the bucket/attachment and excavator boom.

The weight of the bucket or attachment may cause unexpected m ovem ent of bucket/attachment, arm and boom during the procedure.

B l o ck th e bu cke t /a tt a ch m e n t t o avo i d u n ex p e c t e d m o ve m e n t . R e l e a s e t h e pressure in the hydraulic lines slowly until pressure is completely released.

Control the bucket/attachment movement by slowly removing the lock.

Figure 137

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 IMPORTANT: 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.

IMPORTANT: Clean up all spilled oil. Dispose of any hazardous waste in compliance with local environmental regulations.

Do not enter the area under bucket/attachment while lowering or allow others to do so. Failure to comply could result in injury or death.

The following procedure is to be used only in an emergency if the machine is disabled. Proceed with extreme caution. Keep all unauthorized personnel 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.

S2PW00035ZE01NA

Issued 11-08

Bur

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOWERING THE ARM

Figure 139

BS07N386 BS07N385

Figure 138

WARNING: Make certain the area around the machine is clear of people and objects before attempting these procedures. Failure to comply could result in injury or death.

Gradually loosen the hose of rod side connected to the arm (R).

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.

6-58

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fusible Starter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Issued 11-08

Bur

S2PW00035ZE01 NA

7-3 7-3 7-3 7-4 7-5 7-5 7-6

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 7 - ELECTRICAL ELECTRICAL COMPONENTS

FUSIBLE STARTER LINK .

FUSES .

1

Figure 1

BS07N387

WARNING: Make certain the starter switch is in the OFF position before replacing fuses.

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.

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.

S2PW00035ZE01 NA

Issued 11-08

Bur

BS07N388

Figure 2

If the electrical power does not come on when the starter key switch is in the on position, the fusible link may be faulty. 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: 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 severe machine damage.

7-3

CHAPTER 7 - ELECTRICAL BATTERIES

(H)

Perform complete battery service on a new machine after the first 50 hours of engine operation. Check electrolyte (acid) every 50 hours thereafter.

WARNING:

(I)

C

D

D

(J)

E

E

D

3 2

1 B A Figure 4

UPW004007JS1

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 injury or death.

BS07N389

1.

2.

3.

A. B. C. D. E. F. G. H. I. J.

CAP TERMINAL TERMINAL COVER INDICATOR AIR VENT HOLE BLUE RED WHITE UPPER LIMIT LOWER LIMIT GOOD CONDITION REFILLING REQUIRED CHARGING REQUIRED

.

2

1

2

1

Figure 3

F

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.

G

2. The battery is located under the floor plate.

Remove the floor mat and remove the battery cover.

Figure 5

UPW0040008JS1

3. Remove battery cell caps (1) and visually inspect electrolyte (acid) level. Proper level is 10 - 15 mm (0.4 in. - 0.6 in.) 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.

7-4

Issued 11-08

Bur

S2PW00035ZE01NA

CHAPTER 7 - ELECTRICAL ALTERNATOR WARNING: Prevent Battery Explosion: Batteries give hydrogen gases that can explode and cause personal injury.

Keep sparks, open flames and cigarettes away from the batteries.

Keep metallic articles away from batteries.

Keep all ventilation caps tightly secured.

Never check charge by placing metal articles across battery terminals.

Leave battery box open to improve ventilation when charging. Failure to comply could result in severe injury or death.

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.

NOTE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or is difficult to charge.

7. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTE: 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.

NOTE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

S2PW00035ZE01 NA

Issued 11-08

Bur

7-5

CHAPTER 7 - ELECTRICAL WORK LAMPS

.

.

1

4 3

2

5

6

7

Figure 7

BS07N393

Figure 6

BS07N392

A 55W bulb is used for the work lamps.

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 cause machine damage or injury.

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. 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).

NOTE: 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.

7-6

5. Remove the bulb (7) from the socket (5) and replace the bulb with a new one.

6. Assemble the work lamp using the reverse order.

NOTE: If the replacement bulb does not light, check the fuse.

Issued 11-08

Bur

S2PW00035ZE01NA

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Capacities Canopy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 8-3 8-3 8-4 8-4 8-4 8-4 8-5 8-5 8-5 8-6 8-6 8-7 8-8 8-9

LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capscrews and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nuts and 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 11-08

Bur

S2PW00035ZE01 NA

8-11 8-11 8-11 8-12 8-12 8-13 8-13 8-13 8-14 8-15 8-15 8-15 8-15 8-15 8-15 8-15 8-15

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS CANOPY MACHINE DIMENSIONS

Figure 1

BS07N627

CAB MACHINE DIMENSIONS

Figure 2

BS07N628

S2PW00035ZE01 NA

Issued 11-08

Bur

8-3

CHAPTER 8 - 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)

8-4

560/410 (22.0/16.1)

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 8 - 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

S2PW00035ZE01 NA

Issued 11-08

Bur

8-5

CHAPTER 8 - SPECIFICATIONS 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 450 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 1500 kg

2540 lb 1050 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

1430 lb 650 kg

2130 lb 960 kg

910 lb 410 kg

* Rated loads are hydraulic limits rather than tipping load limits

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

10 ft (3.0 m) END - SIDE

12.5 ft (3.8 m) END - SIDE

+7.5 ft (2.3 m)

1410 lb 640 kg

780 lb 350 kg

+5 ft (1.52 m)

2720 lb 1230 kg

1720 lb 780 kg

1880 lb 850 kg

1090 lb 490 kg

1580 lb 710 kg

740 lb 330 kg

+2.5 ft (0.8 m)

3810 lb 1730 kg

1560 lb 700 kg

2340 lb 1060 kg

1010 lb 460 kg

1780 lb 810 kg

710 lb 320 kg

1910 lb 860 kg

680 lb 310 kg

Ground Level

2540 lb 1150 kg

2540 lb 1150 kg

4150 lb 1880 kg

1500 lb 680 kg

2610 lb 1180 kg

970 lb 440 kg

-2.5 ft (-0.8 m)

4170 lb 1890 kg

3070 lb 1390 kg

3960 lb 1790 kg

1500 lb 680 kg

2590 lb 1170 kg

960 lb 430 kg

-5.0 ft (-1.52 m)

5820 lb 2640 kg

3150 lb 1430 kg

3290 lb 1490 kg

1540 lb 700 kg

2130 lb 960 kg

990 lb 440 kg

* Rated loads are hydraulic limits rather than tipping load limits

8-6

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 8 - 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, 551 lb (175 kg) additional 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

+7.5 ft (2.3 m)

12.5 ft (3.8 m) END - SIDE 1410 lb 640 kg

960 lb 430 kg

+5 ft (1.52 m)

2720 lb 1230 kg

2080 lb 940 kg

1880 lb 850 kg

1330 lb 600 kg

1580 lb 710 kg

930 lb 420 kg

+2.5 ft (0.8 m)

3810 lb 1730 kg

1910 lb 860 kg

2340 lb 1060 kg

1250 lb 570 kg

1780 lb 810 kg

890 lb 400 kg

1910 lb 860 kg

870 lb 390 kg

Ground Level

2540 lb 1150 kg

2540 lb 1150 kg

4150 lb 1880 kg

1850 lb 840 kg

2610 lb 1180 kg

1210 lb 540 kg

-2.5 ft (-0.8 m)

4170 lb 1890 kg

3740 lb 1690 kg

3960 lb 1790 kg

1850 lb 840 kg

2590 lb 1170 kg

1200 lb 540 kg

-5.0 ft (-1.52 m)

5820 lb 2640 kg

3820 lb 1730 kg

3290 lb 1490 kg

1900 lb 860 kg

2130 lb 960 kg

1230 lb 550 kg

* Rated loads are hydraulic limits rather than tipping load limits

S2PW00035ZE01 NA

Issued 11-08

Bur

8-7

CHAPTER 8 - 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

8-8

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 (46 in.)

560 mm (46 in.)

Y

Dozer blade - Below

410 mm (40 in.)

410 mm (40 in.)

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 8 - 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 (46 in.)

560 mm (46 in.)

Y

Dozer blade - Below

410 mm (40 in.)

410 mm (40 in.)

S2PW00035ZE01 NA

Issued 11-08

Bur

8-9

CHAPTER 8 - 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: Operator should be fully acquainted with the Operator’s Manual before operating this machine. Rules for safe operation of equipment should be followed at all times. Failure to comply could result in injury or death.

8-10

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.

Issued 11-08

Bur

S2PW00035ZE01 NA

CHAPTER 8 - 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)

S2PW00035ZE01 NA

Issued 11-08

Bur

8-11

CHAPTER 8 - 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

8-12

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)

Issued 11-08

WORKING PRESSURE kgf/cm2 (psi) 350 (4980) 385 (5475) Power Boost

Bur

S2PW00035ZE01 NA

CHAPTER 8 - 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

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

Flare Type 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)

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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.

8-13

CHAPTER 8 - SPECIFICATIONS WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Material (Loose Weight)

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

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S2PW00035ZE01 NA

CHAPTER 8 - SPECIFICATIONS UNITS OF PRESSURE

SOME CONVERSION UNITS UNITS OF WEIGHT

Units of Pressure From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

Bars

UNITS OF LENGTH psi

kg/cm

Units of Length From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

0.06895 2

0.0703

Pa (Pascal)

6894.76

psi

145.04

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

cm3

764554.9

liters

764.555

Liters

UNITS OF FLOW Units of Flow Into

From

Multiply by

Lit/min Gal/min (US liquid)

Liter/min

3.79

Lit/sec

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

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

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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

Issued 11-08

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8-15

CHAPTER 8 - SPECIFICATIONS

NOTES

8-16

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S2PW00035ZE01 NA

CHAPTER 9 - INDEX

Chapter 9

INDEX A Alternator ............................................................. 7-5 Arm Operation ................................................... 4-14 Attachment Lubrication ...................................... 6-17

B Back Filling & Leveling with Front Attachment .. 4-18 Basic Operation of Hydraulic Controls ............... 4-10 Before Operating the Hydraulic Breaker ............ 4-26 Before Operating the Machine ............................. 4-3 Boom Operation ................................................ 4-14 Bucket ................................................................ 6-48 Bucket Operation ............................................... 4-15 Bucket Selection Guide ..................................... 4-20 Burn Prevention ................................................... 2-8

C Cab Dome Light ................................................... 3-5 Cab Door Latch ................................................... 3-3 Cab Machine Dimensions .................................... 8-3 Canopy Machine Dimensions .............................. 8-3 Cleaning Parts ..................................................... 6-4 Cleaning Sand & Soil from Bucket .................... 4-17 Components & Controls Nomenclature ............... 3-9 Connecting Booster Cable ................................... 4-6 Control Decal ....................................................... 4-9 Counter Rotating Machine ................................. 4-12

D Decals ................................................................ 2-10 Disposal of Hazardous Waste ............................. 6-3 Document Pouch ................................................. 3-5

Emergency Engine Shut Down ............................ 4-5 Engine ................................................................. 1-4 Engine Coolant Level ........................................ 6-12 Engine Coolant Tank & Engine Air Cleaner Access Doors ............................................................. 3-7 Engine Electrical ................................................ 6-12 Engine Fluid Leaks ............................................ 6-12 Engine Oil Level ....................................... 6-18, 6-25

F Fire Extinguisher .................................................. 2-8 Fire Prevention .................................................... 2-8 Flare Type Fitting Joints .................................... 8-13 Issued 11-08

G General Information ..............................................1-1 Ground Transportation .......................................4-21 Guidelines for Attachment Lubrication .................6-7 Guidelines to Replace Ground Tools ...................6-7

H Hand Signals ......................................................2-25 Hazardous Chemical Precautions ........................2-8 Hot Surface & Fluids ............................................6-3 How to Handle Life Hammer ................................2-9 Hydraulic Breaker ...............................................4-26 Hydraulic Oil Leaks .................................. 6-15, 6-16 Hydraulic Oil Level .............................................6-14

I Identification Numbers ..........................................1-4 Inspect Waste Oils and Filters ..............................6-4

K Keep Machine Clean ............................................6-3 Key Switch ............................................................3-9

L Lifting Capacities ................................................8-10 Lifting Machine ...................................................4-24 Lifting Machine With Attachment Installed .........4-24 Locking/Unlocking Cab Door ................................3-3

M

E

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Frame Structure ...................................................6-5 Fuel Handling Precautions ...................................2-8 Fuel Level ...........................................................6-13

Bur

Machine Access Compartments and Doors .........3-7 Machine Attachment and Swing .........................4-14 Machine Components ..........................................1-3 Machine Dimensions ............................................8-3 Machine Electrical ..............................................6-17 Machine Operation in Adverse Weather Conditions .

4-19 Machine Storage ................................................4-25 Machine Travel Controls ....................................4-11 Machine Warm Up ................................................4-7 Maintenance Precautions .....................................2-7 Manual Warm Up .................................................4-7 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-11 9-1

CHAPTER 9 - INDEX Metric Fine Thread Standard Tightening Torque Values ......................................................... 8-12 Model, Serial Number, and Year of Manufacture 1-4 Monitor ............................................................... 3-10 Mounting and Dismounting Precautions .............. 2-5

N N2 (Nylon) Tube Fitting Joints ........................... 8-13 Nuts & Sleeves .................................................. 8-13

O Opening and Closing Door Glass ........................ 3-4 Opening and Closing Windshield ........................ 3-4 Operate Boom Smoothly ................................... 4-17 Operating Both Travel Levers Together ............ 4-11 Operating Pattern ................................................ 4-9 Operating Pattern Decal ...................................... 4-9 Operating Precautions ......................................... 2-6 Operating the machine ........................................ 4-3 Operating the Machine in Water ........................ 4-13 Operating the Shovel ......................................... 4-18 Operation at Seashore or Salty Climate ............ 4-19 Operation in Extreme Cold ................................ 4-19 Operation in Extreme Heat ................................ 4-19 Operation in High Altitudes ................................ 4-19 Operation in Humid Climate .............................. 4-20 Operation in Sandy and Dusty Areas ................ 4-19 Operator Cab Nomenclature ............................... 3-9 Operator Precautions .......................................... 2-5 Operator Seat Adjustments ................................. 3-6 Operator’s Compartment Controls and Accessories .

3-8 ORS Joint (O-ring Sealing Type ........................ 8-12

P Personal Safety ................................................... 2-3 Practices to Improve Efficiency ......................... 4-17 Prevent Contamination ........................................ 6-4

R Releasing Hydraulic System Pressure ................ 6-6 Removing and Storing Lower Front Window ....... 3-4 Removing Machine from Storage ...................... 4-25 Removing the Bucket ........................................ 6-54 Required Filters ................................................... 5-4 Required Fluids/Lubricants and Capacities ......... 5-3 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

9-2

S Safety Area ...........................................................2-3 Safety Rules .........................................................2-3 Seals & O-Rings ...................................................6-4 Seat Belt ...............................................................3-6 Seat Belt Precautions ...........................................2-9 Seat Height Adjustment ........................................3-6 Securing Machine to Trailer ...............................4-23 Selection of the Hydraulic Breaker .....................4-26 Specific Precautions to this Machine ....................2-9 Starter Motor ........................................................7-5 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 .......................4-6 Starting Disabled Machine Engine .......................4-6 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable .......4-6 Steps and Handrails ...........................................6-17 Stop Engine ..........................................................6-4 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Operation .................................................4-15

T Torque Specifications .........................................8-11 Track Links .........................................................6-21 Tracks and Components ....................................6-19 Transportation ....................................................4-21 Transporting Precautions .....................................2-8 Travel Safety ......................................................4-13

U Units of Flow .......................................................8-15 Units of Length ...................................................8-15 Units of Power ....................................................8-15 Units of Pressure ................................................8-15 Units of Torque ...................................................8-15 Units of Volume ..................................................8-15 Units of Weight ...................................................8-15 Use Arm in Action ...............................................4-17 Use of Optional Attachment ...............................4-26 Utility Safety .........................................................2-4

W Warm Engine Oil ..................................................6-4 Warming of Hydraulic Oil ......................................4-8 Warming Up of Engine .........................................4-7 Wear Safety Equipment .......................................6-4 Weight of Materials Table ...................................8-14 Issued 11-08

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CHAPTER 9 - INDEX Welding Safety .................................................... 6-5 Work Mode Switch ............................................... 4-8

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9-3

CHAPTER 9 - INDEX

9-4

Issued 11-08

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