Case CX31B Tier 4B (final) Compact Hydraulic Excavator Operator's Manual S2PW00049ZE03 - DOWNLOAD

ORIGINAL INSTRUCTIONS

CX31B Tier 4B (final) Compact Hydraulic Excavator PIN NETN31001 and above

OPERATOR’S MANUAL

Part number S2PW00049ZE03 2nd edition English November 2015 Replaces part number S2PW00049ZE01

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Owner information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Operator's manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Emission control system Warranty – USA only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2 SAFETY INFORMATION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 California proposition 65 warning — California Proposition 65 Warning . . . . . . . . . . . . . . . . . . 2-2 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Operator's seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

3 CONTROLS AND INSTRUMENTS Access to operator's platform Cab access/exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Machine access compartments and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Operator's seat Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Forward controls Controls overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel control levers and pedals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom swing operating pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Proportional hand control (nibbler and breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety lock lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10 3-11 3-13 3-14 3-15 3-17 3-18

Left-hand side controls Radio (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Right-hand side controls Switches (right-hand panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Dozer blade control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Engine throttle lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Air conditioner (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Color multi-display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Electrical equipment Fusible link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

4 OPERATING INSTRUCTIONS Commissioning the unit Daily inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Starting the unit Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection after engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil warm up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-6 4-8 4-9

Stopping the unit Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Parking the unit Parking the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

5 TRANSPORT OPERATIONS Preparing for road transport Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Shipping transport Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6 WORKING OPERATIONS General information Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Optional attachments (Nibbler / breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Angle dozer blade (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Machine operation in water or on soft grounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Getting out of soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Practices to improve efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Lowering the attachment in the event of an engine failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Lowering the bucket in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Lowering the arm in emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Caution while using rubber crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

7 MAINTENANCE General information General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Rotary multi-control valve pattern change (ISO/BHL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Maintenance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Releasing internal pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Biodiesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Maintenance planning Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Every 8 hours Engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator, oil cooler core, and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom, arm, and attachment grease points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioner compressor belt (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioner filters (If equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17 7-19 7-20 7-22 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32

Every 50 hours Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease swing pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil return filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle dozer blade (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-33 7-35 7-36 7-39 7-40 7-42

Every 100 hours Air conditioner condenser (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Every 200 hours Hydraulic oil return filter (Breaker attachment option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Every 250 hours of operation or every 3 months Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dozer blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator, oil cooler core, and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-44 7-46 7-48 7-49 7-50 7-52 7-53 7-54 7-55

Every 500 hours of operation or every 6 months Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioner lines (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioner refrigerant (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-57 7-58 7-59 7-60

Every 1000 hours of operation or annually Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air breather element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil (Breaker attachment option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-62 7-64 7-65 7-67

Every 1500 hours Exhaust Gas Recirculation (EGR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

Every two years Air conditioner filters (If equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 Air conditioner receiver dryer (If equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73

Every 2000 hours Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot line filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idler wheel and rollers change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-74 7-75 7-77 7-80

Every 3000 hours Exhaust Gas Recirculation (EGR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83

Every 5000 hours Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84

As required Work lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield washer reservoir (cab only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber track shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of rubber track shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-86 7-87 7-88 7-92 7-95 7-98 7-99

Fuse and relay locations Fuse and relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100

8 SPECIFICATIONS General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digging data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-2 8-3 8-5 8-6 8-7

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the owner

RAIL14MEX0003FA

1

Read this manual before you start the engine or operate the machine. This manual contains important information about the safe operation and maintenance of your machine. Refer to the index at the back of this manual for locating specific items about your machine. This crawler dozer conforms to current safety regulations.

Consult an authorized dealer or CASE CONSTRUCTION on changes, additions, or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

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

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

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

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1 - GENERAL INFORMATION

RAIL14MEX0003FA

2

The crawler with standard equipment and attachments is intended to be used for general earth moving purposes such as land leveling and above ground material rehandling. DO NOT use this machine for any application or purpose other than those described in this manual, on the safety signs, or other product safety information provided with the machine.

These materials define the machine's intended use.

If the machine is to be used in an application that involves special attachments or equipment, consult your authorized dealer. Consult an authorized dealer on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications may cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

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

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

• All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permits.

This operator’s manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals or manuals in languages other than that of the country of use. Your dealer is at your disposal for any further information, and can provide any after-sales service you may require, as well as genuine Case replacement parts, your guarantee of quality and match.

Case Customer Assistance can be reached at: 1–866–54–CASE6 (1–866–542–2736) or e-mail: casecustomerassistance.na@cnh.com.

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1 - GENERAL INFORMATION

Owner information NOTICE: Modification is prohibited. Personal injury or failures of the machine caused by unspecified modification voids our liability for the machine. Consult an authorized CASE CONSTRUCTION dealer/distributor before you preform modification to the machine.

This manual contains information concerning the adjustment and maintenance of your new equipment. You have purchased a dependable machine, but only by proper care and operation can you expect to receive the performance and long service built into this equipment. Please have all operators read this manual carefully and keep it available for ready reference.

Your authorized dealer will instruct you in the general operation of your new equipment. Your dealer's staff of factory-trained service technicians will be glad to answer any questions that may arise regarding the operation of your machine.

Your authorized dealer carries a complete line of genuine service parts. These parts are manufactured and carefully inspected to insure high quality and accurate fitting of any necessary replacement parts. Be prepared to give your dealer the model and product identification number of your new equipment when ordering parts. Locate these numbers now and record them below. Refer to the 'General Information' section of this manual for the location of the model and product identification numbers of your machine.

PLEASE RECORD THE FOLLOWING INFORMATION

Product Identification Number (PIN) Model Date Purchased

This is the safety alert symbol. It is used with and without signal words to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

WARNING Illustrations in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.

Replace all shields before operating the machine.

Failure to comply could result in death or serious injury.

W0012A

IMPROVEMENTS CNH Industrial is continually striving to improve its products. We reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

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1 - GENERAL INFORMATION

Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

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

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

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

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1 - GENERAL INFORMATION

Product identification Model, serial number, and year of manufacture Record the machine and Product Identification Numbers (PIN). When ordering parts and obtaining information or assistance, always supply your dealer with the type and PIN of your machine or accessories. Keep a record of these numbers and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine identification Model name Product Identification Number (PIN) Model year

The PIN plate is located on the front, right-hand side the machine.

RAIL14MEX0073AA

1

RAIL14CEX0016AA

2

RAIL14CEX0019AA

3

Engine identification Engine make and model Engine serial number

The serial number plate is located on the engine valve cover.

Hour meter Hour meter reading

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1 - GENERAL INFORMATION

Roll-Over Protective Structure (ROPS)

The ROPS serial number plate is located on the upper inside frame of a canopy machine. The ROPS serial number plate is located on the lower part of the frame, behind the seat, on a cab machine.

1-6

RAIL14MEX0071BA

4

RAIL14MEX0072BA

5

1 - GENERAL INFORMATION

Operator's manual storage on the machine Canopy machine: Store the operator’s manual in the compartment in the upper part of the canopy.

Cab machine: Store the operator’s manual in the compartment behind the operator’s seat.

READ THIS MANUAL COMPLETELY and make certain you understand the controls. All equipment has a limit.

Make sure you understand the speed, steering, stability, and load characteristics of this machine before you start to operate.

DO NOT remove this manual from the machine. See your dealer for additional manuals. Always keep the operator's manual in the storage compartment provided on the machine. The operator's manual must be available for use by all operators.

RAIL14CEX1118AA

1

RAIL14MEX0001AA

2

When you see this symbol read your operator's manual.

When you see this symbol refer to your service manual.

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1 - GENERAL INFORMATION

Machine orientation 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.

1.

2.

3.

4.

Front Right Rear Left

RAIL14CEX0007AA

1-8

1

1 - GENERAL INFORMATION

Machine components

RAIL15MEX0001GA

1

Machines with an exhaust pipe exit opening on the side 1. Arm cylinder 2. Boom 3. Cab or canopy 4. Swing cylinder 5. Swing motor 6. Battery 7. Fuel tank 8. Hydraulic oil tank 9. Right-hand side cover 10. Radiator 11. Reserve tank 12. Fuel cooler 13. Air cleaner

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Engine hood Counterweight Engine Oil filter Rubber track shoe Hydraulic pump Muffler Exhaust pipe Travel motor Swing bearing Swivel joint Lower roller Upper roller 1-9

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

Control valve Idler assembly Left-hand side guard Dozer blade Dozer cylinder Boom cylinder Work light Bucket Bucket link Idler link Bucket cylinder Arm

1 - GENERAL INFORMATION

RAIL14MEX0005GA

2

Machines with an exhaust pipe exit underneath the machine 1. Arm cylinder 2. Boom 3. Cab or canopy 4. Swing cylinder 5. Swing motor 6. Battery 7. Fuel tank 8. Hydraulic oil tank 9. Right side cover 10. Radiator 11. Engine hood 12. Reserve tank 13. Air cleaner

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Fuel cooler Counterweight Engine Oil filter Hydraulic pump Travel motor Muffler Swing bearing Lower roller Upper roller Swivel joint Control valve Idler assembly

1-10

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

Guard Rubber track shoe Dozer blade Dozer cylinder Boom cylinder Work light Bucket Bucket link Idler link Bucket cylinder Arm Exhaust pipe

1 - GENERAL INFORMATION

Emission control system Warranty – USA only Your warranty rights and obligations California The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and YANMAR Co., Ltd. hereafter referred to as YANMAR, are pleased to explain the emission control system warranty on your industrial compression-ignition engine. In California, model year 2000 or later off-road compression ignition engines must be designed, built and equipped to meet the state’s stringent anti-smog standards, In all states, 1998 and later nonroad compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. YANMAR warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fiel injection system, the air induction system, the electronic control system and the Exhaust Gas Recirculation (EGR) system. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, YANMAR will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.

Manufacturer’s warranty period: The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period the part will be replaced by YANMAR. If your engine is certified as And its maximum power is Variable speed or constant kW < 19 speed

And its rated speed is

The its warranty period is

Any speed

1,500 h or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years.

1,500 h or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

Constant speed

19 ≤ kW <37

3,000 RPM or higher

Constant speed

19 ≤ kW <37

Less than 3,000 RPM

Variable speed

19 ≤ kW <37

Any speed

Variable speed or constant kW ≥ 37 speed

Any speed

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1 - GENERAL INFORMATION

Warranty coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized YANMAR industrial engine dealer or distributor.

Warranted parts not scheduled for replacement as required maintenance in the operation manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part repaired or replaced under warranty shall be warranted for the remaining warranty period.

During the warranty period, YANMAR is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.

Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce YANMAR’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.

Warranted parts: This warranty covers engine components that are a part of the emission control system of the engine as delivered

by YANMAR to the original retail purchaser. Such components may include the following: • Fuel injection system • Electronic control system • Cold start enrichment system • Intake manifold • Turbocharger systems • Exhaust manifold • EGR system • Positive crankcase ventilation system • Hoses, belts, connectors, and assemblies associated with emission control systems Since emissions-related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.

Exclusions: Failures other than those arising from defects in material and/or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use of non-recommended fuels and lubricating oils; accident caused damage, and replacement of expendable items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss.

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1 - GENERAL INFORMATION

Owner’s warranty responsibilities: As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. YANMAR recommends that you retain all documentation, including receipts, covering maintenance on your non-road compression-ignition engine, but YANMAR cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.

YANMAR may deny your warranty coverage of your non-road compression-ignition engine if a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements.

You are responsible for initiating the warranty process. You must present your engine to a YANMAR dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, or would like information on the nearest YANMAR dealer or authorized service center, you should contact YANMAR America Corporation.

Website: www.yanmar.com E-mail: CSsupport@yanmar.com Toll free telephone number: 1–800–872–2867, 1–855–416–7091

Emission-related installation instructions (REF) Failing to follow these instructions when installing a certified engine in a piece of non-road equipment violates Federal Law (40 CFR1068.105(B)), subject to fines or other penalties as described in the clean air act.

Installation of non-road engines into equipment To ensure engines operate under the certified configurations, YANMAR has established defined application requirements when installing any certified engine into a piece of equipment. The instructions outlined below are included in our certification process and any failure to comply will be considered tampering.

YANMAR certifies engines to operate under variable speed or constant speed conditions. Engines certified as constant speed are prohibited from installation into variable speed applications. The emission control information label will identify an engine certified as constant speed.

Allowable air intake restriction and exhaust back pressure Resistance to intake airflow and exhaust gas flow is generated in the air intake and exhaust systems. Exceeding the limitations will affect the operation of an engine and its certified configuration. Refer to the installation requirements and limitations of the TNM and TNV series Application Manual for the engine being equipped with these systems.

Allowable air intake restrictions Engine model All TNV models

Allowable air intake restrictions ≤ kPa (mmAq) Initial upper limit Upper limit for air cleaner 2.94 (300) 6.23 (635)

Allowable exhaust back pressure Engine model

3TNV74F, 3TNV80F, 3TNM74F 3TNV88F

Allowable exhaust back pressure ≤ kPa (mmAq) Initial upper limit Upper limit for exhaust system cleaning 9.81 (1000) 11.77 (1200) 12.75 (1300) 15.30 (1560)

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1 - GENERAL INFORMATION

Usage not complying with the following use conditions is not covered under warranty.

1. Fuel use conditions • Fuel should comply with the EN590, ASTM D975 or JIS K2240 standard.

• Biofuel should comply with the EN14214, EN590, ASTM D6751, ASTM D7467, or JIS K2390 standard.

• Sulfur content of fuel should be 15 ppm (mass) or less.

• Fuel should be free from zinc and natrium.

• Do not use kerosene.

• Do not use fuel which has been stored in a drum, etc.

• Do not use fuel which is purchased from other than CASE CONSTRUCTION authorized dealers/distibutors.

2. Lubricant use conditions • Lubricant should comply with the CJ-4 (API classification), E-6 (ACEA classification) or DH-2 (JASO classification) standard.

3. Coolant use conditions • Coolant should comply with the SAE J814, SAE J1034, ASTM D3306 or JIS K2234 standard.

• LLC should be mixed with soft water.

• LLC concentration should be 30–60%.

• Change coolant every year.

1-14

2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

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

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

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

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

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

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

2-1

2 - SAFETY INFORMATION

California proposition 65 warning — California Proposition 65 Warning

RCIL08CCH001EAA

1

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 posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

2-2

2 - SAFETY INFORMATION

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

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 the machine before you start to operate this machine.

DO NOT remove this manual from the machine.

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.

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

2-3

2 - SAFETY INFORMATION

Safety rules General safety rules Use caution when you operate the machine on slopes. Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Never permit anyone other than the operator to ride on the machine.

Never operate the machine under the influence of alcohol or drugs, or while you are otherwise impaired.

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.

• Make sure that all components are in good condition. Tighten all connections before you start the engine or pressurize the system.

• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.

• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts.

Wear protective equipment when appropriate.

DO NOT attempt to remove material from any part of the machine while it is being operated or while components are in motion.

Make sure that all guards and shields are in good condition and properly installed before you operate the machine.

Never operate the machine with shields removed. Always close access doors or panels before you operate the machine.

Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

Never operate the engine in enclosed spaces as harmful exhaust gases may build up.

Before you start the machine, be sure that all controls are in neutral or park lock position.

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Always keep windows, mirrors, all lighting, and Slow-Moving Vehicle (SMV) emblem clean to provide the best possible visibility while you operate the machine.

Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations.

2-4

2 - SAFETY INFORMATION

Parking the machine Before you leave the machine: 1. Park the machine on a firm, level surface.

2. Place both travel levers to the neutral position.

3. Lower the bucket and to the ground.

4. :Lower the dozer blade to the ground.

5. Pull the safety lock lever to the LOCK position.

6. Turn off the engine and remove the key.

7. Close the windows, cab door, and all panels.

Travel and general transportation safety Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Block upper structure swing to prevent accidental movement.

Know load limits of bridges and dimensional limits of tunnels.

Lift attachments high enough above ground to prevent accidental contact with the ground.

Check distance between boom/arm and dimensional limits.

When transporting equipment or machine on a transport trailer, make sure machine is properly secured.

Be aware of overhead structures or power lines and make sure the machine and/or attachments can pass safely under.

Be aware of undercarriage position relative to the front of the cab. Confirm front idler is in the front of the machine and the travel motor is in the rear of the machine before movement.

Travel speed should be such that complete control and machine stability is maintained at all times.

Keep the bucket in the direction of travel, approximately 30 - 40 cm (12 - 16 in) above the ground during travel on inclines.

Lower bucket immediately if machine begins to skid.

Do not travel on slopes with an angle exceeding 30 ° Avoid swing operation or steering the machine on a slope. Level the work area first if possible.

Operate controls slowly and cautiously on frozen and/or snow covered work sites to prevent unexpected shifts of the machine on flat ground or slopes.

Slow down before turning.

Follow correct towing procedure for equipment with or without brakes.

2-5

2 - SAFETY INFORMATION

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

Service the machine on a firm, level surface.

Install guards and shields after you service the machine.

Close all access doors and install all panels after servicing the machine.

Do not attempt to clean, lubricate, clear obstructions, or make adjustments to the machine while it is in motion or while the engine is running.

Always make sure that working area is clear of tools, parts, other persons and pets before you start operating the machine.

Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless the equipment is securely supported.

Jack or lift the machine only at jack or lift points indicated in this manual.

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.

Stop the engine and remove the key before you connect or disconnect electrical connections.

Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.

Replace damaged or worn tubes, hoses, electrical wiring, etc.

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components. Wear protective equipment when appropriate.

Do not remove oil caps or plugs immediately after stopping operation. A spout of the high temperature oil or contact of the hot parts may cause a burn. Wait until the temperature of the cap or plug is cool enough to touch it with a bare hand. Slowly loosen the cap or plug to release the internal pressure and then remove the cap or plug.

When welding, follow the instructions in the manual. Always disconnect the battery before you weld on the machine.

Always wash your hands after you handle battery components.

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Fuel handling safety rules Do not smoke or permit open flames while fueling or near fueling operations.

Never remove the fuel cap or refuel machines with the engine running or the engine hot. Never allow fuel to spill on hot machine components. Avoid spilling fuel on the ground or contaminating the environment.

Always maintain control of the fuel filter nozzle when filling the tank. This will help avoid spilling fuel.

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

Tightened the fuel tank cap securely. Should the fuel cap be lost, replace it only with the manufacturer's approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

Use the correct fuel for the operating season.

Never use gasoline for cleaning purposes.

Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Trash, debris, bird nests, or flammable material can ignite on hot surfaces.

Always have a fire extinguisher on or near the machine.

Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

At least once each day and at the end of the day, remove all trash and debris from the machine especially around hot components such as the engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Inspect the electrical system for loose connections and frayed insulation. Repair or replace loose or damaged parts.

Do not store oily rags or other flammable material on the machine.

Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvents before welding or flame-cutting.

Do not expose the machine to flames, burning brush, or explosives.

Promptly investigate any unusual smells or odors that may occur during operation of the machine.

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General battery safety Always wear eye protection when you work with batteries.

Do not create sparks or have open flame near a battery.

Ventilate the area when you charge a battery or use a battery in an enclosed area.

Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

When you weld on the machine, disconnect both terminals of the battery.

Do not weld, grind, or smoke near a battery.

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

Follow the manufacturer’s instructions when you store and handle batteries.

Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling. This is a California Proposition 65 warning.

Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.

Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Keep out of reach of children and other unauthorized persons.

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Seat belts Seat belts must be worn at all times.

Seat belt inspection and maintenance: • Keep seat belts in good condition.

• Keep sharp edges and items than can cause damage away from the belts.

• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear.

• Replace all parts that have damage or wear.

• Replace belts that have cuts that can make the belt weak.

• Check that bolts are tight on the seat bracket or mounting.

• If the belt is attached to the seat, make sure that the seat or seat brackets are mounted securely.

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

• Do not use bleach or dye on the belts because this can make the belts weak.

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Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Top guard : Level 1 equivalent to a Falling Objects Protective Structure (FOPS1), or a cab with a ROPS. A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. The protective structure is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes to the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations: • The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, operator’s seat and suspension, seat belts and mounting components, and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST BE REPLACED. DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

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Air-conditioning system The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury.

The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere.

Do not attempt to service or repair the system.

Only trained service technicians can service, repair, or recharge the air-conditioning system.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

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Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures, and procedures to take in the event of a spill or accidental release.

MSDS are available from your dealer.

Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and on manufacturer containers, as well as the information in this manual, when you service the machine.

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations.

Check with local environmental and recycling centers or your dealer for correct disposal information.

Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

Keep out of reach or children or other unauthorized persons.

Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor of the chemicals before you use them.

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate, to determine the locations of services.

Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should a contact between the machine and an electric power source occur, the following precautions must be taken: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure that you do not make contact with the ground and the machine at the same time.

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

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Electrical storm safety Do not operate machine during an electrical storm.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform.

Do not make contact with the ground or objects outside the machine.

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.

Do not jump off of the machine.

Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Face the machine when you mount and dismount the machine.

Maintain a three-point contact with steps, ladders, and handholds.

Never mount or dismount from a moving machine.

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Working at heights When the normal use and maintenance of the machine requires you to work at heights: • Correctly use installed steps, ladders, and railings.

• Never use ladders, steps, or railings while the machine is moving.

• Do not stand on surfaces that are not designated as steps or platforms.

Do not use the machine as a lift, ladder, or platform for working at heights.

Lifting and overhead loads Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area of movement while the machine is in operation.

Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.

Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically locked or supported if they are left in a raised position for service or access.

Attachments can change the center of gravity of the machine. Use caution on slopes or uneven ground.

Remember to leave appropriate clearance to the ground and other obstacles.

Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.

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Prohibited work operations specific to this machine Never apply the swinging force to a rock slide or to breaking work. This operation would exert excessive force to the machine structure and equipment/attachment.

It could cause severe damage to them to shorten the service life of the swing system.

RAIL14CEX0135AA

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RAIL14CEX0136AA

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Never apply the travel force while you dig with the bucket being wedged into the ground. This would exert excessive force to the machine parts and could cause severe damage to the machine. Never apply travel force to level the ground, it could also result in damage to the machine.

Never use the bucket for hammering and pile driving. It may cause severe damage to machine parts.

Never operate the cylinder to the stoke end. This will generate an excessive load and will cause damage not only to the cylinder but also to the pin, boom and arm. Operate the bucket, boom and arm cylinders to leave some clearance (A) to both stroke ends.

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Do not tip or raise the machine to obtain power to dig.

Before digging a hard bedrock, crack it into pieces by another method.

RAIL14CEX0139AA

5

RAIL14CEX0140AA

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RAIL14CEX0141AA

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Do not operate the bucket to the stroke end of the bucket to generate impact to remove dirt. It may cause damage to the equipment, attachment, and cylinders.

Never lift up the machine with the arm cylinder to the stroke end. It may cause damage to the equipment/attachment and cylinder

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Precautions specific to this machine Walk around the machine’s tool, attachment, or furthermost contact point to view operation danger area.

Keep tracks clear of debris, ice, or snow, as tracks are used when mounting and dismounting the machine. Always use care when entering or exiting the machine cab.

Always wear personal protection equipment when servicing tracks. Wear full coverage face protection when adjusting track tension.

Never push loads in excess of capacity.

Know and understand the job site traffic flow patterns and obey signal personnel, road signs, and flaggers.

Know and understand that job site conditions may change on an hourly basis. It is the operator’s responsibility to monitor the changes and keep the machine, tools, and attachments at a safe distance.

Before operating at night, make certain all work lamps illuminate.

Always inspect the attachments before operating the machine and make certain they are engaged properly.

Improperly locked attachments could release and cause serious injury.

Make certain that locking pins and connections are free of dirt or caked on mud before attempting to engage and disengage the attachment.

Never stand under an attachment or allow others to do so. Do not allow anyone under elevated attachments.

Inspect hydraulic hoses for any leaks or damage.

Visually inspect welds and make any repairs as necessary.

Check for any loose bolts. Torque as required.

Do not modify the machine or attachments. Such modifications can damage and/or effect the integrity of the attachment and can effect safety and function of the attachment and/or machine.

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

Remove the starter key and/or use disconnect switch when leaving the machine parked or unattended.

Check the position of the front idlers (1) before starting operation. The proper travel position is with the front idlers (1) in the forward of the undercarriage and with the travel motors (2) in the back of the undercarriage.

RAIL14CEX0142AA

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When you perform deep excavation with the dozer blade at the front, be careful not to hit the boom cylinder against the dozer blade. If possible, do not set the dozer blade in front for deep excavation operations.

RAIL14CEX0143AA

9

Put the crawler belts at a right angle to the edge of the cliffs or on the shoulder of the roads with the travel motors at the rear of the machine. This helps to prevent the machine from falling during cliff and shoulder work operations.

RAIL14CEX0144AA

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RAIL14CEX0145AA

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This machine is designed and manufactured for digging, loading and ground leveling operations only. Any other use can exert excessive force to the machine, its components, or its systems could result in death or serious injury.

Use extreme caution when you lift or move loads. Use the proper lifting equipment rated at a capacity to handle the load. Do NOT use bucket teeth to lift or move loads.

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WARNING Avoid injury!

When towing, do not enter the area between the machine and towing vehicle. Do not apply a shock load to the wire rope. Keep the wire rope horizontal and perpendicular to the machine frame. Tow in low speed mode.

Failure to comply could result in death or serious injury.

W1193A

It may be necessary to tow the machine if stuck in the soft soil.

1. Attach a wire rope or chain to the lower frame (1) 2. Attach the other end of the wire rope or chain to the towing vehicle.

3. Operate the travel levers in the same direction as the towing vehicle.

NOTICE: For towing the machine body, apply pads to the crawler frame corners to prevent damage to the wire rope and crawler frame.

Shackles must be used for towing.

RAIL14CEX0147BA

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RAIL14MEX0049AA

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The accumulator contains high pressure nitrogen gas.

Improper handling of the accumulator may cause severe personal injury due to a possible explosion.

• Do not disassemble the accumulator.

• Keep the accumulator away from fire. Do not throw it into a fire.

• Do not drill, weld, or gas cut on the accumulator.

• Do not strike or roll the accumulator.

• The charged gas must be removed before disposal.

Contact your authorized dealer for information on handling the accumulator.

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Ecology and the environment Soil, air, and water are vital factors of life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country.

• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.

Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly.

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.

Your CASE CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

• Repair any leaks or defects in the engine cooling or hydraulic system immediately.

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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Operator's seat belt WARNING Roll-over hazard!

Securely fasten the seat belt. Your machine is equipped with a Roll-Over Protective Structure (ROPS) cab, ROPS canopy, or ROPS frame for your protection. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Failure to comply could result in death or serious injury.

W0143A

Seat belt 1. Insert the metal end of the belt strap (2) into the latch mechanism (1).

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1. Latch mechanism 2. Belt strap 2. Lift up the latch mechanism (1) to unlatch the seat belt.

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Safety signs WARNING Avoid injury!

An illegible or missing safety sign can have far-reaching consequences. Inspect safety signs daily.

Clean and replace damaged safety signs as necessary.

Failure to comply could result in death or serious injury.

W0167A

The following safety signs are placed on your machine as a guide for your safety and for those working with you. Walk around the machine and note the content and location of these safety signs before operating your machine.

Keep safety signs clean and legible. Clean safety signs with a soft cloth, water, and a gentle detergent. Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety signs.

Replace all safety signs that are damaged, missing, painted over, or illegible. If a safety sign is on a part that is replaced, make sure the safety sign is installed on the new part. See your dealer for replacement safety signs.

Make sure that you read all the safety signs and all instructional signs. The safety signs are intended for the personal safety of you and those working with you. Review the safety signs with all machine operators.

NOTE: Some safety sign locations may vary slightly between various model configurations.

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

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

Safety signs that display the "Read Operator's Manual" symbol are intended to direct the operator to the operator's manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine. When a safety sign displays this symbol, refer to the appropriate page of the operator's manual.

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This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

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DANGER — Electrical line safety

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DANGER Contact with electrical power lines will result in severe injury or death. Keep machine and attachment a safe distance from electrical power lines as per following instruction.

Voltage 50 kV or less 50 - 200 kV 200 - 350 kV 350 - 550 kV 500 - 750 kV 750 kV or more

PS20T01022P1

Safety distance 3.0 m (10 ft) 4.5 m (15 ft) 6.0 m (20 ft) 7.5 m (25 ft) 10.5 m (35 ft) 13.5 m (45 ft)

Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the seat stand cover.

Safety sign number: PS20T01022P1 Quantity: 1

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WARNING — Read the operator's manual

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WARNING Read and understand operator manual before operating or performing maintenance on this machine. Failure to follow or pay attention to instructions in operator manual can result in injury or death. It is your responsibility to be aware of and follow all local laws and regulations.

Before starting machine, make sure hydraulic control lever is in lockout position and all control levers are in neutral. Sound horn to alert people. Ensure bystanders and obstacles are clear of machine before moving machine or its attachments. Do not carry riders on machine. Before leaving operators compartment, park on level ground, lower attachments to ground, make sure hydraulic control lever is in lockout position and stop engine. Failure to comply with this warning could result in death or serious injury.

This WARNING safety sign is located on the seat stand cover.

Safety sign number: YN20T01016P1 Quantity: 1

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PY20T01073P1

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WARNING — Safety lock lever

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WARNING Machine may move suddenly and cause serious personal injury if a control lever is accidently touched, be sure the safety lever is disengaged and in the locked position before exiting the cab.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the seat stand cover Safety sign number: PY20T01073P1 Quantity: 1

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CAUTION — Attachment interference

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CAUTION Some type of attachment and the combination of attachment may cause an interference with operator’s cab and other sections of machine during operations.

Before starting operation, make sure to check for the enough space for no interference between the attachment and operator’s cab and the other sections.

Since it is more danger when the attachment is moved close to the cab and machine frame and so on, special attention must be paid. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the seat stand cover.

Safety sign number: PS20T01023P1 Quantity: 1

PS20T01023P1

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PS20T01041P1

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DANGER — Keep clear of swing area

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DANGER Keep clear of swing area. Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the counterweight.

Safety sign number: PS20T01041P1 Quantity: 1

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WARNING — Internal hydraulic oil tank pressure

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YT20T01414P1

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WARNING Pressurized hot oil can cause burns. Depress stem or remove cap slowly with engine off to relieve hydraulic tank pressure. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the hydraulic oil tank. Access the hydraulic oil tank from the right-hand side of the machine.

Safety sign number: YT20T01414P1 Quantity: 1

Battery explosion hazard

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• Batteries give of hydrogen gasses that can explode and cause personal injury.

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

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Do not check charge by placing metal articles across the battery terminals.

• Leave the battery box open to improve ventilation when charging the battery.

• There is always the danger of burns and loss of eyesight due to the splashing of dilute sulfuric acid of the battery. If skin and eyes are accidentally splashed with dilute sulfuric acid, wash them with clean water immediately and have treated by a doctor.

This safety sign is located on the seat stand cover.

Safety sign number: PS20T01042P1 Quantity: 1 2-26

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WARNING — Battery explosion hazard

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WARNING

PS20T01043P1

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Prevent battery explosion • Batteries generate hydrogen gases that can explode and cause personal injury.

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

• Keep metal objects away from batteries.

• Keep the fluid level above LOWER level.

• To avoid battery leakage, do not fill the battery above the UPPER level.

• Charge batteries in a well-ventilated area.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the seat stand cover.

Safety sign number: PS20T01043P1 Quantity: 1

WARNING — Booster cable

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WARNING Electric hazard may cause injury when mishandling the cable. Read operator manual for safe and proper handling. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the seat stand cover.

Safety sign number: PS20T01044P1 Quantity: 1

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WARNING — Hot coolant

RAIL14MEX0009AA

PW20T01094P1

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PS20T01024P1

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21

Steam of hot coolant can cause injury or blindness.

Never loosen or open radiator cap when coolant is hot and under pressure.

Before opening radiator cap: • Cool down engine completely.

• Cover radiator with cloth rag.

• Looser cap slowly to relieve pressure.

This WARNING safety sign is located on the upper surface of the radiator.

Safety sign number: PW20T01094P1 Quantity: 1

WARNING — Stop the engine before service

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WARNING Rotating parts can cause personal injury. Keep away from fan and belt when engine is running. Stop engine before servicing. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the fan guard inside the engine.

Safety sign number: PS20T01024P1 Quantity: 1

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CAUTION— Hot Parts

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CAUTION Engine may be hot which could cause burns. Do not touch engine until it cools down. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the engine guard inside the engine compartment..

Safety sign number: YT20T01352P1 Quantity: 1

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YN20T01012P1

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CAUTION — Entanglement hazard

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CAUTION Rotating engine fan, hot engine parts and drive belt can cause severe injury. Do not open engine cover or service engine with engine running. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the engine hood.

Safety sign number: YN20T01012P1 Quantity: 1

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Track tension adjustment hazard

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The grease in the track adjust valve is under extreme pressure and can penetrate the skin causing sever injury. Carefully read the relevant maintenance section prior to performing the track adjustment procedure.

Failure to comply could result in minor or moderate injury.

This safety sign is located on both sides of the crawler frame.

Safety sign number: PS20T01050P1 Quantity: 2

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PE20T01012P1

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DANGER — Keep clear of working area

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DANGER Keep clear of machine. Failure to comply will result in death or serious injury.

Make sure the area is clear of obstacles and persons before machine operation. Sound the horn before you swing the arm.

This DANGER safety sign is located on both sides of the arm.

Safety sign number: PE20T01012P1 Quantity: 2

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WARNING — California proposition 65

YN20T011495P1

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33

WARNING California proposition 65. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Failure to comply could result in death or serious injury.

On a cab machine, this safety decal is located on the right-hand side, inside the cab. On a canopy machine, this safety sign is located on the seat stand cover.

Safety sign number: YN20T01495P1 Quantity: 1

WARNING — California proposition 65

2432T6457

RAIL14MEX0036AA

35

WARNING California proposition 65. Diesel engine exhaust and some of its constituents are know to the State of California to cause cancer, birth defects, and other reproductive harm. Failure to comply could result in death or serious injury.

On a cab machine, this safety decal is located on the right-hand side, inside the cab. On a canopy machine, this safety sign is located on the seat stand cover.

Safety sign number: 2432T6457 Quantity: 1

2-31

36

2 - SAFETY INFORMATION

EPA regulation

RAIL14CEX0049AA

PV20T01100P1

38

PS20T01049P1

40

37

EPA regulation. Use ultra low sulfur fuel only.

This safety sign is located on the side of the fuel tank.

Safety sign number: PV20T01100P1 Quantity: 1

WARNING — Seat belt

RAIL14MEX0007AA

39

WARNING Avoid crushing. Do not jump if machine tips. Buckle up.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the seat stand cover.

Safety sign number: PS20T01049P1 Quantity: 1

2-32

2 - SAFETY INFORMATION

CAUTION — Window lock position (Cab machine only)

RAIL14MEX0038AA

YN20T01416P1

42

PS20T01031P1

44

41

CAUTION Falling front window can cause injury. Always lock securely in place with lock lever on both sides. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the right-hand side, inside the cab.

Safety sign number: YN20T01416P1 Quantity: 1

CAUTION — Pinch hazard (Cab machine only)

RAIL14MEX0038AA

43

CAUTION Be careful not to pinch your hand(s) when operating the lever. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the right-hand side, inside the cab.

Safety sign number: PS20T01031P1 Quantity: 1

2-33

2 - SAFETY INFORMATION

WARNING — Roll Over Protective Structure (ROPS)

RAIL14MEX0036AA

45

WARNING Do not operate this machine if the rollover protective structure (ROPS) is structurally damaged, shoes cracks, is not properly secured as originally installed or has been rolled. Do not repair, modify or add attachments to the ROPS unless authorized in writing by the manufacturer. Do not add attachments to the machine that intrude into the operator’s protective area, reduce visibility, restrict emergency exits or add weight exceeding certification weight of ROPS. Do not operate machine unless seat belt conforming to SAE and/or ASAE standards is fastened. See operator’s manual or contact your dealer for complete inspection requirements and maintenance instructions. Failure to comply could result in death or serious injury.

On a cab machine. This WARNING safety sign is located on the right-hand side, inside the cab. On a canopy machine, this WARNING safety sign is located on the seat stand cover.

Safety sign number: PE20T01028P1 Quantity: 1

PE20T01028P1

2-34

46

2 - SAFETY INFORMATION

WARNING — Rotary multi-control valve

RAIL14MEX0036AA

YN20T01039P1

48

YY20T01384P1

50

47

WARNING This machine equipped with a rotary multi-control valve which allows changing of operating lever control patterns. Operating this machine before checking function of each control lever can cause unexpected machine movement, which can result in serious personal injury. Make sure you check and know function of each control lever before operating. Failure to comply could result in death or serious injury.

On a cab machine, this WARNING safety sign is located on the right-hand side, inside the cab. On a canopy machine, this WARNING safety sign is located on the seat stand cover.

Safety sign number: YN20T01039P1 Quantity: 1

DANGER — Rotary multi-control valve handling hazard

RAIL14MEX0039AA

49

Rotary multi-control. Read operator manual. ISO, BHL lever-lock position and control pattern. DANGER Stop the engine without fail at time of change over. Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the inside of the front cover.

Safety sign number: YY20T01384P1 Quantity: 1

2-35

2 - SAFETY INFORMATION

CAUTION — Burn hazard

PS20T01192P1

RAIL14CEX0038AA

51

CAUTION Tube may be hot which could cause burns. Do not touch tube until it cools down. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the cooler hose.

Safety sign number: PS20T01192P1 Quantity: 1

2-36

52

2 - SAFETY INFORMATION

CAUTION — Nibbler and Breaker operation position

RAIL14MEX0039AA

53

RAIL14MEX0040AA

CAUTION Procedure to change selector valve

RAIL14MEX0088AA

54

Align mark on notch (1) with cap screw (2).

Comply with the following instructions Hydraulic excavator with hydraulic breaker use hydraulic oil severely compared with machine only for digging.

Replace filters and hydraulic oil, referring to the following table.

1. Hydraulic oil change: 1000 h 2. Hydraulic return filter change: First 50 h, Regular: 200 h 3. Before operating breaker, be sure to check the selector valve is in

position. Operation of

breaker with the valve in position could cause machine failure.

Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located inside the front cover.

Safety sign number: PX20T01139P1 Quantity: 1

2-37

55

2 - SAFETY INFORMATION

Nibbler and Breaker operation by switch

RAIL14MEX0037AA

56

CAUTION Grip the right control lever

PY20T01205P1

RAIL14CEX0062AA

57

Breaker (1) Nibbler (2) Operation of breaker and nibbler Breaker Button depressing section OFF Depress the button

Operation Breaker stops operating.

Breaker starts operation.

Operation procedure Slide to the left Slide to the right

Operation Nibbler close Nibbler open

Check the function before operating the machine.

Failure to comply could result in minor or moderate injury.

On a cab machine, this CAUTION safety sign is located on the right-hand side, inside the cab. On a canopy machine, this CAUTION safety sign is located on the seat stand cover.

Safety sign number: PY20T01205P1 Quantity: 1

2-38

58

2 - SAFETY INFORMATION

Securely lock the cab door

PV20T01008P1 RAIL14MEX0014AA

59

WARNING Open or close the door keeping machine horizontally and lock it securely. Unlocking in condition of machine operation may cause injured by unexpected door movement.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located inside the cab door.

Safety sign number: PV20T01008P1 Quantity – 1

2-39

60

2 - SAFETY INFORMATION

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

Start the engine.

RCPH10WHL017BAD

61

RCPH10WHL005BAD

62

RCPH10WHL018BAD

63

Stop the engine.

Come to me.

Wave hands back and forth (palms inward).

2-40

2 - SAFETY INFORMATION

Move away from me.

Wave hands back and forth (palms outward).

RCPH10WHL019BAD

64

RCPH10WHL020BAD

65

RCPH10WHL002BAD

66

RCPH10WHL009BAD

67

Go this far.

All stop and hold.

Stop Move one hand back and forth.

2-41

2 - SAFETY INFORMATION

Emergency stop Move both hands back and forth.

RCPH10WHL004BAD

68

RCPH10WHL008BAD

69

RCPH10WHL007BAD

70

Raise the tool.

Lower the tool.

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3 - CONTROLS AND INSTRUMENTS

3 - CONTROLS AND INSTRUMENTS###_3_### Access to operator's platform

Cab access/exit WARNING Unexpected machine movement!

When you must leave the operator’s seat, always place the safety lever in the LOCKED position. If the safety lever is unlocked and the control lever is moved unexpectedly, a serious accident could result.

Failure to comply could result in death or serious injury.

W1241A

CAUTION Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in minor or moderate injury.

C0075B

Steps and hand-holds • Keep the access to the machine clear of foreign objects and clean. Remove grease or mud from steps and handrails to minimize the risk of slipping.

• Check that the fasteners of steps and handrails are tightened and undamaged.

• Always face the machine and maintain a three point contact with the steps and handrails.

RAIL14MEX0031AA

3-1

1

3 - CONTROLS AND INSTRUMENTS

WARNING Fall hazard!

Always lock the cab doors in the full open or full closed position before using the handrails on the doors.

Failure to comply could result in death or serious injury.

W0133A

Cab door 1. Use the ignition key to lock and unlock the cab door.

RAIL14MEX0019BA

2

RAIL14MEX0013AA

3

RAIL14MEX0014AA

4

Lock the cab door in the open position To lock the door in the open position, slide the door fully open until it locks on the catch (1) on the rear of the cab.

To close the door, pull the lever (2) on the inside of the door to release the door from the catch (1).

3-2

3 - CONTROLS AND INSTRUMENTS

Open the door from the inside To open the door from the inside, pull the lever (2) to open the door.

RAIL14MEX0014AA

3-3

5

3 - CONTROLS AND INSTRUMENTS

Windows CAUTION Pinch hazard!

Make sure you correctly follow the instructions in this manual when handling the windshield. If you do not handle the windshield correctly, it could slip and injure your fingers or hands.

Failure to comply could result in minor or moderate injury.

C0045A

Open and close the front upper window To open the window: 1. Push down on the lock levers (1) on both sides of the upper front window to release the lock.

2. Hold the left and right handles, lift the front window up and slide it overhead until it locks at the rear side of the roof.

To close the window: 3. Perform the reverse procedure of the above Steps 1 and 2.

RAIL14CEX0076AA

6

RAIL14MEX0015AA

7

Remove and store the lower front window After you lock the upper front window in the ceiling: 1. Remove the lower front window by hand from the window frame.

2. Store the lower front window in the rear of the cab.

3. Securely store the lower front window against the stopper (3), in the holder (2), and lock in the upper part of the window frame (1).

3-4

3 - CONTROLS AND INSTRUMENTS

Open and close the right window To open the right window: 1. Release the lock (4) and slide the window open.

To close the right window: 2. Slide the window closed and move the lock (4) to the locked position.

RAIL14MEX0016AA

8

RAIL14MEX0017AA

9

Cab dome light Cab dome light switch operation • ON (1): Turns the lamp on.

• Neutral (2): The lamp is off.

• OFF (3): The lamp is off.

Emergency exit 1. Open the front window and escape through the front window.

2. If the front window cannot be opened, use the emergency exit hammer (1) on the left side of the cab to break the front window.

RAIL14MEX0018AA

3-5

10

3 - CONTROLS AND INSTRUMENTS

3. If the front window is unavailable for you to escape, use the emergency exit hammer (1) to break the glass of the rear window (2).

CAUTION Avoid injury!

Some of the glass could shatter inward. Cover your head, particularly your eyes, while using the hammer. Use a shirt or a jacket, or your arm, for protection.

Failure to comply could result in minor or moderate injury.

C0054A RAIL14MEX0023AA

3-6

11

3 - CONTROLS AND INSTRUMENTS

Machine access compartments and doors Access compartments and doors WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

The engine door, the right side cover, and the cab door have a lock mechanism. Use the ignition key to open and lock the covers and the doors.

RAIL14CEX0875AA

1

RAIL14MEX0019BA

2

RAIL14MEX0020BA

3

To unlock the engine door.

1. Insert the ignition key into the lock.

2. Turn the ignition key counterclockwise.

3. Remove the ignition key and open the engine door.

4. Secure the engine door in the open position with the support rod.

To lock the engine door.

1. Return the support rod to the storage position by placing it into the holder.

2. Close the engine door.

3. Insert the ignition key and turn it in the clockwise direction to lock the engine door.

4. Remove the ignition key.

NOTICE: Insert the key completely for proper operation or damage may occur to the key or locking mechanism.

Lock and unlock the side cover 1. Turn the key clockwise to open the side cover.

2. When you close the side cover, it automatically locks.

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3 - CONTROLS AND INSTRUMENTS

Storage for tools and accessories Tools are stored on the inside of the right-hand side cover.

RAIL14CEX0879AA

4

RAIL14MEX0024AA

5

RAIL14MEX0088BA

6

The grease gun holder is located next to the hydraulic tank Inside the right-hand side cover.

Master disconnect switch The master disconnect switch (1) shuts down the battery circuit.

Locate the master disconnect switch (1) inside the cover at the front of the machine.

Use the starter key to open the cover at the front of the machine.

Switch position I (ON) (B): Turn the switch (1) to the right to connect the electrical circuit.

Switch position 0 (OFF) (A): Turn the switch (1) to the left to disconnect the electrical circuit.

NOTICE: To prevent electric devices from being damaged, do not use the master disconnect switch (1) for any other purposes than described in this manual. Never turn the switch to the 0 (OFF) (A) position while the engine is running. Before you turn the master disconnect switch (1) to the 0 (OFF) (A) position, turn the ignition switch key switch to the OFF position and wait 1 min or more. Then operate the master disconnect switch (1) NOTE: When the master disconnect switch is set to the 0 (OFF) (A) position, all electrical circuits are disconnected.

This position will also clear the preset memory and the clock memory of the radio.

3-8

3 - CONTROLS AND INSTRUMENTS

Operator's seat

Operator's seat WARNING Loss of control hazard!

Do not make seat adjustments while the machine is in motion. All seat adjustments should be made with the machine stationary and the safety lever in the LOCK position.

Failure to comply could result in death or serious injury.

W0393A

Horizontal seat adjustment To slide the seat back and forth: 1. Pull up on the handle (1).

2. Adjust the seat to a distance at which you can easily operate the control levers and pedals.

3. Release the handle (1) and check that the seat is securely locked.

Adjustable length: 105.0 mm (4.1 in) RAIL14CEX0080AA

3-9

1

3 - CONTROLS AND INSTRUMENTS

Forward controls

Controls overview

RAIL14MEX0010FA

1. Left travel pedal 2. Left travel lever 3. Right travel lever

4.

5.

6.

7.

1

Right travel pedal Boom swing foot pedal Travel speed select switch Right control lever

3-10

8. Left control lever 9. Horn switch 10. Safety lock lever

3 - CONTROLS AND INSTRUMENTS

Travel control levers and pedals Travel control pedals and levers NOTE: The words right, left, front, back, clockwise and counter-clockwise are to be referred to the operator position properly sitting in the driver’s seat.

N (a) + (b) (c) + (d) (b) + (c)

Neutral Machine moves forward Machine moves backward Opposite simultaneous rotation of the tracks with consequent counter-clockwise rotation of the machine around its center axis. (a) + (d) Opposite simultaneous rotation of the tracks with consequent clockwise rotation of the machine around its center axis. (a), (b), (c), (d) Positions to move one track only.

Consequently the machine steers pivoting on the stationary track.

RAIL14MEX0012BA

1

RAIL14CEX0089AA

2

WARNING Roll-over hazard!

Use the LOW travel speed when you travel on a slope, or when you unload or load the machine onto a trailer. Sudden changes in travel speed could cause the machine to roll over.

Failure to comply could result in death or serious injury.

W1252A

Travel speed select switch The travel speed select switch is located on the right-hand travel speed lever. Use this switch to select either HIGH (2nd) or LOW (1st) travel speed. When you turn the ignition switch to OFF, the travel speed is automatically set to the LOW travel speed (turtle icon)

3-11

3 - CONTROLS AND INSTRUMENTS

Low travel speed (Turtle icon) Select the low speed when: • traveling on rough or soft terrains • traveling on slopes • traveling in narrow places where powerful tractive force is required • unloading the machine from a truck or trailer RAIL14CEX0090AA

3

RAIL14CEX0091AA

4

High speed (Rabbit icon) Select the high speed when you travel on flat, hard ground.

3-12

3 - CONTROLS AND INSTRUMENTS

Boom swing operating pedal WARNING Loss of control hazard!

Always lock the boom swing foot pedal when you are not using the boom swing operating function.

Failure to comply could result in death or serious injury.

W1337A

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

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

• Left swing (A): Depress the left side of the pedal.

• Right swing (B): Depress the right side of the pedal.

To lock the pedal, pull the pedal locking cover (1) down, over the pedal.

RAIL14CEX0092AA

3-13

1

3 - CONTROLS AND INSTRUMENTS

Proportional hand control (nibbler and breaker) Breaker operating switch (button) The breaker operating switch (button) (1) is located on the grip of the right control lever. It is used to operate the breaker.

To operate the breaker: • Press the breaker operating switch (button) (1).

• Release the button to stop operation.

• Operate the breaker for 30 s, then release the button.

NOTE: The breaker can be operated by sliding the nibbler (crusher) control switch (2) to the left. However, us the breaker operating switch (button) (1) as much as possible.

Breaker button action Hold down the button Release the button

RAPH13CEX0032AA

1

RAPH13CEX0032AA

2

Operating condition Breaker starts operation Breaker stops operation

Option switch (nibbler and breaker) The option switch (2) is located on the grip of the right control lever. It is used to operate the nibbler or the breaker.

NOTICE: Do NOT touch the breaker operating switch (button) (1) when operating the nibbler (crusher).

NOTICE: Make certain the selector valve is switched to the Nibbler mode. Working with the incorrect mode can cause malfunction or machine damage.

Slide the option switch (2) to open or close the nibbler (crusher).

Option switch (2) action Slide the switch to the left Slide the switch to the right

Operating condition Nibbler closes Nibbler opens

3-14

3 - CONTROLS AND INSTRUMENTS

Control levers WARNING Avoid injury!

Inspect the work area or job site to make sure that machine operation can be done safely. Confirm that the lever operation is the same as indicated on the control pattern labels. If not, immediately change the machine control pattern or the label displayed to match the machine control pattern.

Failure to comply could result in death or serious injury.

W1339A

Left and right control levers (ISO pattern) The control levers activate the functions illustrated on the right.

• Confirm that the working area is safe. Ensure that each lever operation is in accordance with the operating pattern indicated on the labels.

• If the configuration on the pattern label does not correspond to that of the control levers, immediately change the pattern label to prevent accidents and/or injury.

• Release the control levers to return them to the neutral position.

• All functions can be activated simultaneously.

2 4

Left control lever D Swing left B Swing right A Arm out Arm in C

1 3

Right control lever E Boom down Boom up G F Bucket out H Bucket in

1

RAPH12CEX1735BA

LELI11E0147AA

3-15

2

3 - CONTROLS AND INSTRUMENTS

Left and right control levers (BHL pattern) The control levers activate the functions illustrated on the right. In the BHL multi-control shifting, the boom and arm functions are opposite to the ISO system.

• Confirm that the working area is safe. Ensure that each lever operation is in accordance with the operating pattern indicated on the labels.

• If the configuration on the pattern label does not correspond to that of the control levers, immediately change the pattern label to prevent accidents and/or injury.

• Release the control levers to return them to the neutral position.

• All functions can be activated simultaneously.

1 2

Left control lever A Boom down Boom up C D Swing left B Swing right

3 4

Right control lever H Bucket in F Bucket out E Arm out Arm in G

RAPH12CEX1735BA

RAIL14CEX0115AA

3-16

3

4

3 - CONTROLS AND INSTRUMENTS

Horn switch WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

The horn switch is located on top of the left-hand control lever.

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

RAIL14CEX0093AA

3-17

1

3 - CONTROLS AND INSTRUMENTS

Safety lock lever WARNING Unexpected machine movement!

When you must leave the operator’s seat, always place the safety lever in the LOCKED position. If the safety lever is unlocked and the control lever is moved unexpectedly, a serious accident could result.

Failure to comply could result in death or serious injury.

W1241A

Safety lock lever The hydraulic safety lock lever is located on the left control console.

When the safety lock lever is set to the LOCKED position (A) : • The hydraulic system is shut down.

• The right and left control levers are inoperative.

• The right and left travel levers are inoperative.

• The attachment, swing motor, and dozer control are inoperative.

NOTICE: Set the boom swing foot pedal to the LOCKED position when you set the safety lock lever to the LOCKED position. Setting the safety lock lever to the LOCKED position does NOT lock the boom swing foot pedal.

When the safety lock lever is set to the UNLOCKED position (B) : • The hydraulic system is active.

• The right and left control levers are operative.

• The right and left travel levers are operative.

• The attachment, swing motor, and dozer control are operative.

3-18

LELI11E0145AB

1

3 - CONTROLS AND INSTRUMENTS

Left-hand side controls

Radio (option)

RAPH12CEX0095FA

1

1. Power switch

5. Preset key

2. AM/FM switch

6. DISP (display change) key

3. Volume control

7. Sound control key

4. UP/DOWN key

8. Display (time/frequency)

1 – Power control Press the power switch (1) and the power is switched from off to on. The band AM or FM will display briefly followed by the frequency or the time.

RAPH12CEX0101AA

3-19

2

3 - CONTROLS AND INSTRUMENTS

2 – Band switching Press the AM/FM key (2) to switch the band from AM to a FM frequency. Each time the key is pressed the band displays in the following order: FM1 — FM2 — AM. When the frequency band is switched, the station last received is selected.

RAPH12CEX0102AA

3

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3 – Volume control To increase volume level, press the + side of the volume control key (3). To reduce volume level, press the — side of the volume control key. The level of volume is displayed along with station, balance, treble, bass. After adjustments, the display will return to frequency or time display.

4 – Selecting stations Radio stations can be selected by: • Manual tuning • Auto select • Preset memory

Manual tuning Press UP or DOWN key (4) to change the frequency.

Auto select Press and hold UP or DOWN key (for more than one second) to change the frequency to the next detected frequency. Auto tuning is interrupted and stops at the received frequency.

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3 - CONTROLS AND INSTRUMENTS

5 – Preset memory Auto preset Received frequencies detected can be memorized into six preset memory keys (5). Press sound control key (7) for at least one second. Detected stations are automatically memorized by the preset buttons.

Manual preset Press one of the six preset keys (5) for at least one second. After the preset key number pressed flashes three times on the display, the current station being received is memorized and the frequency is displayed.

Press one of the six preset keys (5) and the frequency memorized in the preset key is available.

RAPH12CEX0124AA

7

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8

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6 – DISP (display change) key To change the display from the frequency display to the time display, press the DISP key (6) The display key will show either the time or the frequency, dependent on which display is selected.

7 – Sound control key Sound control key (7) adjusts tone and balance. The display changes to BAL, TRE, and BAS in order when the sound control key (7) is pushed.

Balance control • To raise the volume of the left speaker push the UP key (4) while BAL is displayed.

• To raise the volume of the right speaker, push the DOWN key (4) while BAL is displayed.

Treble control • To emphasize the treble, push the UP key (4) while TRE is displayed.

• To weaken the treble, push the DOWN key (4) while TRE is displayed.

Bass control • To emphasize the bass, push the UP key (4) while BAS is displayed.

• To weaken the bass, push the DOWN key (4) while BAS is displayed.

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3 - CONTROLS AND INSTRUMENTS

8 – Display (time/frequency) Time setting 1. Press DISP key (6) for one second or more while the time is displayed. The hour display will flash.

2. Press the UP key (4) to increase the hour.

3. Press the DOWN key (4) to decrease the hour.

4. Press DISP key (6) again and the minute display flashes.

5. Press the UP or DOWN keys (4) to increase or decrease the minutes.

RAPH12CEX0128AA

10

6. Press the DISP key (6) again and the time setting will be complete.

Area setup procedure and check procedure NOTE: Some radio models require area setup. If the set area is not the area in which the radio is to be used, radio waves will not be received correctly. Use the following procedures to either set the appropriate area (region) or check the area (region) setting.

Area setup procedure NOTE: During the procedure if the key operation is stopped for 10 min, the area setup mode is cancelled.

1. Set the key switch to ON. Do not start the engine.

2. If applicable, press the ON/OFF button (3) to turn the radio OFF (time display).

3. Press and hold the AM/FM button (1) and one of the volume control buttons (2) simultaneously for 5 s.

4. The current set area appears on the display (6) (the factory default set area is JP).

RAIL15MEX0006AA

11

RAIL15MEX0011BA

12

5. Use the UP and DOWN buttons (5) to scroll through the available set areas. Stop pressing the buttons when your area (region) appears on the display. ○ JP – Japan area (region) ○ USA – North America and South America area (region) ○ AE – Australia, Europe, and other areas (regions) 6. Press the sound control key (4) to store the setting and return to the time display.

7. Turn the key switch from ON to OFF.

3-22

3 - CONTROLS AND INSTRUMENTS

Check area procedure 1. Set the key switch to ON. Do not start the engine.

2. If applicable, press the ON/OFF button (2) to turn the radio OFF (time display).

3. Press the DOWN button (3) and 4 of the preset button (1) simultaneously. The present set area appears on the display. ○ JP – Japan area (region) ○ USA – North America and South America area (region) ○ AE – Australia, Europe, and other areas (regions)

RAIL15MEX0006AA

4. Turn the key switch from ACC to OFF.

3-23

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3 - CONTROLS AND INSTRUMENTS

Right-hand side controls

Switches (right-hand panel)

RAIL14MEX0010FA

1. Deceleration switch 2. Ignition switch 3. ECO mode (S mode)

4.

5.

6.

7.

1

Work lamp switch Wiper switch (Cab) Engine throttle lever Dozer control lever

Deceleration switch The deceleration selector switch is located next to the ignition switch on the right-hand console.

Press this switch while the engine is running to change the engine to LOW speed. Press the switch again to release the deceleration function. Or, turn the ignition switch from ON to OFF to automatically release the deceleration function.

Use of the deceleration selector switch can improve fuel efficiency and reduce noise.

RAIL14CEX0095AA

3-24

2

3 - CONTROLS AND INSTRUMENTS

Ignition switch The ignition switch is located on the right-hand side of the operator’s console. It is used to start or stop the engine, power the machine’s electrical system and activate preheating.

• OFF – When key is turned to this position, the engine stops and electrical power to the machine’s electrical system is stopped after approximately 3 seconds.

• ON (HEAT) – When key is in the ON position, electrical power is supplied to all the machine’s electrical systems. 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.

RAIL14CEX0880AA

3

RAIL14CEX0097AA

4

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5

• 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.

ECO mode switch (S mode switch) Press the S mode switch to set the engine speed.

If the throttle lever is used to decrease the engine speed below the S mode setting the throttle overrides the S mode setting.

Select the S mode for standard work conditions. S mode provides optimized conditions in terms of performance and fuel consumption.

Work lamp switch The work lamp switch is located on the right-hand console. It is used to turn the work lights on and off on the boom and the machine.

The work lamp switch has two settings: • OFF – Lights are extinguished • ON – Lights are illuminated on the boom and the machine

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3 - CONTROLS AND INSTRUMENTS

Wiper switch (cab option) The wiper switch is located on the right-hand console.

It has four settings: • Wash (left) – Sprays washer fluid • ON – Starts movement of the windshield wipers.

• OFF – Stops movement of windshield wipers • Wash (right) – Sprays washer fluid and operates the wipers simultaneously.

NOTICE: Do not use the washer function for more than 20 s or without washer fluid. This may cause damage to the motor equipped with the washer fluid reservoir.

3-26

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3 - CONTROLS AND INSTRUMENTS

Monitor panel

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Warning lamps Gauges 1. Engine coolant temperature gauge 3. Engine oil pressure lamp (RED) 2. Fuel level gauge 4. Coolant temperature lamp (RED) 5. Battery charge lamp (RED) 6. Low fuel warning (RED) 7. Engine air filter warning (RED)

Indicator lamp 8. High (2nd) travel speed

Engine coolant temperature gauge This gauge indicates the temperature of the engine coolant and operates when the ignition switch is turned to the ON position. The temperature is normal when the indicator needle is in the white range (1). If the needle enters the red range (H), let the engine idle until the coolant cools down and the needle returns to the white range.

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2

3 - CONTROLS AND INSTRUMENTS

Fuel level gauge This gauge indicates the amount of fuel in the tank. The reference F indicates a full fuel tank. Make sure to refuel when the indicator is approaching to reference E. Refill the fuel tank with diesel fuel only. Normally the gauge needle takes some time to move up to the appropriate level after turning the ignition switch to the ON position.

3

RAIL14CEX0107AA

Warning lamps NOTICE: When warning lamps illuminate, stop work immediately. If a warning lamp stays illuminated, stop the engine and determine the cause of the problem. See the maintenance section in this manual or contact your authorized dealer.

Engine oil pressure lamp (Red) This lamp illuminates when the ignition switch is turned to the ON position, and the lamp must turn off after engine start. During machine operation, if the engine oil pressure drops excessively, this lamp will illuminate. Stop the engine and check the quantity of engine oil.

NOTICE: The engine may undergo severe damage if the machine is operated with the engine oil pressure lamp illuminated.

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4

Coolant temperature lamp (Red) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

If the coolant temperature rises abnormally, the coolant temperature lamp 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 the engine coolant temperature reaches a safe operating temperature range.

Once the coolant has cooled down, stop the engine.

See the maintenance section in this manual for checking coolant levels.

NOTICE: The engine may undergo severe damage if the machine is operated with the coolant temperature lamp illuminated.

3-28

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5

3 - CONTROLS AND INSTRUMENTS

Battery charge lamp (Red) This lamp will illuminate when the ignition switch is turned to the ON position and the lamp must turn off after engine start.

If the charging system experiences a malfunction, the lamp will illuminate. Check the charging system if this indicator remains illuminated after engine start.

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6

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Fuel level lamp (Red) If the fuel level is low, the warning lamp will illuminate.

Stop the engine and add fuel. Do NOT allow the machine to run out of fuel.

Engine air filter lamp (Red) The engine air filter lamp illuminates if the air cleaner filter is clogged.

If the lamp illuminates, immediately stop the machine and clean or replace the air filter.

See the maintenance section in this manual for additional information.

8

RAIL14CEX0108AA

Indicator lamps High (2nd) speed travel lamp (Yellow) The high speed travel indicator lamp will illuminate when you select high speed with the travel speed selector switch. The travel speed selector switch is located on the grip of the right travel lever. The travel speed will automatically return to low (1st) speed when the ignition switch is in the OFF position.

LELI11E0133AA

3-29

9

3 - CONTROLS AND INSTRUMENTS

Dozer blade control lever WARNING Avoid injury!

Do not touch the lever unless you perform the dozer operation. Touching it accidentally may cause severe personal injury. If you stop the engine with the dozer raised and then push the dozer control lever, the dozer will fall.

Failure to comply could result in death or serious injury.

W1341A

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

Dozer blade down (A) – Push the lever forward.

Dozer blade up (B) – Pull the lever back.

NOTE: When the dozer blade control lever is released, the lever will be in the neutral position. The dozer blade will stay in the same position it was set in when the dozer blade control lever is released.

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Precautions for dozer operation This dozer blade system is dedicated to a hydraulic excavator. Comply with the following precautions.

• This dozer blade is designed for simple dozing operations. Do not use it for extreme digging. It could damage the dozer blade as well as the travel system.

• Do not apply concentrated or offset load on the dozer blade. Be sure to avoid collisions during traveling because it could cause damage to the dozer blade and travel system.

• When using the dozer blade to lift up the machine, make sure that the supporting ground is strong enough. This type of operation may increase the ground contact pressure locally to weaken the ground. Be sure to ground the dozer blade evenly to avoid offset or concentrated loads.

• Use caution if you perform digging at the dozer blade site (front side), the bucket may interfere with the dozer blade.

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3 - CONTROLS AND INSTRUMENTS

Engine throttle lever Engine throttle lever This lever is located on the right side of the operator’s seat and is used to adjust the engine RPM. A. LO (Low idle) By shifting the lever completely forward, the engine rpm decreases to the minimum B. HI (High idle) By shifting the lever completely rearward, the engine rpm increases to the maximum.

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1

3 - CONTROLS AND INSTRUMENTS

Air conditioner (Option) The air conditioner (if equipped) is located to the right of the operator seat. It provides heating or cooling, removes moisture from humid air and reduces the fog on the window glass.

Three air outlets are located inside the cab; (A), (B), and (C).

Control panel (1) Air outlets (2)

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RAIL14CEX0123AA

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Control panel Air conditioner switch (A/C switch) (1) This switch turns the compressor on or off.

Before you turn the air conditioner switch on, set the fan speed selector (3) to 1, 2, or 3.

When you press the air conditioner switch (1) to turn on the air conditioning, a green lamp will illuminate. The lamp is not lit when the air conditioning is off.

Temperature adjustment switch (2) This switch allows you to adjust the temperature.

To lower the temperature, turn the dial to the left to the cool (blue) range.

To raise the temperature, turn the dial to the right to the warm (hot range.

Fan speed selector switch (3) This switch allows you to change the fan speed of the air conditioner.

• 0 – Stop (off) • 1 – Low (minimum fan speed/air flow) • 2 – Medium (medium fan speed/air flow) • 3 – High (maximum fan speed/ air flow) Recirculation and fresh air selector lever (4) This lever lets you select between fresh air recirculation

and air

.

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3 - CONTROLS AND INSTRUMENTS

Precautions for the air conditioner • Avoid excessive loads on the engine and/or compressor. Turn on the air conditioner after engine start.

• Use the air recirculation option when dust or odors are present in the working environment.

• Prevent freezing of the evaporator, do not operate the air conditioner at the lowest temperature setting for long periods of time.

• If the evaporator freezes, turn the temperature to a higher setting and operate the fan on the “3” setting.

• In hot cab air temperatures, open the doors and windows to replace the hot air before you turn on the air conditioner.

• When there is hot coolant temperatures, it is possible to heat the air with the coolant.

• For health reasons, do not over cool the cab. Periodically ventilate the cab.

NOTICE: Do not splash water on the control panel. Water can cause an unexpected failure.

NOTICE: Keep fire away from the air conditioner.

NOTICE: Adjust the air conditioner according to the ambient temperature and the weather conditions. The optimum difference between the ambient temperature and the temperature inside the cab is 5 to 6 degrees.

Precautions for inspection and maintenance for the air conditioner • To achieve the best performance, have your authorized dealer inspect and maintain the air conditioner.

• Your authorized dealer will use specific tools and instruments to refill the refrigerant gas and to service your air conditioner.

• Operate the air conditioner for two to three times a month (even during the off-season) to sustain the oil in the compressor.

• Check the refrigerant for gas leakage. If there is leakage over a period of time, rust will occur and cause a failure.

• When you clean in the cab, keep electrical components of the air conditioner parts away from water. Water will cause rust which will cause a failure.

NOTE: See 7-15 for regular inspection and maintenance intervals for the air conditioner .

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3 - CONTROLS AND INSTRUMENTS

Color multi-display

RAIL14MEX0052FA

1

The color multi-display (1) consists of gauges (A) and a switch panel (B).

Gauge (A)

Switch panel (B)

Engine coolant gauge (2) Fuel level meter (3) Down arrow switch (4) Up arrow switch (5) Buzzer stop switch (6) Menu switch (7)

NOTICE: When a warning is displayed on the multi-display, stop the work immediately. Inspect and maintain the failure.

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NOTICE: The indications on the multi-display do not assure the condition of the machine. Visually check the machine without relying only on the multi-display.

Engine coolant temperature gauge This gauge indicates the temperature of the engine coolant. The gauge operates when the ignition switch is turned to the ON position.

• White (1): Normal operating range.

• Red (2): Overheat. If the indicator enters the red range, run the engine at low idle until the water cools down.

• Blue (3): Cold, warm up the engine

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3 - CONTROLS AND INSTRUMENTS

Fuel level gauge This gauge indicates the amount of fuel in the tank.

• White (1): Normal operating range.

• Green (2): The “ECO green mark” is illuminated when the fuel consumption is good during machine operation.

• Red (3): Refill. When the fuel level is low, the indicator points to E.

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4

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Switch panel After you start the engine, the main screen is shown as in the right. image.

Buzzer stop switch When a warning is displayed on the multi-display, press the buzzer stop switch (6) to stop the buzzer sound as described in the following tables.

Items in the warnings display lists the warning level and its description Level 1 2 3 4 5

Description This is largely-concerned with the safety and movement of the machine. Stop the machine immediately and perform inspection and maintenance.

This notifies of the mode change of the machine.

This could lead to the failure of the machine. Immediately perform inspection and maintenance.

Difficulty may occur during work. Immediately perform inspection and maintenance.

This notifies of the machine status and maintenance.

Buzzer sound type Buzzer sound type Type 1 Type 2 Type 3

Sounds Continuous Sound 0.2 seconds, stop 0.3 seconds Sound 0.5 seconds, stop 0.5 seconds 3-35

3 - CONTROLS AND INSTRUMENTS

Buzzer sound type Type 4 Type 5 Type 6 Type 7

Sounds Sound Sound Sound Sound

0.5 1.0 2.0 2.0

seconds, seconds, seconds, seconds,

stop stop stop stop

1.0 1.0 1.0 2.0

seconds seconds seconds seconds

Priority Group A Level

multi-display

Machine condition Auto stop The mechatro controller does not send data.

The engine controller judged the status as a disorder.

1

1

Buzzer sounds Manual Type Only stop ignition switch ON

Engine running

—

O

3

O

O

O ( 5 s)

—

1

O

O

Priority Group B Level

multi-display

Machine condition Auto stop

3

3

3

The engine oil pressure is at the specified value or less.

The temperature of the engine coolant is at the specified value or more.

Disorder of the sensor, etc. occurs. The indications are the failure content and the error code.

Buzzer sounds Manual Type Only stop ignition switch ON

—

O

2

O

O

—

O

3

O

O

—

O

3

O

O

Menu button The menu button is available for clock setting and contrast adjustment.

Press the buzzer stop button (2) when you make an adjustment to the contrast or set the clock to return to the main screen.

• Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4) RAIL14CEX0547AA

3-36

Engine running

7

3 - CONTROLS AND INSTRUMENTS

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1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) and move the cursor to “MAINTENANCE”. Press the menu switch (1) to enter “MAINTENANCE”.

3. Use the up and down arrow switches (3,4) and move the cursor to the one of the following items: “ENGINE OIL”, “FUEL FILTER”, “HYD.FILTER”, “HYD.OIL”, or “EXHAUST GAS FILTER”.

4. Press the menu switch (1) and the background color of “REMAINDER” turns blue.

5. Press the down arrow switch (4) to reset “REMAINDER”.

6. Press the buzzer stop switch (2) to return to the user menu screen (b).

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3 - CONTROLS AND INSTRUMENTS

Operating control • Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4)

RAIL14CEX0547AA

RAIL14CEX0558FA

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10

1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) and move the cursor to “OPERATING CONTROL”. Press the menu switch (1) to enter “OPERATING CONTROL”.

3. The operating control table displays the operating time of each day for the current month.

4. Press the down error switch (4) to show the information of the previous month.

5. When three month old information is displayed, press the down arrow switch (4) to return to the current month.

6. Press the buzzer stop switch (2) to return to the user menu screen (c).

NOTE: If you change the clock setting, the data of the operating management information is cleared.

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3 - CONTROLS AND INSTRUMENTS

Clock setting • Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4)

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12

1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) to move the cursor to “CLOCK SETTING". Press the menu switch (1) to enter “CLOCK SETTING”.

3. Use the up and down arrow switches (3,4) to select “YEAR, MONTH, DAY, HOUR, or MINUTE” 4. Press the menu switch (1) to enter screen (e). The background color of the value highlighted turns blue.

5. Use the up and down arrow switches (3,4) to select the desired value.

6. Press the menu switch (1) to set the desired value. The background of the value turns black.

7. Press the buzzer stop switch (2) to return to the user menu screen (c).

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3 - CONTROLS AND INSTRUMENTS

Brightness (day) adjustment • Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4)

RAIL14CEX0547AA

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14

1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) to move the cursor to “SCREEN SETTING". Press the menu switch (1) to enter “SCREEN SETTING”.

3. Use the up and down arrow switches (3,4) to move the cursor to "Brightness (day)”.

4. Press the menu switch (1) to highlight (blue) the number value as shown in screen (e).

5. Use the up and down arrow switches (3,4) to select the desired values.

6. Adjustable range: 1 (dark) to 10 (bright). The default value is 10.

7. Press the menu switch (1) to set the desired value. The background of the set value will turn black.

8. Press the buzzer stop switch (2) to return to the user menu screen (c).

3-40

3 - CONTROLS AND INSTRUMENTS

Brightness (night) adjustment • Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4)

RAIL14CEX0547AA

RAIL14CEX0561FA

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16

1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) to move the cursor to “SCREEN SETTING". Press the menu switch (1) to enter “SCREEN SETTING”.

3. Use the up and down arrow switches (3,4) to move the cursor to "Brightness (night)”.

4. Press the menu switch (1) to highlight (blue) the number value as shown in screen (e).

5. Use the up and down arrow switches (3,4) to select the desired values.

6. Adjustable range: 1 (dark) to 100 (bright). The default value is 4.

7. Press the menu switch (1) to set the desired value. The background of the set value will turn black.

8. Press the buzzer stop switch (2) to return to the user menu screen (c).

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3 - CONTROLS AND INSTRUMENTS

Consumption • Menu button (1) • Buzzer stop button (2) • Up arrow button (3) • Down arrow button (4)

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18

1. Turn the ignition switch ON to display the main screen (a). Press the menu switch (1) to enter the user menu screen (b).

2. Use the up and down arrow switches (3,4) to move the cursor to “CONSUMPTION". Press the menu switch (1) to enter “CONSUMPTION”.

3. The graph indicates the average fuel consumption every 5 min during a 30 min time period. The average fuel consumption of a 30 min time period is also displayed.

4. The graph indicates the average fuel consumption every 2 h during a 12 h time period.

5. To reset these values, press the down arrow switch (4).

6. Press the buzzer stop switch (2) to return to the main screen (c).

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3 - CONTROLS AND INSTRUMENTS

Display for maintenance This screen displays the remaining time to the end of recommended replacement interval specified for the filter and/or oil.

After the machine reaches the end of a replacement interval, inspect and maintain according to the maintenance section in this manual The recommended replacement interval is the accumulated time the engine is running, counted by the controller.

Item Engine oil Fuel filter Hydraulic filter Hydraulic oil

Default 250 h 500 h 1,000 h 5,000 h

• (1) Interval: Recommended time in between an engine oil change.

Remainder: Time remaining until the recommended replacement of the engine oil.

• (2) Interval: Recommended time in between a fuel filter change.

Remainder: Time remaining until the recommended replacement of the fuel filter.

• (3) Interval: Recommended time in between a hydraulic oil filter change.

Remainder: Time remaining until the recommended replacement of hydraulic oil filter.

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• (4) Interval: Recommended time in between a hydraulic oil change.

Remainder: Time remaining until the recommended replacement of hydraulic oil.

Set procedure of maintenance schedule

NOTE: For information on the initial set up of the maintenance time, see the Menu button procedure. When the recommended replacement time is over, its remainder indication turns red. Reset to the initial value when necessary.

Item Engine oil Fuel filter Hydraulic filter Hydraulic oil Exhaust gas filtere

Recommended replacement time 250 h 500 h 1000 h 5000 h 3000 h

3-43

Warns Warns Warns Warns Warns

Multi-display without a buzzer without a buzzer without a buzzer without a buzzer without a buzzer

3 - CONTROLS AND INSTRUMENTS

Operating control screen This screen displays tracks the machine’s operating time in increments of 0.5 h (less than 0.5 h will be rounded down). You can see the operating information of total four months (current month and past three months).

The figure shows the machine operated on June 1st for 1.5 h • (1) — Displays the month • (2) — Displays the date with the blue background • (3) — Displays the operating time of the day RAIL14CEX0860AA

20

A no operation day (the engine was not started) displays as blank.

NOTE: If the battery is removed or the clock setting is changed, the stored data is cleared and all operating information will be displayed as blank.

NOTE: The initial state is "January 1st, 2000". Note the operating time before removing the battery or changing the clock setting, if necessary.

Warning display screens Warning classification (Priority A) Display

Level 1 1

Warning contents The mechatro controller does not send data.

The engine controller judged the status as a disorder.

Remedy Contact your authorized dealer for inspection and maintenance Contact your authorized dealer for inspection and maintenance.

Warning classification (Priority B) Display

Level 3

3

3

4

Warning contents The engine oil pressure is at the specified value or less.

Remedy Immediately stop the engine and check the engine oil level. If the level is low, supply the specified engine oil or replace the old engine oil with the new specified engine oil by referring to the Fluids and lubricants section in this manual.

The temperature of engine coolant Stop the operation and set the engine is at the specified value or more. speed to low idling to lower the coolant temperature and cool down the engine.

After few minutes, if the warning is still displayed, stop the engine and check the coolant level, tension of the fan belt, and clogging of the radiator.

Disorder of the sensor, etc. occurs. Contact your authorized dealer for inspection and maintenance.

The indications are the failure content and the error code.

Check the electric devices for working Disorder of the battery occurs.

(High voltage/ low voltage charge condition and check the charging circuit. error) If the warning does not disappear after a while from the engine start, or if the warning appears while the engine is running, the battery is not charged properly.

3-44

3 - CONTROLS AND INSTRUMENTS

Display

Level 4 5 5 5

5 5 5 5 5

Warning contents The fuel level is at the specified level or less.

Remedy Supply the specified fuel.

The remaining time for replacement of the engine oil reaches to 0.

The remaining time for replacement of the fuel filter reaches to 0.

The remaining time for replacement of the hydraulic oil filter reaches to 0.

The remaining time for replacement of the hydraulic oil reaches to 0.

The remaining time for replacement of the engine oil is little.

The remaining time for replacement of the fuel filter is little.

The remaining time for replacement of the hydraulic oil filter is little.

The remaining time for replacement of the hydraulic oil is little.

Supply the specified new engine oil to the specified level.

Replace the fuel filter with the specified new fuel filter.

Replace the hydraulic oil filter with the specified new hydraulic oil filter.

3-45

Replace the hydraulic oil with the specified new hydraulic oil.

Contact your authorized dealer for inspection and maintenance.

Contact your authorized dealer for inspection and maintenance.

Contact your authorized dealer for inspection and maintenance.

Contact your authorized dealer for inspection and maintenance.

3 - CONTROLS AND INSTRUMENTS

Electrical equipment

Fusible link Handling of the fusible link (for the starter) The fusible link (1) is fuse wiring of large size in a large capacity circuit. It protects electrical components and wiring from burn out due to excess current.

If the starter does not work when the ignition key switch is turned to the ON position, the fusible link (1) is suspected to be disconnected. Check and replace as needed.

RAIL14MEX0026BA

3-46

1

3 - CONTROLS AND INSTRUMENTS

Electronic Control Unit (ECU) Handling the Electronic Control Unit (ECU) The Electronic Control Unit (ECU) is located under the seat stand cover.

NOTICE: Be careful not to splash water, mud, or drinks on the controller. It may cause failure of the machine. If an error occurs on the controller, do NOT disassemble it.

Contact your authorized dealer for repair.

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1

3 - CONTROLS AND INSTRUMENTS

3-48

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS###_4_### Commissioning the unit

Daily inspection The following procedures are to be performed every 8 h or daily, before starting the machine.

• Check the engine for any oil, fuel, or coolant leakage. Repair as required.

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

• Check the hydraulic system components, the hydraulic oil tank, the hoses and the joints for oil leakage. Repair as required.

• Check the travel system, such as the crawlers, front idlers, and sprockets for any damage or wear. Check the cap screws for looseness.

• Check the attachments, dozer blade, cylinders, linkages and hoses for any cracks, wear or looseness. Repair as required.

• Check the guards, steps, and handrails for damage. Check the cap screws for looseness and repair and tighten them as required.

• Check the fan belt.

• Verify that the gauges and the monitor panel function properly.

• Check the work lights.

• Check the exhaust color, sound, and odor.

• Check the safety lever lock.

NOTE: See “Every 8 hours” in the maintenance section of this manual for the expanded procedures on the above checks.

Visually check the machine for deformation and damage Even if deformation of a guard or cover does not appear to be severe, it may interfere with internal hoses and parts.

Contact your authorized dealer for recommended repair.

RAIL14CEX0978AA

1

Check for loose or missing bolts and nuts Check for loose or missing bolts, and hose clamps. If you hear an irregular sound during the check, tighten the bolts and nuts. Refer to 7-5.

4-1

4 - OPERATING INSTRUCTIONS

Starting the unit

Starting the engine WARNING Inhalation hazard!

Make sure there is proper ventilation before starting the engine.

Failure to comply could result in death or serious injury.

W0928A

Start the engine – Normal conditions 1. Securely fasten your seat belt.

2. Place the safety lock lever (1) in the LOCKED position (A).

3. Set all control levers to the neutral position.

LELI11E0191AB

1

LELI11E0192AB

2

4. Set the throttle control lever (2) to a speed slightly above the low idle position.

5. Turn the ignition switch key (3) to the START position (C). Release the ignition switch key as soon as the engine starts. The key will automatically return to the ON (HEAT) position (B).

6. If the engine does not start within 15 s, turn the ignition switch key (3) to the OFF position (A) and wait for 30 s before you try again to start the engine.

RAIL14CEX0869AA

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3

4 - OPERATING INSTRUCTIONS

Start the engine – Cold conditions With cold weather, due to the increase of oil viscosity and the decrease of battery charge, starting the engine may be difficult. Use the pre-heater to start the engine easily under these conditions.

1. Perform steps 1 through 4 in start the engine – normal conditions.

2. Turn the ignition switch key (3) to the ON (HEAT) position (B) for 15 s to warm up the engine.

3. Turn the key to the START position (C). Release the ignition switch key (3) as soon as the engine starts.

The key will automatically return to the ON (HEAT) position (B).

RAIL14CEX0869AA

4. If the engine does not start within 15 s turn the ignition start key (3). to the ON (HEAT) position (B) for 10 s.

Then repeat the above mentioned operations to start the engine.

NOTICE: Do not hold the ignition switch key (3) to the START position (C) for more than 15 s. If then engine does not start, turn the ignition switch key to the OFF position (A).

4-3

4

4 - OPERATING INSTRUCTIONS

Start the engine – With booster batteries WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A LELI11E0195AA

5

LELI11E0196AA

6

LELI11E0197AB

7

WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Explosion hazard!

Booster batteries or jumper cables must be connected properly to prevent battery explosion and/or damage to the electrical system.

Connect positive to positive and negative to negative.

Failure to comply could result in death or serious injury.

W0343A

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

NOTICE: Do not use booster cables that are damaged, i.e. broken insulation, damaged or corroded clips.

The electrical system of this machine is 12 V. 1. Turn the ignition switch key to the OFF position for both the booster vehicle and the disabled machine.

2. Place the safety lock lever in the LOCKED position.

3. Open the right-hand side access door.

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8

4 - OPERATING INSTRUCTIONS

4. Remove the cover from the battery terminals.

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

6. Connect the other terminal of the positive cable (+) (red) to the positive terminal (+) of the battery of the boost vehicle.

7. Connect the other terminal of the booster cable (black) to the negative terminal (-) of the battery of the boost vehicle.

8. Finally, connect the other terminal of the negative booster cable (-) (black) to the upper frame of the disabled machine, away from the battery.

9. Start the engine of the boost vehicle, and operate it for approximately for 10 min at high idle.

Cable connecting order 1>2>3>4 RAPH13CEX0080BA

• Booster battery (A) • Red cable (B) • Discharged battery (C) • To the upper frame of the disabled machine (D) • Black cable (E) 10. Start the engine of the disabled machine.

11. After you start the disabled machine, disconnect the booster cables exactly in the reverse order.

Cable disconnecting order 4>3>2>1 Check and repair the charging system on the disabled machine.

4-5

10

4 - OPERATING INSTRUCTIONS

Inspection after engine start Safety lock lever WARNING Avoid injury!

If the machine responds to the controls with the safety lever in the LOCK position, stop the engine immediately and contact your dealer.

Failure to comply could result in death or serious injury.

W0937A

With the engine running and the safety lock lever in the LOCKED position (1) move the following control levers.

• Left control lever • Right control lever

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• Left and right travel control levers.

Make sure that all of the functions do not actuate when the safety lock lever is in the LOCKED position (1).

NOTICE: The boom swing pedal is live at all times, even with the safety lock lever in the LOCKED (UP) position.

Monitor panel After engine start, make sure that • The engine coolant temperature gauge (1) and the fuel level gauge (2) function.

• The engine hydraulic pressure lamp (3) is not illuminated.

• The battery charge lamp (4) is not illuminated.

4-6

4 - OPERATING INSTRUCTIONS

Check exhaust gas color, sounds, and smells NOTE: Image (A) shows machines with exhaust exiting the machine from the side. Image (B) shows machines with exhaust exiting from underneath the machine.

1. Color classification of exhaust gas during operation: ○ Colorless or light blue – After the engine warms up at no load, normal combustion. ○ Black – Abnormal, DPF failure. ○ White – Abnormal, piston ring or valve guide oil loss.

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

NOTE: The smoke may look white in the winter due to the cold weather.

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

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4-7

3

4

4 - OPERATING INSTRUCTIONS

Engine warm up NOTICE: Do not run the engine idle for more than 20 min.

Extended periods of idling reduce the life of the engine.

To warm up the engine, proceed as follows: 1. Set the throttle lever (1) to intermediate position, between low and high idle.

2. Let the engine run idle for at least 5 min with no load at a medium speed, with the throttle lever (1) between low and high idle.

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4-8

1

4 - OPERATING INSTRUCTIONS

Hydraulic oil warm up NOTICE: Do not start working prior to completing a correct hydraulic oil warm up, since the hydraulic functions would be slowed down and unexpected movements of the machine could occur. Also, some hydraulic components could be damaged by insufficient lubrication.

The hydraulic oil temperature must be between 50 °C (122 °F) and 80 °C (176 °F).

Avoid machine operation when the hydraulic oil temperature is below 20 °C (68 °F).

To warm up the hydraulic oil, proceed as follows: 1. Make sure to perform the engine warm up procedure.

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1

2. To warm up the engine, proceed as follows: 3. Place the safety lock lever (3) in the UNLOCK position and the engine throttle lever (1) on an intermediate speed position.

4. Operate the boom control lever (2) to maintain sufficient ground clearance.

5. Operate the bucket control lever to retract it or extend it completely. Hold in this position for 5 min, then release the lever (2).

6. After the hydraulic oil warms up, slowly extend and retract all cylinders several times. Swing and travel the machine lightly to complete the warm-up operation.

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

4-9

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2

4 - OPERATING INSTRUCTIONS

Stopping the unit

Stopping the engine NOTICE: If the engine stop is abrupt, while it is running at high speed, the engine temperature increases rapidly.

As a consequence, the engine oil is overheated and the joints jam.

Let the engine run idle for at least 5 min before stopping it, to keep it in good conditions.

1. Normally, the attachment should be placed on the ground, before stopping the engine (except for particular situations).

2. Before leaving the operator’s seat, make sure that the safety lock lever (1) is in the LOCK position (A).

3. Bring the throttle control lever (2) to engine low idle.

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4. Let engine run at idle speed for several minutes, in order to ensure gradual cooling.

5. Turn the ignition key (3) to the OFF position to stop the engine.

6. Remove the ignition key (3).

NOTICE: Always rest the bucket onto the ground before stopping the engine. Position the machine on a firm and level ground. Never leave the machine unattended while the engine is running.

RAIL14CEX0880AA

4-10

3

4 - OPERATING INSTRUCTIONS

Parking the unit

Parking the machine • Always park the machine on a firm, level surface.

• Avoid parking on a slope.

When parking on a slope is unavoidable, make sure the bucket teeth are stuck in the ground, lower the dozer to the ground and properly block the crawlers with wedges.

To stop the engine.

1. Turn the ignition key to the OFF position and remove it.

2. To prevent any unexpected movement, place the safety lock ever is in the LOCKED position.

NOTICE: Do not shut off the engine when running at full speed, but let it run idle for some minutes to cool it down.

LELI11E0235AB

1

3. Move both travel control levers (1) to the neutral position.

4. Set the throttle control lever (2) to low idle.

5. Lower the bucket to the ground.

6. Place the dozer blade on the ground.

7. Block both crawlers with chocks.

8. Stop the engine by turning the ignition key to the OFF position.

NOTICE: Do not shut off the engine when running at full speed, let it run idle for some minutes to cool it down.

2

SMIL13MEX0026AB

9.

Set the safety lock lever (3) to the LOCK position (A).

10. Close all of the windows.

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4-11

3

4 - OPERATING INSTRUCTIONS

Lock the following doors and covers: • Cab door (with the ignition key) • Engine door (with the ignition key) • Right-hand side cover (automatically locks when it is closed) )

4-12

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5

4 - OPERATING INSTRUCTIONS

Parking the machine after an emergency stop of engine Avoid emergency stops of the engine as much as possible.

Before you stop the engine, you should operate the engine with no load for approximately 5 min.

NOTICE: If the engine stops immediately after a high speed operation, the engine temperature increases remarkably. As a consequence, the engine oil is overheated and the joints jam, etc.

Even if the engine is not running, keep the safety lock lever in the LOCKED position.

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8

When you perform an emergency stop, there is no time to lower the bucket to the ground. Support the crawlers with wood wedges (1) to lock the crawlers.

When you perform an emergency stop on a slope, block both crawlers at their lower sides.

While you are waiting to restart the engine and the machine, free the working area from people and possible obstacles. Set limits around the machine, taking the appropriate measures so that nobody penetrates this area.

Place the Do Not Operate tag on the machine.

If the trouble cause is not clear or a repair is required, contact your authorized dealer.

After an emergency stop, restart the engine only when the coolant is completely cool.

4-13

4 - OPERATING INSTRUCTIONS

4-14

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### Preparing for road transport

Transporting on a trailer Machine preparation • Know the total weight, length, width and height of the machine to be transported. Refer to the Specifications section in the manual.

• Use only a trailer with a rated capacity sufficient to transport the machine.

• Make sure trailer has ramps or a ramp is available for loading the machine. Use ramps which have sufficient width, length, thickness and strength. The ramp slope should be 15 ° or less.

• Investigate beforehand the conditions of the road to be traveled, weight and size limits, and special local traffic regulations.

• Obtain any permits required from proper government agencies for machine transportation.

• Position the trailer on firm and level ground. Put blocks to the tires of trailer to prevent machine from moving.

• Accurately clean the machine undercarriage and tracks to prevent mud or debris from skidding during transport.

NOTE: if the machine is equipped with the steel crawlers, rubber stripes must be used between trailer and steel crawlers.

Use of a ramp The loading and unloading ramp should be of sufficient width, length, and strength; also ensure that ramp angle is lower than 15 °.

LELI11E0419AA

5-1

1

5 - TRANSPORT OPERATIONS

Make the ramp strong enough so that the machine does not turn over during the loading/unloading operations and the slope sides do not break. If necessary, provide some supporting posts to reinforce both side of the banking.

The height of the platform or ramp must correspond to that of the base of the truck/trailer.

1. Wedges 2. Blocks 3. Ramps LELI11E0420AB

2

Loading the machine • Always select the slow travel speed mode with extreme care and attention.

, proceed

• Avoid steering while driving the machine onto the ramp: danger of machine overturn. Should corrective steering be necessary, move back to ground or trailer surface, change travel direction and resume driving. The ramp end (link spot with the trailer) causes a sudden bump; travel over the bump with extreme care and increase machine stability using the front attachment.

• In order to load the machine with the attachment fitted, travel on the ramp slowly at forward run, keeping the attachment and the dozer positioned ahead.

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4

• After arriving to the required position, lower the dozer and turn the upper structure 180 ° slowly.

• Fully extend the bucket and arm cylinders. Then slowly lower the boom.

• Make sure to block the involuntary rotation of the upper structure by resting the bucket on the ground and by securing the bucket to the flatbed with wire ropes.

NOTE: To prevent the bucket cylinder from damages during transport, apply a wooden block to the edge of bucket link in order not to get down it to the floor.

5-2

5 - TRANSPORT OPERATIONS

Securing the machine After you load the machine 1. Lower the dozer blade.

2. Fully extend the bucket and arm cylinders.

3. Slowly lower the boom.

NOTICE: To protect the bucket (attachment) cylinder from damage during transport, place a wood block at the end of the bucket link to keep the cylinder from making contact with the truck bed.

4. Move the safety lock lever to the LOCKED position (B).

5. Stop the engine, deactivate all of the switches, and remove the starter key.

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5

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6

6. Lock all of the covers and the cab door (if equipped).

7. To prevent machine movement during transport, position blocks (A) at the front and rear of the crawler belts to secure them.

8. Use wire rope/chain (1) to sufficiently tie down the machine for safe transport.

NOTE: See the lashing point decal positions on the lower frame and on the dozer blade.

5-3

5 - TRANSPORT OPERATIONS

Unloading the machine NOTICE: Before unloading the machine, make sure all tie-down chains are removed and the trailer wheels blocked.

1. Position the trailer on firm and level ground. Put chocks to the tires of trailer to prevent machine from moving.

2. Remove the chains or the wire ropes used to secure the machine.

3. Start engine and move the safety lock lever to the UNLOCK position.

4. Raise the attachment and the dozer blade and travel slowly in reverse along the flatbed.

5. Set the arm and the boom to angle between 90 - 110 ° and travel down slowly from trailer to ramps.

6. Travel down on the ramps slowly while operating boom and arm softly until the machine completely passes through the ramps.

5-4

5 - TRANSPORT OPERATIONS

Shipping transport

Lifting the machine WARNING Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

W0256A

The following procedures are for lifting the machine, as built by CASE CONSTRUCTION. This procedure does not take into account modifications made to the machine that affect machine mass or center of gravity.

RAIL14MEX0032FA

Rubber shoe Iron shoe Cable (1,3) (Quantity - 1) Cable (2,4) (Quantity - 2)

1

Cab 3400 kg (7496 lb) 3490 kg (7694 lb) 18.0 mm (0.7 in) X 1400 mm (55 in) 18.0 mm (0.7 in) X 4400 mm (173 in)

Canopy 3250 kg (7165 lb) 3340 kg (7363 lb) 18.0 mm (0.7 in) X 1400 mm (55 in) 18.0 mm (0.7 in) X 4400 mm (173 in)

NOTE: This lifting up procedure is applicable for machines in standard specification. The lifting procedure differs for each attachment type and each machine in option. In such cases, contact your authorized dealer.

Lift the machine from firm level ground as follows:

the machine. Check the operator's seat and area for any loose item, tools, etc. that could fall or cause a problem or injury during the procedure. Remove or secure them.

1. Operate the control levers to set the attachment as shown.

2. Use the swing pedal to straighten the boom.

3. Stop the engine and move safety lock lever to the locked position. Remove the starter key and get off

4. Attach shackles to the two lifting holes (B) on both ends of the dozer blade. Attach the wire rope (2,4) to the shackles.

5-5

5 - TRANSPORT OPERATIONS

5. Attach a shackle to the lifting hole (A) on the boom .

Attach the wire rope (1,3) to the shackle.

5-6

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS###_6_### General information

Operating the controls DANGER Avoid injury!

Keep clear of the machine. Make sure that the area is clear of obstacles and persons before you operate the machine. Always look around before you start the swing operation. Sound the horn before you begin the swing operation.

Failure to comply will result in death or serious injury.

D0124A

The following instructions inform the operator of the basic function of each hydraulic control. Learning these instructions and practicing with the hydraulic controls will increase operator efficiency during machine operation. Prior to machine operation, each operator must read carefully, learn and implement the safety rules described in this manual and located on the machine.

NOTICE: If any fault occurs during machine operation, immediately stop the engine. Make sure to repair any faulty condition before resuming operation. Normal positioning of the machine, for the purpose of determining front, rear, forward and reverse, is with the travel motors located behind the operator’s cab.

6-1

6 - WORKING OPERATIONS

Optional attachments (Nibbler / breaker) When mounting optional attachments, such as a hydraulic breaker or nibbler, on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and oil level for each attachment. To select proper attachments, contact your dealer/distributor.

Before installing a breaker or nibbler, consult with your dealer/distributor for hydraulic connection information. Check the hydraulic return filter and if needed, replace it according to the specified replacement interval. Thoroughly read the operator’s manual for the optional equipment and the safety precautions outlined in this section to avoid damaging the machine or breaker during operation.

While optional attachments are not installed, plug the hydraulic tubes on the bucket/arm end and hoses on the attachment end to prevent dust or water from entering the hydraulic system. Before operating the attachment, check the clamps on all hydraulic tubes and hoses for oil leakage and looseness and tighten as needed.

NOTICE: Continuous operation of the breaker or nibbler for longer than 30 s could cause premature wear or damage to the attachment and machine. If material is not

breaking, reposition the breaker or nibbler and repeat the operation in 30 s intervals.

1. Start the machine and place the safety lock lever in the LOCKED position.

2. Move the throttle lever to the HI position.

3. Using the boom, arm, and the bucket controls, set the breaker or nibbler to the desired position and against material to be broken.

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Setting the selector valve Machines equipped with a nibbler and or breaker attachment must have the hydraulic system selector valve set to the correct position.

NOTICE: Operation of a nibbler or breaker with the selector valve in the wrong position will result in poor performance and may cause damage to the machine. Make sure the selector valve is positioned correctly for nibbler or breaker operation. To assure proper operation, change the selector valve position once a month.

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6-2

2

6 - WORKING OPERATIONS

NOTICE: Lower the attachment to the ground and stop the engine before switching the selector valve to avoid unexpected movement of the attachment or machine.

1. Open the cover at the front of the machine to access the selector valve (1).

2. Use a 5 mm hex wrench to remove the bolt (2).

3. Use a wrench to turn the selector valve (1) to the desired position ( width across flats: 24 mm ).

4. After the selector valve (1) is in the desired position, install and tighten the bolt (2) with the 5 mm hex wrench.

Selector valve shifting position.

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A. To the control valve B. To the attachment C. Use nibbler D. Use breaker E. To the tank

Contamination and deterioration of the hydraulic oil could cause poor function of the control valves, early wear and seizure of the hydraulic pump, and failure of the whole hydraulic circuit.

When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of normal bucket digging work. For the periodic inspection and maintenance schedule of the nibbler and breaker, see 7-15.

6-3

6 - WORKING OPERATIONS

Angle dozer blade (If equipped) The dozer blade control lever (1) operates the dozer blade up and down, and angles the dozer blade left and right.

When the dozer control lever (1) is released, it returns to the neutral position and the dozer blade is held in its last set position.

1

RAIL14MEX0061AA

Lever Operation operating direction Forward Variable speed for lowering the blade.

Dozer blade down (D).

Backward Variable speed for raising the blade. Dozer blade down (B) Right Right-hand side of the blade angles in, towards the machine. Dozer blade angles in to the right (A) Left Left-hand side of the blade angles in, towards the machine. Dozer blade angles in to the left (C).

Hold position Center

PY20T01216P1

6-4

2

6 - WORKING OPERATIONS

Machine travel DANGER Avoid injury!

Keep clear of the swing area. Ensure that any person near the working site is outside the swing area before you start or operate the machine. Sound the horn before you start or operate the machine.

Failure to comply will result in death or serious injury.

D0123A

Forward/reverse travel • Make sure the safety lock lever (1) is in the UNLOCK position.

• Operate the boom, arm, and bucket control levers to raise the attachments from the ground. Keep the bucket at a height of 30 - 40 cm (12 - 16 in) above the ground.

• Operate the control lever to raise the dozer blade.

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• To move the machine forward, push both (right and left) travel levers forward simultaneously (2).

• To move the machine in reverse, pull back both travel levers simultaneously (3).

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

Right turn • Push the left travel lever forward (1) to turn the machine to the right.

6-5

6 - WORKING OPERATIONS

Left turn • Push the right travel lever forward (1) to turn the machine to the left.

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Clockwise rotation • Push the left travel lever forward (1) and at the same time the right travel lever backward (2).

Counter-clockwise rotation • Push the right travel lever forward (1) and at the same time pull the left travel lever backward (2).

Shifting from one travel speed to the other travel speed (2nd gear), press and re• For a HIGH lease the relevant switch on the grip of the right travel lever. The hare indicator (1) on the instrument panel turns on.

• Start the machine by operating the travel levers. travel speed (1st gear), stop • To return to SLOW travelling, press and release the relevant switch.

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

6-6

6 - WORKING OPERATIONS

Stop travelling • Move the left and right travel control levers to the NEUTRAL position to stop machine travel.

• Avoid stopping the machine travel suddenly. Stop the machine travel as slowly as possible.

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Travel precautions Make sure that you know travel motor (1) location before performing any travel operation. Travel with travel motors at the back of the machine for long distance travel.

Travel on the level and firm ground as much as possible.

Also travel in straight and large radius curve as much as possible, avoiding an abrupt pivot turn.

In a narrow area, turn the machine in the opposite direction as many times as possible.

Survey the strength of bridges and shoulders, and strengthen them if necessary.

Be careful not to touch a bridge beam and electrical power line.

Traveling on a rough road has a great impact on the machine. Reduce the engine speed and use the LOW (1st) speed.

Be careful not to hit travel motor with a boulder or run on a boulder to add an excessive load to the crawlers.

On a snowy or icy road, travel slowly and avoid an dash start, stop and turn.

Always move with a lowered bucket, especially on slopes or during transfers. The bucket, however, should be sufficiently raised from the ground to overcome possible obstacles. Do not use the bucket as a man lift or to carry riders.

6-7

6 - WORKING OPERATIONS

WARNING Electrocution hazard!

Contact with overhead power lines can cause severe electrical burns or death from electrocution. Make sure there is enough clearance between equipment and overhead power lines.

Failure to comply could result in death or serious injury.

W0040A

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

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11

Check the strength of bridges and road shoulders. Reinforce them if necessary.

Make sure to keep a sufficient distance from bridges and electrical power lines. Prior to digging, check existence and location of electrical lines, gas ducts, water pipes or other public utilities installations. If in doubt, contact local authorities and/or the distributing companies (electric power, gas, telephone, water, telecommunications, etc).

When travelling on rough ground, use low speed (1st) (A) to reduce vibrations and make sure that the throttle control lever is in engine low idle (B) position.

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

On a snowy or icy roads, travel at slow speed. Avoid starting or stopping abruptly and avoid turning the upper structure suddenly.

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

6-8

6 - WORKING OPERATIONS

Precautions for travelling on slopes NOTICE: Should it be necessary to operate the machine on slopes, carefully observe the following precautions.

This to prevent injuries due to accidental machine overturn.

NOTICE: Always stop the machine before selecting the other travel speed mode. Never shift gears while travelling with the machine. Avoid especially shifting to quick travelling mode while travelling on a slope: it may be dangerous.

When on slopes avoid as much as possible to travel across them.

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15

Always travel at slow speed.

When travelling, lift the bucket up to 30 - 40 cm (11.8 15.7 in) from the ground in the travelling direction. Do not travel down a slope in reverse run.

When the machine slips, immediately lower the bucket to the ground and operate the brakes.

Never attempt to rotate the upper structure downhill: the machine could tip over. If this operation is unavoidable, create on the slope a flat working area.

Never attempt to travel up or down a slope with a gradeability of 30 ° ( 58 %) or more.

When the engine stops on a slope, immediately lower the bucket to the ground and move all control levers to the NEUTRAL position, then start the engine again.

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

When the machine is parked on a slope, even for a short time, lower the bucket (1) and the dozer (2) to the ground, return all control levers to the NEUTRAL position, set the safety lock lever to the LOCK position and block both crawlers by means of wedges (3).

NOTE: When the hydraulic oil is not sufficiently warm, the machine may not be able to develop its full performance.

Before travelling on a steep slope, preheat machine completely.

6-9

6 - WORKING OPERATIONS

Machine operation in water or on soft grounds NOTE: The swing bearing of the upper structure, the pinion of the rotation motor and the rotary control valve should never operate in water or mud.

If the machine is operated in water or mud, the swing bearing and the other components may wear excessively. Immediate replacement of grease or overhaul of the slewing bearing, etc. is required.

Where the river bottom is flat and water flow is slow, the machine may be operated in water, provided that water is not higher than the guide plates of the crawlers (1).

When operating under such condition, use the machine carefully and check condition of river bed. Never enter deeper waters.

1

TUIL12E2B0023AB

On soft ground, the machine body sinks in some cases gradually. Therefore, pay full attention to the machine at all times during operation.

After travelling in sea water, thoroughly wash up the machine to remove salt.

Make sure to lubricate bucket pins and bushing every 4 h if working with materials in wet conditions, supply grease with a grease gun until grease oozes out.

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6-10

2

6 - WORKING OPERATIONS

Getting out of soft ground WARNING Avoid injury!

Keep all persons and objects clear while any part of this machine is in motion.

Failure to comply could result in death or serious injury.

W1282A

WARNING Avoid injury!

Operate controls only when seated in the operator's seat.

Failure to comply could result in death or serious injury.

W0956A

If possible, avoid travelling on soft ground. Avoid getting caught in the mud. In the event that the machine gets caught in the mud, get out of it as follows.

One crawler caught in mud When a crawler gets caught in mud, lay logs or boards on the mud to form a base. Raiser the dozer blade and Operate boom and arm to form a crossing angle between 90 - 110 °. Push outer side of bucket against the ground to lift the machine body.

NOTICE: When you lift up the machine use the bottom of the bucket , not the teeth, to push on the ground.

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Both crawlers caught in mud When both crawlers get caught in mud and the machine does not move because it skids, provide logs and boards, as described in the previous step and anchor the bucket firmly to the ground so that you can help the machine to come out from mud.

If the machine is unable to travel because the crawlers are stuck in mud, sand or gravel, raise each crawler side alternately by pushing the bucket against the ground and scraping off mud, sand, or gravel. Gravel and mud may be cleared off by rotating the raised crawler back and forth.

6-11

6 - WORKING OPERATIONS

Swing control Rotation of the upper structure • When you work on slopes the machine becomes unstable and unbalanced.

• Make sure the rotation area is clear of persons and obstacles before operating the engine.

• Work up and down inclines or slopes, never across.

• Never slew or turn machine around on slopes.

• Operate control levers carefully to prevent sudden movements that may cause the machine to slip or tip over.

• Prepare a level area for the machine to operate.

• Use a flagman to guide the operator.

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1

The upper structure swings when the left control lever is moved rightward or leftward. The swinging speed is determined by the stroke of the lever.

• When moving the left control lever leftward, the turret swings leftward.

• When moving the left control lever rightward, the turret swings rightward.

• When returning the left control lever centrally (neutral position) the upper structure stops moving.

NOTE: when you travel or before you stop the machine and when you are not performing a swing operation, keep the attachment and the crawler frame parallel to each other.

6-12

6 - WORKING OPERATIONS

Practices to improve efficiency • Swinging the upper structure on a slope may cause the machine to overturn. On a slope, it is very dangerous to swing the upper structure downhill with a full bucket.

Prepare a level area for the machine to operate safely.

• Make sure the rotation area is clear of persons and obstacles before operating the engine.

NOTE: The optional attachments offer a wider range of application other than the showed ones.

Digging instructions Use mainly the arm force for digging. Use the full bucket rotation travel to fill it completely. Setting the bucket too deep will decrease the machine’s efficiency.

Maximum digging force position The attachment will provide maximum digging force when arm and boom are positioned at 90 - 110 ° from each other. Operate slowly to get maximum digging force.

Bucket teeth direction LELI11E0228AB

1

LELI11E0229AB

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3

Direct bucket teeth parallel to digging direction. The bucket must be used for shallow diggings, so as to reduce the resistance and avoid damaging the teeth.

Operate boom carefully Activate boom operation by moving the control levers carefully. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

Clean sand and soil from bucket Place the arm in horizontal position and bring the bucket to the dump position. If sand and soil do not fall out, move the bucket lever right and left a few times to remove the soil stuck to the bucket.

6-13

6 - WORKING OPERATIONS

Digging ditches The working efficiency is much improved when the bucket is oriented correctly for digging ditches and parallel to a ditch.

For wide ditch digging, dig the two sides first, then dig the center portion.

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LELI11E0232AA

5

LELI11E0233BB

6

Operating the dozer blade The dozer blade is used to push the soil back into an excavated ditch or for ground levelling.

To distribute the earth heaped up on the ground using the dozer, start from the top or from the sides of the heap. If necessary, adjust the height of the dozer by means of the relevant control lever, to prevent overloading the engine.

Offset (side) digging DANGER Avoid injury!

Keep clear of the machine. Make sure that the area is clear of obstacles and persons before you operate the machine. Always look around before you start the swing operation. Sound the horn before you begin the swing operation.

Failure to comply will result in death or serious injury.

D0124A

NOTICE: When the swing range of the boom is wider, pay attention to the conditions of the surrounding area.

By pressing the left and right side of the boom swing pedal (1) alternately, the boom (2) swings in the left and right direction. This enables offset (side) digging in narrow spaces.

By pressing the left side of the boom swing pedal, the boom swings to the left, and by pressing the right side, the boom swings to the right.

The advantage of this function is that it enables offset (side) digging work as shown in the figure.

6-14

6 - WORKING OPERATIONS

Load The working efficiency can increase if the dump truck collecting the removed earth is parked so that the rotation angle of the arm is minimal. At the same time, the operator’s visibility remains the best.

It is recommended that loading be started from the front side of the dump truck body. This will make loading easier and more soil can be loaded than by loading from the side.

LELI11E0234AB

7

Minimum swing position Extend arm cylinder and bucket cylinder to maximum length, and fold the bucket.

Extend boom cylinder to the maximum length.

Press the left side of the boom swing pedal, and then swing the boom fully to the left.

Operate the control lever to rotate the upper structure..

Minimum swing radius Boom Minimum swing radius with swing Minimum swing radius without swing

Canopy 1910 mm (75 in) (left 70 °) 2300 mm (91 in)

NOTE: These values are for the standard arm specifications.

6-15

Cab 1910 mm (75 in) (left 70 °) 2300 mm (91 in)

6 - WORKING OPERATIONS

Lowering the attachment in the event of an engine failure WARNING Unexpected machine movement!

Only use the following procedure in case of machine failure. Always use extreme caution during operations. Keep other persons away from the bucket, attachment, and boom. The bucket or attachment can move unexpectedly during operations due to weight of the bucket, attachment, arm, or boom.

Failure to comply could result in death or serious injury.

W1364A

CAUTION Crushing hazard!

Keep away from the space under the bucket or attachment when lowering the bucket or attachment.

In cases where the machine fails and the engine stops, lower the attachment using the procedure described in this manual.

Failure to comply could result in minor or moderate injury.

C0169A

NOTICE: Steps 1 through 6 should be completed within five minutes after the engine stops. The accumulator pressure will gradually falls which will disable the ability to lower the attachment.

1. Set the safety lock lever to the LOCKED position.

2. Turn the ignition switch to the OFF position.

3. Set all control levers to the neutral position.

4. Turn the ignition switch to the ON position.

5. Set the safety lock lever to the UNLOCKED position.

6. Use the left and right control levers to slowly lower the attachment until it touches the ground.

Step 1: Bucket down (1) Step 2: Arm down (2) Step 3: Boom down (3)

6-16

RAIL14MEX0096AA

1

RAIL14MEX0095AA

2

6 - WORKING OPERATIONS

Lowering the bucket in emergency situations NOTICE: This procedure is to be used only as an emergency to lower the position of the bucket. Use extreme caution, since the weight of the bucket will tend to move this abruptly, when the hoses of the hydraulic system are disconnected.

Be sure to block the attachments to avoid sudden change of position. Remove the hoses of the hydraulic system slowly, until oil pressure is completely released. Then control the bucket movement by slowly removing the block.

To lower the bucket, proceed as follows: • when the bucket is in digging position (A) (bucket cylinder completely extended), disconnect the hose (H);

LELI11E0255AB

1

LELI11E0256AB

2

• when the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose (R).

NOTICE: Make sure that the hydraulic system or a component of this are not contaminated from polluting agents.

This could cause severe system damages. Contact your Dealer to obtain the proper caps and plugs to be used on this machine.

NOTE: Clean up all spilled oil. Dispose of collected oil, because polluting, according to the local environments.

6-17

6 - WORKING OPERATIONS

Lowering the arm in emergency situations NOTICE: This procedure is to be used only as an emergency to lower the arms. Use extreme caution, since the weight of the arms will tend to move this abruptly, when the hoses of the hydraulic system are disconnected.

Be sure to block the attachments to avoid sudden change of position. remove the hoses of the hydraulic system slowly, until oil pressure is completely released.

Do not enter the area under attachments, while lowering them.

Arm lowering (1) • Gradually loosen the hose, connected to the arm cylinder, from rod side (R).

LELI11E0257AB

1

LELI11E0258AB

2

Boom lowering (2) • Gradually loosen the hose, connected to the boom cylinder, from the head side (H).

NOTE: Clean up all spilled oil. Dispose of collected oil, because polluting, according to the local environments regulations.

Keep the attachment at 30 - 40 cm (11.8 - 15.7 in) from the ground and take the possible movements of the machine into consideration.

Securely retighten the hoses so that the attachment stops lowering.

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

NOTE: If necessary, contact your authorized dealer for repairs.

6-18

6 - WORKING OPERATIONS

Caution while using rubber crawlers Proper usage

Rubber belt

The rubber crawlers offer excellent features which steel crawlers do not possess.

However, if they are used the same way as the steel crawlers, then their advantages cannot be fully exploited.

Operation of the machine varies upon working site and conditions.

Although the rubber crawler offers many advantages thanks to the properties of its material, it also has disadvantages in terms of strength. As a consequence, it is necessary to be familiar with the characteristics of this kind of crawler.

Less vibration Smooth operation Low noise Harmless for paved road Easy handling Resistant Large traction force : Excellent : Good

: Normal

Rubber crawler warranty The warranty does not cover such damages to the rubber crawlers resulting from improper working or if their tension is inaccurate.

Forbidden operations Do not carry out the following operations: Do not travel nor work on following surfaces: gravel-mixed land, rugged and solid rock bed, reinforced concrete, steel plate edges.

LELI11E0259AA

1

LELI11E0260AA

2

Do not operate and/or travel in such places as river beds where there are lots of stones of different sizes. Rocks may get caught into the grooves of the rubber crawlers, thus damaging the crawler or causing it to come off. The life of rubber crawler is shorter, if it skids or rubs against the soil.

6-19

Iron shoe

6 - WORKING OPERATIONS

Do not let oil, fuel, solvents, etc., come in contact with rubber shoes. If this happens, wipe off crawlers with a cloth immediately.

LELI11E0261AA

3

LELI11E0262AA

4

LELI11E0263AB

5

LELI11E0264AA

6

Do not enter such hot places as an open-air fire, steel plate left in the open sun.

Do not work in asphalt levelling.

When storing the machine for a long period (more than three months), keep it in a closed room where it will not be exposed to direct sunshine or rain.

When the machine travels only on one side of the crawler, and keeps the other side floating, the crawler may come off of the rollers or get damaged.

Precautions for use Use care of the following when working.

Rubber crawlers slip easily on icy surfaces.

Take the necessary safety precautions.

Avoid making a spin turn on concrete surfaces.

Avoid abrupt changes of direction as this will cause an early wear or damage of the rubber crawlers.

6-20

6 - WORKING OPERATIONS

Use care so that the bucket does not damage the rubber crawler while working.

Do not move the machine pressing the bucket against a concrete surface or walls.

Lower the machine slowly, if it had previously been lifted by means of the attachment.

LELI11E0265AA

7

LELI11E0266AA

8

LELI11E0267AB

9

If the machine is operated in salty corrosive places, the core metal can detach easily. Do not use the rubber crawler under such circumstances. If the rubber crawlers come in contact with these substances wash them with water.

The rubber crawlers have to be used with a temperature range between -25 °C (-13 °F) and +55 °C (131 °F).

NOTE: Use the rubber crawlers under proper tension, to prevent them from coming off the rollers. Operate the rubber crawler carefully even when tensioning is proper.

Avoid changing direction of the machine on places with different level (about 20 cm (7.87 in)). To overcome the gap, place the machine perpendicular to the obstacle.

When climbing on a slope in reverse, avoid changing the machine direction while climbing between the level ground and the slope.

LELI11E0268AB

6-21

10

6 - WORKING OPERATIONS

If you travel on a slope with the machine higher at one side, this could damage the rubber crawler. Both machine sides must travel at the same level.

LELI11E0269AB

11

LELI11E0270AA

12

Do not change the direction of the machine with the rubber crawlers positioned on earth heaps, as this could cause the rubber crawler to come off or get damaged.

6-22

6 - WORKING OPERATIONS

Machine operation in adverse weather conditions Operation in extreme cold

low dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen.

• Follow procedures on page (Starting the engine in cold conditions) as starting engine may be difficult due to extremely cold temperatures.

• Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates.

• Keep the batteries fully charged.

• During the engine WARM-UP phase do not increase the engine rpm to prevent premature wear or damage to pumps, motors and other components.

NOTICE: in extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain operating temperatures, 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 instrument cluster 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.

• Keep batteries terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine systems.

Check the batteries electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, it is recommended to remove the batteries and store in a warm area.

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

NOTICE: mix coolant to a protection temperature of 5.0 °C (41.0 °F) lower than the machine will experience during operation, storage or transport.

Mud and water adhering to the machine may freeze interfering with proper machine operation. Use the following general guidelines as reference to prevent malfunctions:

• Keep all belts properly tensioned.

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

• If the machine becomes overheated, idle the machine to help cool the engine, turn the engine off and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

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

• Keep a close watch on the instrument cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation. During slow, or no work periods, place throttle control lever to LO position.

Operation in high altitudes • 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 altitude climates.

• Keep close watch on the coolant temperature meter to avoid overheating of the engine.

Operation in sandy and dusty areas Air filter • Check the engine air filter element frequently in sandy or dusty conditions. Clean or replace the filter element at the corresponding intervals Radiator • Clean the radiator regularly to prevent the radiator core from becoming clogged with dust.

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

• Retract the hydraulic cylinder rods as much as possible to reduce the exposed areas of the rods. This will prevent mud or water on the rod faces from damaging the seal.

Operation in extreme heat

Fuel • Be careful not to let contamination in the fuel when refuelling. Inspect the elements and filters at the corresponding interval.

Electrical equipment • Clean the starter and generator especially, at the corresponding interval, to prevent dust from accumulating.

Operation at seashore or salty climate

• Use an engine oil, hydraulic oil and fuel oil designed for use in hot climates.

• Keep batteries fully charged.

• Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods.

• Clean radiator, oil cooler and debris screen often to prevent damage or overheating of the machine. Do not al6-23

6 - WORKING OPERATIONS

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

Operation in humid climate • In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

6-24

7 - MAINTENANCE

7 - MAINTENANCE###_7_### General information

General information WARNING Avoid injury!

Carefully read and observe all the precautionary advice contained in this manual.

Failure to comply could result in death or serious injury.

W0044A

NOTE: Consult your authorized dealer to adjust, disassemble and repair the engine, the reduction unit and the electronic devices (controller, etc).

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.

The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. This procedure illustrates all operations one after the other. The time interval of such operations is indicated in the inspection and maintenance tables.

Basically, lubrication and maintenance intervals are determined by the hourmeter. It is also possible to perform those operations according to calendar time (daily, weekly, monthly, etc.), referring to the service hours displayed. Issues for which a precise service time cannot be specified are explained in chapter “WHEN NECESSARY” .

1

RAIL14CEX0889AA

NOTE: The inspection and maintenance charts provided in this section give only general time intervals. If necessary, a special plan with shorter maintenance intervals will have to be prepared, according to the special situation, for difficult working conditions, such as in dusty or humid environments, etc.

Be sure to dispose of all waste materials correctly.

Use only specified oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. Only use oils and greases with the correct viscosity for the ambient temperature.

Store the containers and cans of lubricating oil, hydraulic oil and grease etc. in closed rooms. Take necessary measures to protect them from dust, water etc.

7-1

LELI11E0273AA

2

7 - MAINTENANCE

Rotary multi-control valve pattern change (ISO/BHL) Changing the pattern on the rotary multicontrol valve This machine is factory equipped with the BHL control function pattern.

RAIL14CEX0994AA

1

RAIL14MEX0099AA

2

RAIL14MEX0098AA

3

To change the control pattern: 1. Place the attachment on the ground and stop the engine.

2. Place the safety lock lever in the LOCKED position.

3. Open the front cover on the machine and locate the rotary multi-control valve (1).

4. Loosen the wing bolt (2) on the rotary multi-control valve and change the lever (3) position to the desired pattern.

5. Tighten the wing bolt (2) by hand to secure the lever (3). Do not use any tools to tighten the lever (3).

6. Close the cover.

7-2

7 - MAINTENANCE

7. Slowly operate the control levers to make sure the functions match the pattern shown in the operator’s station. Practice operation in an open area to become familiar with the new control pattern.

RAIL14CEX0991AA

4

RAIL14CEX0993AA

5

For a canopy machine, affix a control pattern label (1) on the guard divider to the right of the operator’s seat.

For a cab machine, affix a control pattern label (1) inside the cab door.

7-3

7 - MAINTENANCE

Maintenance tool No.

Tool name

Part number

1.

Tag maintenance in progress

LC20T01001P1

2.

Tool case

PW01T01005P1

3.

Wrench for engine oil filter

YJ23H00001P1

If tools are lost or damaged, contact your Dealer to order them.

7-4

Notes

7 - MAINTENANCE

Torque specifications The following torque specifications are indicated in case the actual torque value of a fastener is unknown.

Check the cap screws and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance intervals. Retighten the loose screws and nuts, and install new ones to replace the dropped ones. For the new machine, the check and retightening of loose screws and nuts must be carried out after the first 50 h operation. When replacement is needed, make sure to use genuine parts to the same dimensions. Check the table hereunder for proper torque.

• The table hereunder, is not valid for plastic screws used to fasten hoods, etc.

• For the tightening torque of this kind of screws, contact your Dealer. Over tightening may cause the damages of the parts to be fixed.

• If this manual specifies a different torque, use such value regardless of the table below.

• Numerical indication on the cap screw head shows the classification (A) strength (e.g.: 8.8). No indication is provided for smaller size of cap screws, M5 or less.

Standard tightening torque values.

LELI11E0296AB

1

Be certain to tighten all cap screws and nuts to proper torque values.

Resistance class Nominal dimension M3

P = 0.5

M4

P = 0.7

M5

P = 0.8

M6

P=1

M7

P=1

M8

P = 1.25

M10

P = 1.5

M12

P = 1.75

M14

P=2

M16

P=2

M18

P = 2.5

M20

P = 2.5

M22

P = 2.5

6.8 1.19 N·m (0.88 lb ft) 2.73 N·m (2.01 lb ft) 5.41 N·m (3.99 lb ft) 9.29 N·m (6.85 lb ft) 15.40 N·m (11.36 lb ft) 22.46 N·m (16.57 lb ft) 45.10 N·m (33.26 lb ft) 77.20 N·m (56.94 lb ft) 123.23 N·m (90.89 lb ft) 189.51 N·m (139.78 lb ft) 261.17 N·m (192.63 lb ft) 370.15 N·m (273.01 lb ft) 501.62 N·m (369.98 lb ft)

8.8

10.9 Tightening torque 1.59 N·m 2.24 N·m (1.17 lb ft) (1.65 lb ft) 3.64 N·m 5.12 N·m (2.68 lb ft) (3.78 lb ft) 7.21 N·m 10.14 N·m (5.32 lb ft) (7.48 lb ft) 12.39 N·m 17.43 N·m (9.14 lb ft) (12.86 lb ft) 20.54 N·m 28.88 N·m (15.15 lb ft) (21.30 lb ft) 29.94 N·m 42.10 N·m (22.08 lb ft) (31.05 lb ft) 60.14 N·m 84.57 N·m (44.36 lb ft) (62.38 lb ft) 102.94 N·m 144.75 N·m (75.92 lb ft) (106.76 lb ft) 164.30 N·m 231.05 N·m (121.18 lb ft) (170.41 lb ft) 252.69 N·m 355.34 N·m (186.37 lb ft) (262.09 lb ft) 348.22 N·m 489.69 N·m (256.83 lb ft) (361.18 lb ft) 493.53 N·m 694.02 N·m (364.01 lb ft) (511.88 lb ft) 668.82 N·m 940.53 N·m (493.30 lb ft) (693.70 lb ft)

7-5

12.9 2.69 N·m (1.98 lb ft) 6.15 N·m (4.54 lb ft) 12.17 N·m (8.98 lb ft) 20.91 N·m (15.42 lb ft) 34.66 N·m (25.56 lb ft) 50.53 N·m (37.27 lb ft) 101.49 N·m (74.86 lb ft) 173.70 N·m (128.11 lb ft) 277.26 N·m (204.50 lb ft) 426.41 N·m (314.50 lb ft) 587.63 N·m (433.41 lb ft) 832.83 N·m (614.26 lb ft) 1128.64 N·m (832.44 lb ft)

7 - MAINTENANCE

Resistance class M24

P=3

M27

P=3

M30

P = 3.5

6.8 639.61 N·m (471.75 lb ft) 943.17 N·m (695.65 lb ft) 1280.89 N·m (944.74 lb ft)

8.8 852.82 N·m (629.01 lb ft) 1257.56 N·m (927.53 lb ft) 1707.86 N·m (1259.65 lb ft)

10.9 1199.27 N·m (884.54 lb ft) 1768.45 N·m (1304.34 lb ft) 2401.67 N·m (1771.38 lb ft)

Torque specifications for joints and hydraulic hoses Sleeve-type hose fittings Hose dimensions outer diameter x thickness

Wrench dimension

10 - 1.5 mm (0.39 - 0.06 in)

19 mm

15 - 2.0 mm (0.59 - 0.08 in)

27 mm

18 - 2.5 mm (0.71 - 0.10 in)

32 mm

22 - 3.0 mm (0.87 - 0.12 in)

36 mm

28 - 4.0 mm (1.10 - 0.16 in)

41 mm

35 - 5.0 mm (1.38 - 0.20 in)

55 mm

Tightening torque 39.1 - 48.9 N·m (28.84 - 36.07 lb ft) 127 - 167 N·m (93.67 - 123.17 lb ft) 157 - 197 N·m (115.80 - 145.30 lb ft) 196 - 236 N·m (144.56 - 174.06 lb ft) 246 - 304 N·m (181.44 - 224.22 lb ft) 397 - 485 N·m (292.81 - 357.72 lb ft)

Joints for pipings (with O-rings) Normal screw dimension

Wrench dimension)

1/8 in

14 mm

1/4 in

19 mm

3/8 in

22 mm

1/2 in

27 mm

3/4 in

36 mm

1 in

41 mm

Tightening torque 15 - 19 N·m (11.06 - 14.01 lb ft) 34 - 38 N·m (25.08 - 28.03 lb ft) 69 - 79 N·m (50.89 - 58.27 lb ft) 98.2 - 117.8 N·m (72.43 - 86.88 lb ft) 152.2 - 171.8 N·m (112.26 - 126.71 lb ft) 245.8 - 264.8 N·m (181.29 - 195.31 lb ft)

Hydraulic hose Normal screw dimension

Wrench dimension

1/8 in

17 mm

1/4 in

19 mm

3/8 in

22 mm

1/2 in

27 mm

3/4 in

36 mm

1 in

41 mm

Tightening torque 13.0 - 17.0 N·m (9.59 - 12.54 lb ft) 24.1 - 33.9 N·m (17.78 - 25.00 lb ft) 44.1 - 53.9 N·m (32.53 - 39.75 lb ft) 73.1 - 82.9 N·m (53.92 - 61.14 lb ft) 108.2 - 127.8 N·m (79.80 - 94.26 lb ft) 122 - 152 N·m (89.98 - 112.11 lb ft)

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

7-6

12.9 1439.13 N·m (1061.45 lb ft) 2122.14 N·m (1565.21 lb ft) 2882.01 N·m (2125.66 lb ft)

7 - MAINTENANCE

Installation Metal fitting The pressure exerted by the fitting (3) on the hose (1) ensures tightness (2). Use caution to assemble and disassemble both pieces in order not to damage the seat.

LELI11E0297AB

1

LELI11E0298AB

2

Fitting with O-ring The O-ring (2), allows to insulate the oil pressure inside of hose (1) and to avoids oil spillages.

The tightening torque of the joint of each hydraulic hose (1) is determined by the diameter of the hose fitting thread.

If you notice a fault of operation, repair hose connection or replace it.

When connecting worn parts, pay particular attention to keep sealing surfaces clean from dirt and try not to damage them.

O-ring If the fitting is loose and oil leaks may occur, do not tighten it. It is necessary to install a new O-ring and to check again for tightness.

Never install a damaged and deteriorated O-ring even if it is new one. The use of an O-ring other the specified one, causes oil leakage and short life of hydraulic equipment.

Joint Be careful not to damage hoses, pipes or seal faces, this can impair the tightness.

Keep seal surfaces free from dirt.

Fitting with foreign matter inside causes oil leakage.

Hose Avoid high pressure hoses to twist during connection. Life of twisted hoses is drastically reduced.

Wash pipes and hoses, both inside and outside, with washing fluid and accurately dry them before reconnection.

7-7

7 - MAINTENANCE

Maintenance parts During maintenance, replace parts subjected to wear before expiry, as filters and cartridges. The machine operates more efficiently if worn parts are replaced with new parts.

LELI11E0294EB

No.

Device

1.

Hydraulic oil tank

2.

Hydraulic oil tank

Parts name

Qty.

Return filter (O-ring)

1

Suction strainer (O-ring) Element (outer) (3a) Element (inner) (3b)

1

1

3.

Air filter

4.

Engine oil filter

Cartridge

1

5.

6.

7.

Fuel filter Water separator Radiator

8.

Bucket

9.

Bucket

Cartridge Cartridge Radiator cap Side cutter (right) (7a) Side cutter (left) (7b) Screw Nut Tooth Safety pin Rubber locking pin

1 1 1 1 1 6 6 4 4 4

7-8

1

Replacement interval After 50 h (first change) Every 1000 h (from 2nd change) (Breaker specification: Every 200 h) Every 2000 h After 6th time cleaning or maintenance interval For machines equipped with W (double) element and inner element. Don’t fail to replace the inner element with a new one After 50 h (first change) Every 250 h Every 500 h When required Replace every 1000 h When required

When required

7 - MAINTENANCE

Releasing internal pressure from the hydraulic system WARNING Pressurized system!

System is still under pressure. Release pressure according to instructions in this manual.

Failure to comply could result in death or serious injury.

W1044A

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure.

Rest the bucket or attachment on the ground.

Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.

Failure to comply could result in death or serious injury.

LELI11E0299AA

1

W0161A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

Park the machine on a level surface. Fully retract the arm cylinder and bucket cylinder. Lower the boom to rest the bucket onto the ground, and lower the dozer.

In case of pilot operating lines (boom, arm, bucket, slewing) stop the engine, then operate the control levers to release pressure from each system.

NOTE: This procedure is the only way to release internal pressure.

To release the internal pressure from the hydraulic system, proceed as follows: 1. Bring the throttle lever to low idle. Set the safety lock lever to the LOCKED position.

2. Stop the engine, remove the ignition key and wait until the machine is cold.

3. Clean the hydraulic oil tank upper side to prevent dirt contamination in the hydraulic system.

4. Open the right side access door (1) . Support the door with the support rod.

5. Press the breather cap (2) several times to release the inner pressure of the hydraulic tank.

6. This completes the bleeding of pressure remaining in the hydraulic tank.

7. Check and service the hydraulic system.

7-9

RAIL14CEX0892AA

2

7 - MAINTENANCE

Biodiesel fuel Biodiesel usage in CASE CONSTRUCTION products Introduction to Fatty Acid Methyl Ester (FAME) biodiesel FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

NOTICE: Your emissions control system is compatible with up to 20 % biodiesel fuel (B20). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE CONSTRUCTION Warranty coverage.

Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: • B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.

• B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels.

• B100: indicates pure biodiesel, or 100 % biodiesel fuel.

Do not use.

Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel.

• Biodiesel has a greater cetane number and burns cleaner.

• Biodiesel produces less particulate matter and reduces smoke emissions.

Biodiesel blends are covered by: • United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009.

United States fuel suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network.

• United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20.

Pure biodiesel (B100) specification is covered by the following requirements: • ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.

NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place.

Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products).

NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and comply with the North America Standard ASTM D6751.

NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any CASE CONSTRUCTION product.

NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by CASE CONSTRUCTION.

Biodiesel fuel usage conditions

• Biodiesel is fully biodegradable and non-toxic.

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.

Diesel and biodiesel fuel specifications Tier 4a diesel fuel specifications are covered by the following: • ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

The main concerns related to operation with biodiesel fuels are:

7-10

7 - MAINTENANCE

• Filters and injector blockage caused by poor fuel quality.

• Wear and corrosion of internal components due to water content, which affects lubricity.

• Deterioration of some rubber sealing compounds in the fuel system.

• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.

NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information.

The use of biodiesel blends above B5 through B20 will not void the CASE CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system.

NOTICE: For machines using Tier 4a engines with an exhaust aftertreatment system in regions where the biodiesel blend stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of compliance to the special limits for Group I Metals, Group II Metals and the reduced phosphorus content specified above be obtained on every delivery of fuel from the fuel supplier. Failure to comply with this requirement can result in damage to the catalyst of the aftertreatment system which will not be covered under warranty.

NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced to 250 h when using biodiesel blends greater than B5 up to B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines.

Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first.

Regular oil sampling is highly recommended to monitor for oil and engine deterioration.

For machines using Tier 4a engines with an exhaust aftertreatment system:

NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer.

1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it fully complies with the following special requirements:

When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

• Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

• Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

• Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg per ASTM D4951.

2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potassium) and for Group II Metals (Calcium + Magnesium).

Storage The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 diesel fuel is used.

NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.

Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week.

NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.

7-11

7 - MAINTENANCE

Fluids and lubricants Component to be filled

Quantity

Consumable

CASE AKCELA NO. 1™ ENGINE OIL SAE 3.9 - 6.7 L 10W-30 Engine oil pan (1.0 CASE AKCELA NO. 1.8 US gal) 1™ ENGINE OIL SAE 15W-40 0.6 L (0.2 US Travel motor gal) x 2 CASE AKCELA GEAR 55.0 cm³ Upper rollers 135 H EP 80W-90 (3.4 in³) x 2 80.0 cm³ Idler wheels (4.9 in³) x 2 65.0 cm³ CASE AKCELA Lower rollers (4.0 in³) x ENGINE OIL 10W-30 10 1.8 L (0.5 US CASE AKCELA gal) 3.8 L Radiator (1) PREMIUM ORGANIC (1.0 US ANTI-FREEZE gal) (total system) 42.0 L — (11.1 US Fuel tank gal) 20.4 L (5.4 US gal) 44.8 L CASE AKCELA (11.8 US Hydraulic oil tank (2) HYDRAULIC gal) EXCAVATOR FLUID (hydraulic system) Boom, arm, linkage, and attachment 15 places Dozer blade cylinder 4 places Slewing bearing 1 place Swing pinion 1 place Boom swing cylinder pin 2 place CASE AKCELA MOLY As needed, GREASE disassemOperating lever and pedal bly is required Belt / track tension adjust. See 1 place adjustment procedure section 0.60 kg Air conditioning R134A (1.32 lb) 120 cm³ SANDEN SP-10 Compressor (7.32 in³) LUBRICANT

Manufacturer specifications

International specifications

MAT3507 API CI 4/CH-4 ACEA E7/E5 MAT3507

MAT3511

API GL 5

MAT3521

API CI 4/CH-4 ACEA E7/E5

ASTM D 3306

—

EN 590

MAT3509

—

MAT3550

NLGI 2

—

—

—

—

NOTE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 6 l (1.59 US gal) NOTICE: (2) Hydraulic system total volume: ~ 44.8 L (11.8 US gal) . If the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 (option), take note that this oil cannot be mixed with mineral hydraulic oil.

7-12

7 - MAINTENANCE

Temperature operating ranges

Engine Travel motor, upper rollers and idler wheels Hydraulic system

Consumable CASE AKCELA NO. 1™ ENGINE OIL CASE AKCELA GEAR 135 H EP 80W-90 CASE AKCELA HYDRAULIC EXCAVATOR FLUID

7-13

Viscosity SAE 10W - 30 SAE 15W - 40

Temperature operating range -25.0 - 25.0 °C (-13.0 - 77.0 °F) -15.0 - 40.0 °C (5.0 - 104.0 °F)

SAE 80W - 90

-25.0 - 45.0 °C (-13.0 - 113.0 °F)

ISO VG-46

-20.0 - 50.0 °C (-4.0 - 122.0 °F)

7 - MAINTENANCE

Use of biodegradable oils When you use biodegradable oil, please refer to following: • There are two types of biodegradable oil available: vegetable-based and synthetic-based. We recommend using synthetic oils, because vegetable ones have a maximum operating temperature of 80 °C (176 °F). For this reason, the degradation of vegetable-based oil occurs more rapidly, and they have a reduced service life.

• Do not mix bio-oil with original factory-filled mineral oil; in case it is necessary to use bio-oil, flush the hydraulic system that was filled with bio-oil three times.

• If you use bio-oil, the performance of the rotation brake and that of the parking/travel brake will be reduced, because of the lower friction factor of bio-oil compared to that of mineral oil.

• For further information about the type of biodegradable lubricant and the relevant specifications for use and maintenance, please refer to chapter ACCESSORIES.

Use of coolant • There are two types of coolant depending on the corrosion inhibitors base: ORGANIC-base and INORGANIC base.

• Both type can be used, BUT THEY CANNOT BE MIXED. Flush the cooling system before change coolant type.

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7 - MAINTENANCE

Maintenance planning

Maintenance chart Replace Cleaning Grease Drain fluid Check

Adjust Change fluid Bleed Lubricate

Maintenance action Engine coolant level Engine oil level Fuel level Hydraulic oil level Belt tension Warning lamps Work lights Radiator, oil cooler core, and filter Drain water separator Boom, arm, and attachment grease points Air conditioner compressor belt (If equipped) Air conditioner filters (If equipped) Battery Fuel tank Track tension Grease swing pinion Hydraulic oil return filter (Initial) Angle dozer blade (If equipped)

Page no.

Every 8 hours x x x x x x x x x x x x Every 50 hours x x x x

7-17 7-19 7-20 7-22 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-35 7-36 7-39 7-40 7-42

x x Every 100 hours x 7-43 Air conditioner condenser (If equipped) Every 200 hours x 7-43 Hydraulic oil return filter (Breaker attachment option) Every 250 hours of operation or every 3 months x Fan belt 7-44 x Radiator hoses 7-46 x Air cleaner element 7-48 x Engine oil 7-49 x 7-50 Engine oil filter x 7-52 Bleed air from the fuel system x 7-53 Swing bearing x Dozer blade 7-54 x 7-55 Radiator, oil cooler core, and filter Every 500 hours of operation or every 6 months x 7-57 Fuel filter x Water separator 7-58 x 7-59 Air conditioner lines (If equipped) x 7-60 Air conditioner refrigerant (If equipped) Every 1000 hours of operation or annually x 7-62 Hydraulic oil return filter x Air breather element 7-64 x Radiator coolant 7-65 x 7-67 Hydraulic oil (Breaker attachment option) Every 1500 hours x 7-69 Exhaust Gas Recirculation (EGR) system 7-15

7 - MAINTENANCE

Replace Cleaning Grease Drain fluid Check Maintenance action Fuel injection system Crankcase breather

Adjust Change fluid Bleed Lubricate Page no.

x x Every two years

7-70 7-71 x x

Air conditioner filters (If equipped) Air conditioner receiver dryer (If equipped)

7-72 7-73

Every 2000 hours x

Travel reduction unit oil Suction strainer Pilot line filter Idler wheel and rollers change oil Exhaust Gas Recirculation (EGR) system

7-74 7-75 7-77 7-80

x x x Every 3000 hours x Every 5000 hours

7-83 x

Hydraulic oil

7-84

As required Work lamps Windshield washer reservoir (cab only) Bucket Rubber track shoe Replacement of rubber track shoe Control levers Electrical system

x x x x x x x

7-16

7-86 7-87 7-88 7-92 7-95 7-98 7-99

7 - MAINTENANCE

Every 8 hours

Engine coolant level WARNING Burn hazard!

Always remove the recovery tank cap BEFORE you remove the filler cap. Never remove either cap while the engine is running or the coolant is hot. Stop the engine and let the system cool. Using a thick cloth, loosen the cap slowly and allow the pressure to escape.

Failure to comply could result in death or serious injury.

W0361A

Check the coolant level NOTICE: The engine coolant level is higher than normal when engine is warm. The coolant level will lower as the engine temperature lowers. Maintain the coolant level at the FULL mark when the engine is cold.

The radiator reservoir tank (3) is located on the right side of the engine compartment. Check the coolant level with a cold engine only.

1. Check the radiator reservoir tank (3) for the proper coolant level. The proper coolant level is between the FULL and LOW marks visible on the radiator reservoir tank (3).

2. Open the cap (2) of the radiator reservoir tank (3).

3. If the coolant level is below the LOW mark, fill the radiator reservoir tank (3) to the FULL mark with the proper coolant.

4. Close and tighten the cap (2) of the radiator reservoir tank (3).

RAIL14CEX0687BA

1. If the radiator reservoir tank is empty, check the engine cooling system for any leaks and items in need of repair.

2. Remove the radiator cap (1) and check for the proper coolant level.

3. If the coolant level in the radiator is low, fill the radiator with the proper coolant mixture.

4. Fill the radiator reservoir tank (3) with the proper coolant mixture.

5. Close and securely tighten the radiator cap (1).

6. Before you operate the machine, contact your authorized dealer for repairs.

7-17

1

7 - MAINTENANCE

Check for coolant leaks WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

It is possible that there are leaks in the cooling system when the coolant level lowers in the radiator while there is no change in the reservoir level.

1. Make sure the coolant level meets the specification.

2. Pressurize the system to check for leaks.

3. Contact your authorized dealer for suggestions and/or repairs.

4. Make sure to repair leaks before you resume operation.

7-18

7 - MAINTENANCE

Engine oil level WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Check the engine oil level with the machine on a level surface.

Check the engine oil level before you start the engine.

Wait at least 30 min before you check the engine oil level after you shutdown the engine.

1. Open the engine door with the ignition key.

2. Pull out the engine oil dipstick (2) and clean it with a dry cloth.

3. Reinsert the engine oil dipstick (2) completely. Pull out the engine oil dipstick (2) and check the engine oil level.

4. Verify the engine oil level is between (H) and (L).

NOTICE: If the engine oil is heavily contaminated or deteriorated, change it regardless of the periodic scheduled maintenance. Refer to the specification section of this manual for the oil specifications.

5. If the engine oil level is too low, remove the filler cap (1) and refill with the proper engine oil.

6. Check the oil level again after you refill.

7. Clean and install the filler cap (1).

8. Close and lock the engine door with the ignition key.

RAIL14MEX0027BA

7-19

1

7 - MAINTENANCE

Fuel level WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

NOTICE: Dispose of the hazardous waste according to environmental laws and regulations.

LELI11E0190AA

1

RAIL14CEX0552AA

2

RAIL14CEX0551AA

3

1. Turn the ignition switch (1) to the ON position to illuminate the monitor panel (2) and to activate the fuel gauge.

2. Check the fuel level gauge (2). If the fuel level is low, refuel.

Fuel tank capacity: 42 L (11 US gal).

To refuel: 1. Remove the fuel cap (3).

NOTICE: Do not remove the fuel tank filter (4) while you refuel to prevent contamination.

2. After you refuel, install the fuel cap (3)

We recommend that you refuel at the end of the work day. A full fuel tank reduces air volume which reduces condensation. Fuel freezing, rust, and air seepage in the fuel system could result from an unfilled fuel tank.

The air would then have to be bled from the fuel tank.

7-20

7 - MAINTENANCE

Check for fuel leaks Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leaks can be caused by a faulty drain plug, by cracks in the hoses or by loose hose clamps.

Make sure to immediately stop the engine after detection of a fuel leak. Contact your authorized dealer to repair the fuel leak before you resume operation.

• Water separator (1) • Fuel filter (2) • Fuel tank (3) • Fuel cooler (4) • Fuel hoses (5) RAIL14MEX0028AA

7-21

4

7 - MAINTENANCE

Hydraulic oil level Hydraulic oil level check WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Avoid injury!

Pressurized hot oil can cause burns. Depress the stem or remove the cap slowly with the engine off to relieve the hydraulic tank pressure.

Failure to comply could result in death or serious injury.

LELI11E0176AA

1

RAPH13CEX0048AA

2

RAIL14CEX0861AA

3

W1238A

1. Park the machine on firm, level ground. Position the bucket (1) and dozer blade (2) as shown.

1. Check the hydraulic oil level through the site level gauge on the side of the hydraulic tank.

• L level – The oil temperature should be between 10 - 30 °C (50 - 86 °F).

• H level – The oil temperature should be between 50 - 80 °C (122 - 176 °F).

7-22

7 - MAINTENANCE

Refill the hydraulic oil tank NOTICE: Refer to the specifications section in this manual for the recommended hydraulic oil.

1. Open the right side access door. Support the door with the support rod.

2. Press the breather cap (2) several times to release the inner pressure of the hydraulic tank.

After the internal pressure is released: 3. Remove the bolts (1) from the cover (3).

4. Remove the cover (3).

RAIL14MEX0047AA

4

RAIL14MEX0048BA

5

RAIL14MEX0047AA

6

5. Fill the reservoir (4) to the proper level with the specified hydraulic oil.

6. As you pour the hydraulic oil, check the oil level at the level gauge (A).

7. Install the cover (3) and fasten the bolts (1).

Torque to: 20.7 - 25.3 N·m (15.3 - 18.7 lb ft)

7-23

7 - MAINTENANCE

8. Start and run the engine for 5 min to 7 min at low idle.

9. Operate each cylinder through its full travel and swing operation. This will remove any air from the hydraulic system.

10. Return the machine to the hydraulic oil level check position.

11. Stop the engine and check the oil level. Add oil as necessary.

12. Remove the door support rod and close the right access door.

7-24

7 - MAINTENANCE

Belt tension WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

LELI11E0182AA

1

RAIL14CEX0921AA

2

Check the belt for insufficient tension, wear, or damage.

Insufficient belt tension may 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 damaged prematurely.

To check the belt tension, apply a force of 98 N (22 lb) to the center of the belt between the pulleys. Measure the belt deflection.

Belt deflection New belt tension 8 - 12 mm (0.3 - 0.5 in)

Used belt tension 10 - 14 mm (0.4 - 1 in)

7-25

7 - MAINTENANCE

Warning lamps WARNING Unexpected machine movement!

When you must leave the operator’s seat, always place the safety lever in the LOCKED position. If the safety lever is unlocked and the control lever is moved unexpectedly, a serious accident could result.

Failure to comply could result in death or serious injury.

W1241A

Check the function of the warning lamps 1. Make sure the safety lock lever is in the LOCKED position.

2. Make sure all control levers are in the neutral position.

3. Set the manual throttle lever to the low idle position.

4. Turn the starter key to the ON position. Check that the warning lamps turn on.

(A) — Red (B) — Yellow Refer to the table below.

RAIL14CEX0866AA

Key operation Lamp 1 2 3 4 5 6

Engine oil pressure lamp Battery charge lamp Low fuel warning lamp Engine air filter lamp 2nd speed travel lamp Coolant temperature lamp

OFF-->ON Before start Light ON Light ON Light OFF Light OFF Light OFF Light OFF

7-26

START-->ON Just after start Light OFF Light OFF Light OFF Light OFF Light OFF Light OFF

1

7 - MAINTENANCE

Work lights 1. Turn the ignition key to the ON position.

2. Turn on the work light switch.

3. If the work lights do not illuminate, replace the bulb.

4. If the work lights still do not illuminate, the electrical wire may be broken. Contact your authorized dealer for repair.

LELI11E0186AA

7-27

1

7 - MAINTENANCE

Radiator, oil cooler core, and filter 1. Open the right-hand side access door.

2. Visually inspect the filter for: • Mud, • Dust, and • Leaves NOTICE: If the filter is extremely dirty and/or the cooling performance is decreased, see “Radiator, oil cooler core, and filter” in the 250h maintenance section to clean the system.

7-28

7 - MAINTENANCE

Drain water separator If the red ring (3) of the water separator is sunk to the bottom of cup (4), water does not enter. If the red ring (3) floats, water enters under the ring. Drain the mixed water according to the following procedure.

1. Move the safety lock lever to the “LOCKED” position and then stop the engine.

2. Open the engine food and raise cock (1) of the water separator to “Close” position (C).

3. Loosen drain cock (2) to drain the accumulated water to a container.

4. Tighten drain cock (2).

5. Lower cock (1) to "Open" (D).

6. After draining, bleed the system (Refer to 7-52) 1.

Fuel cock

2.

Drain cock

3.

Ring (red)

4.

Cup

A. Fuel inlet B. Fuel outlet C. Close

RAIL14CEX0985BA

D. Open

7-29

1

7 - MAINTENANCE

Boom, arm, and attachment grease points For a new machine, grease the greasing points of the attachment every 8 hours during the first 50 hours of operation. After that, grease them every 50 hours.

For the work with a special attachment, grease it before work every day.

For the digging work in the water, grease the submerged parts before and after the work every day.

Grease the attachment before the work if it has not been used for one month or longer.

1. Set the attachment in the greasing position and then stop the engine.

2. Before greasing, wipe off the grease nipples. Replace any damaged nipples with new ones.

RAIL14CEX0987AA

1

RAIL14CEX0986AA

2

RAIL14CEX0988AA

3

3. Use the grease gun to apply grease to the grease nipples.

4. After applying grease, wipe off old grease which is pushed out.

ID

Parts to grease

Boom foot pin Boom cylinder foot pin Boom cylinder rod pin Arm cylinder foot pin Arm cylinder rod pin Boom and arm connecting pin

No. of points 1 1 1 1 1 1

9.

10.

11.

12.

13.

14.

7.

Bucket cylinder foot pin

1

15.

Idler link pin Arm and idler link connecting pin Bucket link pin Arm and bucket connecting pin Swing cylinder foot pin Swing cylinder rod pin Swing bracket and frame connecting pin

8.

Bucket cylinder rod pin

1

ID

Parts to grease

1.

2.

3.

4.

5.

6.

7-30

No. of points 2 1 1 1 1 1 2

7 - MAINTENANCE

Air conditioner compressor belt (If equipped) WARNING Rotating parts!

Stop the engine before you inspect and/or adjust the compressor belt. You could be injured by the rotating cooling fan or by the rotating fan belts.

Failure to comply could result in death or serious injury.

W1363A

NOTE: If the air conditioning compressor belt flakes or if breakage is found during the inspection, replace the air conditioner compressor belt with a new one.

Keep the belt away from oils, the service life could be shortened if oil is present and the belt slips on the oil.

NOTE: Replace the air conditioner compressor belt every 2 years or sooner if it is damaged or worn.

Inspect and adjust the air conditioning compressor belt 1. Park the machine on a firm, level surface.

2. Move the safety lock lever to the LOCKED position.

3. Open the access door with the starter key. Hold the door open with the support rod.

NOTE: Normal belt deflection is 4.7 mm (0.2 in) when you apply a force of 19.0 N (4.3 lb) to the center of the air conditioner compressor belt.

If you need to adjust the air conditioner compressor belt: 4. Slightly loosen the nut (1) of the idle pulley.

5. Turn the adjusting bolt (2) to adjust the belt tension.

6. Torque to: 23.0 N·m (17.0 lb ft) +/- 2.3 N·m (1.7 lb ft) 7. After the adjustment, run the engine a low idle for 5 min.

8. Check the belt tension again..

9. Remove the support rod.

10. Close the access door.

11. Lock the access door with the starter key.

7-31

RAIL14MEX0091AA

1

7 - MAINTENANCE

Air conditioner filters (If equipped) CAUTION Flying debris!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in minor or moderate injury.

C0049A

Remove the air conditioning filters The fresh air filter (1) is located on the right-hand side of the cab.

1. Hold the handle grip of the fresh air filter (1) and pull it straight up and out.

The recirculation air filter (2) is located on the right-hand side of the cab.

2. Hold the handle grip of the recirculation air filter (2) and pull it straight out to the side.

RAIL14MEX0093AA

Clean the air conditioner filters 3. Clean the fresh air filter (1) and the recirculation air filter (2) with compressed air.

Attach the air conditioner filters 4. Attach the clean or new fresh air filter (1) and recirculation air filter (2) in reverse order as instructed in steps 1 and 2.

7-32

1

7 - MAINTENANCE

Every 50 hours

Battery WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

Perform the inspection earlier in summertime as the battery electrolyte decreases faster due to high temperature. If the battery with a low electrolyte level is used continuously, it will become unusable. Check the electrolyte level periodically, and if it is lower than the specified level, supply distilled water before starting the engine (before charging).

Observe the following safety precautions when working on a battery: • Wear protective glasses, long-sleeve shirt and rubber gloves when handling or servicing batteries.

• Do not bring a fire near the battery, or the flammable hydrogen gas generated by the battery may cause explosion.

• If the dilute sulfuric acid in the battery is splashed onto the skin or into the eyes, it causes burns or blindness. At such case, immediately wash the skin or eyes with sufficient clean water, and ask a doctor to treat it as soon as possible.

• Before performing inspection and maintenance on the battery, be sure to stop the engine.

• When removing the battery terminal, remove the grounding side (negative terminal) first and conversely, when attaching the battery terminal, attach the grounding side last.

• Do not put tools and hardware on the protective cover at installed on the battery upper section. It may cause a short circuit resulting in a fire or explosion.

7-33

7 - MAINTENANCE

Check indicator (A) shown in the figure. Red or white indicates a low electrolyte level or low charge. Take appropriate measures so that the indicator is displayed in blue.

1.

Terminal

2.

Ventilation cap

3.

Terminal cover

A. Indicator B. Vent hole C. Blue D. Red RAIL14CEX0908AA

1

RAIL14CEX0910AA

2

E. White F.

(Upper limit)

G. (Lower limit) H. Good I.

Low electrolyte level

J.

Low charge

Checking battery electrolyte level 1. Move the safety lock lever to the "LOCKED" position, and then stop the engine.

2. Remove the floor mat and the left battery cover.

3. Remove ventilation cap (2) for each cell to check the electrolyte level.

4. If the level is low, supply distilled water to the specified level ( 10 - 15 mm (0.4 - 0.6 in) above the electrode plate).

5. Clean the vent of ventilation cap (2) to prevent clogging and tighten the cap securely.

6. If terminals (1) are dirty, clean them with hot water, and then tighten them. Apply grease or spray a commercial rust preventive lubricant. If the terminals are oxidized, grind them with a wire brush or emery paper before attaching them.

If the engine speed does not rise at start-up and the engine fails to start, measure the specific gravity of the battery electrolyte.

If it is lower than the specified specific gravity, auxiliary charge is required.

Standard specific gravity of battery electrolyte: 1.28 at 20 °C (68 °F)).

In adverse conditions such as cold weather, adjust the specific gravity of the battery electrolyte so that the charging rate is kept close to 100%. If the specific gravity is not increased by auxiliary charge, the battery must be replaced.

NOTICE: The specific gravity of battery electrolyte is measured with a hydrometer, and its value varies depending on the temperature. For measurement of the specific gravity of battery electrolyte and auxiliary charge, contact your authorized dealer/distributor.

7-34

7 - MAINTENANCE

Fuel tank WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

Since the water is deposited during the night, drain the water and sediment before starting up the engine in the morning.

1. Swing the upper structure to a position where the drain valve under the fuel tank can be opened, place the bucket on the ground, stop the engine, and move the safety lock lever to the LOCKED position.

2. Place an empty container under drain valve (1) to catch the discharged fuel.

3. Open drain valve (1) and drain the water and sediment deposited on the bottom. Be careful not to be splashed by the flushed fuel.

4. Close drain valve (1) when the clean fuel is discharged.

RAIL14CEX0911AA

7-35

1

7 - MAINTENANCE

Track tension Adjusting the tension of the track shoes properly can extend the service life of them and traveling devices and prevent track shoes from coming off due to insufficient tension.

NOTICE: Perform this work in pairs and the operator should move the machine according to signals of the partner.

You need to lift up one side of the machine to check the track shoe. The machine could unintentionally fall when you perform this check. Never operate the machine when you perform this check.

Rubber track shoe 1. The wear status varies depending on the work condition and soil characteristic. Check the wear and tension as needed. Especially, when a new rubber track shoe is installed, adjust the tension frequently during the first 30 hours because of the initial elongation.

LELI11E0353AA

1

RAIL14CEX0912AA

2

RAIL14CEX0913AA

3

Inspection 1. Move the rubber joint (M mark) of the rubber track shoe to the upper center between the axles.

2. Swing the machine 90 degrees, place the bucket on the ground, and retract the boom cylinder to raise the track shoe to be checked. Support the lower frame with safety strut (1).

7-36

7 - MAINTENANCE

3. At the center of the crawler frame, measure gap (A) between the lower surface of the crawler frame and the upper surface of the track shoe.

1.

Crawler Frame

2.

Lower Roller

3.

Iron Track Shoe

4.

Rubber Track Shoe

Proper tension A. Rubber: 70.0 - 80.0 mm (2.8 - 3.1 in) B. Iron: 120.0 - 135.0 mm (4.7 - 5.3 in) 4. If the tension is not proper, adjust as explained below.

RAIL14CEX0914AA

4

RAIL14CEX0915AA

5

NOTICE: When you work with loose track shoes, they may come off the machine. Early wear could result from working with loose track shoes.

Adjustment It is necessary to adjust the track shoe tension depending on the work condition at the working site. At the working site covered with many gravels and cobbles, loosen the track shoe tension as much as possible within the proper range. On the firm ground, increase the tension slightly within the proper range.

Observe the following safety precautions when working on the tracks: • Grease nipple (1) can pop out due to the inner high pressure grease. Do not loosen it more than 1 turn.

• The high pressure grease is charged in the grease cylinder of the track spring. When adjusting the shoe tension or disassembling the shoe for maintenance, loosen grease nipple (1) within one turn to discharge the grease gradually.

• Keep the face and body away from grease nipple (1) when loosening it.

7-37

7 - MAINTENANCE

Increasing track shoe tension 1. Prepare a grease gun.

2. Use the grease gun to press grease into grease nipple (1) so that the track shoe tension becomes proper.

3. In order to make sure that the tensions of the left and right track shoes are equal and proper, travel the machine forward and backward to even out the pressure.

1.

Grease Nipple

2.

Grease Cylinder

A. Grease Injection B. Pressure

RAIL14CEX0916AA

6

RAIL14CEX0917AA

7

RAIL14CEX0918AA

8

RAIL14CEX0919AA

9

4. Check the track shoes tension again, and repeat the adjustment for a proper tension as needed.

NOTICE: If the tension is still loose after pressing sufficient grease, replacement of the track shoe or seal in the grease cylinder may be required, or there may be a failure in the cylinder body. Contact our authorized dealer/distributor for repair or replacement.

Loosening track shoe tension Observe the following safety precautions when working on the tracks: • It is very dangerous to discharge the grease by using procedures other than the one described below.

• If the grease does not come out and the track shoe tension is not loosened after loosening the grease nipple, contact our authorized dealer/distributor near you for repair.

• Never disassemble the grease nipples. It is dangerous.

1. Loosen grease nipple (1) of the grease cylinder gradually to drain the grease. Do not loosen grease nipple (1) more than one turn.

2. If the grease does not come out well, move the machine (track shoe) forward and backward.

3. Tighten grease nipple (1). Torque to 58.8 - 88.2 N·m (43.4 - 65 lb ft) 4. In order to check that the tension is proper, travel the machine forward and backward. Check the track shoes tension again, and repeat the adjustment for a proper tension as needed.

7-38

7 - MAINTENANCE

Grease swing pinion NOTICE: Do not swing the machine while greasing the swing pinion.

NOTICE: Lubricate the swing pinion every eight hours during the first 50 hours of operation of a new machine.

1. Inject grease of 50 g (about 20 times with grease gun) from grease nipple (1) of the swing pinion for each of four directions while swinging the machine by 90 degrees.

RAIL14CEX0920AA

7-39

1

7 - MAINTENANCE

Hydraulic oil return filter (Initial) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTICE: Immediately after the engine is stopped, the inside of the hydraulic oil tank is heated and pressurized and it is very dangerous. Before removing the return filter, stop the engine and then press the valve head on top of the breather cap to release the pressure in the hydraulic oil tank.

NOTICE: Replace the return filter with a new one after 50 hours of operation for the first time.

NOTICE: When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of the normal bucket digging work.

NOTE: When the bucket is attached, change the hydraulic oil return filter at the standard intervals.

1. The return filter needs delicate treatment because it works as an important part in removal of contaminant in the hydraulic oil to prevent failure of hydraulic components and maintain a long service life.

7-40

LELI11E0385AA

1

LELI11E0389AA

2

7 - MAINTENANCE

2. Park the machine in the hydraulic oil inspection position on the level and firm ground, and then stop the engine.

3. Use the starter key to release the lock, open the right side cover and support it with the stay.

4. Clean around the filter mounting area to prevent foreign materials such as dust from entering into.

5. Press the valve head on top of breather cap (6) several (5 to 7) times to release pressure from the hydraulic oil tank.

6. Remove the bolts (1) and remove cover (2).

7. Remove the spring (3), valve (4) and filter element assembly (A) from the tank.

8. Replace the O-ring (5) on the mounting surface of cover (2).

9. Clean the removed parts with light oil.

10. Reinstall the element by the reverse procedures of the above Steps 6 and 7 .

11. Reinstall the cover (2). Torque to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

12. Start the engine, set the machine in the hydraulic oil inspection position by moving each control lever and check the hydraulic oil level.

13. Release the support stay, close the right side cover, and lock it with the starter key.

RAIL14CEX0940BA

7-41

3

7 - MAINTENANCE

Angle dozer blade (If equipped) For normal use, grease the dozer pins every 50 h.

Under special circumstances, observe the following greasing intervals.

For the digging work in the water, grease the submerged parts before and after the work every day.

Grease the machine before operation if the machine has not been used for one month or longer.

1. Stop the engine after you set the attachment and dozer pins to the greasing position.

2. Before greasing, wipe all of he grease points shown in the figure.

3. Replace any broken grease point.

4. Apply grease to the grease points with the grease gun.

5. Wipe off the old grease that is pushed out.

• Angling cylinder (1) • Dozer blade mounting part (2) • Dozer cylinder (3) • Dozer foot pin (4)

RAIL14MEX0094BA

7-42

1

7 - MAINTENANCE

Every 100 hours

Air conditioner condenser (If equipped) NOTE: Contact your authorized dealer for maintenance and cleaning of the air conditioner condenser.

Every 200 hours

Hydraulic oil return filter (Breaker attachment option) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTICE: Immediately after the engine is stopped, the inside of the hydraulic oil tank is heated and pressurized and it is very dangerous. Before removing the return filter, stop the engine and then press the valve head on top of the breather cap to release the pressure in the hydraulic oil tank.

NOTICE: Replace the return filter with a new one after 50 hours of operation for the first time.

NOTICE: When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of the normal bucket digging work.

NOTE: When the bucket is attached, change the hydraulic oil return filter at the standard intervals.

1. The return filter needs delicate treatment because it works as an important part in removal of contaminant in the hydraulic oil to prevent failure of hydraulic components and maintain a long service life.

7-43

LELI11E0385AA

1

LELI11E0389AA

2

7 - MAINTENANCE

2. Park the machine in the hydraulic oil inspection position on the level and firm ground, and then stop the engine.

3. Use the starter key to release the lock, open the right side cover and support it with the stay.

4. Clean around the filter mounting area to prevent foreign materials such as dust from entering into.

5. Press the valve head on top of breather cap (6) several (5 to 7) times to release pressure from the hydraulic oil tank.

6. Remove the bolts (1) and remove cover (2).

7. Remove the spring (3), valve (4) and filter element assembly (A) from the tank.

8. Replace the O-ring (5) on the mounting surface of cover (2).

9. Clean the removed parts with light oil.

10. Reinstall the element by the reverse procedures of the above Steps 6 and 7 .

11. Reinstall the cover (2). Torque to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

12. Start the engine, set the machine in the hydraulic oil inspection position by moving each control lever and check the hydraulic oil level.

13. Release the support stay, close the right side cover, and lock it with the starter key.

RAIL14CEX0940BA

3

Every 250 hours of operation or every 3 months

Fan belt WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

NOTICE: Be sure to stop the engine before inspection and maintenance. Inspecting and maintaining the running engine may cause injury by being caught in the cooling fan or fan belts.

7-44

7 - MAINTENANCE

1. Check the belt for insufficient tension, wear and damage and adjust it properly in order to maintain the maximum engine performance and the service life.

NOTICE: Be sure to check the deflection and tension after adjusting the tension and tightening screws.

LELI11E0372AA

1

RAIL14CEX0921AA

2

2. Use the ignition key to release the lock, open the right side cover of the machine and support it with the rod.

3. Slightly loosen the attaching nut (1) and adjusting bolt (2).

4. Loosen adjusting bolt (3). Adjust the fan belt to the specified tension and tighten attaching nut (1) and adjusting bolt (2).

5. After the adjustment, run the engine at low idling for about 5 minutes and check the belt tension again.

6. Run the engine and check the fan belt tension.

7. Release the support rod, close the side cover and lock it with the ignition key.

Belt Fan

Tension of new belt 8 - 12 mm (0.32 - 0.47 in)

Tension of belt in use 10 - 14 mm (0.39 - 0.55 in)

Pushing force 98 N (22 lb)

NOTE: "Belt in use" refers to the belt that has been used for five or more minutes since it is attached to the engine and the engine starts running.

7-45

7 - MAINTENANCE

Radiator hoses WARNING Burn hazard!

Always remove the recovery tank cap BEFORE you remove the filler cap. Never remove either cap while the engine is running or the coolant is hot. Stop the engine and let the system cool. Using a thick cloth, loosen the cap slowly and allow the pressure to escape.

Failure to comply could result in death or serious injury.

W0361A

WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

NOTICE: The radiator hoses should be replaced before it becomes unusable. Replacing hoses early can reduce the cost and prevent serious troubles such as engine overheating. It also can minimize the unexpected interruption of work.

1. Inspect each hose for indications of coolant leakage due to looseness of clamps or cracks or a deformity in the hose or excessive wear.

2. Tighten any loose clamps. If necessary, replace hoses.

LELI11E0377AA

7-46

1

7 - MAINTENANCE

If necessary, replace radiator hoses Observe the following safety precautions: • Inside the radiator, the high pressure steam occurs and it may cause personal injury.

• Do not loosen or remove the radiator cap when the coolant is under high pressure and temperature.

• Stop the engine before removing the radiator cap.

• Allow enough time for the coolant to cool down before removing the radiator cap.

1. Loosen the radiator cap (1) slowly. After making sure that the pressure is completely released, push the cap down, loosen and remove it.

2. Remove the drain plug cover. Remove the drain plug (2) to drain the coolant into a container.

3. Loosen the clamp, remove the damaged hose, and replace it with a new one.

4. Reinstall the drain plug and cover.

5. Fill the radiator (4) with the coolant and fill expansion tank (3) with the coolant. See 7-17.

6. After filling up, tighten the radiator cap securely.

7. Install the cover.

RAIL14CEX0922BA

7-47

2

7 - MAINTENANCE

Air cleaner element WARNING Flying debris!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in death or serious injury.

W0307A

Observe the following safety precautions: • Wear protective glasses or respirator when using compressed air.

• Stop engine first and clean and replace the air cleaner element.

NOTICE: When replacing the element, cover the engine inlet with a clean cloth to prevent dust entering after removing the element.

NOTICE: The filter element can be cleaned and reused for six times. After cleaning for six times, replace the filter element with a new one.

Cleaning or replacement of outer element 1. Remove the clamps (1) of the air filter.

2. Remove the outer element (2) from the housing.

3. Clean the inside of the housing.

4. To remove clogged dust or dirt, blow compressed air ( 0.7 MPa (102 psi)) up and down along the folds on the inside and outside of element (2).

5. After cleaning, check the element (2) for thinned spots, pin holes and damage on the packing by illuminating the inside with a light. Replace the element with a new one, if necessary.

6. Install the outer element (2) in the housing.

RAIL14CEX0923AA

1

RAIL14CEX0924AA

2

7. Install the cover using the clamps (1) with the "TOP" mark facing upward.

8. If there is a pin hole or damage on the packing, replace the outer element with a new one, even when the cleaning has not yet been performed six times.

NOTICE: Be careful when attaching the O-ring. If water enters inside, an engine failure occurs.

7-48

7 - MAINTENANCE

Engine oil Follow the below safety precautions: • Do not perform oil change immediately after stopping the engine, as the parts are heated. Wait for the oil to cool down to prevent burns.

• Change the engine oil after 50 hours of operation for the first time.

1. Set a container for drain oil under drain plug (3) at the bottom of the engine.

2. Remove the under cover under the drain plug.

3. Loosen drain plug (3) slowly to drain the engine oil into the container. Be careful not to be splashed by the oil.

Clean up any oil around the engine.

4. Check the drain oil, and if many metallic powder or foreign materials are contained, contact our authorized dealer/distributor.

5. After the oil is fully drained, tighten drain plug (3) to the original position.

6. Open the engine hood, remove yellow oil filler cap (1), and fill the specified engine oil. For recommended oil, see Fluids and lubricants .

7. Start the engine, run it at idling for several minutes, and then stop the engine. Check that the oil level is in the range of "H" and "L" of oil level gauge (2). Refer to 7-19 .

7-49

RAIL14CEX0926AA

1

RAIL14CEX0688BA

2

7 - MAINTENANCE

Engine oil filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas. Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

W0156A

Observe the following safety precautions: • The oil filter cannot be reused because it is a cartridge type. Also, it cannot be disassembled for internal cleaning. Replace it by the set.

• Replace the engine oil filter after 50 hours of operation for the first time.

• Use the attached filter wrench to remove the engine oil filter.

LELI11E0374AA

1

RAIL14CEX0928AA

2

RAIL14CEX0927AA

3

Replace the engine oil filter with a new one after 50 hours of operation for the first time.

1. Stop the engine, open the engine hood, and remove the under cover.

2. By using the filter wrench, turn filter cartridge (1) to the left to remove it.

3. Wipe the sealing surface of the filter base with a clean cloth to prevent dust and foreign materials from being seized.

4. Apply a thin film of clean engine oil to packing (A) of new filter cartridge (1), tighten it by hand, and then tighten an additional two-thirds of a turn.

5. Start the engine, run it at idling for several minutes, and then check the filter cartridge mounting surface for oil leakage.

6. Close the engine hood and attach the under cover.

7-50

7 - MAINTENANCE

NOTICE: When using the machine in sandy or dusty places, shorten the replacement cycle.

NOTICE: Check the removed element, and if metal powder is attached, consult our authorized dealer/distributor.

7-51

7 - MAINTENANCE

Bleed air from the fuel system If air enters or remains in the fuel system, fuel cannot be sent to the fuel injection pump. When the fuel tank is emptied or when the fuel filter is replaced, be sure to bleed the remaining air.

Air bleeding procedure 1. Move the safety lock lever to the "LOCKED" position and stop the engine.

2. Refill the fuel tank to the maximum.

3. Confirm that the valve of water separator (2) is set to "OPEN" position (D).

4. Turn the starter key to the "ON" position and wait for 15 to 20 seconds to send oil to the fuel system using the fuel supply pump.

1.

Fuel filter

2.

Water separator

3.

Fuel cock

4.

Drain cock

NOTE: If the entire piping is emptied due to running out of gas, wait for 60 seconds after turning the starter key to the "ON" position.)

A. Fuel inlet B. Fuel outlet C. Close D. Open RAIL14CEX0936BA

1

NOTICE: Do not continue to run the starter for 15 seconds or longer to send oil to the fuel system. It could heat the starter and might cause damage to the coil, pinion gear, and ring gear, etc.

NOTICE: Wait for 30 seconds or longer before using the starter again.

7-52

7 - MAINTENANCE

Swing bearing NOTICE: Never slew the upper structure while applying grease to the slewing bearing.

NOTICE: The lubrication of the balls must be carried out by one person only. Before lubricating the slewing bearing, keep people away from the machine’s working range.

Before leaving the cab, arrange machine and controls as follows: • Place the machine on a level surface.

• Rest the bucket onto the ground.

• Bring the throttle control lever to minimum speed, stop the engine and remove the starter key, then set the safety lever to the LOCKED position.

• With the upper structure stopped, inject grease through the grease nipple (1).

• Start the engine, raise the bucket approximately 20 cm (7.87 in) from the ground and slew the upper structure by 45° (1/8 of a turn).

• Rest the bucket onto the ground.

• Repeat the procedure above three times. Always observe the safety indications prescribed.

• Grease should be injected until it comes out of the seals. Do not inject grease excessively.

7-53

LELI11E0371AB

1

7 - MAINTENANCE

Dozer blade Observe the following safety precautions: • For the digging work in the water, grease the submerged parts before and after the work every day.

• Grease the attachment before the work if it has not been used for one month or longer.

1. Set the attachment in the greasing position and then stop the engine.

2. Before greasing, wipe off the grease nipples. Replace any damaged nipples with new ones.

3. Use the grease gun to apply grease to the grease nipples.

4. After applying grease, wipe off old grease which is pushed out.

RAIL14CEX0930AA

No. 1 2

Parts to grease Dozer cylinder foot pin Dozer cylinder rod pin

Points 1 1

7-54

No. 3

Parts to grease Dozer foot pin

Points 2

1

7 - MAINTENANCE

Radiator, oil cooler core, and filter WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

Cleaning and replacing the radiator cap Observe the following safety precautions: • Inside the radiator, the high pressure steam occurs and it may cause personal injury.

• Do not loosen or remove the radiator cap when the coolant is under high pressure and temperature.

• Stop the engine before removing the radiator cap.

• Allow enough time for the coolant to cool down before removing the radiator cap.

NOTICE: A loose radiator cap will let hot steam and coolant escape from the cooling system during operation and it may cause burns.

1. After the radiator cap has cooled enough to touch with bare hands, remove cap (1).

2. Loosen cap (1) slowly to release the pressure, then push cap (1) down and loosen it to remove it.

3. Inspect locations A through C for foreign materials and damage to cap (1). Use a clean cloth to wipe cap (1) and replace it if necessary.

4. Inspection locations A. Contact surface between negative pressure valve (2) and gasket (5) B. Both surfaces of pressure valve (3) and gasket (5)

RAIL14CEX0931AA

1

RAIL14CEX0932AA

2

C. Both surfaces of external lid (4) and gasket (6) 5. Securely tighten cap (1).

7-55

7 - MAINTENANCE

Cleaning radiator, oil cooler core and filter NOTICE: Direct strike of compressed air, steam or high pressure water on the body can cause injury. Wear protective glasses, or goggles, mask, and protective shoes, etc.

NOTICE: When using compressed air or high pressure water, keep a safe distance from the fin to prevent it from being damaged. If the fin is damaged, it may cause water leakage or overheating.

6. Open the side cover on the right side of the machine and remove the undercover.

7. Pull up stopper (2) to release the lock and pull out filter (1).

8. Clean filter (1) with compressed air ( 0.2 MPa (29 psi)) or water.

9. Check radiator (3) and oil cooler (4) to clean any mud, dust or leaves off.

10. Insert filter (1) into the original position and pull down stopper (2) to lock it.

11. After cleaning, close the side cover on the right side and install the undercover.

7-56

RAIL14CEX0933AA

3

RAIL14CEX0934AA

4

RAIL14CEX0935AA

5

7 - MAINTENANCE

Every 500 hours of operation or every 6 months

Fuel filter CAUTION Burn hazard!

Wait for all components to cool before performing any operation.

Failure to comply could result in minor or moderate injury.

C0053A

NOTICE: The oil filter cannot be reused because it is a cartridge type. Also, it cannot be disassembled for internal cleaning. Replace it by the set.

1. Stop the engine, and open the engine hood.

2. By using the fuel filter wrench, turn filter cartridge (1) to the left (A) to remove it.

3. Wipe the sealing surface of the filter base with a clean cloth to prevent dust and foreign materials from being seized.

4. Apply a thin film of clean engine oil to packing (A) of new filter cartridge, tighten it by hand, and then tighten an additional two-thirds of a turn.

5. Bleed the fuel system (See Page 7-52).

6. Start the engine, run it at idling for several minutes, and then check the filter mounting area for fuel leakage.

7-57

RAIL14CEX0937AA

1

RAIL14CEX0927AA

2

7 - MAINTENANCE

Water separator 1. Move the safety lock lever to the "LOCKED" position and then stop the engine.

2. Open the engine food and raise cock (2) of the water separator to the "Close" position (C).

3. Loosen ring (9) to remove case (5).

4. Check the water drained to the container. If dirt is heavy, clean element (6) and inside of case (5).

5. Remove element (6)and wash it with light oil.

6. Replace O-ring (8) with a new one. Install element (6) to the body of the water separator.

7. Attach O-ring (8) to case (5) and tighten it with ring (9) .

8. Lower cock (2) to "OPEN" (D).

9. Bleed the fuel system (See Page 7-52).

1.

Air vent bolt

2.

Fuel cock

3.

Drain cock

4.

Ring (red)

5.

Case

6.

Element

7.

Spring

8.

O-ring

9.

Ring

RAIL14CEX0938BA

1

RAIL14CEX0939AA

2

A. Fuel inlet B. Fuel outlet C. Close D. Open NOTICE: Do not wash the element with gasoline.

7-58

7 - MAINTENANCE

Air conditioner lines (If equipped) NOTE: Contact your authorized dealer for inspection and maintenance of the air conditioning lines.

7-59

7 - MAINTENANCE

Air conditioner refrigerant (If equipped) DANGER Avoid injury!

Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant.

Failure to comply will result in death or serious injury.

D0043A

WARNING Escaping refrigerant may cause frostbite!

Always wear protective goggles when handling refrigerant. If you get refrigerant in your eye, immediately flush your eyes with water for 15 minutes. Seek medical assistance immediately.

Failure to comply could result in death or serious injury.

W0339A

WARNING Avoid injury!

Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service.

Failure to comply could result in death or serious injury.

W1000B

Check the air conditioner refrigerant NOTICE: When filling or changing refrigerant, confirm the type of refrigerant and use the specified refrigerant.

Refrigerant type and quantity: R-134a/590 g±50 g The use of unspecified refrigerant may cause damage of components.

1. Park the machine on a firm, level surface.

2. Start the engine.

3. Set the engine throttle lever to the middle speed position.

4. Set the temperature adjustment switch (2) to C (lowest) (window and door closed) 5. Set the fan selector speed (3) to 3 (high).

6. Turn the air conditioner switch (1) ON.

RAIL14CEX0123AA

7-60

1

7 - MAINTENANCE

7. Determine the refrigerant volume based on the following checks by looking through the sight glass (inspection window) on the receiver dryer.

Figure (A): The refrigerant volume is proper.

Figure (B): The refrigerant is over-charged. This will make both high and low pressure rise. This over-charged condition will have an adverse effect on the pressure switch operation and the air conditioning system.

Figure (C): The refrigerant is insufficient. Contact your authorized dealer to recharge the refrigerant.

RAIL14MEX0092BA

2

NOTICE: Operate the air conditioner at least once a week for several minutes to rotate the compressor regardless of the season.

NOTICE: If an oil stain is found around a pipe joint, it is a sign of gas leakage. Contact your authorized dealer/ distributor for inspection.

NOTICE: Extract the sealed refrigerant from unit when disposing this unit.

NOTE: Do not release the refrigerant which is sealed in this unit to the atmosphere.

7-61

7 - MAINTENANCE

Every 1000 hours of operation or annually

Hydraulic oil return filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTICE: Immediately after the engine is stopped, the inside of the hydraulic oil tank is heated and pressurized and it is very dangerous. Before removing the return filter, stop the engine and then press the valve head on top of the breather cap to release the pressure in the hydraulic oil tank.

NOTICE: Replace the return filter with a new one after 50 hours of operation for the first time.

NOTICE: When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of the normal bucket digging work. See 7-43.

1. The return filter needs delicate treatment because it works as an important part in removal of contaminant in the hydraulic oil to prevent failure of hydraulic components and maintain a long service life.

7-62

LELI11E0385AA

1

LELI11E0389AA

2

7 - MAINTENANCE

2. Park the machine in the hydraulic oil inspection position on the level and firm ground, and then stop the engine.

3. Use the starter key to release the lock, open the right side cover and support it with the stay.

4. Clean around the filter mounting area to prevent foreign materials such as dust from entering into.

5. Press the valve head on top of breather cap (6) several (5 to 7) times to release pressure from the hydraulic oil tank.

6. Remove the bolts (1) and remove cover (2).

7. Remove the spring (3), valve (4) and filter element assembly (A) from the tank.

8. Replace the O-ring (5) on the mounting surface of cover (2).

9. Clean the removed parts with light oil.

10. Reinstall the element by the reverse procedures of the above Steps 6 and 7 .

11. Reinstall the cover (2). Torque to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

12. Start the engine, set the machine in the hydraulic oil inspection position by moving each control lever and check the hydraulic oil level.

13. Release the support stay, close the right side cover, and lock it with the starter key.

RAIL14CEX0940BA

7-63

3

7 - MAINTENANCE

Air breather element CAUTION Burn hazard!

Wait for all components to cool before performing any operation.

Failure to comply could result in minor or moderate injury.

C0053A

WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

1. Park the machine on the level and firm ground, extend the bucket cylinder, retract the arm cylinder, lower the bucket to the ground, and place the dozer on the ground as shown to the right figure and stop the engine.

2. Open the right side cover and support it with the stay.

3. Press the rubber cap of the breather on the top of the hydraulic tank several times (5 - 7 times) to release the inner pressure of the hydraulic tank.

4. Remove breather cap (1) and nut (2).

5. Turn the cover (3) in counter clockwise direction to remove the cover. Remove the element (4).

RAIL14CEX0941AA

1

RAIL14CEX0862AA

2

RAIL14CEX0942AA

3

6. Install the new element (4) and reinstall the cover (3) along the groove.

7. Make sure that no water and dirt entered the air intake and exhaust between cover (3) and body (5).

8. Reinstall the cover (3) with the nut (2).

NOTICE: To avoid the breakage of bolts, do not tighten nut (2) too much. Torque to 10 - 14 N m (7.3 - 10.3 lb ft).

9. Reinstall the breather cap (1).

10. Remove the stay and return the right side cover to the specified position.

NOTICE: To keep the hydraulic oil clean and to extend the service life of hydraulic components, replace the filter element at regular intervals

7-64

7 - MAINTENANCE

Radiator coolant WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas.

Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

W0156A

WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

LELI11E0391AA

1

LELI11E0392BB

2

W0367A

NOTICE: Never use sealant additives to stop leaks from the cooling system. Failure to observe this rule might cause system obstruction with consequent insufficient flow of coolant, temperature increase and engine overheating.

Park the machine on a level surface.

Rest the bucket to the ground.

Bring throttle control lever to minimum speed, stop the engine and remove starter key, then position safety lever on LOCK position.

Wait until the machine is cold.

Open engine guard and lock it in open position.

With cold engine, remove plug (1) from radiator and plug (2) from level tub (3).

Remove draining plug (4) and let coolant drain inside a container of suitable capacity. When this operation is finished, reinstall plugs (4) and (2).

Carefully inspect the sleeves for integrity and seal (replace them if necessary) and tighten possibly loose clamps. Check the radiator for leaks, damages and/or dirt build-up.

Proceed with system filling through plug (1) until the radiator is completely full.

NOTE: When adding coolant, proceed slowly to avoid formation of air bubbles in the system.

7-65

7 - MAINTENANCE

Install cover (1).

Start the engine and let it run for several minutes, so as to heat the coolant.

Stop the engine, wait until it cools down and check the coolant level on the level tub (3). The coolant level should be set between references FULL and LOW. If the level is low, remove plug (2) and restore level.

Close engine guard and radiator compartment lid.

NOTE: Handle and dispose of coolant according to current legislation. Use only authorized disposal procedures. If in doubt, contact authorities concerned.

NOTE: If “Long life coolant” is not used, replace the coolant twice a year (in spring and autumn).

7-66

LELI11E0393AA

3

7 - MAINTENANCE

Hydraulic oil (Breaker attachment option) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTICE: When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of the normal bucket digging work.

NOTICE: Do not drop bolts or others into the tank during the work.

Observe the safety precautions that follow: • The oil in the hydraulic oil tank is under high temperature and pressure.

• Stop the engine first, remove the breather cap, press the valve, release the pressure from the tank before you remove the cover.

• Immediately after operation, the oil is hot and it may cause burns. Wait until the oil temperature cools down before attempting to change the hydraulic oil.

1. Park the machine on the level and firm ground, swing the upper structure so that drain plug (1) on the bottom of hydraulic oil tank is positioned to the midpoint of right and left track shoe.

2. Retract the arm cylinder and bucket cylinder, place the bucket and dozer (when installed) on the ground and stop the engine.

3. Move the safety lock lever to the “LOCKED” position.

4. Remove the cover under the hydraulic oil tank.

5. Clean the surface around the hydraulic oil tank to keep it away from foreign materials.

6. Press the breather cap (2) on the top of the hydraulic tank several times (5 - 7 times) to release the inner pressure of the hydraulic tank.

RAIL14CEX0953AA

1

RAIL14CEX0943AA

2

7. Remove the bolt (3) of the tank upper cover and remove cover (4).

7-67

7 - MAINTENANCE

8. Place a container for drain oil under drain plug (1) on the bottom of the hydraulic oil tank.

9. Loosen drain plug (1) on the bottom of hydraulic oil tank slowly and drain hydraulic oil completely.

10. Clean drain plug (1) and install it in place. Torque to 98 - 118 N·m (72.3 - 87.0 lb ft).

11. Refill hydraulic oil through fuel inlet (F) on the top of the hydraulic oil tank. Pour the oil while checking the oil level with level gauge (G).

12. Attach filler port cover (4) with bolt (3). Torque to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

13. Start the engine, run it at low idling for several (5 to 7) minutes. After that, operate each cylinder and swing the machine to return it to the hydraulic oil inspection position. Stop the engine and check the oil level, and if it is low, add the hydraulic oil.

RAIL14CEX0954BA

7-68

3

7 - MAINTENANCE

Every 1500 hours

Exhaust Gas Recirculation (EGR) system Exhaust Gas Recirculation (EGR) cooler — Clean NOTE: Contact your authorized dealer to perform this procedure.

The EGR cooler has a tendency to become contaminated with rust and scale which deteriorates the cooling performance.

Carbon accumulation in the exhaust gas passage of the cooler hinders circulation of the exhaust gas. This results in the deterioration of the exhaust gas cleanup performance. Contact your authorized dealer to have your EGR cooler cleaned.

7-69

7 - MAINTENANCE

Fuel injection system Check, adjust, and clean the fuel injection valves NOTE: Contact your authorized dealer to preform this check and adjustment.

Poor condition of the fuel injection valves may cause: • Abnormal exhaust color • A lower engine output than normal

Check and adjust the fuel injection timing NOTE: Contact your authorized dealer to preform this check and adjustment.

To have the best engine performance, have your authorized dealer adjust the timing.

7-70

7 - MAINTENANCE

Crankcase breather Inspection of the crankcase breather NOTE: Contact your authorized dealer to inspect the crankcase breather.

Proper operation of the crankcase breather system is required to maintain the emissions requirements of the engine.

7-71

7 - MAINTENANCE

Every two years

Air conditioner filters (If equipped) Remove the air conditioning filters The fresh air filter (1) is located on the right-hand side of the cab.

1. Hold the handle grip of the fresh air filter (1) and pull it straight up and out.

The recirculation air filter (2) is located on the right-hand side of the cab.

2. Hold the handle grip of the recirculation air filter (2) and pull it straight out to the side.

RAIL14MEX0093AA

Replace the air conditioner filters 3. Attach the new fresh air filter (1) and the new recirculation air filter (2) in reverse order as instructed in steps 1 and 2.

7-72

1

7 - MAINTENANCE

Air conditioner receiver dryer (If equipped) NOTE: Contact your authorized dealer for receiver dryer replacement.

7-73

7 - MAINTENANCE

Every 2000 hours

Travel reduction unit oil With a new machine the first oil change is to carry out after the first 50 service hours.

NOTICE: This must though remain strictly outside the maneuvering range of the engine. Never carry out maintenance or inspection on translation motor circuits on slopes.

They are highly pressurized because of the machine weight.

NOTICE: The oil is hot immediately after travel operations.

Wait for the temperature of the oil to cool down before you service the travel reduction units.

1. Park the machine on a level surface. The reduction units should be positioned as to have the drain plug (3) down as shown.

2. Remove the drain plug (3).

NOTE: If there is residual pressure in the travel motor, oil could flow out and the drain plug (3) could pop out.

3. Remove the level plug (1) and the fill plug (2).

4. Drain the oil into a suitable container.

5. After the oil is completely drained, attach the drain plug (3) securely in place.

6. Fill with the specified oil through the fill plug (2) until the oil overflows from the level plug (1).

7. Attach the level plug (1) and the fill plug (2).

8. Repeat this procedure for the travel reduction unit on the other side of the machine.

7-74

RAIL14MEX0100AA

1

7 - MAINTENANCE

Suction strainer NOTICE: Do not drop bolts or others into the tank during the work.

1. Park the machine in the hydraulic oil inspection position on a level and firm ground. Stop the engine.

2. Move the safety lock lever to the "LOCKED" position.

3. Clean the surface around the hydraulic oil tank to keep away from foreign materials.

4. Press the breather cap (1) on the top of the hydraulic tank several times (5 - 7 times) to release the inner pressure of the hydraulic tank.

5. Remove the bolts (2) of the tank upper cover and remove cover (3).

7-75

RAIL14CEX0944AA

1

RAIL14CEX0943AA

2

7 - MAINTENANCE

6. Remove the suction strainer (4).

7. Clean the strainer with light oil or cleaning solvent, dry it and check it for damage. If damaged, replace the strainer with a new one.

NOTE: The length of the suction strainer (L) should be between 537.5 - 539.5 mm (21.16 - 21.24 in).

8. Check the O-rings (5) and (6) on the bottom of the strainer, replace if necessary.

9. Install the strainer (4).

10. Install the cover (3) with the bolts (2). Torque the bolts to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

RAIL14CEX0945AA

3

RAIL14CEX0946BA

4

11. Start the engine, run it at low idling for several (5 to 7) minutes. After that, operate each cylinder and swing the machine to return it to the hydraulic oil inspection position. Stop the engine and check the oil level, and if it is low, add the hydraulic oil.

7-76

7 - MAINTENANCE

Pilot line filter WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

Internal pressure always exists in the hydraulic circuit.

Do not inspect or maintain the machine before releasing the internal pressure.

To release the internal pressure of the hydraulic oil tank, press the valve on top of the breather cap to release the pressure in the hydraulic oil tank.

Wipe off spilled hydraulic oil to prevent a fire.

On each port P of the pilot valves for left and right hand operator control levers, the pilot valve for travel, and the solenoid valve, the filtered connector is attached. If dust is adhered to these filters, the flow of hydraulic oil will be interrupted. If dust enters into the valves, it may cause failure. Remove them periodically to clean them.

When cleaning the pilot line filters, place the machine in the parking position, set the safety lock lever to the "LOCKED" position, and stop the engine. Then bleed the air of the hydraulic circuit. See 7-9.

7-77

7 - MAINTENANCE

Pilot valves for control levers 1. Remove the rubber boot of the control lever, refer to Page 7-98.

2. To remove cover (5) of the left side lever, loosen two bolts (8) and remove cover (5).

3. To remove cover (6) of the right side lever, loosen two bolts (9) to remove cover (7) and then loosen three bolts (8) to remove cover (6).

4. Remove hose (1) connected to the port P of pilot valve (4).

5. Remove the filtered connector (2).

6. Attach a plug to the lubrication hole to keep it away from foreign materials.

RAIL14CEX0947AA

1

RAIL14CEX0948BA

2

RAIL14CEX0949BA

3

7. Spray light oil or air to clean the dust accumulated on the filter.

8. Check the O-ring (3). Replace if necessary.

9. Reinstall the connector (2) and hose (1).

7-78

7 - MAINTENANCE

Pilot valve for travel 1. Open the cover (5) on the left-hand side of the machine.

2. Remove the hose connected to the port P of the pilot valve (4).

3. Remove the elbow (1).

4. Attach a plug to the lubrication hole to keep it away from foreign materials.

5. Spray light oil or air from the side where filter (3) is attached to clean the dirt and dust accumulated inside elbow (1).

6. Check the O-ring (2). Replace if necessary.

7. Reinstall the connector and hose. See 7-5.

RAIL14MEX0106AA

4

RAIL14CEX0951AA

5

RAIL14MEX0107BA

6

Solenoid valve 1. Open the cover (5) on the left hand side of the machine.

2. Remove the hose and tee fitting on the inline filter (1).

Remove inline filter (1). Attach a plug to the lubrication hole to keep it away from foreign materials.

3. Remove the inline filter (1).

4. Attach a plug to the lubrication hole to keep it away from foreign materials.

5. Clean the inline filter (1) with light oil.

6. Reinstall the inline filter (1), tee fitting and hose. See 7-5.

7-79

7 - MAINTENANCE

Idler wheel and rollers change oil WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

Remove lower roller and idler wheel to discharge oil.

The procedures for removal, installation and change of gear oil are described hereunder.

LELI11E0410AA

1

LELI11E0411AA

2

LELI11E0412AB

3

Crawler idler adjuster For oil discharge, remove rubber crawler according to relevant side.

NOTICE: The inspection of the crawler tension is carried out with one side of machine raised. This can generate a falling risk if the machine is hit erroneously. Never operate the machine except the rubber crawlers during such work.

Start the engine and use the boom and the arm to lower the bucket bottom to the ground on the relevant side.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground.

Place some supports under the frame to support the machine.

Pull off the idler wheel (1) and adjuster (2) from the crawler frame.

Weight of the idler wheel: 60 kg (132 lb) Loosen the cap (3) and let the oil drain into a container.

Fill gear oil through the plug hole (3).

7-80

7 - MAINTENANCE

Apply a sealing (teflon) tape on the thread of the plug (3), then tighten the plug. Dry oil residues.

Apply grease to the sliding surface (A) of the piston (4), of the cylinder (5) and of the crawler idler (2).

Install the idler so that the plug (3) and the grease nipple (6) of the crawler idler are facing outwards.

Tension the rubber crawler.

After confirmation of rubber crawler engagement with the idler and the conditions for tension, lower the machine to the ground, removing the safety support, etc.

LELI11E0413AB

4

LELI11E0414AB

5

LELI11E0415AB

6

Upper roller For oil discharge, remove rubber crawler according to relevant side.

After stopping the engine, ensure that the machine is in parking position.

Loosen the rubber track (1) of the side on which gear oil (2) is to be changed.

Raise the track with an hydraulic jack (3).

Remove the nuts (4) and the cap screws (5) from the support fixing the shaft of the upper roller (7). Remove roller.

Remove oil filling plug (8) by means of a wrench and drain oil from the roller into a container.

Fill reduction gear oil [ 55.0 cm³ (3.4 in³) through filling port (8).

Apply sealing (teflon) tape on the thread of drain plug (8), and securely tighten it.

Wipe off any oil around the plug.

Install the roller in reverse order from removal.

After applying thread lock sealant on thread of the cap screws (5), tighten the screws.

Tightening torque: 103 - 127 N·m (76 - 94 lb ft).

7-81

7 - MAINTENANCE

Lower roller To change the oil of the lower roller, remove from the crawler frame and refill.

1.

Travel motor

2.

Sprocket

3.

Lower roller

4.

Track shoe

5.

Upper roller

6.

Idler

RAIL14CEX0979AA

7

RAIL14CEX0980AA

8

LELI11E0411AA

9

Loosen the rubber track shoe on the relevant side.

Loosen the lower roller bolt (1) (about one turn)

Start the engine and use the boom and the arm to lower the bucket bottom to the ground on the relevant side.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground.

Support the machine with steady supports and stop the engine.

Remove the bolts (1) and washers (2). Then remove the lower roller (3).

Remove fuel inlet plug (4) with an Allen wrench to drain the old engine oil.

Fill with the specified volume ( 65.0 cm³ (4.0 in³)) through the fuel inlet.

Apply LOCTITE® 262™ to the screw of the bolts (1) and temporarily tighten the lower roller (3) to the crawler frame.

Remove the supports and lower the machine completely to the ground.

Tighten the bolts (1). Torque to 249.6 - 308.4 N·m (184.1 - 227.5 lb ft).

Lift up the machine to adjust the track shoe tension.

See 7-36.

7-82

RAIL14CEX0980AA

10

7 - MAINTENANCE

Every 3000 hours

Exhaust Gas Recirculation (EGR) system Inspect and clean the Exhaust Gas Recirculation (EGR) valve Contact your authorized dealer to inspect and clean the EGR valve.

7-83

7 - MAINTENANCE

Every 5000 hours

Hydraulic oil WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

NOTICE: When the hydraulic breaker is attached, the deterioration of the hydraulic oil is faster than that of the normal bucket digging work. See 7-67 .

NOTICE: Do not drop bolts or others into the tank during the work.

Observe the safety precautions that follow: • The oil in the hydraulic oil tank is under high temperature and pressure.

• Stop the engine first, remove the breather cap, press the valve, release the pressure from the tank before you remove the cover.

• Immediately after operation, the oil is hot and it may cause burns. Wait until the oil temperature cools down before attempting to change the hydraulic oil.

1. Park the machine on the level and firm ground, swing the upper structure so that drain plug (1) on the bottom of hydraulic oil tank is positioned to the midpoint of right and left track shoe.

2. Retract the arm cylinder and bucket cylinder, place the bucket and dozer (when installed) on the ground and stop the engine.

3. Move the safety lock lever to the “LOCKED” position.

4. Remove the cover under the hydraulic oil tank.

5. Clean the surface around the hydraulic oil tank to keep it away from foreign materials.

6. Press the breather cap (2) on the top of the hydraulic tank several times (5 - 7 times) to release the inner pressure of the hydraulic tank.

RAIL14CEX0953AA

1

RAIL14CEX0943AA

2

7. Remove the bolt (3) of the tank upper cover and remove cover (4).

7-84

7 - MAINTENANCE

8. Place a container for drain oil under drain plug (1) on the bottom of the hydraulic oil tank.

9. Loosen drain plug (1) on the bottom of hydraulic oil tank slowly and drain hydraulic oil completely.

10. Clean drain plug (1) and install it in place. Torque to 98 - 118 N·m (72.3 - 87.0 lb ft).

11. Refill hydraulic oil through fuel inlet (F) on the top of the hydraulic oil tank. Pour the oil while checking the oil level with level gauge (G).

12. Attach filler port cover (4) with bolt (3). Torque to 20.7 - 25.3 N·m (15.3 - 18.7 lb ft).

13. Start the engine, run it at low idling for several (5 to 7) minutes. After that, operate each cylinder and swing the machine to return it to the hydraulic oil inspection position. Stop the engine and check the oil level, and if it is low, add the hydraulic oil.

RAIL14CEX0954BA

7-85

3

7 - MAINTENANCE

As required

Work lamps A 55 W halogen lamp is used for the working lights of this machine.

1. This section describes the replacement of a lamp. If no abnormality is found in the lamp, see 7-100 to check the fuse.

NOTICE: Because a lighted lamp becomes hot, its life may be shortened if grease or other oil is adhered on it. When replacing the lamp, hold the flange part so as not to touch the glass part with fingers.

LELI11E0324AA

1

LELI11E0325AB

2

Attachment mounting part 1. Remove the screw (1), rim (2) and lens part (3) from the housing (4).

2. Remove the spring (6) that fixes the socket (5).

3. Remove the lamp (7) from the socket (5) and install a new lamp.

4. Tighten and fix the removed parts in the reverse order of Step 1.

NOTICE: Be careful not to damage the lens when replacing the lamp. Hold the lens when removing screw (1), or it will come off to be damaged.

7-86

7 - MAINTENANCE

Windshield washer reservoir (cab only) The window washer reservoir (1) is located inside the cab near the lower left side of the operator’s seat.

When the fluid level becomes low, remove the cap (2) and fill the reservoir with washer fluid.

LELI11E0163AB

1

NOTICE: Do not operate the windshield washer when the reservoir is empty. This could cause damage the windshield washer reservoir motor.

7-87

7 - MAINTENANCE

Bucket CAUTION Avoid injury!

Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.

Failure to comply could result in minor or moderate injury.

C0145A

1. Park the machine on a firm level surface. When working in team, send and receive signals to each other and use extreme caution to ensure the safety.

2. Do not operate the front attachment abruptly as it may cause danger.

3. When aligning the pin with a pin bore, never insert your fingers into the bore.

4. Place the removed bucket in the stable condition.

Removing the bucket 1. Put the bucket bottom on the level ground and stabilize it at the position where the load is not applied on the pins of bucket and arm.

2. Place the O-rings (1) on the bucket boss.

3. Remove the retaining ring (1), pin (3), pull pins (4) and (5). Remove the bucket (6).

NOTICE: Use caution to prevent sand or mud from attaching the removed pin.

NOTICE: Both ends of the arm (7) and bucket link (8) have the dust seals (11). Use caution to avoid damaging them.

LELI11E0332BB

7-88

1

7 - MAINTENANCE

Installing bucket 1. Clean each pin and pin bore and apply grease sufficiently.

2. Move the bucket cylinder to align the pin bores of the bucket (6) and bucket link (8) with each other, and insert the pin (4).

3. Raise the boom and slightly raise the bucket from the ground.

4. Move the arm (7) to align the pin bores of the bucket (6) and arm (7) with each other, and insert the pin (5).

5. Insert the pin (3) and install the retaining ring (2). Fit the O-ring (1) in place.

LELI11E0333AB

2

LELI11E0335AB

3

LELI11E0326AA

4

RAIL14CEX0895AA

5

6. Apply grease to the grease nipples for each pin until the grease comes out through the gap between pins and bore.

NOTICE: If O-ring (1) is cracked or has lost elasticity, replace it with a new one.

Replacing tooth point and side cutter 1. Check the bucket tooth points (1) and side cutters for wear.

Replace any tooth point (1) with holes or cracks before the adapter (4) begins to wear.

NOTICE: When replacing a tooth point or side cutter, apply a safety block to the bottom face of the bucket.

2. If a side cutter shows severe wear, replace it immediately. If you delay the replacement, the body of the bucket will be damaged.

1.

Tooth point

2.

Rubber lock pin

3.

Locking pin

4.

Adapter

5.

Adapter nose

7-89

7 - MAINTENANCE

Replacing the tooth points CAUTION Flying objects!

Wear eye protection. Do not strike steel parts with a steel hammer. Parts may break.

Failure to comply could result in minor or moderate injury.

C0024A

When replacing the tooth points or side cutters, contact our authorized dealer/distributor

Removing the tooth point 1. To hammer out the tooth pin, place the bucket on safety block (6), making the tooth parallel to the ground.

2. With a hammer (7) and punching tool (8), drive out the locking pin (3). Be careful not to break rubber lock pin (2).

3. Inspect the locking pin (3) and rubber lock pin (2). If locking pin (3) is too short or rubber lock pin (2) is in poor condition as shown, replace it with a new one.

RAIL14CEX0896AA

6

LELI11E0328AB

7

Installing the tooth point 1. Push rubber lock pin (2) into the hole of the adapter nose.

2. Install the tooth point (1) on the adapter nose (5).

3. Hammer the locking pin (3) until it aligns with the point surface.

NOTICE: Align the rear face of the pin bore on the tooth point with that on the adapter nose or insert the tooth point more deeply.

7-90

7 - MAINTENANCE

Replacing the side cutters 1. Remove any sand and soil around the attaching bolts.

Use an acetylene torch to cut off the bolts, and then remove the side cutters.

2. Clean the mounting surfaces and install the new side cutters. When replacing the side cutters, replace the bolts and nuts with new ones. Torque to 249.6 308.4 N·m (184 - 227 lb ft).

3. After tightening the nuts, spot-weld the nuts.

NOTICE: If you delay replacement, the body of the bucket will be damaged. CASE CONSTRUCTION recommends early replacement.

7-91

RAIL14CEX0897AA

8

RAIL14CEX0898AA

9

7 - MAINTENANCE

Rubber track shoe Repair or replacement of the rubber track shoes is required if you observe the following conditions. Contact your authorized dealer/distributor for repair or replacement.

1.

Rubber shoe

2.

Lower roller

3.

Core metal

4.

Steel cord

5.

Lug

RAIL14CEX0899AA

1

RAIL14CEX0900AA

2

RAIL14CEX0902AA

3

Lug height 1. As lug height (A) decreases due to wear, the tractive force is reduced. When (A) is 5 mm (0.2 in) or less, replace the shoes with new ones.

2. When lugs are worn and steel cord (1) inside the shoe is exposed across two links or more, replace the shoe with a new one.

Break of steel cord 3. If lugs are worn and more than half of one steel cord (B) is broken, replace the shoe with a new one.

7-92

7 - MAINTENANCE

Crack of rubber track shoe 4. If crack (A) of 60 mm (2.4 in) or longer occurs between lugs of the rubber track shoe, repair it. In addition, if a shorter crack (B) occurs and inner steel cord (1) is exposed, immediately repair it.

NOTICE: Contact our authorized dealer/distributor for judgment of replacement or repair of the rubber track shoe.

RAIL14CEX0901AA

4

RAIL14CEX0903AA

5

Detachment of core metal of rubber track shoe Even if no damage or wear is found on the lug side (outside) of the rubber track shoe, the core metal side (inside) can be worn by interference or rubbing with roller, idler, or sprocket in some usage condition, finally resulting in detachment of core metals.

1.

Lower roller

2.

Core metal

3.

Rubber

4.

Canvas

5.

Steel cord

A. Damage due to interference

NOTICE: Our warranty does not cover damage caused by prohibited use of the rubber track shoes or use of them with an improper shoe tension.

5. If any one of the core metals (1) on a rubber track shoe is detached, replace it with a new one.

LELI11E0341AB

7-93

6

7 - MAINTENANCE

6. If a crack occurs on a rubber track shoe and a core metal (1) stands out, replace it with a new one.

LELI11E0342AB

7

RAIL14CEX0904AA

8

7. Cracks (A) which occur where core metals contact with the roller do not need repair.

NOTICE: Prohibited use of the rubber track shoe can easily cause detachment of core metals.

7-94

7 - MAINTENANCE

Replacement of rubber track shoe This work must be done carefully by two people. The operator must operate the machine as instructed by the signals of the partner.

Having to carry out visual controls with the crawler in motion, remain always at an emergency distance and outside from the moving range of the machine. Whatever service to the crawlers must be carried out with the machine set up in the following way: • Throttle lever at idle run.

• Engine shut down.

• Starter key removed.

• Safety lever in LOCKED position.

LELI11E0303AA

1

LELI11E0304AB

2

WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

Before removing the rubber crawler, check that the grease pressure has been completely released.

Personnel must observe the instructions given in paragraph “Replacement of rubber crawler”, otherwise there is a risk of injury.

Removing of rubber crawler Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

7-95

7 - MAINTENANCE

Open the grease nipple (2) slowly so as to let grease come out and to relieve the pressure.

One turn, one turn and a half of the grease nipple (2) is sufficient, to loosen the crawler.

LELI11E0305AB

3

LELI11E0306AB

4

LELI11E0307AB

5

LELI11E0308AB

6

Insert some steel pipes (3) in the rubber crawler, then slowly rotate the sprocket backward.

When the rubber crawler leans on the pipes, slide it aside to remove it.

Installing rubber crawlers Turn the upper structure by 90° and lower the bucket to lift the crawler as shown.

Keep the angle between the boom and the arm to 90° and 110° and position the round part of the bucket on the ground. Place some supports (1) under the frame to support the machine.

Engage the crawler into sprocket and engage it into the crawler idler.

Slowly rotate the sprocket backwards and set the rubber crawler into position.

Engage a steel pipe (2) into the rubber crawler, and rotate the sprocket backward again to securely engage the rubber crawler with the idler adjuster.

7-96

7 - MAINTENANCE

Stop the sprocket (3) and check whether the rubber crawler (4) is correctly positioned on the crawler idler, on the lower rollers (5) and on the sprocket.

LELI11E0309BB

7-97

7

7 - MAINTENANCE

Control levers 1. In the rotation sliding system, remove the rubber boot of the pilot valve.

2. Apply a small amount of grease to the push rod and top end (1).

RAIL14CEX0905AA

1

RAIL14CEX0906BA

2

Removing the boot 1. Insert a flat-head screwdriver between boot (2) and plastic cover (3) to release four clicks one by one.

2. After applying the grease, install plastic cover (3) and boot (2).

7-98

7 - MAINTENANCE

Electrical system Follow the below safety precautions: • Contact your authorized dealer/distributor if frequent replacement of fuses is needed or a sign of short circuit is found.

• Be sure to turn the master battery disconnect switch to the O (OFF) position before checking the electrical system. This could lead to an unintentional shortcircuit and result in a fire.

1. Check the electrical wiring for breaking or signs of short circuit, the fuses for damage and the terminal connections for looseness or damage.

2. Check the battery, starter and generator wiring. Also check the operation of the monitor panel (instrument).

RAIL14CEX0907BA

7-99

1

7 - MAINTENANCE

Fuse and relay locations

Fuse and relay locations The fuses protect the wiring and electrical components from burn out due to excess current. If the electrical system does not work properly, check and replace any blown fuses.

If a corroded fuse generates white powder or if the fuse is loose in its holder, replace the fuse.

Replacing fuses The spare fuses are stored in the fuse and relay box. A blown fuse must be replaced with a fuse with the same capacity or it may cause damage to the electrical system.

If fuse replacement is frequent, it may be caused by a failure in the electrical system. Contact your authorized dealer.

NOTICE: The ignition switch key must be turned to the OFF position before you replace a fuse.

The main fuse box is positioned under the seat stand cover.

1. Lower to bucket to the ground.

2. Place the safety lock lever in the LOCKED position.

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

4. Use the ignition switch key to unlock the cover. (2).

5. If the fuse box cover (1) is locked, unlock it.

RAIL14CEX0963AA

1

RAIL14CEX0962AA

2

6. If a fuse looks like it is blown, replace it with a spare fuse.

7. After fuse replacement, be sure to push the lock of the fuse box cover (1) until it clicks.

7-100

7 - MAINTENANCE

Fuse capacity and circuit name

RAIL14CEX0956FA

Wiper motor, washer motor (1) — 20 A Air conditioner (2) — 5 A Air conditioner (3) — 10 A Air conditioner (4) — 15 A Travel alarm (5) — 5 A Lever lock (6) — 5 A Rotating beacon (7) — 5 A Travel in HIGH (2nd ) speed, deceleration motor (8) — 10 A Gauge cluster, hour meter (9) — 5 A

3

Relay, fuel pump (10) — 5 A Horn (11) — 5 A Room lamp (12) — 5 A Engine stop solenoid (13) — 30 A Sequence valve (14) — 10 A Hand control solenoid (15) — 10 A Socket, radio (16) — 10 A Working light (17) — 20 A Controller (18) — 10 A

7-101

7 - MAINTENANCE

7-102

8 - SPECIFICATIONS

8 - SPECIFICATIONS###_9_### General specifications Complete machine weight Rubber crawler belt Canopy 3250 kg (7165 lb)

Iron crawler shoe Canopy Cab 3340 kg (7363 lb) 3490 kg (7694 lb)

Cab 3400 kg (7496 lb)

Speed and gradeability Detail

Rubber crawler belt

Rotation speed Travel speed

Low (1st) 2.5 km/h (1.6 mph)

Gradient

Iron crawler shoe 8.4 RPM High (2nd) Low (1st) High (2nd) 4.4 km/h 2.5 km/h 4.2 km/h (2.7 mph) (1.3 mph) (2.6 mph) 58 % ( 30 °)

Engine Model Total displacement Power

YANMAR 3TNV88F-E 1.642 L (81.16 in³) Maximum power 17.2 kW (23.4 Hp) at 2400 RPM

Swing and dozer Type Boom swing angle

Boom swing by hydraulic cylinder 60 ° 70 ° 395.0 mm (15.6 in)/ 320.0 mm (12.6 in)

Right Left

Stroke of dozer (up/down)

8-1

8 - SPECIFICATIONS

Dimensions specifications Canopy

RAIL14MEX0110FA

1

RAIL14MEX0103FA

2

Cab

8-2

8 - SPECIFICATIONS

Digging data Canopy

RAIL14MEX0043FA

Item

Attachment

Arm Bucket

A A’ B C D E F G G’ H J K L X Y

Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front swing radius Minimum front swing length Height at minimum swing radius 2.44 m (8 ft) digging depth Horizontal digging stroke at ground Stroke level Minimum Above Dozer strokes Below

8-3

1

Standard arm 1.32 m (4.33 ft) 0.09 m³ (0.12 yd³) 5200.0 mm (204.7 in) 5040 mm (198 in) 2820.0 mm (111.0 in) 4800.0 mm (189.0 in) 3420.0 mm (134.6 in) 1300.0 mm (51.2 in) 2360.0 mm (92.9 in) 2300.0 mm (90.6 in) 2300.0 mm (90.6 in) 3700.0 mm (145.7 in) 2350.0 mm (92.5 in) 2230.0 mm (87.8 in) 1710.0 mm (67.3 in) 395.0 mm (15.6 in) 320.0 mm (12.6 in)

8 - SPECIFICATIONS

Cab

RAIL14MEX0044FA

Item A A’ B C D E F G G’ H J K L X Y

Attachment

Arm

Bucket Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum front swing radius Minimum front swing length Height at minimum swing radius 2.44 m (8 ft) digging depth Horizontal digging stroke at ground Stroke level Minimum Above Dozer strokes Below

8-4

2

Standard arm 1.32 m (4.33 ft) 0.09 m³ (0.12 yd³) 5200.0 mm (204.7 in) 5040.0 mm (198.4 in) 2820.0 mm (111.0 in) 4800.0 mm (189.0 in) 3420.0 mm (134.6 in) 1300.0 mm (51.2 in) 2360.0 mm (92.9 in) 2300.0 mm (90.6 in) 2300.0 mm (90.6 in) 3700.0 mm (145.7 in) 2350.0 mm (92.5 in) 2230.0 mm (87.8 in) 1710.0 mm (67.3 in) 395.0 mm (15.6 in) 320.0 mm (12.6 in)

8 - SPECIFICATIONS

Crawler type Types of crawler shoes

Type

Width

Length between the center of the idler wheel and the center of the travel motor

300.0 mm (11.8 in)

300.0 mm (11.8 in)

Basic pressure Canopy

Cab

1700.0 mm (66.9 in)

28.9 kPa (4.2 psi)

30.3 kPa (4.4 psi)

1700.0 mm (66.9 in)

29.7 kPa (4.3 psi)

31.1 kPa (4.5 psi)

Rubber crawler

Steel crawler

8-5

8 - SPECIFICATIONS

Bucket Width with side Width without cutter side cutter

500.0 mm (19.7 in)

460.0 mm (18.1 in)

8-6

Capacity

Number of teeth

Weight

0.09 m³ (0.12 yd³)

4

76.0 kg (167.6 lb)

8 - SPECIFICATIONS

Lifting capacities Lifting capacity specifications are based on the standard machine with 1.32 m (4.33 ft) arm and 300.00 mm (11.81 in) shoes and without a bucket.

1

RAIL14MEX0101AA

Canopy machine

PW11Z00277P1

8-7

2

8 - SPECIFICATIONS

Cab machine

PW11Z00278P1

3

1. .Do not attempt to lift or hold any load that is greater than these lift capacities at their specified lift point radius and height. Weight of all accessories must be deducted from the above lift capacities.

2. .Lift capacities are based on machine standing on level, firm and uniform ground. User must make allowance for job conditions such as soft or uneven ground out of level conditions, side loads, sudden stopping of loads, hazardous conditions, experience of personnel, etc.

3. Arm top pin is defined as lift point.

4. The above lift capacities are in compliance with SAE J/ISO 10567 They do not exceed 87% of hydraulic lift capacity or 75% of tipping load.

Lift capacities marked with an asterisk (*) are limited by hydraulic capacity rather than tipping load.

5. .The operator should be fully acquainted with the operator's machine and rules for safe operation of equipment should be adhered to at all times.

6. Under the condition that the machine is only manufactured by our company and it equips our attachment, these lifting capacities can be applied to the machine.

8-8

Index ###_Index_###

Air breather element . . . . . . . . . .

Air cleaner element . . . . . . . . . . .

Air conditioner (Option) . . . . . . . . .

Air conditioner compressor belt (If equipped) Air conditioner condenser (If equipped) . .

Air conditioner filters (If equipped). . . . .

Air conditioner lines (If equipped) . . . . .

Air conditioner receiver dryer (If equipped) .

Air conditioner refrigerant (If equipped) . .

Angle dozer blade (If equipped). . . . . .

. . . . . . . . . .

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A . . . . . . . . . . . . . . . . . . . .

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. . 7-64 . . 7-48 . . 3-32 . . 7-31 . . 7-43 7-32, 7-72 . . 7-59 . . 7-73 . . 7-60 6-4, 7-42

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

Belt tension . . . . . . . . . . . . .

Biodiesel fuel. . . . . . . . . . . . .

Bleed air from the fuel system . . . . .

Boom, arm, and attachment grease points Boom swing operating pedal . . . . . .

Bucket . . . . . . . . . . . . . . .

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B . . . . . . . . . . . . . .

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. . 7-33 . . 7-25 . . 7-10 . . 7-52 . . 7-30 . . 3-13 7-88, 8-6

C Cab access/exit . . . . . . . . . . . . . . . . . . . . . . . .

California proposition 65 warning — California Proposition 65 Warning Caution while using rubber crawlers . . . . . . . . . . . . . . . .

Color multi-display . . . . . . . . . . . . . . . . . . . . . . .

Control levers . . . . . . . . . . . . . . . . . . . . . . . . .

Controls overview. . . . . . . . . . . . . . . . . . . . . . . .

Crankcase breather . . . . . . . . . . . . . . . . . . . . . . .

Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . .

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. . 3-1 . . 2-2 . . 6-19 . . 3-34 3-15, 7-98 . . . 3-10 . . . 7-71 . . . 8-5

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D . . . . . . . . . . . .

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Ecology and the environment. . . . . . . .

Electrical system . . . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . .

Electronic Control Unit (ECU) . . . . . . .

Emission control system Warranty – USA only Engine coolant level. . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . .

Engine oil filter . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . .

Engine throttle lever . . . . . . . . . . . .

Engine warm up . . . . . . . . . . . . .

Exhaust Gas Recirculation (EGR) system . .

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

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

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E . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . .

Daily inspection . . . .

Digging data . . . . . .

Dimensions specifications Dozer blade . . . . . .

Dozer blade control lever Drain water separator . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

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. . . . . .

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. 4-1 . 8-3 . 8-2 . 7-54 . 3-30 . 7-29

. . 2-20 . . 7-99 . . 1-4 . . 3-47 . . 1-11 . . 7-17 . . 7-49 . . 7-50 . . 7-19 . . 3-31 . . 4-8 7-69, 7-83

F Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

Fuel injection system Fuel level . . . . .

Fuel tank . . . . .

Fusible link . . . .

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7-70 7-20 7-35 3-46

G General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Getting out of soft ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Grease swing pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Horn switch . . . . . . . . . . . . . . . . . .

Hydraulic oil . . . . . . . . . . . . . . . . . .

Hydraulic oil (Breaker attachment option) . . . . .

Hydraulic oil level . . . . . . . . . . . . . . . .

Hydraulic oil return filter . . . . . . . . . . . . .

Hydraulic oil return filter (Breaker attachment option) Hydraulic oil return filter (Initial) . . . . . . . . . .

Hydraulic oil warm up . . . . . . . . . . . . . .

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H . . . . . . . . . . . . . . . .

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3-17 7-84 7-67 7-22 7-62 7-43 7-40 4-9

I Idler wheel and rollers change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 Inspection after engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 L Lifting capacities . . . . . . . . . . . . . . . . . .

Lifting the machine . . . . . . . . . . . . . . . . .

Lowering the arm in emergency situations . . . . . . .

Lowering the attachment in the event of an engine failure Lowering the bucket in emergency situations . . . . . .

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. 8-7 . 5-5 . 6-18 . 6-16 . 6-17

M . . . . . . . . . . . . . . . . . . . .

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3-7 1-9 6-23 6-10 1-8 6-5 7-15 7-8 7-4 3-27

N Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Machine access compartments and doors . . . .

Machine components . . . . . . . . . . . . .

Machine operation in adverse weather conditions .

Machine operation in water or on soft grounds . .

Machine orientation . . . . . . . . . . . . . .

Machine travel . . . . . . . . . . . . . . . .

Maintenance chart . . . . . . . . . . . . . .

Maintenance parts . . . . . . . . . . . . . .

Maintenance tool . . . . . . . . . . . . . . .

Monitor panel . . . . . . . . . . . . . . . .

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. 6-1 . 1-7 . 2-21 . 6-2 . 1-3

Parking the machine . . . . . . . . . . . .

Personal safety . . . . . . . . . . . . . . .

Pilot line filter. . . . . . . . . . . . . . . .

Practices to improve efficiency . . . . . . . .

Product identification . . . . . . . . . . . .

Proportional hand control (nibbler and breaker) .

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. 4-11 . 2-3 . 7-77 . 6-13 . 1-5 . 3-14

Operating the controls . . . . . . . . . .

Operator's manual storage on the machine Operator's seat belt . . . . . . . . . . .

Optional attachments (Nibbler / breaker) . .

Owner information . . . . . . . . . . .

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R Radiator, oil cooler core, and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28, 7-55 Radiator coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

Radiator hoses . . . . . . . . . . . . . . . . . .

Radio (option) . . . . . . . . . . . . . . . . . .

Releasing internal pressure from the hydraulic system .

Replacement of rubber track shoe . . . . . . . . .

Rotary multi-control valve pattern change (ISO/BHL) .

Rubber track shoe . . . . . . . . . . . . . . . .

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7-46 3-19 7-9 7-95 7-2 7-92

Safety lock lever . . . . .

Safety rules . . . . . . .

Safety signs . . . . . . .

Starting the engine . . . .

Stopping the engine . . . .

Suction strainer. . . . . .

Swing bearing . . . . . .

Swing control . . . . . .

Switches (right-hand panel)

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. . 3-18 2-1, 2-4 . . 2-22 . . 4-2 . . 4-10 . . 7-75 . . 7-53 . . 6-12 . . 3-24

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Torque specifications . . . . .

Track tension. . . . . . . . .

Transporting on a trailer . . . .

Travel control levers and pedals Travel reduction unit oil . . . .

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Warning lamps . . . . . . . . . . .

Water separator . . . . . . . . . .

Windshield washer reservoir (cab only) Work lamps . . . . . . . . . . . .

Work lights. . . . . . . . . . . . .

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7-26 7-58 7-87 7-86 7-27

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

© 2015 CNH Industrial America LLC. All Rights Reserved.

Case is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.