New Holland E80B Tier 3 Crawler Excavator Operator's Manual 87490337 - PDF DOWNLOAD

OPERATOR’S MANUAL CRAWLER EXCAVATOR

E80B TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01April 08 Printed in U.S.A. • Book/Form Number 87490337 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

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

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

This unit first became available 04-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01April 08

E80B Tier 3 Crawler Excavator

87490337 NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

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

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

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

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

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

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

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America LLC. Carol Stream, IL 60188 U.S.A.

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

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

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

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

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

CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 L.C.D. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Switch and Meter Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 right Hand Operator Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Operating Levers and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Starting and Stopping Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting and Stopping Machine Engine in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 87490337 NA

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50 hour Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

6-17 6-23 6-24 6-25 6-31 6-37 6-39 6-45 6-47

CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Working Range - Face Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER E80B TIER 3 CRAWLER EXCAVATOR

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

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

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

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

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

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

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

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

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

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

Your New Holland Dealer is available for any further information. They will also provide any after-sales service you may need, and genuine New Holland spare parts, your guarantee of quality and match.

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CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

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

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 12 11

13

10

14 15

8

9

7

16 17

6 5

18 4 3 2 35 1

19

20 21

34 22

23

33

24

25

26

27

29

35 28

31

32 35 30 Figure 2

BS08C419

MACHINE COMPONENTS 1. ENGINE

10. BOOM

2.

3.

4.

5.

6.

7.

8.

11.

12.

13.

14.

15.

16.

17.

HYDRAULIC PUMP ENGINE MUFFLER MAIN CONTROL VALVE HYDRAULIC OIL TANK FUEL TANK SWING MOTOR SWIVEL JOINT

9. BOOM CYLINDER

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ARM CYLINDER ARM BUCKET CYLINDER IDLER LINK BUCKET LINK BUCKET CAB

18. SWING BRACKET

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19.

20.

21.

22.

23.

24.

25.

26.

27.

DOZERCYLINDER DOZER BLADE TRACK ASSEMBLY TRACK IDLER TRACK SPRING LOWER ROLLER UPPER ROLLER TRACK GUIDE SLEWING RING

29. TRAVEL MOTOR 30.

31.

32.

33.

34.

35.

36.

RADIATOR OIL COOLER AIR COOLER COUNTERWEIGHT AIR CLEANER HOOD SWING FLASHER

28. BATTERY

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

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

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

Figure 4

BS08B163

ENGINE ➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS Figure 3

BS07N556

PRODUCT IDENTIFICATION PLATE ➤

➤ Hydraulic Pump ➤ Swing Reduction Gear

Model ➤

➤ Travel Reduction Gears

Serial Number ➤

➤ Travel Control Valve

Manufacturing Year

➤ Attachment Control Valve ➤ Swing Control Valve

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Counterweight Lifting Eyes - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Above Ground - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressurized Hot Oil- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Hot Coolant- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Rotating and Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Parts- Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Battery - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Battery - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Handling Battery - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Grease Gun - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Interior Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Insert Hand in Moving Part - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lock front window in housed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Brake Release - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation by Foot Pedal (Option) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Change Lever and Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Selector Valve (Nibbler and Breaker Option) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary Multi Control Valve (Option) - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary Multi Control Valve (Option) - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Use Specified Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 04-08

Bur

87490337 NA

2-10 2-11 2-11 2-12 2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-18 2-19 2-19 2-20 2-21 2-21 2-22 2-22 2-23 2-23 2-24 2-24 2-25 2-25 2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2-2

Issued 04-08

Bur

87490337 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

M171C

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

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

• The first panel indicates the nature of the hazard.

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

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

and

STOP

if

SAFETY AREA

1

1

2 Figure 1

BS08B164

Figure 2

BC02N198

OPERATOR’S MANUAL STORAGE SPACE

1. WORKING AREA 2. SAFETY AREA

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

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

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

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

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

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

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

87490337 NA

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Bur

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS UTILITY SAFETY Safety precautions MUST be followed when working near buried and overhead Utility Lines.

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

• • • •

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

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

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

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

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

Figure 3

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

2-4

Issued 04-08

Bur

87490337 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

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

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

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

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

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

See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

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

who

has

the

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

STARTING AND STOPPING PRECAUTIONS

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

Sound the horn, if equipped, before starting.

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

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer before starting the machine.

GENERAL

• It is the responsibility of the operator to read and

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

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

• Start and operate the machine only from the

• DO NOT OPERATE this machine or perform

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

maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

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

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

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

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

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

• Remove all loose object stored in the machine.

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

operator’s seat.

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

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

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

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

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

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

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

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Issued 04-08

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2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS OPERATING PRECAUTIONS

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

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

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

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

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

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

• Know and understand that job site conditions may

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

• Use the recommended transport devices when roading the machine.

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

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

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

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

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

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

• Contact

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

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

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

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

• If a part of the machine touches high voltage

• Watch for bystanders and never allow anyone to

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

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

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

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

Provide an escort for roading where required.

2-6

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

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

Issued 04-08

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87490337 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• DO NOT OPERATE the machine if you do not feel

• Avoid lubrication or mechanical adjustments with

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

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

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

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

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

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

MAINTENANCE PRECAUTIONS

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

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

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

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

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

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

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

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

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

Figure 4

DC04E084

• Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operator’s console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will prevent accidental starting of the machine.

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

• Wear gloves to protect hands when handling

• Observe proper maintenance procedures.

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

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

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

cable.

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

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2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Hot coolant can spray out if the radiator cap is

FUEL HANDLING PRECAUTIONS

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

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

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

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

HAZARDOUS CHEMICAL PRECAUTIONS

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

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

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

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

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

M144B

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

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

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

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

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

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

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

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

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system Issued 04-08

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

SEAT BELT PRECAUTIONS

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

1

• Never smoke while refueling.

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

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

• Do not perform “hammering” operation with the

2

bucket.

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

BC02N375

intended purpose.

• DO NOT OPERATE bucket and arm cylinders to

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

stroke end repeatedly.

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

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

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

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

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

M422A

EMERGENCY EXIT HAMMER

Figure 6

DC04D572

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

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

CE-NA000

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

CE-NA000

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

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

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

• DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED.

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

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as

2-10

and

STOP

if used are RED.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT LIFTING EYES - DANGER Located on top of counterweight (2 Required) - Part Number YN20T01221P1

Figure 7

BS08C420/YN20T0122P1

WORKING ABOVE GROUND - WARNING Located on hydraulic tank - Part Number YN20T01049P1

Figure 8

BS08C420/YN20T01049P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS PRESSURIZED HOT OIL- WARNING Located on hydraulic tank - Part Number PW20T01007P1

Figure 9

BS08C420/PW20T01007P1

SWING - DANGER Located on rear side door - (2 Required) - Part Number PE20T01014P1

Figure 10

BS08C420/YN20T01049P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOSTER CABLE - WARNING Located on battery relay cover - Part Number YN20T01015P2

Figure 11

BS08C420/YN20T01015P2

BOOSTER CABLE - WARNING Located on battery relay cover - Part Number YN20T01338P1

Figure 12

BS08C420/YN20T01338P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT COOLANT- WARNING Located on engine hood - Part Number YN20T01015P2

Figure 13

BS08C420/YN20T01010P1

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

Figure 14

BS08C420/YN20T01009P1

2-14

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ROTATING AND HOT PARTS - CAUTION Located on engine hood - Part Number YN20T01012P1

Figure 15

BS08C420/YN20T01012P1

HOT PARTS- CAUTION Located on right side door - Part Number YN20T01220P1

Figure 16

BS08C420/YN20T01220P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ADJUSTING TRACK TENSION Located on crawler frame (2 Required) - Part Number YN20T01813P1

Figure 17

BS08C420/YN20T01813P

HOT PARTS - CAUTION Located on engine hood support - Part Number YN20T01867P1

Figure 18

BS08C420/YN20T01867P1

2-16

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING BATTERY - WARNING Located on battery relay cover - Part Number YN20T01017P1

Figure 19

BS08C420/YN20T01017P1

HANDLING BATTERY - WARNING Located on battery relay cover - Part Number YN20T01001P1

Figure 20

BS08C420/YN20T01001P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING BATTERY - DANGER Located on counterweight - Part Number PY20TO1069P1

Figure 21

BS08C420/PY20T01069P1

CALIFORNIA PROPOSITION 65 - WARNING Located on battery relay cover - Part Number YN20T01495P1

Figure 22

BS08C420/YN20T01495P1

2-18

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING BATTERY - WARNING Located on the counterweight - Part Number YN20T01854P1

Figure 23

BS08C420/YN20T01854P1

HANDLING GREASE GUN - CAUTION Located on engine dust cover - Part Number YN20T01287P1

Figure 24

BS08C420/YN20T01287P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CAB INTERIOR SAFETY DECALS Located in cab interior - right hand side - Part Number LC20T01187P1 Includes Travel Speed, Adjusting Track Tension, Leaving Machine, Read Manual, Engine Stop, Bucket to Cab Contact, And Electrical Power Line Information.

Figure 25

BS08B167/LC20T01187P1

2-20

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT INSERT HAND IN MOVING PART - CAUTION Located on seat stand cover - Part Number YN20T01339P1

Figure 26

BS08B169/YN20T01339P1

LOCK FRONT WINDOW IN HOUSED POSITION Located inside cab - right hand side - Part Number ZL11M0608

Figure 27

BS08B167/ZL11M06008

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2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SWING BRAKE RELEASE - CAUTION Located on rear cover - Part Number YN20T01639P1

Figure 28

BS08C420YNT01639P1

OPERATION BY FOOT PEDAL (OPTION) - CAUTION Located inside cab right hand side - Part Number PY20T01062P1

Figure 29

BS08B167/PY20T01062P1

2-22

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING CHANGE LEVER AND SELECTOR VALVE - CAUTION Located inside cab right hand side - Part Number YT20T01284P1

Figure 30

BS08B1677/YT20T01284P1

CHANGE SELECTOR VALVE (NIBBLER AND BREAKER OPTION) - CAUTION Located inside cab right hand side - Part Number YN20T01285P1

Figure 31

BS08B167/YT20T01285P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ROTARY MULTI CONTROL VALVE (OPTION) - WARNING Located inside cab right hand side - Part Number YN20T01039P1

Figure 32

BS08B167/YN20T01039P1

ROTARY MULTI CONTROL VALVE (OPTION) - DANGER Located on fuel tank - Part Number YY20T01208P1

Figure 33

BS08B168/YY20T01208P1

2-24

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS KEEP CLEAR OF WORKING AREA - DANGER Located on arm (two required) - Part Number YN20T01337P1

Figure 34

BS08C421/YN20T01337P1

USE SPECIFIED FUEL Located on fuel tank - Part Number PV20T01068P1

Figure 35

BS08C420/PV20T01068P1

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOM TO CAB CONTACT Located inside cab - right hand side (Optional)- Part Number LF20T01012P1

BS08B166/PV20T01068P1

2-26

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

MOVE LOAD IN HORIZONTALLY

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

RAISE LOAD VERTICALLY

DC04E040

Figure 38

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

MOVE LOAD OUT HORIZONTALLY

Figure 36

DC04E038

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

LOWER LOAD VERTICALLY

DC04E041

Figure 39

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

RAISE BOOM

Figure 37

DC04E039

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

DC04E042

Figure 40

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

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

DC04E043

ARM IN

Figure 41

Figure 44

DC04E046

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

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

SWING LEFT

ARM OUT

DC04E044

Figure 42

Figure 45

DC04E047

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

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

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 43

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

2-28

Figure 46

DC04E048

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

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

CLOSE BUCKET (BUCKET IN OR DIG)

Figure 47

DC04E049

DC04E052

Figure 50

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

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

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

Figure 48

DC04E050

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

DC04E053

Figure 51

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

TRAVEL REVERSE TURN LEFT

Figure 49

DC04E051

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

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DC04E054

Figure 52

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

2-29

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

DE04E055

STOP

Figure 53

Figure 56

DC04E058

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

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

MOVE THIS MUCH

EMERGENCY STOP

DC04E056

Figure 54

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

Figure 57

DC04E059

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

MOVE SLOWLY STOP ENGINE

DC04E057

Figure 55

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

2-30

Figure 58

DC04E060

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

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87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

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

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

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

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

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

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

Opening and Closing Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Seat Front and Rear Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Back Reclining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arm Rest Adjustment (4 Inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components & Controls Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Hand Operator Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10 3-11 3-11 3-11 3-11 3-11

MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buzzer Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Wiper & Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Display Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Accel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

L.C.D. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A. Normal Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Buzzer Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12 3-12 3-13 3-13 3-14 3-14 3-15 3-15 3-16 3-16 3-17 3-17 3-17

L.C.D. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 LCD Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Monitor Time Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 SWITCH AND METER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cup Holder and Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Select Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Adjust the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 04-08

Bur

87490337 NA

3-22 3-23 3-23 3-23 3-23 3-24 3-24 3-24 3-24 3-25 3-25 3-25 3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND OPERATOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Climate Control - Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Air Outlet Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 basic Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 OPERATING LEVERS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Left and Right Travel Levers & Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Dozer Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-2

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND CONTROLS DOCUMENT POUCH

CAB DOOR LATCH

1 Figure 1

BS08B164

Figure 3

DC04D504

DOCUMENT POUCH

1. DOOR LATCH

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

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

2. Release door latch by pushing release lever down to release door from latch.

LOCKING/UNLOCKING CAB DOOR WARNING: Never use the lever for door latch release as a handle to mount and/or dismount from the machine.

1 1 Figure 2

DC04D503

1. DOOR LOCK

Use the ignition key to lock or unlock cab door. Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door.

Figure 4

DC04D506

1. PUSH RELEASE LEVER

3. Push release lever located inside the door, and door opens from the inside of cab.

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Issued 04-08

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3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING WINDSHIELD Front window (upper) can be stored in ceiling.

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

WARNING: A falling window can cause injury to you or others. Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in injury, machine damage, or death.

REMOVING AND STORING LOWER FRONT WINDOW

1

1 2

Figure 5

BS06J091

Figure 7

DC04D509

1. LOWER FRONT WINDOW

1. LOCK LEVER 2. UPPER CENTER HANDLE

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

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

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

1

3 2 BS06J092

3 1

2 Figure 6

1. LOCK LEVER 2. CENTER HANDLE 3. WINDSHIELD STORED IN CEILING POSITION

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

3-4

2

2

Figure 8

DC04D510

1. LOWER FRONT WINDOW 2. HOLDER 3. REAR WINDOW

3. To store lower window, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING SUNROOF

EMERGENCY ESCAPE

1

1 Figure 9

BS08B171

2

1. To open the sunroof, pull locks on right and left sides inward, and sunroof opens through the aid of a gas spring.

2. Close sunroof by pulling locks inward. Slide the sunroof closed and lock it.

BS08B172

Figure 10

1. FRONT INSIDE CAB DECAL 2. REAR INSIDE CAB DECAL

1. Be proactive and familiarize yourself with the emergency exits and escape hammer. If it is impossible to open the cab door in an emergency, escape can be made through the front window. Read the steps for opening the front window in this section.

2. If it is not possible to escape through the front window, use the emergency hammer, and break the rear window. If both of these alternate escapes are blocked, open and use the sunroof.

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3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

2 1 Figure 11

DC04D529

1. BUCKLE 2. RED BUTTON

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

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

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

3. When the seat belt is used, draw it out moderately long and insert it in the buckle until it locks in place. Release hands, and the length is automatically adjusted.

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

5. Press the red button of the buckle, and the belt is unfastened.

WARNING: Always wear seat belt while sitting in operator seat. Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BACK RECLINING ADJUSTMENT

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

8

The adjustment areas are as follows: SEAT FRONT AND REAR HEIGHT ADJUSTMENT

7

1 3

2 4 5 4 Figure 12

BS08B173

1.

2.

3.

4.

SEAT WEIGHT ADJUSTMENT KNOB SEAT HEIGHT ADJUSTMENT LEVER RECLINING ADJUSTMENT LEVER SEAT FORWARD - BACKWARD BAIL

• Rotate the weight adjustment knob (1) until weight close to operator’s weight is at the top end of the dial.

• Pull height adjustment lever (2) up to raise or lower rear of seat.

• Push height adjustment lever (2) down to raise or lower front of seat.

6 Figure 13

DC04D523

5.

6.

7.

8.

ARM REST ADJUSTMENT ARM REST CONTROL DIAL LUMBAR SUPPORT HEAD REST

• Lower arm rest (5) and turn adjustment wheel (6) until arm rest is in desired position.

• Adjust lumbar support (7) by turning the knob clockwise or counterclockwise to adjust support. to desired pressure.

• Pull reclining adjustment lever (3) up to set

• Move head rest forward or backward to desired

desired reclining angle. Release the reclining adjustment lever to lock seat in position.

reclining angle. Raise or lower head rest to desired height.

• Pull up on seat adjustment bail (4) and move seat forward or backward to desired position.

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3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS ARM REST ADJUSTMENT (4 INCH)

CONTROL LEVER ADJUSTMENT

2 1 B A C

Figure 15

BS08B476-01

1. To adjust the right/left control stand, remove bolt (1).

2. Adjust the height of hole on plate (2) to the desired position and tighten plate (2) securely with bolt (1).

2

3. Adjust height stand on both sides to desired position.

A. Low Position

1

B. Middle Position C. High Position

3

BS08B175

Figure 14

To adjust the arm rest (4 inch): 1. Loosen knob (1) and move it forward slightly.

2. Adjust arm rest (2) to desired height and match to aligning hole of bracket (3).

3. Tighten knob (1).

3-8

Issued 04-08

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87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS HYDRAULIC FUNCTION CANCELLATION LEVER

FUEL CAP

1 1 2

Figure 16

BS06H080

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

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

Always, before leaving the cab, shut down the engine, and place the function cancellation lever in the locked (up) position.

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

Failure to comply could result in injury or death.

87490337 NA

Issued 04-08

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Figure 17

BS08B258

1. FUEL TANK CAP

Stop engine and remove cap on fuel tank. Use key switch to unlock cap if locked. Fill to desired level or to full capacity. See Chapter 5 for proper tank capacity. Use diesel fuel only. Do not remove strainer (if equipped). If sediment becomes imbedded on strainer, remove strainer and clean with air gun or light oil. Replace strainer to fill port.

WARNING: Make sure engine is OFF and keep battery cover and engine hood closed when fueling. Failure to comply could result in injury or death.

ENGINE COVER Open engine cover with ignition key (if locked) after stopping engine. Use strut to support door.

ATTENTION: Always make sure to use the door struts to lock door open while performing inspection and/or maintenance.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

3

4

5

6

8

7

9 10 25 12 14 13 15

2

1

11 16 26

17 18 20 19 24 20 21 A 22 23

Figure 18

BS08C423

COMPONENTS 1. LEFT HAND OPERATOR 9. HOUR METER CONTROL LEVER (HORN SWITCH)

17. WORKING LIGHT SWITCH (BOOM, DECK)

24. OPERATOR SEAT

2. SAFETY LOCK LEVER

10. GAUGE CLUSTER

18. RADIO

25. SWING PARKING BRAKE RELEASE SWITCH

3. OPERATING PEDAL (BREAKER AND NIBBLER OPTION

11. DOZER OPERATING LEVER 12. CUP HOLDER

19. AIR CONDITIONING CONTROL PANEL

26. FUSE & RELAY BOX

4. LEFT TRAVEL PEDAL 5. LEFT TRAVEL LEVER

13. ASH TRAY

20. CAP FOR OPTIONAL SWITCH

6. RIGHT TRAVEL LEVER 7. RIGHT TRAVEL PEDAL 8. OPERATING PEDAL (BOOM SWING)

3-10

14. RIGHT HAND OPERATOR 21. CIGARETTE LIGHTER CONTROL LEVER 15. STARTER KEY SWITCH 22. EMERGENCY HAMMER 16. THROTTLE 23. 12 VOLT SUPPLY POTENTIOMETER

Issued 04-08

Bur

87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR CAB NOMENCLATURE

THROTTLE POTENTIOMETER

The Operator Cab Nomenclature points out locations of operator controls of the New Holland hydraulic excavator. Study these areas and locate the components on the machine. Specific information regarding these components are explained on the following pages of this section.

The throttle potentiometer is located on the right hand operator console and controls engine RPM. When the throttle potentiometer is rotated to any position, it increases or decreases engine RPM and maintains engine at the programed RPM for that particular position on the dial.

LO (Low idling)

WARNING: DO NOT OPERATE this machine unless you have read and understand the instructions in this manual.

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

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

Engine speed will reduce to a minimum when the throttle potentiometer is turned completely to the left.

HI (High idling) Engine speed rises to the maximum when the potentiometer switch is turned completely to the right.

RIGHT HAND OPERATOR CONSOLE AND MONITOR KEY SWITCH

Figure 19

BS06H116

1. KEY SWITCH 2. THROTTLE POTENTIOMETER

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

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

ACC - With key in the ACC position, only the cigarette lighter, tuner, and horn will have power.

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

START - When key is turned to this position, electr ical power is supplied to the star ter solenoid causing the starter to start the engine.

After engine starts key should be released to go back to the ON position.

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3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MONITOR

11

1

2 3

10 6 4

9

8

5

7 Figure 20

BS06H115

1.

2.

3.

4.

5.

6.

ENGINE COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE SCREEN CHANGE SWITCH BUZZER STOP SWITCH WORK MODE SELECT SWITCH WASHER SWITCH

7.

8.

9.

10.

11.

WIPER SWITCH TRAVEL SPEED SELECT SWITCH AUTO ACCEL SWITCH SELECT SWITCH L.C.D. DISPLAY

WORK MODE SWITCH

Figure 21

W h e n t h e e n g i n e s t a r t s, i t i s s e t t o H m o d e automatically. To select the proper work mode from the 4 modes shown below according to the work conditions. The work modes are H and S. H mode is for heavy duty digging work which gives priority to the workload at high engine rpm’s.

S mode is for standard digging and loading.

BS06H065

3-12

Issued 04-08

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87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS Windshield Wiper & Washer Switch

Buzzer Stop Switch

2

1

Figure 22

BS06H065

When a warning is displayed on the monitor, press the buzzer stop switch and the buzzer sound will stop. If the engine coolant temperature is too high, or var ious sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently. and can not be stopped.

BS06H066

Figure 23

Wiper Switch

• Press it once - Wiper moves intermittently.

• Press it again - Wiper moves continuously.

• Press it once more - Wiper stops moving.

Washer Switch Press this switch, and washer fluid is sprayed while it is depressed.

The washer fluid reservoir is located back of floor plate in cab.

IMPORTANT: Make certain the Washer Reservoir has washer fluid before operating washer. Operating washer without fluid can damage the washer fluid motor.

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3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS SCREEN CHANGE SWITCH

A

1

2 B

4

3

Figure 24

BS06H102 / BS06H071

SCREEN DISPLAY SWITCH. After turning the key switch on or starting the engine, the display screen (A) is changed each time that the display switch (B) is pushed. This will display the remaining time until the next service interval for each of the displays shown on the screen.

1. Remaining time until oil change.

2. Remaining time until fuel filter change.

3. Remaining time until hydraulic filter change.

4. Remaining time until hydraulic oil change.

NOTE: If the change screen switch (B) is not operated for 30 seconds keeping the screen for maintenance displayed, the screen will automatically return to the main screen.

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Issued 04-08

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87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS Auto Accel Switch

Travel Speed Select Switch

BS06H067

Figure 25

BS06H068

This switch is used to activate and cancel the auto accel function.

When the key switch is turned on, the auto-accel system activates. The auto-accel system reduces the e n g i n e s p e e d t o t h e i d l e l eve l r e d u c i n g f u e l c o n s u m p t i o n a n d n o i s e u n d e r t h e fo l l ow i n g conditions.

1. The auto-accel dial position is set over the idle level.

2. The control lever or pedals are not operated for 4 seconds or more.

When the control lever or pedals are operated, the engine speed goes back to the accel dial setting gradually.

WARNING: Never attempt to load or unload machine with the Auto Accel function activated. Sudden change of engine speed could be experienced causing possible damage, serious injury or death.

NOTE: All New Holland excavators will default to the auto acceleration function when the key switch is turned to the OFF position.

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Figure 26

The travel speed select switch is located on the gauge cluster switch panel. Each time engine is started, travel speed is automatically set to LOW 1st speed. Press the travel speed switch on the gauge cluster, the speed is changed to the HIGH 2nd, the fast speed travel icon is indicated on the multi display, and the light indicator above the switch is turned ON. Set to LOW when moving the machine on a rough or soft road, slope, or in narrow place, or when powerful tractive force is required.

Set to HIGH when moving the machine on flat, hard ground.

WARNING: Do not use high speed when performing delicate operations such as pipe laying, fine grading or loading machine onto a trailer.

Do not change travel speed while loading, machine could become unstable and cause serious injury, equipment damage and/or death.

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS A4. Engine Lubrication Cumulative Time

L.C.D. DISPLAY

256 hours have elapsed since the change of engine oil.

This icon shows the total cumulative time since the last time the engine oil was changed.

A5. Fuel Filter Cumulative Time 256 hours have elapsed since the change of fuel filter.

This icon shows the total cumulative time since the last time the fuel filter was changed.

A6. Hydraulic Filter Cumulative Time Figure 27

DC04D540

The LCD Display is illustrated below and will display the icons listed in this section. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

A. NORMAL DISPLAYS A1. System Status Display This icon will display after key switch is turned “ON” and all machine system and components are checked by CPU and found to be good working order.

A2. Day and Time Display Five seconds after the system status is shown on the LCD, the time will be displayed on the monitor. See “Monitor Time Adjustment” in this section for details on how to set the 24 hour clock feature.

256 hours have elapsed since the change of hydraulic oil filter.

This icon shows the total cumulative time since the last time the hydraulic oil filter was changed.

A7. Hydraulic Oil Cumulative Time 256 hours have elapsed since the change of hydraulic oil.

This icon shows the total cumulative time since the last time the hydraulic oil was changed.

A8. Travel Independent Mode Display This icon will display every time the independent travel mode is activated (Optional).

A3. Engine R.P.M. Display Actual engine speed. When auto accel is deactivated, RPM shown corresponds to the throttle potentiometer position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS B. Warning Displays Warning Condition Priority of Group

Warning Level

A

B

Screen

Condition

Buzzer Sounds

Key On Only

Engine Running

Type

Auto Stop

Manual Stop

1

DATA COMMUNICATION ERROR

Data from the mechatro controller is not received.

O

O

3

X

O

1

SWING BRAKE DISENGAGED

The swing parking brake switch is turned ON.

O

O

2

O

O

1

ENGINE STOP

Engine is stopped after Engine oil pressure Low Warning.

O

1

O

X

2

LOW ENGINE OIL PRESSURE

Low Engine oil pressure disconnection.

O

2

X

O

3

HIGH ENGINE WATER TEMPERATURE

The engine water is more than 105° C (221° F)

O

O

3

X

O

3

CLOGGED AIR FILTER

The Air Filter is clogged

O

O

3

X

O

3

(SELF DIAGNOSIS SCREENS)

According to the self diagnosis control

O

O

3

X

O

4

CHARGE ERROR

Battery error - High voltage/low voltage/poor charge

O

O

4

X

X

4

LOW FUEL LEVEL

Displayed when fuel level is low

O

O

4

X

CHANGE ENGINE OIL

Remaining time to specified engine oil gauge is zero

O

O

5

X

X

TRAVEL INDEPENDENT MODE

Displayed when the travel independent select switch is on

O

O

5

X

X

Warning Level 1. These may effect safety and the machine performance 2. These warn that the machine control mode is switched.

3. Equipment/System failure.

4. Normal priority warning.

5. Low priority message Buzzer Sounds 1. Constant 2. Beep ON 0.2 sec. OFF 0.3 sec.

3. Beep ON 0.5 sec. OFF 0.5 sec.

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3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS

L.C.D. DISPLAY

Engine Stop Display

Controller CPU Display This icon will display when a problem exists in the Data Communication System.

Turn key switch “OFF”, wait for 4 seconds until the system shuts down completely, then turn the switch back to “ON” to reset the CPU program.

Should this icon remain on display, stop operation, shut down the engine, remove rear panel cover and flip the Swing Parking Brake switch to the “RELEASE” position. Contact a New Holland Construction technician for repair.

Swing Parking Brake Release Display Turn the “Swing Parking Brake Release Switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed.

While this war ning is displayed, the swing parking brake does not actuate. This switch should be used only in t h e eve n t o f e m e r g e n c y.

Contact a New Holland Construction technician for repair.

Engine Air Cleaner Display This icon will display should the Engine Air Cleaner Element(s) ( F I LT E R S ) become too dir ty to allow proper air flow to the engine.

Should this icon display, stop engine immediately and clean or replace engine air cleaner element(s) as required.This icon will display only if alternator is charging.

3-18

When the Engine Stop Display i s s h own , th e bu z ze r w i l l sound for 5 seconds and the engine is stopped. The oil pressure is low and this is a high priority warning.

Check the oil level. If the level is correct and the filter does not require replacing, contact your authorized dealer. Do not attempt to run the machine.

Engine Oil Pressure Display This icon will display and the alarm will sound should the Engine Oil Pressure drop b e l o w a s a fe o p e r a t i n g pressure.

Stop the engine immediately and check engine oil level. Fill engine to proper level with approved motor oil. If engine has LOW OIL PRESSURE, it will automatically go to “LO” Idle, and immediately shut down.

This icon will Display only if alternator is charging.

Engine Coolant Temperature Display This icon will display and the alarm will sound should the Engine Coolant Temperature r ise above safe operating temperature.

Reduce engine RPM to idle and stop operation until engine coolant temperature rea ches a sa fe o pera ting Temperature range.

Issued 04-08

Bur

87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS Battery Charging System Display This icon will display when the electrical charging system is not functioning properly.

Should this icon display, have the electrical charging system repaired immediately.

I c o n d i s p l ay s o n l y w h e n engine is running with normal oil pressure and a problem occurs in the charging system.

Fuel Level Display This icon will display when the Fuel Level is low.

Should this icon display, refill fuel tank immediately using approved diesel fuel.

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Replace Engine Oil Display This icon displays every 500 hours of machine operation to remind operator of scheduled engine oil change.

The recommended oil change interval is every 500 hours of operation. Proceed with oil change and make sure to recalibrate the engine oil change interval.

Travel Independent Mode Display This icon will display when the travel independent select switch is on. Turn the switch O F F t o c a n c e l t h e t r ave l independent mode.

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD Contrast Adjustment

A

B

C

D

E

A

F Figure 28

BS06H076 / BS06H077

1. Turn key switch on and display main screen (A), and press select switch and display ”SWITCH STATUS CLOCK CONTRAST” select screen (B).

2. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “SWITCH STATUS CLOCK CONTRAST” screen (C) and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (D) is displayed.

3. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “ADJUST CLOCK ADJUST CONTRAST” and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (E) is displayed.

4. Press select switch and the “ADJUST CONTRAST 55555” screen (F) is displayed.

5. Vary the values by pressing the desired figure in operations UP ARROW (washer switch) and DOWN ARROW (wiper switch). The available setting range is in 9 steps from “11111” to “99999”. (Example) 11111 (faint) to 99999 (clear). *Initial setting value is 55555.

6. Press select switch and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to the main screen (A).

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87490337 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR TIME ADJUSTMENT

A

B

A

C

D

E Figure 29

BS06H076 / BS06H078

1. Turn key switch on and display main screen (A) for the operator, and press select switch and display “SWITCH STATUS CLOCK/CONTRAST” select screen (B).

2. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “CLOCK/CONTRAST” screen (C) and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (D) is displayed.

3. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “ADJUST CLOCK” and then press select switch and the “ADJUST CLOCK” screen (E) is displayed.

4. Select any of “Y-M-D-H-M” in operation of UP ARROW (washer switch) and DOWN ARROW (wiper switch) and vary the values in operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch).

5. After adjustment, press the select switch and the adjusted values are stored as memory and time setting is completed, and then the screen returns to the main screen (A).

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Issued 04-08

Bur

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

SWITCH AND METER LOCATIONS

11

12

1

10

2 4

3 5 6

7 8 A 9 Figure 30

BS08B184

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

STARTER KEY SWITCH THROTTLE POTENTIOMETER WORK LIGHT SWITCH (BOOM, DECK) INDEPENDENT TRAVEL SELECT SWITCH RADIO AIR CONDITIONER CONTROL PANEL CAP (OPTIONAL SWITCH) CIGARETTE LIGHTER 12 VOLT POWER SUPPLY HORN SWITCH HOUR METER SWING PARKING BRAKE RELEASE SWITCH

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 12 VOLT POWER SUPPLY

Work Light Switch

Figure 31

BS08B185

Press the switch and the work lights on the boom (left) and deck (right) will illuminate. Press the bottom of the switch and the lights will turn off.

CAB DOME LIGHT

BS08B253

Figure 33

The 12 volt power supply is located beside the rear side cover. Remove the cover from the power supply and insert a 12 volt male socket. Replace cover after use.

CIGARETTE LIGHTER

1

Figure 32

BS06H100

1. CAB DOME LIGHT

1. Turn Cab Dome Light “ON” by pushing the Dome Light Switch downward.

BS08B252

Figure 34

The cigarette lighter is located on the right wall of the cab. Do not use the cigarette lighter as a power supply for 12 volt accessories. It is a 24 volt outlet.

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

3. Place Dome Light Switch in the “CENTER” position and the light will be operated by the door switch. When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

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3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL SWITCHES

Hour Meter

1

1 Figure 35

BS06H106

Figure 37

BS06H093

1. HOUR METER

1. LOCATION FOR OPTIONAL SWITCHES

The Hour Meter indicates the total time that the engine has run. It meters the time continuously as long as the engine is running.

This additional switch panel is provided on the right side console for any machine customizing if desired.

HORN SWITCH

CUP HOLDER AND ASHTRAY

1

2 Figure 36

BS08B254

HORN SWITCH

Located on the left hand control lever, this is a momentary push button. Always sound the horn before starting the engine to alert personnel the machine is going to be operated.

Figure 38

BS06H094

1. CUP HOLDER 2. ASHTRAY

A cup holder is provided on the right side panel, below the monitor, and the ashtray is located on the right side console.

WARNING: Always sound the horn before starting the engine or moving the machine.

Failure to comply could result in injury or death.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO

HOW TO SELECT STATIONS a. How to select the radio station manually: Press the Power switch to turn ON the radio and press the station selector buttons up or down to select the desired radio station. This radio functions in two main frequency bands: AM and FM. When the frequency band reaches the upper or lower limit, the radio automatically switches to the opposite limit., that is: from the upper to the lower or vice versa.

1

b. How to preset the radio stations:

Figure 39

BS06H093

1. RADIO

The radio is located on the right side control panel.

The LCD Display shows the radio station selected as well as its frequency band.

Control Switches The following table describes the different functions available to use the radio:

Once the desired radio station is selected manually, press any of the preset station buttons (1 ~ 6) for more than 1.5 seconds to record it in i t s r e s p e c t i ve m e m o r y. T h e r e c e p t i o n i s tem po rar ily lost du r in g the me mo r izatio n process. Once the reception is recovered, the station is preset on the desired preset station button. Repeat this procedure to preset a total of 6 different radio stations.

NOTE: The preset stations are cancelled when the radio is removed for maintenance or the batteries are disconnected.

HOW TO ADJUST THE CLOCK a. After the radio is turned ON, press button (4) to activate the time function. Then press button (8): H, M and RST to set the time accordingly. Use H to set the hour and M to set the minutes.

NOTE: The radio LCD screen will return to normal functioning after 5 seconds of inactivity on the time control button. b. The RST button works as follows: (If trying to adjust time to 10:00 hours):

Figure 40

DC04D548

• If minutes are within 0 and 29 - when pressing RST button, minutes will be taken to “10:00”. Then press M to set the proper minutes.

SWITCH

FUNCTION AND USAGE

1

Power switch and volume control

2

Tone control

3

FM & AM selector

4

Time set selector

5

Station selector

6

Preset selector buttons

7

LCD display

8

Time adjusting buttons

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• If minutes are within 30 and 59 - when pressing RST button, minutes will be taken to “10:30”. Then press M to set the proper minutes.

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS

RIGHT HAND OPERATOR CONSOLE

CONTROL PANEL

CLIMATE CONTROL - AIR CONDITIONER

2

3

4

5

1 2 1

2

6 Figure 42

DC03D550

1.

2.

3.

4.

5.

6.

7.

8.

2 BS06H079

7

8

9

Figure 41

1. AIR CONDITIONER CLIMATE CONTROL PANEL 2. AIR OUTLETS

The Air Conditioner Climate Control provides a comfor table indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reduces window glass fogging.

The Climate Control - AC unit is installed behind the operator’s seat and sends cold air or hot air into the cab.

AIR OUTLET DIFFUSER Select a preferable air diffuser direction that is most comfortable by moving the diffuser grill by hand.

AIR OUTLET MODE SELECTOR SWITCH FRESH AND RECIRCULATE AIR SELECTOR SWITCH LCD DISPLAY COMPRESSOR SWITCH AUTO CONTROL SWITCH MAIN POWER SWITCH FAN SPEED SELECTOR SWITCH TEMPERATURE SETTING SWITCH & °C / °F SELECTOR SWITCH 9. DEFROSTER SWITCH

IMPORTANT: The LCD display indicates temperature, air outlet mode, compressor ON - OFF AUTO, recirculate, fresh air, and fan speed.

The background of the control panel is illuminated whenever the A/C system is activated.

BASIC USE Before turning the Air Conditioner ON, close the door and windows to achieve the best performance. a. Press the AUTO control switch to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (65 .3°F) to 31.5 °C (8 8.7°F). th e AUTO indicator in the LCD display will come on.

The outlet temperature, outlet opening and fan speed are adjusted automatically so that indoor temperature of the cab comes closer to the set temperature. b. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF. c. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control is not preferable. The AUTO indicator in the LCFD display goes out. Press AUTO switch to return to automatic climate control.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Control Panel Functions

a. Press the main power switch to activate the Climate Control-AC and the LCD display will illuminate.

A. Main Power Switch and Display

b. Press control switch AUTO, and fan speed and air outlet are automatically controlled, and “AUTO” indicator lamp on LCD display is illuminated.

2

c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power sw i t c h i s p r e s s e d a g a i n , t h e C l i m a t e Control-AC will come on in the auto control mode.

C. Temperature Setting Switch and Display

1 Figure 43

DC04D550

2

1. MAIN POWER SWITCH 2. LCD DISPLAY

a. LCD display is illuminated when the Climate Control-AC is operating. When the Climate Control-AC is stopped, LCD will turned off. b. Press main power switch, and all functions for the Climate Control-AC will switch ON or OFF. Each time when this switch is pressed, the f u n c t i o n sw i t c h e s O N a n d O F F. W h e n switched ON, the Control Climate-AC starts operating at the point set before switching OFF (When it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

NOTE: The key switch will switch air-conditioner OFF, but the operating condition just before switching off may not be restored when the key switch is turned ON. B. Auto Control Switch and Display

2

3

1 Figure 45

DC04D550

1. TEMPERATURE SETTING SWITCH AND °C / °F SELECTOR SWITCH 2. LCD DISPLAY

a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from °C to °F or vice-versa in the LCD display. c. Press the temperature set switch Down or UP to change the set temperature. The temperature goes up or down by 0.5°C (0.9°F) in graduation. The set Temperature may be raised or lowered by continued pressing of the switch.

1 Figure 44

DC04D550

1. MAIN POWER SWITCH 2. LCD DISPLAY 3. AUTO CONTROL SWITCH

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d. The set temperature 18°C (64.4°F) is the l owe s t c o o l i n g t e m p e r a t u r e, a n d 3 2 ° C (89.6°F) is the highest heating temperature.

Control beyond either of these limits is not possible.

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS D. Air Outlet Mode Selector Switch and Display

E. Defroster Switch and Display

2 2 1

1 Figure 48

DC04D550

Figure 46

DC04D550

1. DEFROSTER SWITCH 2. LCD DISPLAY

1. AIR OUTLET MODE SELECTOR SWITCH 2. LCD DISPLAY

a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet Mode Switch in the condition where auto display light is on, and the display mode is fixed, AUTO indicator lamp on LCD display goes out, and AUTO control of the air outlet opening is released. Press it again, and the level is changed to: VENT

BI-LEVEL

FOOT

FACE

a. Press Defroster Switch, the defroster indicator will be displayed. b. Press Air Outlet Mode selector Switch, and it returns to air outlet mode just before pressing defroster switch. c. Press Defroster Switch in so the AUTO display is indicated, AUTO indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

F. Fresh and Recirculate Air Selector Switch and Display

1

DC04D551

2

Figure 47 Figure 49

DC04D550

1. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 2. LCD DISPLAY

a. Suction (fresh air intake) mode is indicated on LCD display. b. Each time Fresh and Recirculate Air Selector Switch is pressed, the mode is switched to either recirculate or fresh air intake.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS G. Compressor Switch and Display

2

1

DC04D552

Figure 50

DC04D550

1. COMPRESSOR SWITCH 2. LCD DISPLAY

Figure 51

Press UP or DOWN of fan speed selector switch, and auto control of fan speed is released, and the “AUTO” indicator lamp on LCD display goes out.

a. Press the Compressor Switch (1), and the snow flake icon will be indicated on LCD display (2). b. Press it again, the compressor turns off, and its indicator icon on the LCD display goes out.

H. Fan Speed Selector Switch and Display

2

1 DC04D550

1. FAN SPEED SELECTOR SWITCH 2. LCD DISPLAY

When it is set to MANUAL mode, fan speed on LCD display is as follows.

Display

Fan Speed

LCD 4 bars are lit up.

MAX.

LCD 3 bars are lit up.

HIGH

LCD 2 bars are lit up

MEDIUM LOW

LCD 1 bar is lit up.

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3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATING LEVERS AND CONTROLS LEFT AND RIGHT TRAVEL LEVERS & PEDALS

3

4

5

3

5

2

1

1

7

4

8 6

2 2

6 6 3

1 2

4 5 Figure 52

BS08C424

1.

2.

3.

4.

5.

6.

SAFETY LOCK LEVER CONTROL LEVER (ISO CONTROL PATTERN) OPERATING PEDAL (BREAKER AND NIBBLER OPTION) TRAVEL LEVER OPERATING PEDAL (BOOM SWING) DOZER OPERATING LEVER

7

8

Figure 53

BS08C425

Left Control Lever 1. Swing Right

The safety lock lever is provided to prevent any u n ex p e c t e d o p e ra t i o n d u e t o t h e a c c i d e n t a l movement of the control lever.

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

• FORWARD - Variable speed forward track movement.

• BACKWARD - Variable speed reverse track movement.

• CENTER - Neutral position.

2. Swing Left 3. Arm Out 4. Arm in Center - Neutral - Upper structure and arm are held in position.

Right Control Lever 5. Boom Down 6. Boom Up 7. Bucket Digging 8. Bucket Dumping Center - Neutral - Boom and bucket are held in position.

WARNING: Confirm that the operating pattern of the levers conforms to the machine lever decal. If decal and lever pattern does not match, replace the decal immediately.

Failure to comply could result in injury or death.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS BOOM SWING OPERATION PEDAL

TRAVEL LEVERS AND PEDALS

Figure 54

BS08B256

Use the operating levers to move the track either backward or forward. The pedals can also be used to move either the left or right track.

BS08C427

( a ) Fo r w a r d - va r i a b l e s p e e d fo r w a r d t r a c k movement.

Use the boom swing control pedal (1) to operate the boom right and left swing.

(b) Backward - variable speed backward track movement.

To unlock the pedal, pull the pin (2) right as shown.

(N) - Center - neutral position

To lock the pedal, push the pin (2) left and engage the pin into the notch as shown.

WARNING: Be aware of the crawler frame direction. When travel motor is on the front side, the travel lever functions will be opposite. Failure to comply could result in injury or death.

Figure 55

WARNING: Make certain the pedal is in the locked position when the boom swing is not being used. Failure to comply could result in injury or death.

A. Right pushed down - Right swing - max 82° B. Left pushed down - Left swing - max 50° Neutral - Stop

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3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOZER LEVER

1

Figure 56

BS08C426

The dozer blade is attached on the lower frame with pins and is used for backfilling and leveling after digging operations. Move the blade up and down with the dozer lever.

The dozer blade lever (1) is located on the right side of the right hand operator console.

With machine in position and the safety cancellation lever in the unlocked (down) position, move the throttle potentiometer to the HI idle position.

Use boom, ar m and bucket controls to set the attachment to the desired position.

Pull (A) the dozer blade operating lever to lift the blade up.

Push (B) the dozer operating lever forward to lower the dozer blade.

WARNING: The dozer blade control function is live at all times, even with the lock lever in locked (up) position. Read and understand how the blade functions. Failure to comply could result in injury or death.

BBS08B256

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CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

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

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

Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operate Boom Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ditch Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Selection of the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Before Operating the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Hydraulic Oil Level Check and Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Setting Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

OPERATING THE MACHINE

CE-NA000

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

2. Carry out the daily maintenance operations.

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

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

5. Check the track assemblies.

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

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

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

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

CE-NA000

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

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

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

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

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

10. Remove any obstructions which hinder visibility.

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

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

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

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

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

The operator must be alone on the machine.

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

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

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

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

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

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

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

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 13. See Lifting Procedures for the Machine in this chapter when it is necessary to lift the machine.

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

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

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

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

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

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

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

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

Fasten the seat belt.

2. Move throttle control to “LO” position.

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

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

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

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

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

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

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

STOPPING THE MACHINE

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

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

Figure 1

BS07M794

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

2. Move throttle to “LO” position. Allow engine to idle for 5 minutes.

3. Turn Key Switch to OFF position.

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

5.

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CHAPTER 4 - OPERATING INSTRUCTIONS

STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES

STARTING MACHINE ENGINE WITH BOOSTER CABLES CONNECTING BOOSTER CABLE

STARTING ENGINE 1. Move throttle control to “LO” position.

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

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

WARNING: Improper booster cable connections can cause an explosion resulting in personal injury.

Always follow the correct procedures when connecting and disconnecting the booster cables.

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

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

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

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

CAUTION: Do not allow the vehicle or machine used for boosting to touch metal to metal with the disabled machine. This could short circuit electrical systems and cause extensive damage to the CPU and other components.

NOTE:

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

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

• When cranking engine, the absence of “blue” or “white” smoke from the exhaust Stopping the Machine

2. Make certain key switch of disabled machine is in the OFF position before proceeding with booster cable connection.

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

WARNING: AVOID ACID BURNS Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

Wear eye protection and protective clothing when handling or servicing batteries.

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention. Failure to comply could result in injury or death.

Figure 2

BS08B259

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position with attachments resting safely on the ground.

2. Move throttle control to “LO” position. Allow engine to idle for 5 minutes.

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

3. Turn key switch to OFF position.

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS DISCONNECTING BOOSTER CABLES

3

1

2

3

1

2

4 4 1

2

3

4

DC04D588

Figure 3

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY BEING USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY BEING USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

3. Locate and connect one end of the booster cable to the positive (+) terminal on the battery of the disabled machine.

4. Connect other end of positive booster cable to positive (+) terminal of battery being used for boosting.

5. Locate and connect second cable to the negative (-) ter min al of the batter y being used for boosting.

6. Connect other end of negative (-) cable to the upper frame of disabled machine as far away from battery as possible.

STARTING BOOSTING MACHINE ENGINE 1. Start engine boosting machine in normal manner according to climate conditions.

4

3

2

1 Figure 4

DC04D588

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

After disabled machine engine is running, follow these steps to disconnect the cables.

1. Disconnect the negative (-) cable from disabled machine upper frame.

2. Disconnect negative (-) cable from battery used for boosting.

3. Disconnect positive (+) cable from battery used for boosting.

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

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

2. Allow 5 minutes or more to provide partial charge to the discharged batteries.

STARTING DISABLED MACHINE ENGINE 1. Start engine of disabled machine in normal manner according to climate conditions.

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CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE WARM UP WARNING: While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions. Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

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

MANUAL WARM UP 1. Warming Up Engine a. Allow the engine to run for 5 minutes under no load conditions with throttle control at “LO” idle position. b. During warm up, visually and audibly inspect engine for abnor mal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises. c. Should problem areas be noticed, stop engine, locate and repair problem areas before restating or operating the machine.

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4-7

CHAPTER 4 - OPERATING INSTRUCTIONS CHECK MONITOR PANEL

Figure 7

DC04D474 BS06H082

Figure 5

Check all gauges and indicators on the monitor after s t a r t i n g t h e e n g i n e. M a ke c e r t a i n t h e wa t e r temperature (1) is in the normal range, fuel (2) is adequ ate, and o th er indica to r lamps are no t illuminated or indicating any engine abnormalities.

WARMING HYDRAULIC OIL CAUTION: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab. a. Move throttle control to HI idle position.

DC04D473

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

WARNING: While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions.

Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

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

Figure 6

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

BS07M796

Figure 8

BS07M797

Figure 9

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

FUNCTION CANCELLATION LEVER 1. Unlocked Position

2

WARNING: Normal positioning of the machine for the purpose of determining Front, Rear, Forward, Reverse are with the travel motors located behind the operator’s cab. Failure to comply could result in injury or death.

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

1

Figure 10

BS06H080

1. UNLOCKED POSITION 2. LOCKED POSITION

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

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

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

WARNING: Failure to place Function Cancellation Lever in Locked (up) position could result in serious injury or death as well as serious damage to the machine and its components.

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CHAPTER 4 - OPERATING INSTRUCTIONS TRAVEL SPEED SELECT SWITCH

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

OPERATING BOTH TRAVEL LEVERS TOGETHER

BS06H082

Figure 11

DC04D477

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

Figure 13

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

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

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

Figure 12

DC04D478

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS TURNING THE MACHINE

Figure 17

DC04D482 DC04D479

Figure 14

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

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

Figure 18

DC04D483 DC04D480

Figure 15

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

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

Figure 19

DC04D484 DC04D481

Figure 16

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

IMPORTANT: A. Climbing ability of a machine can change depending upon shoe type, engine lubrication, etc.

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

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

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

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

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

TRAVEL SAFETY a. Know the position of the travel motor before beginning travel. b. Travel on firm, level surfaces as much as possible.

BS08B260

Figure 20

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

NOTE: If the machine is operated while the swing bearing is submerged in water, then the swing bearing, swing pinion, and the swivel joint may wear out prematurely. Immediate replacement of grease in grease bath and flushing of the swing bearing is required. See Maintenance Section.

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

Avoid these areas.

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CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC CONTROL LEVERS

Figure 21

BS08C428

The operating and travel controls of the machine are factory set to ISO standard operating patterns for optimum performance of the machine and its systems. Make certain the operating pattern control matches the decal inside the machine on the right side window.

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

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

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

Figure 22

DC04D485

a. Pulling right control lever BACK raises boom.

DC04D487

Figure 24

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

DC04D488

Figure 25

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

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

Figure 23

DC04D486

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET OPERATION

SWING OPERATION

IMPORTANT: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

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

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

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

NOTE: Use swing flashers during swing operations.

DC04D489

Figure 26

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

Figure 28

DC04D491

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

DC04D490

Figure 27

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

Figure 29

DC04D492

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY BUCKET TOOTH DIRECTION

USE ARM IN ACTION

Figure 30

BS07M852

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

BS08B264

Figure 32

Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and to help prevent tooth damage.

OPERATE BOOM SMOOTHLY

OPERATE BOOM SMOOTHLY

BS08B265

Figure 31

BS08B263

Figure 33

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS BACK FILLING AND LEVELING

CLEANING SAND & SOIL FROM BUCKET

BS07M854

Figure 34

Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

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

Figure 36

BS08B267

Do not push or pull material with the bucket, but move the bucket back and forth horizontally.

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

USING THE SHOVEL

SWING MOTION

Figure 37

BS08B268

BS08B266

Figure 35

Release swing lever before reaching the final point of digging or dumping in order to stop swing motion early.

Using the arm cylinder, scrape the ground. Be careful not to bump the reversed bucket into the cab. The excavating power during shovel operations is less than during back hoe operations. Scrape the ground at 2-3 inches to improve draining in areas near the groundwater level.

If bucket is equipped with a lifting eye, make certain the eye will clear arm with bucket cylinder in the full extended (full dump) position.

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CHAPTER 4 - OPERATING INSTRUCTIONS For back filling and leveling work after digging, use the dozer to push the soil back into the ditch or to level ground.

USING THE DOZER

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

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

2. Use the dozer to back fill a trench.

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

1

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

Figure 38

BS08C429

1. The dozer blade operating lever (1) is located on the right side of the right hand operator control console. Use it to lift or lower the dozer blade.

2. Start the machine and place the safety lock lever in the UNLOCKED (down) position.

3. Move throttle potentiometer to the Hi idle position.

4. Using boom, arm, and bucket controls, set the attachment to the desired position.

5. Pull (A) the dozer blade operating lever to lift up the blade.

6. Push (B) the blade operating lever forward to lower the dozer blade.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS OFFSET DIGGING

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS OPERATION IN EXTREME COLD 1. Follow procedures at the beginning of this chapter as starting the engine may be difficult due to extremely cold temperature.

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

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

BS07M858

Figure 39

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

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

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

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

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

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

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

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

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

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

3. Keep all belts properly tensioned.

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CHAPTER 4 - OPERATING INSTRUCTIONS 4. Make certain that the engine coolant mixture is sufficient to keep the machine safe.

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

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

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

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

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

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

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

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

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

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

OPERATION AT SEASHORE OR SALTY CLIMATE

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

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

LONGER UNDERCARRIAGE LIFE Undercarriage life varies upon the operation method.

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

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

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

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

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

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

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

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

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

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET SELECTION GUIDE

HYDRAULIC BREAKER

Bucket selection is extremely impor tant to a machine’s productivity, durability, and stability.

1. Selection of the Hydraulic Breaker

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

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

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

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

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

If the machine is to continuously dig rock, wasted shale, river cobble or other severe applications the narrowest bucket possible should be utilized. This will allow the greatest possible penetration and minimal twisting of the attachment (boom and arm).

Bucket capacity is not to be the prime consideration for severe applications.

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

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

W h e n m o u n t i n g a b r e a ke r o n t h e hy d r a u l i c excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each breaker. To select hydraulic breakers, contact your dealer.

2. Before Operating the Hydraulic Breaker Consult your dealer for the piping needed for the boom and arm when installing a hydraulic breaker.

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

Thoroughly read the Hydraulic Breaker Operation Manual and SAFETY PRECAUTIONS from this Section, as well as the Safety Precaution’s Section in this manual to avoid damaging the machine or hydraulic breaker during operation. Select the appropr iate hydraulic flow for the breaker by fo l l o w i n g t h e i n s t r u c t i o n d e t a i l e d i n t h e NIBBLER/BREAKER BASIC M AC H I N E OPERATION in this section.

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

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

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

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

1 Figure 42

BS07M860

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

Breaker Figure 40

BS06H080

Button section 1. FUNCTION CANCELLATION LEVER

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

Operation

OFF

Breaker stops operating

Depress button B

Breaker starts operating

Nibbler Button section

Operation

Depress button A

Nibbler closes

Depress button B

Nibbler opens

IMPORTANT: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine.

If material is not breaking, reposition breaker or nibbler and repeat operation in one (1) minute intervals.

Figure 41

BS07M859

b. Move throttle control to HI idle position. c. Using boom, arm and bucket controls set the breaker or nibbler to desired position. d. Release control pedal lock rod. e. Make certain breaker or nibbler is in desired position and against material to be broken. f. To operate breaker, press the switch (D).

Release to stop operation. g. To close nibbler, press switch (C). To open nibbler, press switch (D). h. Operate breaker or nibbler at one 30 second intervals.

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

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE SET-UP SETTING SELECTOR VALVE

1

B

N

Figure 45

BS08B272

Figure 43

BS08B270

Turn the Lever to either the Nibbler or Breaker position.

N: Use Nibbler B: Use Breaker

1. SELECTOR VALVE

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

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

1

Lower the attachment to the ground and stop the engine. Set the cancellation lever in the locked (up) position.

Figure 46

BS08B273

1. SHUT OFF (STOP) VALVE

2

ATTACHMENT HYDRAULIC OIL VALVE POSITIONS

Attachment Hydraulic Oil Shut off valve

3 BS08B271

Figure 44

1. Use a 3 mm Allen wrench to loosen bolt (2) on the selector valve. Turn the lever (3) to the desired position.

2. After valve is in position, tighten bolt (2).

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NOTE: Make sure to switch the position of the stop valves to the CLOSED position before removing the attachment.

The valve is used to shut off the flow of hydraulic oil when changing the attachment. Use a 24 mm spanner wrench to open and close valves.

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CHAPTER 4 - OPERATING INSTRUCTIONS Oil Flow

OPERATING PEDAL

A 1

B Figure 47

BS08B274

Always check the foot pedal control pattern before operating.

Release pedal lock on the right front side of driver’s seat to operate pedal

1

Figure 49

BS08C432

Nibbler When the toe side (A) of pedal is depressed, oil will flow into the left hose of the attachment. When the heel side (B) of the pedal is depressed, oil flows into the right hose of attachment.

Depress toe section . . . . . . . . . . . . . . Nibbler closes Depress heel section . . . . . . . . . . . . . .Nibbler opens Breaker Pedal operation is only active on the toe side Depress toe section . . . . . . . . . . . . Breaker operates Pedal in neutral. . . . . . . . . . . . . . . . . . .Breaker stops

Figure 48

BS08B275

Raise the lever (1) upward, and shift the lever to position (A) to lock the lever.

When the breaker is used, shift lever (1) to position B When nibbler is used, shift lever (1) to position (C)

WARNING: Set the pedal lock to LOCED position when the breaker or nibbler is not used. Unexpected contact with unlocked pedal could cause sudden movement. Do not put foot on pedal except when using attachment. Failure to comply could result in injury or death.

BS08B333

Figure 50

WARNING: Do not leave the machine with engine running. Failure to comply could result in injury or death.

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

C. BREAKING OVERSIZE ROCKS

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

A. PROPER BREAKER POSITIONING

Figure 52

DC03M066

DC03M065

Figure 51

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

B. APPLIED PRESSURE ON BREAKER

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

D. SURFACE ROCK DEMOLITION

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

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

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

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

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Figure 53

DC03M067

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

Do not try to break too much at one time.

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CHAPTER 4 - OPERATING INSTRUCTIONS E. EXCAVATING AND TRENCHING

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

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

A. USE FOR INTENDED PURPOSE

Figure 54

DC03M068

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

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

DC04E061

Figure 55

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

B. PASSENGERS Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT

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

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

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

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

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

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

8. DO NOT OPERATE breaker submerged in water.

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

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

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DC04E062

Figure 56

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

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CHAPTER 4 - OPERATING INSTRUCTIONS F. HOSE SURGE

D. CYLINDERS

Figure 59

DC04E065 DC04E063

Figure 57

DO NOT OPERATE boom, arm or bucket cylinders at stroke ends when using a breaker attachment.

Doing this can cause undue stress on the cylinder rods and result in damage.

E. AVOID CONTINUOUS OPERATION

Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an authorized dealer for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

G. DO NOT USE DROPPING FORCE

DC04E064

Figure 58 Figure 60

DC04E066

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

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

H. DO NOT USE SWING FORCE

Figure 61

DC04E067

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

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CHAPTER 4 - OPERATING INSTRUCTIONS I. DO NOT LIFT

TOWING THE MACHINE

Figure 62

DC04E068

BS08B337

Figure 64

BS08B338

Figure 65

Never use optional attachment to lift or transport objects or materials. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

J. WORKING RANGES

Figure 63

Towing the machine is not recommended, however, if circumstances require towing, always tow the machine slowly in low speed. Do not pull the machine using brackets welded on the lower plates of the undercarriage. These brackets are intended for pulling lightweight objects.

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

Use tow straps or chains of adequate strength, and if necessary one machine in front and one machine in back to act as a braking source.

DC04E069

WARNING: Keep all unauthorized personnel clear of the area. Do not allow anyone to enter the area between the machine and the towing vehicle when towing. Failure to comply could result in machine damage, injury, or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

Figure 66

BS08C434

Marked dimensions do not include height of shoe lug Dimension are with 2.13 m (7 ft 0in) arm, 0.22 m3 (0.29 cubic yd.) bucket and 3.67 m (12 ft 0 in) boom NOTE: When the long arm (2.13 m (7 ft 0”) equipped machine is transported, remove the bucket as illustrated.

Figure 67

BS08C435

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CHAPTER 4 - OPERATING INSTRUCTIONS IMPORTANT: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

LOADING THE MACHINE

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

Figure 68

BS08B335

WARNING: Never attempt to load or unload machine without ramps. Failure to comply could result in injury or death. a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower ramps of trailer. c. Start the machine. d. Set travel speed to LOW - 1st speed. e. Move throttle control to low idle position. f. Raise the attachment and slowly move machine up trailer ramps and over rear axles of trailer. g. Slowly move machine completely onto trailer until in proper transport position.

Figure 69

BS08B336

h. Slowly swing machine 180° until attachment is toward rear of trailer. i. Slowly lower boom until attachment rests on trailer bed. j. Do not have bucket and arm cylinder at full stroke during transport as this may cause damage to cylinders. k. Place hydraulic function cancellation lever in the LOCKED (up) position. l. Turn machine OFF, remove key and lock all doors, filler caps and access panels.

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DC04D581

Figure 70

Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer. Also, make sure to secure front and rear of each track.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE

Figure 71

BS07M870

MACHINE IN STORAGE POSITION

PREPARE MACHINE

CARE DURING STORAGE

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

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

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

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

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

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

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

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

4. Move machine to an indoor location for storage.

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

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

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

Replace all hoses showing signs of deterioration.

6. Rest the bucket on a stable wood block.

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

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

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

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WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply with this warning could result in injury or death.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES ENGINE Type of Oil . . . . . . . . . . . . . . Engine Oil SAE 15W30 Capacity: Total Capacity . . . . . . . . . . . . . .11 liters (2.9 gal) Engine Oil with filter change . 10.3 liters (2.7 gal) NOTE: See ENGINE OIL LEVEL in Chapter 6 for proper oil filling and/or checking engine oil level.

HYDRAULIC Type of Oil . . . . . . . . . . . . . . . . . Hydraulic Oil AW 46 Capacity: Hydraulic Tank. . . . . . . . . . . . .48 liters (13.0 gal) Hydraulic System . . . . . . . . . .90 liters (24.0 gal)

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

in

SWING MOTOR REDUCTION UNIT Type of Oil . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil Capacity . . . . . . . . . . . . . . . . . 1.5 liters (0.4 gal) SWING BEARING Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2 Capacity . . . As required (1 place - swing 90° x 4) NOTE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

NOTE: 1. See HYDRAULIC OIL LEVEL in Chapter 6 for proper filling and/or checking hydraulic oil level.

FUEL TANK Type of Fuel . . . . . . . . . . . . . Diesel Fuel grade No. 2 Capacity . . . . . . . . Fuel Tank - 120 liters (32 gal)

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

RADIATOR

NOTE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

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

TRAVEL MOTOR REDUCTION UNIT Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil Capacity . . . . . . . . . . . .1.35 liters (0.4 gal) Each

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL

-34°C (-29.2°F)

50% mixed

in Chapter 6 for proper filling and/or checking oil level.

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

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Capacity: Radiator . . . . . . . . . . . . . . . . . . . . . . . .5.7 L (1.5 gal) Total cooling System . . . . . . . . . . 8.5 liters (2.24 gal) NOTE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

5-3

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

HYDRAULIC

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

Engine

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

• Engine Fuel Filter • Water separator element OPERATOR CAB

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

CLIMATE ZONE

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

FRIGID -30°C~15°C (-22°F~59°F)

FRIGID -20°C~30°C (-4°F~86°F)

FRIGID-WARM -25°C~40°C (-13°F~104°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 5°C~55°C (41°F~131°F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT

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

FRIGID -30°C~30°C (-22°F~86°F)

WARM -5°C~40°C (23°F~104°F)

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

SAE10W30

SAE15W40*

SAE15W50

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

CLIMATE ZONE

LUBRICANT

FUEL

LUBRICANT

FRIGID -15°C ~ -25°C (5°F ~ -13°F)

WARM -5°C ~ -15°C (23°F ~ 5°F)

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

WINTERIZED ASTM D975 No.1

ASTM D975 No.2

ASTM D975 No.2

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL (For General Purpose Lubrication)

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

LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

Extreme Pressure Multi Purpose Grease No.2 EP Type Grease

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

ANTIFREEZE (LLC) -34°C (-29.2°F)

FLUID ENGINE COOLANT (50% MIXTURE)

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

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

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

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

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

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

Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Alternator/Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Engine Oil and Filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic Return Filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-17 6-17 6-18 6-19 6-22

100 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Engine Mount Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 120 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Swing Motor Reduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INspect Alternator/Air Conditioner Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator and oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cooler Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6-25 6-25 6-25 6-26 6-26 6-26 6-27 6-29 6-30 6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Change Swing Motor Reduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Travel Reduction Gear (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Check Air Conditioner Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Engine Mount Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Replace Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Hydraulic Suction Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Change Swing Motor Reduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Swing Reduction Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Check Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Engine Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Replacing the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Removing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Installing bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Releasing Travel Motor Brakes Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Releasing Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Releasing Swing Brake Manually With Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Releasing Swing Brake Manually Without Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Bleeding the Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Lowering Bucket Attachment on a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57

6-2

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION GENERAL SAFETY

WARNING: Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in injury or death.

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

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

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

KEEP MACHINE CLEAN

DC04B669

Figure 1

DC04B668

1. It is recommended that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine.

Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

Figure 2

Thoroughly clean machine before perfor ming inspection and maintenace procedures. It is easier and safer to locate problems, perform maintenance and also reduce r isk of hydraulic s ystem contamination when machine is clean.

HOT SURFACE & FLUIDS

2. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance as a guide. Also, refer to the inspection and maintenance charts for general service interval recommendations. If you doubt your ability to perform these tasks, contact your dealer for assistance.

NOTE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

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

87490337 NA

Issued 04-08

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DC04B670

Figure 3

Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool down before performing maintenance procedure.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PREVENT CONTAMINATION

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

TAG-OUT MACHINE

Figure 6

DC04B673

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

DC04B671

Figure 4

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

INSPECT WASTE OILS AND FILTERS

IMPORTANT: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

SEALS AND O-RINGS Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

STOP ENGINE DO NOT attempt any maintenance with engine running. Always stop the engine and allow machine to cool.

WEAR SAFETY EQUIPMENT Wear hard hat, safety goggles or face shield, work gloves, safety shoes, and well fitting work clothes when perfor ming inspection and maintenance procedures on this machine.

DC04B672

Figure 5

Before disposal, inspect all waste oils, fluids, and filters for debris and foreign material. Cut open the oil filters to determine any abnormal wear.

CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

WARNING: Never use gasoline, diesel fuel or other flammable solvents to clean parts.

Always clean parts in a well ventilated area.

Failure to comply could result in injury or death.

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY

STEPS AND HAND HOLDS

1. Turn key switch to OFF position.

2. Remove negative (-) cable from battery terminal.

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

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

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

NOTE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding is required, consult your authorized dealer for proper procedures. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding. Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

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1. Inspect daily all mounting steps and hand holds on the machine to make sure they are clean and in safe working condition.

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

IMPORTANT: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition free of grease, oil, mud, ice, and snow.

MACHINE ACCESS COMPARTMENTS AND DOORS The machine has a several machine compartment doors. Use the ignition key to lock and unlock these compartments.

The batteries, radiator, oil cooler and air cooler are located behind the left compartment door.

The engine air cleaner, oil check and fill are located in the main engine compartment.

Always use the struts to secure the doors in an open position. When closing doors, make certain doors are securely closed, and no tools or other objects are left on or in the door compartments.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

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

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

Figure 8

BS08B339

5. Make certain the hydraulic oil temperature is below 40° C (104° F).

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

7. Press the rubber cap (1) on the top of the hydraulic tank 5 to 7 times.

BS08B259

Figure 7

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

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

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

Pilot control switch must be on.

3. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the ignition key to the OFF position.

4. Set the safety lock lever to LOCKED position.

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply with this warning could result in injury or death.

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

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

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GUIDELINES TO REPLACE GROUND TOOLS

GUIDELINES FOR ATTACHMENT LUBRICATION

It is very important to keep bucket teeth and side cutters properly tightened. Loose or missing bolts will increase loads and eventually cause tool failure.

Extended operation with loose hardware can cause the bolts to stretch and wear on the support mounting holes. Heating of hardware and support mounting holes will cause the same effect. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters.

Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubrication intervals are based on an average duty cycle. Average duty cycle is defined as Most typical digging application, road construction in natural bed clay, digging 50% - 60% of the daily work schedule

• When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

• Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT.

• When installing end bits, start at the center and work toward the outside edges.

• Always torque bolts according to specifications.

• For best results, strike all head bolts with a heavy hammer to seat them properly before final torque.

WARNING: Wear safety glasses whenever striking metal objects with a hammer. Failure to comply could result in injury or death.

• When new parts are used, the mating surfaces will seat more uniformly and the bolts torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

• Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points.

Because of these high spots, it is recommended that the front attachment or the repaired area be lubricated a minimum of once every eight (8) hours for the first 50 hours for a standard machine working in an average duty cycle. This lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand operated grease dispenser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standard lubr ication procedure is modified. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. Therefore, to avoid this situation, the front attachment has to be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

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

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

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Issued 04-08

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6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-14

Fan and air conditioning drive belt

6-29

Air filter

AR

6-31

Fuel tank filter

AR

8-11

Bolt and nut torque

AR

6-47

Bucket teeth, side cutters, clearance

6-26

Radiator cap

6-10

Grease bucket, boom, arm cylinder, dozer

6-12

Engine oil level

8

6-12

Coolant level

8

6-13

Fuel tank level

8

6-13

Electrical connections

8

6-14

Water separator

8

6-14

Fan/alternator belt tension

8

6-15

Hydraulic reservoir level

8

6-15

Hydraulic lines

8

6-16

Crawler belt

8

6-17

Drain fuel tank sediment

6-18

Engine oil and filter

6-19

Track tension

50

7-5

Battery check

50

6-21

Bolt and nut torque

50

6-22

Hydraulic return filter

Every 100 hours

6-23

Engine mount bracket

RM

Engine maintenance

Contact your authorized dealer for initial 100 hour check

Every 120 hours

6-24

Swing reduction oil

Run-in

6-24

Travel reduction unit oil

120

6-25

Engine cooling system

250

6-25

Fan/alternator belt tension

250

6-26

Intake system hose

250

6-26

Air cooler hose

250

6-27

Boom, arm cylinder, dozer

6-29

Engine air cleaner element

6-29

Hydraulic return filter (Breaker attachment)

6-30

Air conditioner

250

8-11

Bolt and nut torque

250

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

6-8

Drain

Lubricate

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

AR

AR

AR Run-in

8

50 Run-in

50

Run-in

50 100

120

250 250 250

Issued 04-08

250

Bur

87490337 NA

6-31

Fuel water separator

6-31

Fuel cap and strainer

6-32

Fuel filter

500

6-33

Engine oil and filter

500

6-34

Swing reduction gear

Run-in

500

6-35

Travel reduction gear

Run-in

500

6-36

Air conditioner

RM

Engine grid heater

7-5

Battery

6-37

Engine air cleaner

6-37

Engine bracket mount

6-38

Hydraulic return filters

1000

6-45

Hydraulic oil (breaker)

1000

RM

Engine maintenance

6-39

Hydraulic suction strainer

2000

6-40

Pilot line filter

2000

6-41

Swing reduction oil

2000

6-42

Travel reduction gears

2000

6-43

Engine coolant

2000

RM

Seat belt

Contact your authorized dealer

RM

Swing gear grease

Contact your authorized dealer

6-45

Hydraulic oil

Drain

Lubricate

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 500

Every 500 hours

Every 1000 hours

Every 2000 hours

Every 5000 hours

500 Contact your authorized dealer 1000 1000 1000

Contact your authorized dealer

2000

5000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection. If using a nibbler or breaker, these intervals may be shorter.

NOTE: RM = See Repair Manual or contact Authorized Dealer

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6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

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

3

GREASE MACHINE AND ATTACHMENTS

1 2

BS08B340

Figure 9

4

During the initial 50 hours of operation during the run-in period, grease bucket, boom, arm cylinder and dozer every 8 hours. After the initial run-in period, grease every 250 hours.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the bucket/attachment on the ground.

Turn the engine off.

Figure 10

BS08B341

1.

2.

3.

4.

BOOM CYLINDER AND ROD PINS (1) (2) BOOM FOOT PIN (3) ARM CYLINDER HEAD PIN (3) BOOM FOOT (CENTER) PIN (4)

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

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

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5

6 7 Figure 11

BS08B342

Figure 14

BS0C437

5. ARM CYLINDER ROD PIN (5) 6. ARM TO BOOM PIN (6) 7. BUCKET CYLINDER HEAD PIN (7)

13. SWING CYLINDER HEAD AND ROD PINS

DOZER PIN GREASE POINTS

9 15

10

14 15

10 11 8 14 Figure 12 BUCKET LINK PIN (8) BUCKET CYLINDER ROD PIN (9) IDLER LINK TO ARM PIN AND ARM TO BUCKET PIN (10) ARM TOP PIN (11)

BS08B343

8.

9.

10.

11.

Figure 15

BS08B344

14. DOZER CYLINDER ROD AND HEAD (12) 15. DOZER BLADE LINK PIN (13)

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

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

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

Figure 13

BS08C436

12. SWING BRACKET PINS

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6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL LEVEL

ENGINE COOLANT LEVEL

2 2 1 1

Figure 17

BS08B346

1. RESERVOIR 2. RESERVOIR CAP

1

3

Check coolant level every 8 hours. Coolant should be changed at 1000 hours. The coolant reservoir tank is located on the left side of the engine compartment.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the bucket/attachment on the ground.

Turn the engine off.

4

2. Proper coolant level is between FULL and LOW marks.

Figure 16

BS08B345

1.

2.

3.

4.

OIL DIPSTICK FILLER CAP OIL DRAIN HOSE

Check oil level every day or each 8 hour shift. Oil should be changed at 50 hour run-in period and at every 500 hours thereafter.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the bucket/attachment on the ground.

Turn the engine off.

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

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

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

2. Raise the engine cover.

3. Pull engine dipstick out, clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again to visually inspect the engine oil level on dipstick.

4. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

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

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE ELECTRICAL

FUEL LEVEL

1

Figure 18

DC04C292

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

WARNING: Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel.

Repair or replace faulty components immediately.

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Figure 19

BS08C438

1. FUEL TANK CAP

1. Turn the ignition switch key ON and the fuel gauge in the cluster will indicate the fuel tank level.

2. To refuel the machine, remove the fuel tank cap.

Do not remove the fuel screen (if equipped) for fueling. Refill fuel tank to full mark to reduce air volume (condensation). Failure to do so could create problems such as r usting and fuel freezing, as well as other associated problems.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DRAIN WATER SEPARATOR

INSPECT ALTERNATOR/FAN BELT CONDITION Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time and every 250 hours thereafter.

4

1 3 2 BS08C264-01

1.

2.

3.

4.

Figure 20

WATER SEPARATOR DRAIN VALVE AIR BLEED PLUG

1. Inspect water separator every 8 hours. Drain and clean at 500 hours.

Figure 21

BS08B350

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

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

2. Visually inspect separator. If float sinks to bottom of case, no water is present.

4. Open valve (3) and air bleed plug (4). Drain until clean fuel is discharged.

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

5. Repair or replace damaged hoses and lines before any operation.

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

3. When float is suspended, drain water and sediment.

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

6-14

Belt

New belt tension

Used belt tension

Force N (lbf)

Alternator Fan

4-6 mm (0.16 -0.24 in)

7-9 mm (0.28-0.35 in)

98 (22)

Air Conditioner

3-4 mm (0.12 -0.16 in)

5-6 mm (0.20-0.24 in)

24 (5.1)

Issued 04-08

Bur

87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL

1

2

Figure 24

BS08B349

Figure 22

BS08B259

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

1. PRESSURE RELEASE BUTTON 2. MOUNTING BOLTS

A. Release all pressure from hydraulic tank. (See releasing hydraulic pressure for additional information.) Depress air release button (1) several times to release hydraulic tank pressure.

WARNING: Gasses from hydraulic tank may be hot. Wear personal safety equipment.

Failure to comply could result in injury or death.

B. Slowly remove the mounting bolts (2) from the cover plate.

C. Add hydraulic oil, filling hydraulic tank to the proper level.

Figure 23

BS08B348

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

Cold: L level oil temperature 10-30° C (50-80° F) Operating: H level oil temperature 50-80° C (122-176° F) 3. Refill if oil level is below L. 4. To add hydraulic oil, open the right side cover and support with strut.

D. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic oil and install the O-ring.

E. Install cover plate, cap screws and washers.

Torque the cap screws to 46.5 ± 4.6 Nm (34 ± 3.4 lbf ft).

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

WARNING: Never operate the machine with faulty control or function. Make all necessary repairs before allowing any operation. Failure to comply could result in machine damage, injury or death.

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

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

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6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEAKS

Figure 26

DC04C300 DC04C287

Figure 25

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

CHECK CRAWLER BELTS Keep crawler belts free of dirt and imbedded rock for maximum traction. Visually check the idlers, sprockets, bolts for any damage, wear, or looseness.

1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure.

2. Check all hoses and lines for signs of damage.

3. Repair or replace damaged hoses and lines before any operation.

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

6-16

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE: DRAIN FUEL TANK SEDIMENT

1

2

Figure 27

BS08B436

1. DRAIN VALVE 2. DRAIN HOSE

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

Failure to comply could result in injury or death.

Draining water and sediment is most effectively performed in the morning.

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

2. Place a suitable container under the drain hose (2) to catch the discharged fuel.

3. Slowly loosen the drain valve (1) to drain water and sediment. When clean fuel begins to flow, tighten the drain valve.

4. Check for fuel leakage after tightening drain valve. If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

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6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL AND FILTER (INITIAL)

2 1

Figure 29

BD08B4372

1. OIL FILTER

1

3

BS08B345

1.

2.

3.

4.

6. Use the filter wrench and turn counter clockwise to remove the oil filter.

4

Figure 28

OIL DIPSTICK FILLER CAP OIL DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a new machine, then at every 500 hours thereafter.

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

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

3. Remove bolts and engine belly pan cover.

4. Place an empty oil container [15 L (4 gal) capacity] under the plug. Attach the quick drain hose (4), and drain the oil into the container.

5. After draining oil, remove drain hose, and tighten drain cap securely. Remove any spilled oil.

Figure 30

BD07N040

7. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head.

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

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

9. Fill with the specified amount of oil through filler port (2) and install oil filler cap.

10. Before starting the engine, check oil level using the dipstick. The level should be between the L and H limits as shown. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

11. Install under cover to its original position.

6-18

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87490337 NA

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

1

Figure 31

BS07M874

Frequently check for wear and tension, particularly on a new crawler belt as there will be an initial stretch during the first 50 hours of operation.

1. Visually inspect track for signs of excessive wear or damage.

BS08B438

2. Keep all unauthorized personnel clear of the area.

Figure 33

4. Measure the clearance in the center of the track, between the bottom of the track frame and the track shoe surface.

Measure Clearance (A) Proper tension . . . . . . . 200 - 230 mm (7.9 - 9.1 in.)

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

1

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

Figure 32

BS07N042

3. Move the upper structure at 90° to the crawler frame. Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Support the lower travel structure with a safety support (1).

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6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING: Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury.

Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in injury or death.

2

1

Figure 34

DC04C307

Figure 36

BS07N045

1.

2.

A. B.

GREASE FITTING GREASE CYLINDER GREASE FILL PRESSURE

INCREASING TRACK TENSION

1

BS07N044

Figure 35

5. Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance.

6-20

Figure 37

BS07N046

6. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting (1) with a grease gun until proper tension is reached.

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

Contact your authorized dealer.

Issued 04-08

Bur

87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BOLT AND NUT TORQUE

ADJUSTING FOR LESS TENSION

When the hour meter registers 50 hours, check the bolt torque of the counterweight. The counterweight mounting should be torqued to: 490 ± 48 Nm (362 ± 35 lbf ft) Check other bolts and nuts on a regular basis to assure tightness and good mechanical wear.

1

Figure 38

BS07N046

1. Gradually loosen the grease fitting to release grease under pressure. Do not loosen the grease fitting (1) more than one turn.

2. If the grease does not release adequately, move the machine forward and backward.

1

Figure 39

BS07N047

3. After grease has been released, tighten the grease fitting.

Torque to: 59 ± 10 Nm (44 ± 7 lbf ft). Move the machine forward and backward to confirm the correct tension of the crawler belt. If necessary, adjust again.

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6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER (INITIAL)

2 3 4 5

BS08B259

Figure 40

Replace the hydraulic return filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 1000 hours thereafter.

6

6

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

2. Make certain to remove all hydraulic pressure from the system.

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

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

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

1

Figure 42

BS08B439

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

7. Take the spring (4), valve (5), element assembly, and O-ring (6) out of the tank.

8. Replace O-ring (6) and assembly (A).

IMPORTANT: Make certain side marked TOP is upward. Use care when replacing assembly, as joint (C) once in place cannot be disassembled.

9. Install element by reversing the disassembly procedure.

10. Install cover (3). Torque bolts to specified value.

See torque charts.

11. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in position to check the oil level.

Stop the engine and check the oil level adding oil, if needed.

BS08B339

Figure 41

5. Remove breaker cap and press the valve (1) several times: 5 to 7 times to bleed the hydraulic oil tank of the remaining pressure.

6-22

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

NOTE: Machines equipped with breaker attachment require reduced service intervals.

Issued 04-08

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

100 HOUR MAINTENANCE ENGINE MOUNT BRACKET

3,4

3

ENGINE MAINTENANCE

3,4 2

1

3,4 2

The intake and exhaust manifold, the oil pan, and components, along with the turbo charger for this machine should be checked by your authorized dealer when the machine registers 100 hours on the hour meter.

3 3,4 2 1

2

2 Figure 43

BS08B440

Check the engine mounting bracket when the hour meter registers 100 hours and every 100 hours thereafter.

If there is any damage or deterioration to bracket (1) or the rubber mount (2), contact your authorized dealer.

If there is no visible damage, check the torque of bolts (3 and 4), tightening to specifications. Bolt torques for the machine can be found in Chapter 8 Specifications.

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6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

120 HOUR MAINTENANCE SWING MOTOR REDUCTION OIL

TRAVEL REDUCTION GEAR Check the travel reduction gear oil level when the hour meter registers 120 hours

1

The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil every 2000 hours thereafter.

2

2

Figure 44

BS08B411

Check the swing motor reduction unit oil level when the hour meter registers 120 hours 1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area. Place the cancellation safety lever in the locked position.

WARNING: Never work on a machine when machine oils and components are hot. Allow the machine to cool prior to performing any maintenance. Failure to comply could result in injury or death.

1 Figure 45

BS08B351

1. DRAIN PORT 2. FILL PORT

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

2. When parking the machine, make certain the drain port (1) is at the bottom.

2

2. Check gear oil level with dip stick (1). If addition of oil is necessary, remove the plug (2) from oil fill port and fill to full level with specified gear oil.

Refer to Lubricant Capacities in Chapter 5.

3. Return the dipstick to its original position. Clean the fill plug with light oil, tape with teflon tape, and install the plug securely.

1

4. Torque to: 69.1 ± 4.4 Nm (51 ± 3.2 lfb ft) Figure 46

BS08B441

WARNING: Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in injury or death.

6-24

3. Remove the oil level fill plug (2) in order to check the oil level. If the oil level is up to the fill plug the oil level is correct. If less than fill level, fill with the specified oil through the fill plug area.

4. Clean oil FILL plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

5. Check drained oil for any metal particles. If contaminants are present, contact your dealer.

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE INSPECT ALTERNATOR/AIR CONDITIONER FAN BELT CONDITION

RADIATOR AND OIL COOLER

Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time and every 250 hours thereafter.

1 3 2

5 BS08C439

Figure 48

Clean the radiator and oil cooler when the hour meter registers 250 hours.

Figure 47

BS08B350

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

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

1. Open engine hood. Push the lever of filter (1) towards front of the machine. Clean the filter.

2. Check the filter, radiator (2) oil cooler (3), and air cooler for debris or clogging. Remove any debris using low pressure compressed air.

1

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

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

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

BS08C440

Belt

New belt tension

Used belt tension

Force N (lbf)

Alternator Fan

4-6 mm (0.16 -0.24 in)

7-9 mm (0.28-0.35 in)

98 (22)

Air Conditioner

3-4 mm (0.12 -0.16 in)

5-6 mm (0.20-0.24 in)

24 (5.1)

87490337 NA

Issued 04-08

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Figure 49

3. Push the filter (1) toward machine front and secure in place with lever. Close and lock door.

WARNING: Hot fluids and hot surfaces can cause severe burns. Coolant is under high pressure when hot. Never remove the radiator cap when system is hot. Allow sufficient time for machine to cool down.

Failure to comply could result in injury or death.

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RADIATOR HOSES

INTAKE HOSES

2

1

1

2 2

1

1 2

1

1

2 2 1 Figure 51

BS08B445 BS08B443

Figure 50

Check radiator hoses when the hour meter registers 250 hours. Replacement of hoses is good maintenance practice.

If there are cracks, fatigue, or water leakage, replace the hose. Tighten any loose clamps.

Repairing and Replacing Hoses

Check intake hoses when the hour meter registers 250 hours.

Check to make certain clamps (2) are secure. Check hoses (1) for cracks, fatigue, or deterioration.

Replace if necessary.

AIR COOLER HOSE

1. Drain coolant into clean container for reuse if not changing coolant.

2

2. Clean the areas where the new hose will be connected.

1

3. Remove the clamps (if reusing old clamps) from the old hose and install them to the new hose.

2

4. Coat the inside ends of the new radiator hose with grease and install. Tighten clamps securely.

5. Fill radiator with coolant.

6. Install radiator cap, start engine, and bring engine temperature to about 90°C (194°F).

2

7. Run engine at low idle, check for leaks and repair as needed.

1 2

8. Install radiator lower cover and close engine cover.

2

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

9. Inspect radiator cap for proper fit and pressure, and replace if needed.

1 2 Figure 52

BS08B446

Check air cooler hoses when the hour meter registers 250 hours. Check to make certain clamps (2) are secure. Check hoses (1) for cracks, fatigue, or deterioration. Replace if necessary.

6-26

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87490337 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GREASE MACHINE AND ATTACHMENTS

3

1 Figure 53

BS08B340

During the initial 50 hours of operation during the run-in period, grease bucket, boom, arm cylinder and dozer every 8 hours. After the initial run-in period, grease every 250 hours.

2

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

4

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

Figure 54

BS08B341

1.

2.

3.

4.

BOOM CYLINDER AND ROD PINS (1) (2) BOOM FOOT PIN (3) ARM CYLINDER HEAD PIN (3) BOOM FOOT (CENTER) PIN (4)

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

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

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6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5

6 7 Figure 55

BS08B342

Figure 58

BS0C437

5. ARM CYLINDER ROD PIN (5) 6. ARM TO BOOM PIN (6) 7. BUCKET CYLINDER HEAD PIN (7)

13. SWING CYLINDER HEAD AND ROD PINS

DOZER PIN GREASE POINTS

9

14

15

15

10 10 11 8 14 Figure 59

BS08B344

BS08B343

8.

9.

10.

11.

Figure 56

BUCKET LINK PIN (8) BUCKET CYLINDER ROD PIN (9) IDLER LINK TO ARM PIN AND ARM TO BUCKET PIN (10) ARM TOP PIN (11)

14. DOZER CYLINDER ROD AND HEAD (12) 15. DOZER BLADE LINK PIN (13)

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

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

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

BS0C436

Figure 57

12. SWING BRACKET PINS

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING ENGINE AIR FILTER Clean the air filter element every 250 hours. After cleaning six times or at six month intervals, the element should be replaced at 1000 hours. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance.

6. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing d a m a g e. R e p l a c e w i t h a n ew e l e m e n t , i f necessary.

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

8. Install the cover and refasten clamps.

WARNING: When using pressurized air for cleaning, always wear full face safety coverage, safety glasses, and respirator.

Flying debris can cause accidents.

H Y D R AU L I C R E T U R N F I LT E R ( M AC H I N E EQUIPPED BREAKER ATTACHMENT)

Figure 60

I f yo u r m a c h i n e i s e q u i p p e d w i t h a b r e a ke r attachment, the replacement for the hydraulic return filter should be completed at 250 hours. See page 6-22 for further information.

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

The use of attachments such as a breaker will shorten maintenance intervals.

BS08C262

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

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

3. Remove the air cleaner outer element (1) from the housing. Do not remove the inner element (if equipped).

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

Figure 61

BS07N132

5. To clean the outer element (1), blow compressed air (less than 0.3 MPa {43 psi}) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

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6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BOLT AND NUT TORQUE When the hour meter registers 250 hours, check all machine bolts and nuts for proper torque. See charts in Chapter 8 - Specifications.

FRESH AIR FILTER

1

Figure 62

BS08B447

Clean the fresh air filter when the hour meter reaches 250 hours and every 250 hours thereafter.

1. Remove cover (1) on the left rear side of operator seat.

2

BS08B448

Figure 63

2. Pull the fresh air filter (2) upward and out. Clean the filter with low pressure air.

WARNING: When using pressurized air for cleaning, always wear full face safety coverage, safety glasses, and respirator.

Flying debris can cause accidents.

6-30

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE DRAIN WATER SEPARATOR

1

5

4 3

6 7

2 Figure 65

BS08B449

OUT

IN A

4

4

2

11

6 6 3 3 77

5. Clean the element (4) and case.

6. Replace the O-ring with a new one.

2

B

7. Reassemble the components, set the O-ring 5 to the case and tighten with ring (6).

8. Push the valve handle (1) down to set at Open position (b).

3

3 Figure 64

XPX0040013E02

1.

2.

3.

4.

5.

6.

7.

VALVE RING CASE ELEMENT O-RING RING SPRING

FUEL TANK CAP AND STRAINER Clean the fuel tank strainer when the hour meter registers 500 hour and every 500 hours thereafter.

1

1. Inspect water separator every 8 hours. Drain and clean at 500 hours.

2. Visually inspect separator. If float sinks to bottom of case, no water is present.

3. To drain, turn valve handle up to the Close position (A).

4. Loosen ring (2) and remove the case (3), and drain the water. Check water for contaminants.

BS08C438

Figure 66

1. Remove fuel cap.

2. Check cap (1) and seal for damage. If damaged, replace with new cap.

3. Remove strainer and clean with light oil. Replace strainer into tank opening, securing in place.

4. Replace cap and lock with starter key.

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6-31

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

1

Figure 68

BD07N040

5. Apply a thin coating of grease to the seal of the new filter. Install and tighten by hand, turning about 2/3 of a turn after the seal contacts the engine.

BS08C264

Figure 67

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

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

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

Bleed the fuel system Fill fuel tank with fuel.

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

The machine is equipped with an automatic bleed feature. Turn the star ter key switch to ON and operate for several minutes. Air should automatically bleed in approximately two minutes.

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

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

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

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE ENGINE OIL AND FILTER

2 1

Figure 70

BD08B437

1. OIL FILTER

1

3

4

Figure 69

BS08B345

1.

2.

3.

4.

6. Use the filter wrench and turn counter clockwise to remove the oil filter.

OIL DIPSTICK FILLER CAP OIL DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a new machine, then at every 500 hours thereafter.

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

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

3. Remove bolts and engine belly pan cover.

4. Place an empty container [15 L (4 gal) capacity] under the plug. Attach the quick drain hose (4), and drain the oil into the container.

5. After draining oil, remove drain hose, and tighten drain cap securely. Remove any spilled oil.

BD07N040

Figure 71

7. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head.

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

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

9. Fill with the specified amount of oil through filler port (2) and install oil filler cap.

10. Before starting the engine, check oil level using the dipstick. The level should be between the L and H limits as shown. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

11. Install under cover to its original position.

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6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE SWING MOTOR REDUCTION OIL

1

3. Clean plug (3) with light oil and dry. Replace plug and torque to 108 Nm (80 lbf ft).

4. Remove fill plug (2) and fill with gear oil in specified quantity, referring to Lubricant and Fluid Specifications.

2

5. Check gear oil level with dip stick (1). When reading is within the specified range on the dipstick (1), clean the fill plug with light oil and wind with teflon tape. Torque plug to 69.1 ± 4.4 Nm (51 ± 3.2 lfb ft) 6. Check drained oil for metal flakes or contaminants. If any contaminants are found, call your authorized dealer.

7. Dispose of all waste according environmental regulations.

to

local

3 BS08B411

Figure 72

Change the swing motor reduction unit oil when the hour meter registers 500 hours for a new machine during run-in.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area. Place the cancellation safety lever in the locked position.

WARNING: Never work on a machine when machine oils and components are hot. Allow the machine to cool prior to performing any maintenance. Failure to comply could result in injury or death.

2. Use a container of suitable size to drain oil.

Remove plug from drain (3), and allow oil to drain.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR (INITIAL) The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil every 2000 hours thereafter.

2

WARNING: Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in injury or death.

1 Figure 73

BS08B351

1. DRAIN PORT 2. FILL PORT

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

2. When parking the machine, make certain the drain port (1) is at the bottom.

2

1 Figure 74

BS08B441

3. Remove the oil level fill plug (2) and drain plug (1) and allow the oil to drain into a suitable size container (3 L or 1 gal).

4. After completely draining oil, clean drain plug (1) with light oil and replace the plug.

5. Fill with the specified oil at the upper fill port.

When oil runs out the fill port, replace, clean and replace with fill plug.

6. Check the drained oil for metal flakes or contaminants. If any contaminants are found, contact your authorized dealer.

7. Dispose of drained oil in accordance with local environmental regulations.

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6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK AIR CONDITIONER REFRIGERANT

A

B

BS08C263

Check air conditioner charging capacity when the hour meter reaches 500 hours. Refrigerant is toxic and should only be used by a qualified air conditioner technician.

Refrigerant used is R-134a: 900 g±50 (2.0±1 lb). Use of unapproved refrigerant can cause damage to the air conditioning system.

C Figure 75

BS08B493

a. Figure (A) shows that the refrigerant volume is proper. b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and may damage pressure switch operation and the air conditioning system. c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your New Holland Construction Dealer.

4

NOTE:

• New Refrigerant HFC-134a is used in this machine. Do not mix HFC-134a with CFC-12.

3

2

• Operate the air conditioner at least once every 1

BS08492

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

week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor.

• Air Conditioning Unit should only be serviced by a qualified technician.

2. Start the engine and set engine speed to middle speed position. Turn the air condition switch (1) ON. Turn fan switch (2) to the HI position. Set temperature adjustment switch (3) to lowest temperature position. Turn switch (4) to the ON position. Close all windows and doors.

3. Check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver-dryer.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE REPLACING ENGINE AIR FILTER

2

After cleaning six times or at six month intervals, the element should be replaced at 1000 hours. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance.

1

3

NOTE: If the machine is equipped with an inner element, do not clean inner element. It must be replaced.

Figure 77

BS08B494

5. Remove the inner element (if equipped) and replace with new element. Fit the inner element (2) to connect. Replace primary element with new filter element. Make certain the filter element seals at rear. Make cer tain the arrow mar positions faces up.

Figure 76

BS08C262

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

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

3,4

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

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

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

3

1

3,4 2

3,4 2

2

3 3,4 2 1 2

BS08B440

Figure 78

Check the engine mounting bracket when the hour meter registers 1000 hours.

If there is any damage or deterioration to bracket (1) or the rubber mount (2), contact your authorized dealer.

If there is no visible damage, check the torque of bolts (3 and 4), tightening to specifications. Bolt torques for the machine can be found in Chapter 8 Specifications.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE HYDRAULIC RETURN FILTER

2 3 4 5

BS08B259

Figure 79

Replace the hydraulic return filter when the machine registers 1000 hours on the hour meter. The hydraulic return filter should be replaced every 1000 hours thereafter.

6

6

IMPORTANT: Machines equipped with breaker attachment require reduced service intervals. (250 hours). Change the hydraulic oil at 1000 hours if using a breaker.

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

2. Make certain to remove all hydraulic pressure from the system.

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

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

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

1

Figure 81

BS08B439

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

7. Take the spring (4), valve (5), element assembly, and O-ring (6) out of the tank.

8. Replace O-ring (6) and assembly (A).

IMPORTANT: Make certain side marked TOP is upward. Use care when replacing assembly, as joint (C) once in place cannot be disassembled.

9. Install element by reversing the disassembly procedure.

10. Install cover (3). Torque bolts to specified value.

See torque charts.

11. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in position to check the oil level.

Stop the engine and check the oil level adding oil, if needed.

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

ENGINE MAINTENANCE

BS08B339

Figure 80

5. Remove breaker cap and press the valve (1) several times: 5 to 7 times to bleed the hydraulic oil tank of the remaining pressure.

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The intake and exhaust manifold, the oil pan, and components, along with the turbo charger for this machine should be checked by your authorized dealer when the machine registers 100 hours on the hour meter.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE HYDRAULIC SUCTION STRAINER CLEANING

2

The hydraulic tank suction strainer should be cleaned when the engine hour meter registers 2000 hours and every 2000 hours there after.

3

4

Figure 82

BS08B259

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

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

6 Figure 84

BS08B495

5. Loosen the cap screws (2) and lock washers.

Remove cover (3). Be careful not to accidently drop bolts or nuts into the tank during this procedure.

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

5

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

1

BS08C441

Figure 85

6. Remove strainer (4) and clean with light oil or by washing. If damaged, replace.

7. Check O-rings (5) and (6) for wear or damage. If damaged, replace O-rings.

8. Insert strainer (4) into suction tube. Install cover (3) with cap screws (2) and lock washers. Torque to: 46.5 ± 4.6Nm (34 ± 3.4 lbf ft).

Figure 83

BS07N146

3. Release all pressure from the hydraulic system.

Press the valve 5 to 7 times together with the breather cap (1).

9. Start the engine and operate at low idle for 5 to 7 minutes. Operate each cylinder and swing.

Retur n the machine to the hydraulic level checking position. Stop the engine and check the hydraulic oil. If level is low, add oil.

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PILOT LINE FILTER Clean the pilot valve filter when the hour meter r e g i s t e r s 2 0 0 0 h o u r s a n d eve r y 2 0 0 0 h o u r s thereafter.

The P port of right and left pilot valves (for operation and travel) and the solenoid valve are equipped with a connector with a filter. Dirt that adheres on the filter will decrease oil flow.

3 2 1

BS08B259

Figure 86

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

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

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

Figure 87

BS08B496

3. Disconnect the hose (1), connector (2) and line filter (3).

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

5. Clean line filter with light oil.

6. Wear face protection. Use compressed air to remove any material.

7. Reassemble in reverse order.

2. Release all pressure to the hydraulic system.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE SWING MOTOR REDUCTION OIL

SWING REDUCTION LUBRICATION

1

1 2

2

Figure 88

BS08B411

Figure 89

BS08B498

3 Change the swing motor reduction unit oil when the hour meter registers 2000 hours and every 2000 hours thereafter.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area. Place the cancellation safety lever in the locked position.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area. Place the cancellation safety lever in the locked position.

2. Using a grease gun, lubricate with about 40 cc grease through grease inlet (1) of the slewing reduction gear or lubricate until grease comes from the relief valve (2).

CHECK SWING BEARING

WARNING: Never work on a machine when machine oils and components are hot. Allow the machine to cool prior to performing any maintenance. Failure to comply could result in injury or death.

2. Use a container of suitable size to drain oil.

Remove plug from drain (3), and allow oil to drain.

3

3. Clean plug (3) with light oil and dry. Replace plug and torque to 108 Nm (80 lbf ft).

2

4. Remove fill plug (2) and fill with gear oil in specified quantity, referring to Lubricant and Fluid Specifications.

5. Check gear oil level with dip stick (1). I When reading is within the specified range on the dipstick (1), clean the fill plug with light oil and wind with teflon tape. Torque plug to 69.1 ± 4.4 Nm (51 ± 3.2 lfb ft) 6. Check drained oil for metal flakes or contaminants. If any contaminants are found, call your authorized dealer.

7. Dispose of all waste according environmental regulations.

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to

4

1 BS08B499

Figure 90

Deterioration of grease may cause damage of pinion shaft and swing bearing of swing reduction unit.

Grease may be cloudy due to water contamination. If water is present, loosen bolts (1) and spring washers (2) on lower side of lower frame. Remove cover (3) and packing (4) and drain water.

NOTE: Grease change requires disassembling the upper structure. Contact your authorized dealer.

local

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR The travel reduction gear oil should be changed at 500 hours for a new machine during run-in. Change the travel reduction gear oil ever y 2000 hours thereafter.

2

WARNING: Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in injury or death.

1 Figure 91

BS08B351

1. DRAIN PORT 2. FILL PORT

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

2. When parking the machine, make certain the drain port (1) is at the bottom.

2

1 BS08B441

Figure 92

3. Remove the oil level fill plug (2) and drain plug (1) and allow the oil to drain into a suitable size container (3 L or 1 gal).

4. After completely draining oil, clean drain plug (1) with light oil and replace the plug.

5. Fill with the specified oil at the upper fill port.

When oil runs out the fill port, replace, clean and replace with fill plug.

6. Check the drained oil for metal flakes or contaminants. If any contaminants are found, contact your authorized dealer.

7. Dispose of drained oil in accordance with local environmental regulations.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE COOLANT CHANGE

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

Allow sufficient time for the engine to cool down before changing fluids.

Figure 95

BS08B537

2. RADIATOR DRAIN VALVE

3. Locate the lower cover beneath the radiator.

Figure 93

BS08B259

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

4. Remove cover to obtain access to the radiator drain hose. Place an empty container, with sufficient capacity for engine coolant, below the radiator drain hose. Turn valve counter clockwise to open drain.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

WARNING: Use extreme caution when removing the radiator cap. The coolant is under pressure when hot. Never remove the radiator cap when system is hot. allow sufficient time for machine to cool down.

1 3 Figure 96

BS08B490

3. RADIATOR DRAIN PLUG

5. Remove the engine lower covers.

6. Locate the engine coolant drain plug (3).

Remove it to drain coolant. Use a funnel with hose attached to direct the drained coolant toward the container.

Figure 94

BS08B500

1. RADIATOR CAP

2. Raise the engine cover, secure it open, and place a rag or paper towel on the radiator cap.

Slowly remove the cap (1). The system could be under pressure.

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7. After draining, close the drain valve and install the drain plug. Fill cooling system with fresh water, preferable with hot water.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 8. Keep others away from the machine. Start the engine and bring engine cooling temperature to about 90°C (194°F). Then run engine at low idle.

Remove engine drain plug, open radiator drain plug, and run fresh water into radiator until draining water comes out clear (about 10 minutes flushing is sufficient).

4

9. When flushing is completed, stop engine and turn off water. Drain engine cooling system completely. Close drain valve and install drain plug.

10. Prepare a mixture of radiator detergent according to the manufacturing specs. and pour the solution into the radiator.

11. Repeat step 8 and start the engine, and run engine at low idle for 30 minutes before draining and flushing.

12. After flushing is completed, use teflon tape on the engine drain plug for additional sealing.

Install plug and tighten securely.

Figure 97

BS08B489

4. ENGINE COOLANT RESERVOIR

18. Return throttle to low idle and stop engine. Wait about 3 minutes and check engine coolant reservoir for proper level.

13. Close the radiator drain valve.

14. Add a mixture of engine coolant according to specifications indicated in the ENGINE C O O L A N T M I X T U R E t a b l e . R e fe r t o LUBRICATION, FILTERS, AND FLUIDS section for proper system capacity.

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

NOTE:

• Change contaminated and foamy coolant with new coolant mixture as soon as possible.

• Cooling water other than long life coolant should be changed two times a year, in Autumn and Spring.

15. Install radiator cap. Start engine and run it at low idle for 5 minutes. Check and make sure there is no leakage.

16. Install engine and radiator lower covers. See Specification section for proper torque values.

17. Repeat steps 8, start the engine and run engine at high idle for 5 minutes to bleed out any air from the cooling system.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL

2

Figure 100

BS08B540

Figure 98

BS08B259

Change the hydraulic oil when the hour meter registers 5000 hours or more often if conditions so require. If using a nibbler, change the hydraulic oil when the hourmeter registers 1000 hours.

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

4. Make certain all pressure is removed from the hy d r a u l i c s y s t e m . C l e a n a r e a t o a v o i d contaminating the hydraulic system.

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

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

4

3

BS08B538

5. Press the valve (2) 5 to 7 times and bleed the remaining pressure from the hydraulic oil tank.

6. Place a container (48 L {12.7 gal.}) beneath the drain plug (1). Remove the drain plug (1) and drain the remaining oil.

1

Figure 99

BS08B539

2. Park the machine so the drain plug (1) on the hydraulic oil tank comes midway between both crawlers.

NOTE: Use caution not to drop bolts or nuts inside hydraulic tank. Do not allow fluid to come in contact with skin.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

BS08B539

Figure 101

7. Clean drain plug and reinstall it. Tighten the drain plug (1) to tightening torque 108 ± 10 Nm (80 ± 7 lbf. ft.)

1

BS08B348

Figure 102

8. Fill the hydraulic oil tank with hydraulic oil at filling port according to machine specifications.

9. Install cover (4) with bolts (2) and lock washers (3). Tightening torque: 46.5 ± 4.6 Nm (34 ± 3.4 lbf. ft.)

10. After starting the engine, run at low idle. Perform several telescopic movements of each cylinder and the swing operation. Return the machine to the hydraulic oil level check position, and check the oil level.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

ABRASION OR DAMAGE ON TOOTH POINTS AND SIDE CUTTERS Check for wear and/or looseness of bucket tooth points. Tooth point life cannot be determined only by the number of operating hours.

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

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

7

8

6 2

Figure 104

BS07N272

6. SAFETY BLOCK 7. HAMMER 8. PUNCHING TOOL

1. Using a hammer and punch, hammer out the locking pin. Take care not to damage the rubber lock pin (3).

4

3

1 2

2 5 BS07N273

Figure 103

BS07N271

1.

2.

3.

4.

5.

ADAPTER TOOTH POINT RUBBER LOCK PIN LOCKING PIN ADAPTER NOSE

Figure 105

2. Inspect the locking pin (4) and rubber lock pin (3). Replace them if the locking pin (4) is too shor t or the r ubber lock pin (3) is in poor condition.

3. Clean the surface of the adapter nose (1) with a putty knife to remove any adhered soil.

4. Fit the tooth point (2) onto the adapter nose (1).

5. Push the rubber lock pin (3) in the hole of the adapter nose (1).

6. Drive the locking pin (4) until it is aligned with the point face.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE SIDE CUTTERS

REMOVING BUCKET

1

Figure 106

BS07N274

1. Remove all sand and soil adhering around the bolts. Use an acetylene torch to cut off the bolts, then remove the side cutter.

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the bolts and nuts with new ones.

3. Tightening torque: 115±12 Nm {84.6±8.7 lbf ft} 4. After tightening the nuts, spot-weld them.

Figure 108

BS08B541

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

2. Make certain the attachment is stable. Roll O-rings on to the bucket boss. After removing the pins, place them back in the original position.

7 2 8

2 3

2 4 5

1

4 6

3 Figure 107

DC04C362

1.

2.

3.

4.

NUTS SIDE CUTTER BOLT TOOTH POINT

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

Figure 109

BS08B542

3. Extend retaining ring (2) and remove pin (3), and pull pins (4), (5) out. Remove bucket (6).

4. Keep pins clean. Do not allow dirt, sand, etc. to contaminate them. Use care not to damage dust seals on both ends of arm (7) and bucket/bucket link (8).

BS07N276

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING BUCKET

9 7

2 3

8

2 3

4

9

5 4 5 BS07N278

6

6 Figure 110

BS08B543

4. Align bucket (6) with the pin hole of arm (7), and insert pin (5).

1. Clean each pin and pin hole and grease sufficiently.

5. Insert pin (3) and fit lock ring (2).

Fit O-ring (1) to the normal position.

2. Move the bucket cylinder to match the pin bores or the bucket (6) and bucket link (8) with each other, then insert the pin (4).

6. Apply grease on the grease nipples for respective pin until the grease comes out through the gap between pins and bore.

3. Raise the boom and slightly raise the bucket from the ground.

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

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOVING A DISABLED MACHINE WARNING: Read and understand all safety precautions and procedures before attempting any operation, inspection, maintenance, or repair of this machine, any attachment or any of its systems. Failure to comply could result in injury or death.

RELEASING TRAVEL MOTOR BRAKES MANUALLY A. Tools & Equipment Required 1. Four (4) chock blocks.

2. One (1) 10 mm Allen type socket wrench.

3. One (1) 8 mm Allen type socket wrench.

4. Two (2) 2.1 liter (0.6 gal) capacity drain pans.

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

Failure to comply could result in injury or death.

GENERAL This machine incorporates automatically applied spring brake systems in the travel motors and swing motor. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine. These sections contain the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachments to the ground should sudden engine failure be experienced.

5. One (1) M10 -1.5 x 30 mm lifting eyes.

6. Overhead lifting device capable of lifting and holding 45 kg (100 lbs).

7. Torque wrench 73.4 N·m (54.2 ft-lbs) capacity or better.

8. Thread sealant (for drain and check/fill plugs), and loctite #515 for cover bolts.

9. Rubber or soft face mallet.

Procedures

Figure 111

BS08B545

CHOCK BLOCK

1. Position travel motors with drain plug down and lower attachment to ground.

2. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

WARNING: Make certain chock blocks are secure at front and rear of each track before attempting to release brakes. Never stand in the path of the tracks when releasing brakes.

3. Turn key switch to OFF position and remove key.

4. Place a clean 4 liter (1.1 gal) capacity drain pan under each travel motor drain plug.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2

1 Figure 112

BS08B441

BS08B548

5. Remove oil “FILL” and “DRAIN” plugs (1 and 2) to drain oil into the container.

Figure 115

Remove sun gear from the planetary gear assembly.

WARNING: Reduction unit may be under pressure. Remove plugs slowly.

BS08B549

Figure 113

BS08B546

Remove drain plug from each travel motor with 10 mm socket head wrench. Place a clean drain pan under each travel motor drain plug and remove the drain plug. After all oil has drained, cover drain pans to prevent contamination.

Figure 116

Install fill and drain plugs into cover plates and replace gear oil into travel reduction units through fill port to proper level.

After procedures have been performed on both travel reduction units, the machine may be towed for repairs. After repairs are complete, install the drive gear in revers order.

Torque to: Cover Bolts (M6) 13.7 ± 1.0 Nm (10.1 ± 0.7 lbf ft) Plugs 49.0 ± 4.90 Nm (72.3 ± 14.5 lbf ft) Thrust Plate Bolts 35.3 ± 2.0 Nm (26 ± 1.5 lbf ft)

Figure 114

BS08B547

Remove the plate mounting bolts from the travel motor reduction unit cover plates to expose the planetary gears. Be careful not to damage the cover plate seal or its surface lip.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING SWING BRAKE

Figure 117

BS08B550

The use of a hydraulic hand pump to release the swing brake manually when the engine fails to start is highly recommended.

WARNING: Make certain that the attachment is on the ground to help prevent sudden rotation of the upper structure before attempting to release the swing brake. Refer to “Lowering Attachment When Sudden Engine Failure Occurs” in this section.

Remove the hose on port P and install the proper connector on port P. Install the hydraulic hand pump and apply hydraulic pressure: 29 kgf/cm2 (413 psi).

IMPORTANT: In highly contaminated environments, removing the whole swing motor assembly is recommended and if a hydraulic hand pump is not available. Cover the swing reduction unit. If it becomes contaminated, flush and clean the swing reduction unit.

Tools & Equipment Required Hand tools required for removal of hydraulic tubes, hoses and fittings.

• • • • •

Plugs and caps for tubes, hoses and fittings.

10 mm allen type socket head wrench.

5 mm allen type socket head wrench.

Figure 118

BS08C442

1. Lower attachment to ground and block to avoid sudden movement. Refer to previous pages for proper procedures in lowering the attachment.

2. Remove all hoses and tubes from the swing motor top plate.

Two M10 - 1.5 x 18 mm Lifting Eye. Overhead lifting device capable of lifting and holding 45 kg (100 lbs).

• Plenty of clean, dry shop rags and/or paper towels.

• 14 mm allen type socket head wrench.

• 441 N·m (325 ft-lb) torque wrench.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING SWING BRAKE MANUALLY WITH HYDRAULIC HAND PUMP WARNING: Make certain that the attachment is on the ground to help prevent sudden rotation of the upper structure before attempting to release the swing brake. Refer to “Lowering Attachment When Sudden Engine Failure Occurs” in this section.

New Holland Construction highly recommends the use of a hydraulic hand pump to release the swing brake manually when the engine fails to start.

Figure 119

DC04B673

3. Install the proper plugs and caps onto hoses. tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

2

IMPORTANT: Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

IMPORTANT: Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

1 1

2 Figure 120

DC03M072

1. LIFTING EYES

2. COVER BOLTS

4. Remove the two (2) plugs on top of the swing motor cover and install 2 x M10 -1.5 x 18 mm eye bolts, and place a reference mark between top cover and housing.

NOTE: Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the Top Plate.

Figure 123

BS07M471

1. SWING SHOCKLESS VALVE

2. LIFTING BOLT HOLES

Code

Name

Size

Torque N·m

ft. lbs

5. Carefully loosen the four (4) top plate mounting bolts with the 17 mm socket head wrench.

A, B

Main Port

2 - PF 1/2

108

80

M

Make-up Port

PF 1/4

167

123

6. Remove two (2) top plate mounting bolts from corners opposite of each other.

DB

Drain Port

PF 3/8

74

55

PG

Brake Release Port

PF1/4

36

27

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

L

Gear Oil Level Port

PT 1/4

98

72

IP

Gear Oil Level Port

PT 3/4

98

72

Pressure PA, PB Measurement Port

PF 1/4

36

27

Figure 121 Figure 122 87490337 NA

Issued 04-08

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6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Remove the hose and install the proper connector on PG port.

2. Remove all hoses and tubes from the swing motor top plate.

Install the hydraulic hand pump to the PG port and apply 29 kgf/cm2 (413 psi) pressure.

RELEASING SWING BRAKE MANUALLY WITHOUT HYDRAULIC HAND PUMP If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed with the following procedures.

IMPORTANT: In highly contaminated environments it is recommended to remove the whole swing motor assembly. When the Swing Motor is removed, make sure to use caps and plugs on hoses, tubes, and fittings to protect the hydraulic system from any contamination. Also, a cover must be used to protect the Swing Gear compartment. If this approach is taken, and the swing gear grease bath becomes contaminated, make sure to flush and clean the swing gear compartment. Refer to LUBRICATIONS, FILTERS, AND FLUIDS Chapter 5 for proper grease and component capacity. Contact your New Holland Construction Dealer’s Service Department for assistance.

Figure 124

DC04B673

3. Install the proper plugs and caps onto hoses. tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

IMPORTANT: Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

IMPORTANT: Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

WARNING: Use safety protection such as: Hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

A. Tools & Equipment Required 1. Hand tools required for removal of hydraulic tubes, hoses and fittings.

2. Plugs and caps for tubes, hoses and fittings.

3. 10 mm allen type socket head wrench.

Figure 125

BS08B585

4. 5 mm allen type socket head wrench.

5. Two M10 - 1.5 x 18 mm Lifting Eye. 6. Overhead lifting device capable of lifting and holding 45 kg (100 lbs).

7. Plenty of clean, dry shop rags and/or paper towels.

4. Loosen the four top plate mounting bolts with the 10 mm allen wrench.

NOTE: Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the Top Plate.

8. 14 mm allen type socket head wrench.

9. 441 N·m (325 ft-lb) torque wrench.

B. Procedures 1. Lower attachment to ground and block to avoid sudden movement. Refer to previous pages for proper procedures in lowering the attachment.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BS08B587

Figure 126

DC04B587

5. Install eye bolts as indicated in figure.

6. Remove two (2) top plate mounting bolts from corners opposite of each other.

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shock valve assembly and away from the swing motor.

BS08B588

Figure 127

BS08B586

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

8. Carefully remove the remaining two (2) bolts from the top mounting plate.

NOTE: The top plate will raise from spring pressure as the last two (2) bolts are removed. Some movement of the upper frame may be experienced as the spring tension is released.

IMPORTANT: Make certain the top plate dowel pins and the distributor plate holes mesh together.

Figure 128

Figure 129

10. Carefully remove all brakes springs and place in a container filled with fresh, clean hydraulic oil.

T h e n , s e a l t h e c o n t a i n e r t o p r ev e n t contamination.

11. Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing. Use grease to hold the distributor plate on the top cover, aligned with dowel pins, before installing.

12. Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate. Slowly lower the top plate into position on the swing motor and install by hand the four (4) top plate mounting bolts 13. After the machine upper structure is positioned for towing, remove the swing motor cover again and reinstall the swing brakes springs.

14. Repeat Steps 11~13 to lock the upper frame into position for proper transportation. Make sure to use grease to hold the distributor plate on top cover before installing.

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6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BLEEDING THE PILOT SYSTEM Whenever the hydraulic system is opened for repairs, pilot line change, etc., it is highly recommended that you bleed the pilot system to prevent erratic or delayed operation of the machine functions.

Figure 132

DC04C340

3. Make sure that the throttle control is positioned in LOW idle and sound horn before starting.

Figure 130

S08B259

1. Place the machine on firm level ground and the attachment in oil level check position.

WARNING: Use a rag or paper towels on the pilot connections to protect yourself from spraying during bleeding.

5. With the engine running at low idle, loosen the pilot lines from the top side of the spools in the Control Valve, one at a time, and operate the function for the spool being bled to bleed the air out of the pilot system. Make sure to bleed each one of the spools indicated in the figure. Tighten hose connections to 50 N · m (37 ft-lb) after bleeding each line.

1

Figure 131

DC04B339

1. AIR RELEASE BUTTON

2. Depress air release button to release hydraulic tank pressure.

WARNING: Use safety protection such as: Hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

6-56

4. Start the engine and let run at low idle for about 10 minutes.

6. Make sure hydraulic oil level is within specifications, and clean up any oil spilled.

Check all connections, repair any leakage and reinstall control valve top cover.

WARNING: Avoid oil spills, use containers, rags, and/or paper towels to contain any oil leakage. Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to Government Regulations.

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87490337 NA

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

MANUAL OPERATION FOR THE RELIEVING OF HOLDING VALVE 1. Loosen the lock nut (1).

2. Rotate the thread (2) four turns clockwise to tighten. The inner spool valve will be switched. and the holding valve is relieved.

3. To activate the holding valve, rotate the thread (2) counterclockwise fully to the end. Tighten the lock nut (1).

IMPORTANT: This procedure is to be used only in an emergency if the machine is disabled. Proceed with extreme caution. Keep all unauthorized personnel away from the bucket/attachment and excavator boom.

1

2

Figure 133

BS08B589

1. LOCK NUT 2. THREAD FOR MANUAL OPERATION

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

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

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

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

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

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Figure 134

BS08B590

To lower the bucket position, proceed carefully as follows: When the bucket is in digging position (A) (bucket cylinder completely extended, see figure) disconnect hose head (H) side. When the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose rod (R) side IMPORTANT: Do not allow the hydraulic line or components to become contaminated. This could cause severe system damage to the hydraulic system. Contact your dealer to obtain the proper caps and plugs to be used.

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

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

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

Figure 135

BS07N386

LOWERING THE BOOM G ra d u a l l y l o o s e n t h e h o s e o f h e a d ( H ) s i d e connected to the boom cylinder.

Stop lowering the attachment at 30 - 40 cm (12 - 16 in.) above ground level to allow for moving the machine.

1. Tighten the hose fitting.

2. After moving the machine to the service area, slowly loosen the hose fitting to lower the attachment to the ground.

3. Contact your dealer for machine repairs

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CHAPTER 7 - ELECTRICAL

CHAPTER 7

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

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

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

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

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

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

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

87490337 NA

Issued 03-08

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

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

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87490337 NA

CHAPTER 7 - ELECTRICAL

ELECTRICAL COMPONENTS ALTERNATOR Ask your Dealer to check the alternator.

1

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

FUSES Follow this procedure to replace “blown” or “faulty” fuses.

Figure 2

BS06H104

1. Move seat and seat base completely forward.

1. FUSE BOX COVER

Open the fuse compartment and remove fuse box cover from fuse box.

2 1

3. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

WARNING: Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

4. Refer to fuse box cover or the following figure for fuse amperage and their functions.

Figure 1

BS08B591

2. Loosen four machine screws (2) used to install cover (1).

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CHAPTER 7 - ELECTRICAL

BS08C444

Figure 3

BS08C443

Figure 4

WARNING: Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

7-4

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87490337 NA

CHAPTER 7 - ELECTRICAL BATTERIES NOTE: Batteries is also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

.

WARNING:

BS06H237

Figure 6

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

WARNING: Prevent Battery Explosion: Batteries give hydrogen gases that can explode and cause personal injury.

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

Keep metallic articles away from batteries.

Keep all ventilation caps tightly secured.

Never check charge by placing metal articles across battery terminals.

Leave battery box open to improve ventilation when charging.

Figure 5

BS07M459

1. Batteries are located on the left side of the machine.

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7-5

CHAPTER 7 - ELECTRICAL 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTE: Use hydrometer manufacturer’s instruction.

according

to

its

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

7. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

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

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

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

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CHAPTER 7 - ELECTRICAL WORK LAMPS

.

.

1

4 3

2

5

6

BS07N393

Figure 7

BS07N392

A 55W bulb is used for the work lamps.

WARNING: Do not touch a lighted bulb.

Shut off lamp and allow it to cool. Make certain work lamp switch is in the OFF position. Failure to comply could cause machine damage or injury.

NOTE: The service life of a bulb is shortened if oil or grease is on the bulb at the time of installation. When replacing the bulb, hold it at the flange area. Do not touch the bulb glass with your fingers. Wipe the bulb with a clean cloth after installation.

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Issued 04-08

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7

Figure 8

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

2. Disconnect the electrical connector, then remove the work lamp from the machine with a wrench.

3. Remove screw (1), then remove rim (2) and lens (3) from the casing (4).

4. Remove spring (6) that secures the socket (5).

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

6. Assemble the work lamp using the reverse order.

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

7-7

CHAPTER 7 - ELECTRICAL

NOTES

7-8

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CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Nuts and Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 04-08

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87490337 NA

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

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

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87490337 NA

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS The specifications found in this section are given on the Standard Hydraulic Excavator as manufactured by New Holland Construction: Arm 2.13 m (7 ft. 0 in.) and bucket SAE heaped of 0.22 m3 (0.29 cubic yards.)

Measurements do not include height of shoe lug No modification or options are taken into consideration in regard to these specifications.

MACHINE DIMENSIONS

Figure 1

BS08C433

A. B. C. D. E. F. G. H. I. J. K. L. M.

Overall length with attachments ............................................................................................7060 mm (23 ft 2 in) Overall height ..........................................................................................................................2940 mm (9 ft 8 in) Overall width ...........................................................................................................................2490 mm (8 ft 2 in) Width of crawler shoe.................................................................................................................600 mm (23.6 in) Height to top of cab .................................................................................................................2740 mm (9 ft 0 in) Ground clearance..........................................................................................................................360 mm (14 in) Tail swing radius ....................................................................................................................1790 mm (5 ft 10 in) Machine length with dozer blade...........................................................................................3880 mm (12 ft 9 in) Length without attachments ....................................................................................................2860 mm (9 ft 5 in) Length to idlers........................................................................................................................2240 mm (7 ft 4 in) Rear ground clearance* ............................................................................................................730 mm (2 ft 5 in) Upper structure width ..............................................................................................................2230 mm (7 ft 4 in) Blade lift (below and above ground)................................................................. 305 mm (12 in) 475 mm (18.7 in)

The attachment is with arm 2.13 m (7 ft. 0 in) and bucket SAE heaped of 0.22 cubic m (0.29 cubic yard) attached. *Dimensions do not include height of shoe lug.

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8-3

CHAPTER 8 - SPECIFICATIONS SPEED AND GRADEABILITY 11.5 min1 (11.5 RPM)

Swing Speed

Travel Speed

Gradeability

Low (1st)

High (2nd)

2.8 km/h (1.7 mph)

5.3km/h (3.3 mph) 70% (35°)

Ground pressure............................................................................................................................28.6 kPa (4.15 psi) ENGINE Model Type Number of cylinders - Bore X Stroke Total Displacement Output Rating Maximum Torque Starting Motor Alternator

ISUZU DIESEL ENGINE AU-4LE2X Water cooled, 4 cycle type direct injection with intercooler turbo charger 4 - 88 mm X 90 mm (4 - 3.46 in. X 3.54 inch) 2.77 liters (169 cubic inch) 42.0 kW @ 2200 rpm 184 Nm (136 lb ft) @ 1800 rpm 12 V (2.3 kW) 50 amp

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston pump

Hydraulic Motor

Axial piston

Hydraulic Motor with Reducer (Travel)

2 - Axial piston, 2-speed motor

Control Valve

10- spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer) Return Filter

8-4

Double action cylinder Filter type with bypass valve (30 microns)

Issued 04-08

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87490337 NA

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE Backhoe attachment

Figure 2

DC03JK130

Item

1.87 m (6’-2") Arm + 0.22 m3 (0.29 cu yd) Bucket

Attachment

2.13 m (7’-0") Arm + 0.22 m3 (0.29 cu yd) Bucket

Maximum digging reach

7260 mm

(23 ft 10 in)

7640 mm

(25 ft 1 in)

A’

Maximum digging reach at ground level

7110 mm

(23 ft 4 in)

7500 mm

(24 ft 7 in)

*B

Maximum digging depth

4430 mm

(14 ft 6 in)

4700 mm

(15 ft 5 in)

*C

Maximum digging height

6780 mm

(22 ft 3 in)

7240 mm

(23 ft 9 in)

*D

Maximum damping clearance

4770 mm

(15 ft 8 in)

5190 mm

(17 ft 0 in)

*E

Minimum damping clearance

1970 mm

(6 ft 6 in)

1840 mm

(6 ft 0 in)

*F

Max. vertical wall digging depth

3230 mm

(10 ft 7 in)

3810 mm

(12 ft 6 in)

G

Minimum swing radius

2560 mm

(8 ft 5 in)

3130 mm

(10 ft 3 in)

*H

Height at min. swing radius

5400 mm

(17 ft 9 in)

5430 mm

(17 ft 10 in)

*J

8 feet level digging depth

4000 mm

(13 ft 1 in)

4360 mm

(14 ft 4 in)

K

Horizontal digging stroke at ground level

Stroke

3190 mm

(10 ft 6 in)

3350 mm

(10 ft 8 in)

Minimum

2360 mm

(7 ft 9 in)

2690 mm

(8 ft 10 in)

A

L

* Dimensions do not include height of shoe lug 87490337 NA

Issued 04-08

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8-5

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE - FACE SHOVEL Face shovel attachment

Figure 3

BS08B593

Item

1.87 m (6’-2") Arm + 0.22 m3 (0.29 cu yd) Bucket

Attachment

2.13 m (7’-0") Arm + 0.22 m3 (0.29 cu yd) Bucket

Maximum digging reach

7340 mm

(24 ft 1 in)

7720 mm

(25 ft 4 in)

A’

Maximum digging reach at ground level

7200 mm

(23 ft 7 in)

7580 mm

(24 ft 10 in)

*B

Maximum digging depth

4510 mm

(14 ft 10 in)

4780 mm

(15 ft 8 in)

*C

Maximum digging height

6920 mm

(22 ft 8 in)

7350 mm

(24 ft 1 in)

*D

Maximum damping clearance

4780 mm

(15 ft 8 in)

5250 mm

(17 ft 3 in)

*E

Minimum damping clearance

4230 mm

(13 ft 11 in)

4460 mm

(14 ft 8 in)

*F

Max. vertical wall digging depth

1890 mm

(6 ft 2 in)

1760 mm

(5 ft 9 in)

G

Minimum swing radius

2560 mm

(8 ft 5 in)

3130 mm

(10 ft 3 in)

*H

Height at min. swing radius

5400 mm

(17 ft 8 in)

5430 mm

(17 ft 10 in)

*J

8 feet level digging depth

4090 mm

(13 ft 5 in)

4460 mm

(14 ft 8 in)

K

Horizontal digging stroke at ground level

Stroke

2250 mm

(7 ft 5 in)

2710 mm

(8 ft 11 in)

Minimum

4830 mm

(15 ft 10 in)

4750 mm

(15 ft 7 in)

A

L

* Dimensions do not include height of shoe lug

8-6

Issued 04-08

Bur

87490337 NA

CHAPTER 8 - SPECIFICATIONS Type

Grouser Shoes

Specifications

Use

Flat Shoes

Rubber Shoes

450 mm (17.7”)

600 mm (23.6")

450 mm (17.7")

450 mm (17.7")

For General Soil (Standard)

For Soft Soil (Optional)

For Soft Soil (Optional)

For Soft Soil (Optional)

Working Weight

kg

8360

8590

8550

8270

Height to Top Cab

mm

2740

2740

2740

2740

Ground Clearance of Under carriage

mm

360*

360*

360*

360*

Basic Machine Length

mm

3880

3880

3880

3880

Overall Length of Crawler

mm

2860

2860

2860

2860

Overall Width of Crawler

mm

2490

2490

2490

2490

Ground Pressure

kPa

37.1

28.6

38.0

36.7

87490337 NA

Issued 04-08

Bur

8-7

CHAPTER 8 - SPECIFICATIONS BUCKET AND ARM COMBINATIONS Front attachment: The machine is equipped with attachments of various types. When a large capacity bucket is used, it should be used with short lift arms for stability. When an extended reach arm is used, use a smaller capacity bucket.

NOTE: If any other bucket is used (non-approved) when turning over and using for excavation, damage to the arm and bucket may occur. Install only approved attachments recommended by New Holland on the machine. New Holland is not liable for any damage to the machine or attachment arising from the use of unapproved/specified attachments.

Type

Bucket (m3) (cu•yd)

Outside width of bucket (mm)

SAE SAE With side (Heape (Struck) cutters d)

Use as shovel

Without side cutters

No of Teeth

1.87 m Arm

2.13 m Arm

Arm

Weight

1.87 m

2.13 m

0.11 (0.14)

0.09 (0.11)

—

400

3

Yes

Yes

150

General Operation

General Operation

0.14 (0.18)

0.12 (0.16)

480

410

3

Yes

Yes

160

General Operation

General Operation

0.18 (0.23)

0.14 (0.18)

550

480

3

Yes

Yes

170

General Operation

General Operation

0.22 Hoe Bucket (0.29)

0.18 (0.24)

650

580

4

Yes

Yes

190

General Standard Operation Combination

0.28 (0.37) (STD)

0.21 (0.27)

750

680

4

Yes

Yes

210

0.35 (0.46)

0.26 (0.34)

850

780

4

Yes

Yes

220

Light Operation

0.35 0.26 (0.46) (0.34) side pin

850

780

4

Yes

Yes

210

Light Operation

Prohibited

Standard Light Combination Operation

Prohibited

Breaker

—

—

—

—

—

—

—

—

General Operation

General Operation

Nibbler

—

—

—

—

—

—

—

—

General Operation

General Operation

8-8

Issued 04-08

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87490337 NA

CHAPTER 8 - SPECIFICATIONS BUCKET SELECTION CHART

Application

General Purpose

Heavy Duty

Arm

Capacity m3 (yard3)

Width m (inches)

Weight kg (lbs)

0.23 (0.175)

0.457 (18)

153 (337)

H

0.26 (0.198

0.508 (20)

163 (360)

H

0.33 (0.252)

0.609 (24)

182 (400)

H

0.43 (0.328)

0.762 (30)

209 (459)

M

0.53 (0.405)

0.914 (36)

244 (537)

L

0.23 (0.175)

0.457 (18)

206 (454)

H

0.26 (0.198

0.508 (20)

216 (476)

H

0.33 (0.252)

0.609 (24)

240 (527)

M

0.43 (0.328)

0.762 (30)

291 (641)

L

0.914 (36)

335 (737)

X

0.53 (0.405) kg/m3

2.07 m (6’ 9”)

lb/yrd3).

H - Used with material weight up to 1,780 (3,000 M - Used with material weight up to 1,483 kg/m3 (2,500 lb/yrd3).

L - Used with material weight up to 1,186 kg/m3 (2,000 lb/yrd3).

X - Not recommended.

87490337 NA

Issued 04-08

Bur

8-9

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radius and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

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

5. Capacities apply to the machine as originally manufactured and normally equipped by the manufacturer.

IMPORTANT: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. Example: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then the additional 100 kg (220 lbs) must be subtracted from every value indicated in the Lifting Chart accordingly.

2. If a larger bucket than indicated is used (heavier weight) then the additional weight must be subtracted from every value indicated in the Lifting Chart accordingly.

3. If a smaller bucket than indicated is used (lighter weight), then the difference between the charted bucket and the lighter weight bucket can be added to every value indicated in the Lifting Chart accordingly.

Figure 4

BS08B595

Lifting Capacities Chart Legends: A - Reach swing center line to bucket hook (Load Radius).

B - Bucket hook height above/below ground.

C - Lifting capacities in pounds (lb) and kilograms (kg).

Front Lifting.

8-10

Side Lifting.

Issued 04-08

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87490337 NA

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 2.13 M ARM, 0.22 M3 BUCKET, 600 MM TRIPLE GROUSER SHOES Lifting Capacities based on machine with: Arm: 7 ft. 0 in. (2.13 m) Bucket: 0.37 yd3 (0.28 m3) Shoes: 23.6” (600 mm) triple grouser shoe A

5’ 0” (1.5 m)

10’ 0” (3.0 m)

15’ 0” (4.6 m)

20’ 0”(6.1 m)

B

C

20' (6.1 m)

lb kg

15' (4.6m)

lb kg

* 3240 * 1470

3240 1470

10' (3.0m)

lb kg

* 3920 * 1780

3910 1770

2770 1260

2370 1070

5' (1.5m)

lb kg

8100 3670

6620 3000

4220 1910

3580 1620

2640 1200

2250 1020

GROUND LEVEL

lb kg

7430 3370

6010 2720

3930 1780

3300 1490

2520 1490

2130 960

-5' (-1.5m)

lb kg

* 9270 * 2840

* 6270 * 2840

7360 3330

5950 2700

3810 1730

3190 1440

-10' (-3.0m)

lb kg

* 10690 * 4840

* 10690 * 4840

* 7290 * 3310

6120 2770

3910 1770

3280 1480

STANDARD LIFT - MACHINE WITH 2.13 M ARM, 0.22 M3 BUCKET, 600 MM TRIPLE GROUSER SHOES Lifting Capacities based on machine with: Arm: 7 ft. 0 in. (2.13 m) Bucket: 0.29 yd3 (0.22 m3) Shoes: 23.6” (600 mm) triple grouser shoe

A

5’ 0” (1.5 m)

10’ 0” (3.0 m)

15’ 0” (4.6 m)

20’ 0” (6.1 m)

B

C

20' (6.1 m)

lb kg

15' (4.6m)

lb kg

* 3240 * 1470

* 3240 * 1470

10' (3.0m)

lb kg

* 3920 * 1780

3910 1770

2770 1260

2370 1070

5' (1.5m)

lb kg

8100 3670

6620 3000

4220 1910

3580 1620

2640 1200

2250 1020

GROUND LEVEL

lb kg

7430 3370

6010 2720

3930 1780

3300 1490

2520 1140

2130 1010

-5' (-1.5m)

lb kg

* 6270 * 2840

* 6270 * 2840

7360 3330

5950 2700

3810 1730

3280 1440

-10' (-3.0m)

lb kg

* 10690 * 4840

* 10690 * 4840

* 7290 * 3310

6120 2770

3910 1770

3280 1480

87490337 NA

Issued 04-08

Bur

8-11

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

CAPSCREWS & NUT METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES Make certain to tighten all Capscrews & Nuts to proper torque values.

Metric Coarse Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

1.77 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1)

14.6 ± 1.5 (105 ± 10.8)

12.3 ± 1.2 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6)

12.8 ± 1.3 (92.5 ± 9.4)

10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50.5 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

TORQUE VALUE UNIT: kgf (ft-lbs)

8-12

Issued 04-08

Bur

87490337 NA

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES Tighten all Capscrews & Nuts to proper torque values.

Metric Fine Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M8

P=1

1.15 0.11 (8.3 ± 0.8)

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190)

212 ± 21 (1530 ± 150)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ±43 (3090 ± 310)

357 ± 36 (2580 ± 260)

TORQUE VALUE UNIT: kgf (ft-lbs)

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

Hose mouth ring and Coupling

87490337 NA

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf·m (ft-lbs)

1 - 14 UNS

30 - 32

14 ± 1.4 (101 ± 10)

1 - 3/16 12 UN

36 - 41

18 ± 1.8 (130 ± 13)

1 - 7/16 12 UN

41 - 46

21 ± 2.1 (152 ± 15)

Issued 04-08

Bur

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

8-13

CHAPTER 8 - SPECIFICATIONS NUTS & SLEEVES Nuts and Sleeves

MANUFACTURER’S NAME

WORKING PRESSURE kgf/cm2 (psi)

350 (4980) Travel line only

NIPPON A.M.C.

350 (4980) Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS Flare Type Fitting Joints

TUBE SIZE O.D. X THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE kgf·m (ft-lbs)

10 X 1.5 (0.394 X 0.059)

19

4.5 ± 0.5 (33 ± 4)

15 X 2.0 (0.591 X 0.079)

27

15 ± 2 (108 ± 14)

18 X 2.5 (0.709 X 0.098)

32

18 ± 2 (130 ± 14)

22 X 3.0 (0.866 X 0.118)

36

22 ± 2 (159 ± 14)

28 X 4.0 (1.10 X 0.157)

41

28 ± 3 (203 ± 22)

35 X 5.0 (1.38 X 0.20)

55

35 ± 4.5 (253 ± 29)

N2 (NYLON) TUBE FITTING JOINTS N2 (Nylon) Tube Fitting Joints

Overtightening of flare type (Union Nut Type) metal joints may cause damage to nuts, seat surfaces, and prevent optimum sealing resulting in oil leaks.

NOMINAL SIZE (PIPE THREAD)

TORQUE VALUE

1/4”

2.5 ± 0.3 (18.1 ± 1.8)

3/8”

5 ± 0.5 (36.2 ± 3.6)

1/2”

6 ± 0.6 (43.4 ± 4.3)

3/4”

12 ± 1.2 (86.8 ± 8.7)

1”

14 ± 1.4 (101 ± 10)

1-1/4”

17 ± 1.7 (123 ± 12)

1-1/2”

21 ± 2.1 (152 ± 15)

2”

42 ± 4.2 (304 ± 30) Unit: kgf·m (ft.-lbs)

8-14

1. Clean Tube and make sure certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

Issued 04-08

Bur

87490337 NA

CHAPTER 8 - SPECIFICATIONS TORQUE VALUES FOR MOST COMMON BOLTS [Bolt Size] Units: kgf (ft-lbs) Location

Qty 5

Fuel Tank sending unit mounting

[M5] 0.2 ± 0.01 (1.4 ± 0.1)

6

A/C condenser mounting

[M6x50] 0.46 (3.3)

1

Hyd. tank sending unit mounting

15 ± 2 (108 ± 14)

6

A/C pulley mounting on damper

[M8x16] 4 (29)

4

Coolant reservoir mounting

1.1 ± 0.1 (8 ± 0.7)

4

A/C compressor mounting

[M8x100] 1.1 ± 0.1 (8 ± 0.7)

1

A/C idler pulley nut

[M10] 4 - 5.5 (29 - 40)

2

Pilot pump mounting bolts

[M10] 4 ± 0.4 (29 ± 3) Apply Loctite # 262

8

Hydraulic oil tank cover mounting

[M10] 4.7 ± 0.6 (34 ± 4)

2

Swing grease bath inspection cover mounting

[M10} 3 ± 0.6 (22 ± 4)

8

Swivel joint dust cover mounting

[M10} 1.5 ± 0.3 (11 ± 2)

6

Muffler support bracket mounting

[M10] 4 ± 0.4 (30 ± 3)

16

Engine mounting (engine body side)

[M10] 6.6 ± 0.4 (48 ± 3) Apply Loctite # 262

4

Travel lever mounting

[M10] 2.4 ± 0.3 (17 ± 2)

3

Stepping motor mounting

[M10] 1.9 (14) Apply Loctite # 242

12

Hydraulic pump housing to engine block mounting

[M10] 6.6 ± 0.6 (48 ± 4) Apply Loctite # 262

35

Lower cover mounting

[M10] 5.3 ± 0.6 (38 ± 4)

2

A/C compressor cover mounting

[M10x45] 6.2 (45)

10

Travel motor cover mounting

8.4 ± 0.8 (61 ± 6) Apply Loctite # 262

16

Cab support mounting bolts

4.7 (34)

3

Swivel joint mounting

11 ± 1 (79 ± 7) Apply Loctite # 262

4

Nuts for cab mounts

19 (137)

4

Idler and idler adjuster connection

[M16] 28.5 ± 3 (206 ± 22) Apply Loctite #262

4

Hydraulic oil tank and fuel tank mounting

[M16] 22 ± 2 (159 ± 14) Apply Loctite # 262

4

Radiator bottom support mounting

[M12] 12.3 ± 1.2 (89 ± 9)

1

Swivel joint locking nut

[M16] 15.9 ± 2 (115 ± 14)

8

Hydraulic pump coupling mounting

[M16] 22 ± 1 (159 ± 7) Apply Loctite # 262

8

track guide mounting

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Engine mounting (Upper frame side)

[M18] 23 ± 2 (166 ± 14) Apply Loctite # 271

44

Sprocket mounting

[M18] 40.4 ± 4(292 ± 29) Apply Loctite # 262

56

Lower roller caps

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Hydraulic pump mounting

[M20] 44 ± 4 (318 ± 29) Apply Loctite # 262

12

Swing reduction unit mounting

[M20] 55 ± 6 (397 ± 43) Apply Loctite # 262

36

Swing bearing inner race mounting

[M20] 57.4 ± 5.8 (415 ± 42) Apply Loctite # 262

33

Swing bearing outer race mounting

[M20] 40 ± 4 (289 ± 29) Apply Loctite # 262

184

Shoe bolt mounting

[M20] 86.8 ± 5 (628 ± 36)

4

Upper roller mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

34

Travel motor mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

4

Counterweight mounting

130 ± 13 (939 ± 94) Apply Loctite # 242

8

Side cutter mounting

[M24] 95 - 105 (686 - 758)

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CHAPTER 8 - SPECIFICATIONS [Bolt Size] Units: kgf (ft-lbs) Location

Qty 2

Idler adjuster grease fitting mounting

[5/8”-18UNF] 5.9 ± 1 (43 ± 7)

2

Connector for heater hoses

2.5 (18) Apply three bond # 1110B

1

Nut on breather valve

1 - 1.4 (7 - 10)

4

Breather mounting bolts

0.48 (3.5)

1

Hydraulic tank plug

16.5 (119) Apply teflon tape

4

Top nuts for U-bolts muffler mounting

1.1 ± 0.1(8 ± 1)

4

Bottom nuts for U-bolts muffler mounting

0.9 ± 0.1 (6.5 ± 1)

1

Engine temperature sensor

2.5 ± 0.6 (18 ± 4) Apply three bond # 1110B

2

A/C hose connection on Compressor

2.4 ± 0.2 (17 ± 1.4)

2

A/C hose connection on Condenser

1.0 ± 0.1 (7.2 ± 0.72)

4

Cover mounting on swing motor

[M20] 43.8 (317)

1

Swing reduction unit oil plug

5.7 (41) Apply teflon tape

2

Oil plugs on travel reduction unit cover

5.7 (41) Apply teflon tape

WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted & broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

Material (Loose Weight)

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CHAPTER 8 - SPECIFICATIONS CONVERSION UNITS UNITS OF WEIGHT Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

UNITS OF LENGTH Units of Length From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

UNITS OF POWER Units of Power From

Into

Multiply by

HP

kW

0.7457

kW

HP

1.341

UNITS OF FLOW Units of Flow Into

Multiply by

Lit/min

3.79

Lit/sec

0.0631

From

Gal/min (US liquid)

Liter/min

cm

3/min

3785.4

ft3/min

0.1337

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

87490337 NA

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgfm

0.1382552

N·m

1.35582

lbf-in

12

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8-17

CHAPTER 8 - SPECIFICATIONS Units of Pressure

Units of Volume

Units of Pressure From kg/cm2

psi

MPa (MegaPascal)

Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

Bars

0.06895

kg/cm2

0.0703

Pa (Pascal)

6894.76

psi

145.04

Units of Volume From

Liters

Multiply by

Gal (US Liquid)

0.264

in3

61.02

yard

3

3

0.00131

quarts

1.0567

ounces (US)

33.81

m3

0.765

3

46656

3

27

in Yard

8-18

Into

ft

cm3

764554.9

liters

764.555

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Alternator ............................................................. 7-3 Arm Operation ................................................... 4-15

B Back Filling & Leveling with Front Attachment .. 4-19 Basic Operation of Hydraulic Controls ............... 4-10 Batteries .............................................................. 7-5 Before Operating the Hydraulic Breaker ............ 4-22 Before Operating the Machine ............................. 4-3 Bleeding the Pilot System .................................. 6-56 Boom Operation ................................................ 4-15 Bucket ................................................................ 6-47 Bucket Operation ............................................... 4-16 Bucket Selection Guide ..................................... 4-22 Burn Prevention ................................................... 2-8 Buzzer Stop Switch ........................................... 3-13

C Cab Dome Light .......................................... 3-5, 3-23 Cab Door Latch ................................................... 3-3 Cleaning Parts ..................................................... 6-4 Cleaning Sand & Soil from Bucket .................... 4-18 Components & Controls Nomenclature ............. 3-11 Connecting Booster Cable ................................... 4-5 Control Decal ....................................................... 4-9 Counter Rotating Machine ................................. 4-12

D Decals ................................................................ 2-10 Disposal of Hazardous Waste ............................. 6-3 Document Pouch .......................................... 3-3, 3-8

Frame Structure ...................................................6-5 Fuel Cap ...............................................................3-9 Fuel Filter Cumulative Time ...............................3-16 Fuel Handling Precautions ...................................2-8 Fuel Level ...........................................................6-13 Fuses ....................................................................7-3

G General Information ..............................................1-1 Ground Transportation .......................................4-30 Guidelines for Attachment Lubrication .................6-7 Guidelines to Replace Ground Tools ...................6-7

H Hand Signals ......................................................2-27 Hazardous Chemical Precautions ........................2-8 Heavy Lift - with 600 mm Triple Grouser Shoes .8-11 Hot Surface & Fluids ............................................6-3 How to Handle Life Hammer ................................2-9 Hydraulic Breaker ...............................................4-22 Hydraulic Filter Cumulative Time .......................3-16 Hydraulic Oil Cumulative Time ...........................3-16 Hydraulic Oil Leaks ............................................6-16 Hydraulic Oil Level .............................................6-15

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

K Keep Machine Clean ............................................6-3 Key Switch ..........................................................3-11

E

L

Engine ................................................................. 1-4 Engine Coolant Change .................................... 6-43 Engine Coolant Level ........................................ 6-12 Engine Cover ....................................................... 3-9 Engine Electrical ................................................ 6-13 Engine Fluid Leaks ............................................ 6-13 Engine Lubrication Cumulative Time ................. 3-16 Engine Oil Level ................................................ 6-18

L.C.D. Display ....................................................3-16 Lifting Capacities ................................................8-10 Locking/Unlocking Cab Door ................................3-3

F Fire Extinguisher .................................................. 2-8 Fire Prevention .................................................... 2-8 Flare Type Fitting Joints .................................... 8-14 87490337 NA

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M Machine Attachment and Swing .........................4-15 Machine Components ..........................................1-3 Machine Dimensions ............................................8-3 Machine Electrical ..............................................6-17 Machine Operation in Adverse Weather Conditions .

4-20 Machine Storage ................................................4-32 Machine Travel Controls ....................................4-11 Machine Warm Up ................................................4-7 9-1

CHAPTER 9 - INDEX Maintenance Precautions .................................... 2-7 Manual Warm Up ................................................. 4-7 Metric Coarse Thread Standard Tightening Torque Values ......................................................... 8-12 Metric Fine Thread Standard Tightening Torque Values ......................................................... 8-13 Model, Serial Number, and Year of Manufacture 1-4 Monitor ............................................................... 3-12 Mounting and Dismounting Precautions .............. 2-5

N N2 (Nylon) Tube Fitting Joints ........................... 8-14 Nibbler/Breaker .................................................. 4-23 Nuts & Sleeves .................................................. 8-14

O Opening and Closing Sunroof ............................. 3-5 Opening and Closing Windshield ........................ 3-4 Operate Boom Smoothly ................................... 4-17 Operating Both Travel Levers Together ............ 4-11 Operating Pattern ................................................ 4-9 Operating Pattern Decal ...................................... 4-9 Operating Precautions ......................................... 2-6 Operating the machine ........................................ 4-3 Operating the Shovel ................................ 4-19, 4-20 Operation at Seashore or Salty Climate ............ 4-21 Operation in Extreme Cold ................................ 4-20 Operation in Extreme Heat ................................ 4-20 Operation in High Altitudes ................................ 4-21 Operation in Humid Climate .............................. 4-21 Operation in Sandy and Dusty Areas ................ 4-21 Operator Cab Nomenclature ............................. 3-11 Operator Precautions .......................................... 2-5 Operator Seat Adjustments ................................. 3-7 Operator’s Compartment Controls and Accessories .

3-10 ORS Joint (O-ring Sealing Type ........................ 8-13

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

R Radio ................................................................. 3-25 Releasing Hydraulic System Pressure ................ 6-6 Releasing Swing Brake Manually With Hydraulic Hand Pump ................................................. 6-53 Releasing Swing Brake Manually Without Hydraulic Hand Pump ................................................. 6-54 Releasing Travel Motor Brakes Manually .......... 6-50 9-2

Removing and Storing Lower Front Window ........3-4 Removing Machine from Storage .......................4-32 Required Filters ....................................................5-4 Required Fluids/Lubricants and Capacities ..........5-3 Right Hand Operator Console and Monitor ........3-11 Right, Left, Front, and Rear of the Machine .........1-2 Roll-Over Protective Structure (If equipped) ........2-8

S Safety Area ...........................................................2-3 Safety Rules .........................................................2-3 Screen Change Switch ............................. 3-14, 3-22 Seals & O-Rings ...................................................6-4 Seat Belt Precautions ...........................................2-9 Seat Height Adjusment .........................................3-7 Seat Reclining Adjustment ...................................3-7 Securing Machine to Trailer ...............................4-31 Selection of the Hydraulic Breaker .....................4-22 Specific Precautions to this Machine ....................2-9 Starter Motor ........................................................7-3 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) .....................4-4 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) ......................4-5 Starting and Stopping Precautions .......................2-5 Starting Boosting Machine Engine .......................4-6 Starting Disabled Machine Engine .......................4-6 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable .......4-5 Steps and Handrails ...........................................6-17 Stop Engine ..........................................................6-4 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Operation .................................................4-16

T Throttle Potentiometer ........................................3-11 Torque Values For Most Common Bolts ............8-15 Tracks and Components ....................................6-19 Transportation ....................................................4-30 Transporting Precautions .....................................2-8 Travel Independent Mode Display ......................3-16 Travel Safety ......................................................4-13 Travel Speed Select Switch ...............................3-15

U Units of Flow .......................................................8-17 Units of Length ...................................................8-17 Units of Power ....................................................8-17 Units of Pressure ................................................8-18 Units of Torque ...................................................8-17 Units of Volume ..................................................8-18 Issued 04-08

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CHAPTER 9 - INDEX Units of Weight .................................................. 8-17 Use Arm in Action .............................................. 4-17 Use of Optional Attachment ............................... 4-22 Utility Safety ......................................................... 2-4

W Warm Engine Oil ................................................. 6-4 Warming of Hydraulic Oil ..................................... 4-8 Warming Up of Engine ........................................ 4-7 Wear Safety Equipment ....................................... 6-4 Welding Safety .................................................... 6-5 Wiper Switch ...................................................... 3-13 Work Mode Switch ...................................... 3-12, 4-8

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9-3

CHAPTER 9 - INDEX

9-4

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