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OPERATORS MANUAL

COMPACT CRAWLER EXCAVATOR

CX36B
TIER 4

READ, UNDERSTAND, AND FOLLOW ALL SAFETY


PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS
MANUAL BEFORE OPERATING THE MACHINE.
Bur Issued 01Jan 08
Printed in U.S.A. Book/Form Number 87722071 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 01-2008
REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Jan 08

CX36B Tier 4 Compact Crawler Excavator

87722071 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:

Is instructed in safe and proper use of the machine.

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

Reads and understands ALL Safety Decals on the machine.

Clears the area of other persons.

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job
site.
It is your responsibility to observe pertinent laws and regulations and follow 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
Operators Manuals, Parts Catalogs, Service Manuals, and maintenance records.
Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your
machine so your Dealer can provide the correct manuals for your machine.
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..

TABLE OF CONTENTS
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
Cap and Key Cover - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Stop Engine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
CHAPTER 3
INSTRUMENTS AND CONTROLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operators Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHAPTER 4
OPERATING INSTRUCTIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Starting and Stopping Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting and Stopping Machine Engine in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
CHAPTER 5
LUBRICATION, FILTERS, AND FLUIDS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CHAPTER 6
MAINTENANCE AND ADJUSTMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
50 hour maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
87722071 NA

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


1500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

II

Issued 01-08

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87722071 NA

CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION
TO THE OWNER
CX36B COMPACT CRAWLER EXCAVATOR - TIER 4

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety
regulations. The risk of accidents can never be completely excluded. That is why it is essential to observe
elementary safety rules and precautions.
Read this manual carefully, paying particular attention to the instructions concerning safety, operation and
maintenance so as to avoid the risk of injury while operating or servicing the machine.
The standard attachments and tools of this machine are designed to carry out all kinds of earth moving and
rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure
that it is equipped to carry out this kind of work. For this type of application, the machine must be equipped with
safety valves, a load handling chart corresponding to the type of machine and its attachment and a load fixing
point. All legal requirements must also be strictly observed.
Do not use this machine for any application or purpose other than those described in this manual. If the machine is
to be used for work involving the use of special attachments, accessories or equipment, consult your Case Dealer
in order to make sure that any adaptations or modifications made are in keeping with the machine's technical
specifications and with prevailing safety requirements.
Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial
conformity with safety requirements.
The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult
your authorized Case 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 Case Dealer.
Your Case Dealer is available for any further information. They will also provide any after-sales service you may
need, and genuine Case spare parts, your guarantee of quality and match.

87722071 NA

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1-1

CHAPTER 1 - GENERAL INFORMATION

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE


The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen
from the operator's seat when the cab is over the idler wheels.
The following illustration shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is
over the idler wheels. The travel reduction gears are at the rear of the upper structure.

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

Issued 01-08

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87722071 NA

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

33

32

30
31
36

15
16
17

34

8
18
12

35
37

19

13

3
5
4
6
1

14
11
29
20
7
28
27
24
25

26
23

10
21
22

9
Figure 2

BS07M601

MACHINE COMPONENTS

1.
2.
3.
4.
5.
6.
7.

ENGINE
OIL FILTER
RADIATOR
RESERVOIR TANK
AIR CLEANER
MUFFLER
FUEL TANK

11.
12.
13.
14.
15.
16.
17.

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

21.
22.
23.
24.
25.
26.
27.

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

8. HYDRAULIC TANK

18. THROTTLE LEVER

28. DOZER BLADE

9. HYDRAULIC PUMP

19. MONITOR PANEL

29. DOZER CYLINDER

20. BATTERY

30. BOOM

10. SWING MOTOR

87722071 NA

Issued 01-08

Bur

31.
32.
33.
34.
35.
36.
37.

BOOM CYLINDER
ARM CYLINDER
WORK LAMP
ARM
LINK
BUCKET CYLINDER
BUCKET

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS
MODEL, SERIAL NUMBER, AND YEAR OF
MANUFACTURE

ENGINE

When ordering par ts, obtaining infor mation or


assistance, always supply your Case Dealer with the
t y p e a n d s e r i a l n u m b e r o f yo u r m a c h i n e o r
accessories.
Write the following in the spaces below: The type,
serial number and year of manufacture of your
machine, accessories and the serial numbers of the
various hydraulic and mechanical components.

Figure 4

BS07M603

ENGINE

Make and Model

Serial Number

Figure 3

BS07N400

PRODUCT IDENTIFICATION PLATE

COMPONENT SERIAL NUMBERS

COMPONENT SERIAL NUMBERS


Model

Hydraulic Pump
Serial Number

Swing Reduction Gear


Manufacturing Year

Travel Reduction Gears

Travel Control Valve

Attachment Control Valve

Swing Control Valve

1-4

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS


TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom and Arm Movement - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Controls - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Surfaces - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressurized Fluids and Lubricants - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counterweight Swing Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
track Tension Adjuster - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keep Clear of Working Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Lock Lever - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Falling Front Window - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Check Position - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Engine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Confirm Attachment Movement- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate This Machine- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24
2-24
2-24
2-24
2-24
2-24
2-25
2-25

Issued 01-08

Bur

87722071 NA

2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-2

Issued 01-08

Bur

87722071 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

2
Figure 1

BS06H091

Figure 2

BC02N198

1. OPERATORS 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.
87722071 NA

Issued 01-08

Bur

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


UTILITY SAFETY
Safety precautions MUST be followed when working
near buried and overhead Utility Lines.
During operation it is likely that you will be working
around or near buried or overhead utility lines which
may include, but are not limited to:

Electrical Power Line


Gas Line
Water Line
Communication Line - Telephone or Cable
Television

Telephone or Cable Television


IMPORTANT: Before beginning any machine
operation, it is your responsibility to be aware of all
such utility lines buried and overhead in the area of
your project and to avoid them.
ALWAYS have all local utility companies mark the
location of their lines.
In U.S.A. and Canada call one of many One Call
System 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 01-08

Bur

87722071 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 manufacturers 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 machines 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 Operators 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


manufacturers 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.

operators seat.

Do not bypass the machines 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 operators 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.

87722071 NA

Issued 01-08

Bur

2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


OPERATING PRECAUTIONS

Check brakes, steering and other machine control


devices in accordance with the manufacturers
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 01-08

Bur

87722071 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 manufacturers
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 manufacturers 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 operators 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.

87722071 NA

Issued 01-08

Bur

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 01-08

Bur

87722071 NA

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.

Never smoke while refueling.


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

Do not use swinging force of the machine for


operations.

Do not perform hammering operation with the

bucket.

Do not use this machine for anything other than its


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 machines 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.

87722071 NA

Issued 01-08

Bur

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS
WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean
and replace damaged decals as necessary.
CE-NA000

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that
are destroyed, lost, painted over or no longer legible, with new ones. When parts bearing decals are
replaced, be sure to put new decals on each new part.
CE-NA000

NOTE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.
NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on
all decals for the machine, consult your authorized dealer.
NOTE: Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:

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

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

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

The first panel indicates the nature of the hazard.


The second panel indicates the appropriate avoidance of the hazard.
Background color is YELLOW
Prohibition symbols such as

2-10

and

STOP

if used are RED.

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


BOOM AND ARM MOVEMENT - CAUTION
Located on seat stand cover - Part Number YN20T01013P1

Figure 7

BS08A058/BS07M647

HYDRAULIC OIL - WARNING


Located on hydraulic tank- Part Number PW20T01007P1

Figure 8

BS07M639/PW20T01007P1

87722071 NA

Issued 01-08

Bur

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 9

BS08A058/BS07M647

HOT SURFACES - CAUTION


Located on engine door hinge - Part Number YN20T01220P1

Figure 10

BS07M640/YN20T01220P1

2-12

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


PRESSURIZED FLUIDS AND LUBRICANTS - WARNING
Located on radiator duct - Part Number PW20T01094P1

Figure 11

BS07M444/PW20T01094P1

ENGINE STOP - CAUTION


Located on hood support- Part Number YN20T01012P1

Figure 12

BS07M444/BS07M448

87722071 NA

Issued 01-08

Bur

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


COUNTERWEIGHT SWING AREA - DANGER
Located on radiator cover- Part Number PE2T01014P1

Figure 13

BS07M646/BS06J055

ENGINE STOP - CAUTION


Located on engine radiator- Part Number YN20T01009P1

Figure 14

BS07M606BS07M649

2-14

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 15

BS07M641/BS07M650

TRACK TENSION ADJUSTER - WARNING


Located on crawler frame - Part Number 243T6110

Figure 16

BS07M645/BS07M651

87722071 NA

Issued 01-08

Bur

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 17

BS07M652/UPX00100013E01

DOZER BLADE - CAUTION


Located on seat stand cover- Part Number PY20T01077P1

Figure 18

BS08A057/BS07M653

2-16

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


BATTERY - DANGER
Located on battery box cover- Part Number PY20T01069P1

Figure 19

BS07M652/PY20T01069P1

ELECTRICAL LINE SAFETY - DANGER


Located on seat stand cover- Part Number YN20T01006P1

Figure 20

BS08A058//BS07M654

87722071 NA

Issued 01-08

Bur

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


SELECTOR VALVE - CAUTION
Located on seat stand cover- Part Number PE20T01016P1

Figure 21

BS07M607/UPX00100022E01

SAFETY LOCK LEVER - WARNING


Located on seat stand cover- Part Number PY20T01073P1

Figure 22

BS08A058/UPX00100017E01

2-18

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


FOOT PEDAL- CAUTION
Located on seat stand cover- Part Number PY20T01062P1

Figure 23

BS07M607/UPX00100018E01

SEAT BELT - WARNING


Located on seat stand cover- Part Number PE20T01027P1

Figure 24

BS07M607/UPX00100019E01

87722071 NA

Issued 01-08

Bur

2-19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 25

BS07M655/UPX00100026E01

FALLING FRONT WINDOW - CAUTION


Located on inside front window - Part Number PM20T01035P1

Figure 26

BS07M655/UPX00100021E01

2-20

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CAB DOOR - WARNING


Located inside cab door - Part Number PV20T01008P1

Figure 27

BS07M657/UPX00100023

HYDRAULIC OIL CHECK POSITION - NOTICE


Located on seat stand cover- Part Number 243P3379

Figure 28

BS08A058/UPX00100017E01

87722071 NA

Issued 01-08

Bur

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CAP AND KEY COVER - CAUTION


Located near fuel fill cap - Part Number PW20T01090P1

Figure 29

BS07M610/UPX00100028E01

STOP ENGINE - DANGER


Located on inside of side cover- Part Number YN20T01214P1

Figure 30

BS07M605/UPX00100031E01

2-22

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 31

BS07M656/UPX00100032E01

DO NOT OPERATE THIS MACHINE- WARNING


Located on inside of right window (cab). Located on ceiling (canopy) - Part Number PE20T01028P1

Figure 32

BS07M656/UPW00100075E01

87722071 NA

Issued 01-08

Bur

2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


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

Figure 33

BS07M656UPJ00010005E01

CALIFORNIA PROPOSITION 65 - WARNING


Located on inside right window (cab). Located on ceiling (canopy) - Part Number YN20T01495P1

Figure 34

BS07M656UPJ00010006E01

2-24

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


HOT PARTS (OPTIONAL CAB WITH AIR CONDITIONING)
Located on compressor - Part Number PH20T01102P1

Figure 35

BS07M656/BS07N559

87722071 NA

Issued 01-08

Bur

2-25

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

Figure 38

DC04E040

Face Machine Operator, extend right arm toward


operator with hand facing operator and move hand in
direction of movement required.
MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 36

Face Machine Operator, raise right forearm vertical,


with index finger pointing up and move hand in a
small circular motion.
LOWER LOAD VERTICALLY

Figure 39

DC04E041

Face Machine Operator, extend right arm toward


operator with back of hand facing operator and move
hand in direction of movement required.
RAISE BOOM

DC04E039

Figure 37

Face Machine Operator, extend right arm down,


point index finger down and move hand in small
circular motion.
Figure 40

DC04E042

Face Machine Operator, extend right ar m out


horizontally from shoulder, make a fist with thumb up.
LOWER BOOM
2-26

Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


ARM IN

Figure 41

DC04E043

Face Machine Operator, extend right ar m out


horizontally from shoulder, make a fist with thumb
down.
SWING LEFT

DC04E046

Figure 44

Face Machine Operator, bend at elbows with arms


facing operator, make fists and point thumbs in
toward each other.
ARM OUT

Figure 42

DC04E044

Face Machine Operator, extend right ar m out


horizontally from shoulder, make a fist with index
finger pointing in swing direction.
SWING RIGHT

DC04E047

Figure 45

Face Machine Operator, bend at elbows with arms


facing operator, make fists and point thumbs out
away from each other.
COUNTER ROTATE LEFT

Figure 43

DC04E045

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.

87722071 NA

Issued 01-08

Bur

DC04E048

Figure 46

Face machine Operator, place right hand on top of


hard hat, bend left arm at elbow to the right, make a
fist with left hand with index finger pointing out and
rotate hand in a reverse circular motion.

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


COUNTER ROTATE RIGHT

DC04E049

CLOSE BUCKET (BUCKET IN OR DIG)

Figure 47

Figure 50

DC04E052

Face Machine Operator, place left hand on top of


hard hat, bend right arm at elbow to the left, make a
fist with right hand with index finger pointing out and
rotate hand in a forward circular motion.

Face Machine Operator, hold left hand in, closed and


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

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 48

Face Machine Operator, bend both elbows in, make


fists and rotate fists one over the other in a reverse
circular motion

Figure 51

DC04E053

Face Machine Operator, hold left hand in, open and


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

TRAVEL REVERSE
TURN LEFT

DC04E051

Figure 49

Face Machine Operator, bend both elbows in, make


fists and rotate fists one over the other in a forward
circular motion.

2-28

Figure 52

DC04E054

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.
Issued 01-08

Bur

87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS


TURN RIGHT

STOP

Figure 53

DE04E055

DC04E058

Figure 56

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

Figure 54

DC04E056

Face Machine Operator, raise both forearms up,


hands open and facing each other, move hands in
laterally indicating how far to go.

DC04E059

Figure 57

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

Figure 55

DC04E057

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).
87722071 NA

Issued 01-08

Bur

DC04E060

Figure 58

Face Machine Operator, right arm at side, draw left


thumb or index finger across throat.

2-29

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

NOTES

2-30

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS


TABLE OF CONTENTS
OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening Right Window Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Front and Rear Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7


Engine Door Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Window Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
OPERATORS COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Components & Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Right Hand Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Warning Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Operating Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Left Hand Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Right Hand Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Left Hand Operator Control Lever
(BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Right Hand Operator Control Lever (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Left and Right Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Issued 01-08

Bur

87722071 NA

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT


LOCKING/UNLOCKING CAB DOOR

CAB DOOR LATCH

3
Figure 1

BS07M259

Figure 2

BS07M259

1. The cab door can be latched in an open position


by opening door until it is locked in place by the
door latch (1) located on the cab.

1. DOOR CATCH
2. HANDLE
3. KEY

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


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

WARNING: Never use the lever for door


latch release as a handle to mount and/or
dismount from the machine. Failure to
comply could result in injury or death.

Figure 3

BS07M660

1. DOOR RELEASE LEVER

2. Release door latch by pulling the release lever


backward to release door from latch.

87722071 NA

Issued 01-08

Bur

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS


REMOVING AND STORING LOWER FRONT
WINDOW

OPENING AND CLOSING WINDSHIELD


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

Figure 6

DC04D662

1. LOWER FRONT WINDOW

1. After placing upper front window in ceiling, and


locking it in place, remove lower front window by
hand, lifting it from the window frame.
Figure 4

UPW00200038J01

1. Pull lock lever down (1) on front window upper


section to unlock the window.

2. Securely store the removed lower front window


in the holder in the rear of cab behind the
operators seat.
3. To store it, insert the right and left sides of glass
in holder in front of the rear window. Make certain
it is secure in front of the retaining tabs.
OPENING RIGHT WINDOW GLASS

1
Figure 5

BS07M661

1. LOCK LEVER

2. Hold handles on left and right sides of the front


window. Lift the front window up and slide
overhead all the way to the back. The window
will automatically lock when in position.
WARNING: Special attention must be paid
not to injure hands and others when the front
window is closed. Always make sure to
properly lock the front window in place to
avoid injury. Failure to comply could result in
injury or death.

3-4

Figure 7

BS07M663

1. LOCK

1. Open cab door by releasing lock and sliding the


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

Issued 01-08

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87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


CAB DOME LIGHT

DOCUMENT POUCH

Figure 8

BS06H100

CAB DOME LIGHT

DOCUMENT POUCH

1. Turn Cab Dome Light ON by pushing the Dome


Light Switch downward.
2. Turn OFF by pushing switch all the way up.

87722071 NA

Issued 01-08

Figure 9

BS06H091

Bur

T h e O p e r a t o r a n d Pa r t s M a n u a l s t o r a g e
compartment is a pouch located on the back of the
operators seat. Keep the Operator and Parts Manual
for this machine in this location at all times for quick,
easy reference.

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS


OPERATOR SEAT ADJUSTMENTS

SEAT BELT

The operator seat incorporates several adjustment


mechanisms to insure operator comfort, ease of
operation and operator safety.
The adjustment areas are as follows:
SEAT FRONT AND REAR HEIGHT ADJUSTMENT

2
1
Figure 11

DC04D529

BS07666

1. BUCKLE
2. RED BUTTON

Figure 10

SEAT FRONT & REAR ADJUSTMENT LEVER

Move the seat adjustment lever to the right. Adjust


the seat forward or backward to the desired
position.

Release lever to lock the seat in position.

1. Sit on the operators seat and adjust the seat


position so that the operators 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 youre pulling it out,
release the tension and continue pulling it out.
3. Pull the belt out moderately long and insert it in
the buckle until it snaps securely in place.
Release hands, and the length will automatically
adjust.
4. After locking, the belt can be adjusted about 25
mm (1 in) to fit comfortably.
5. Press the red button on the buckle, and the belt
will release.
WARNING: Always wear seat belt while
sitting in operator seat. Always check
condition of seat belt and seat belt mounting
hardware to make certain seat belt is in good
condition and properly secure. Failure to
comply could result in injury or death.

NOTE: Replace the seat belt every three years


regardless of appearance. Note date of replacement
on support mount for reference.

3-6

Issued 01-08

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87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS


ENGINE DOOR COVER

3
1

4
Figure 12

DC04D529

Figure 14

BS07M668

2. RIGHT HAND SIDE COVER


3. ENGINE DOOR
4. LEFT HAND SIDE COVER

1. LOCK
2. RELEASE

A lock is provided for the engine doors. Use the


ignition key to open and lock the engine doors.

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


3. To close, return the strut to the storage position,
and close cover. Lock the compar tment by
turning the key in a counter clockwise direction.
WARNING: Secure the engine doors in open
position with strut when servicing. Failure to
comply could result in injury or machine
damage.
WINDOW WASHER TANK

2
Figure 13

BS07M668

1. KEY CYLINDER

1. After releasing the lock, remove the key and


open cover.

1
Figure 15

BS07M670

1. WASHER TANK
2. CAP
3. MOTOR

The window washer tank is located on the left rear of


the cab. When the washer fluid becomes low,
remove the cap and fill with washer fluid. Do not
operate the windshield washers when the tank is
empty, as this may damage the washer tank motor.
87722071 NA

Issued 01-08

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3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATORS COMPARTMENT CONTROLS AND ACCESSORIES

7
19

20

14

15
13
12
10
17
18
11
16

Figure 16

BS07M671

COMPONENTS
1. RIGHT OPERATING LEVER
2. LEFT OPERATING LEVER

6. BOOM SWING (OPERATING


11. WORK LIGHT SWITCH
PEDAL)
7. OPTION PEDAL
12. THROTTLE LEVER
(NIBBLER AND BREAKER)

3. SAFETY LOCK LEVER

8. HORN SWITCH

13. STARTER SWITCH

4. RIGHT TRAVEL LEVER

9. TRAVEL SPEED SELECT


SWITCH

14. DECELERATION SWITCH


(OPTIONAL)
15. DOZER BLADE
OPERATING LEVER

5. LEFT TRAVEL LEVER

3-8

10. MONITOR PANEL

Issued 01-08

16. OPERATORS SEAT


17. WIPER SWITCH
(CAB MODEL)
18. HEATER SWITCH
(OPTIONAL)
19. LEFT TRAVEL PEDAL
20. RIGHT TRAVEL PEDAL

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


OPERATOR CAB NOMENCLATURE

RIGHT HAND CONSOLE AND MONITOR

This chapter points out locations of operator controls


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

KEY SWITCH

WARNING: DO NOT OPERATE this


machine unless you have read and
understand the instructions in this manual.
Improper machine operation is dangerous
and could result in injury or death.
COMPONENTS & CONTROLS
The following information provides a brief description
and function of the components and controls of this
machine.
All personnel associated with this machine should
read and understand this information BEFORE
beginning any work with or on this equipment.

Figure 17

BS07M672

KEY SWITCH

The Key Switch is located on the right hand operator


console and has 4 operating functions.

OFF - When key is turned to this position, the


e n g i n e s t o p s a n d e l e c t r i c a l p owe r t o t h e
machines electrical system is stopped after
approximately 3 seconds.
ON - When key is in the ON position, electrical
power is supplied to all the machines electrical
systems.
START - Turn the key to this position to start the
engine and release it after the engine starts. The
key will automatically return to the On position.
HEAT - When engine start-up is difficult due to
cold temperatures, turn the key to this position to
activate the pre-heat feature. Hold the key in this
position for approximately 15 seconds and then
turn the key to the START position to start the
engine. Release the key after the engine starts.

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3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS


MONITOR

Figure 18

BS07M673

1.
2.
3.
4.

ENGINE COOLANT TEMPERATURE GAUGE


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

5.
6.
7.
8.

BATTERY CHARGE LAMP (RED)


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

GAUGES

BS07M674

Figure 19

1. BLUE: COLD CONDITION


2. WHITE: OPERATING CONDITION
3. RED: OVER HEATING

COOLANT TEMPERATURE GAUGE


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

Figure 20

BS07M675

1. WHITE: OPERATING CONDITION


2. RED: REFILL

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

If the indicator is in the blue range, warm up engine


and hydraulic oil.
3-10

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


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

IMPORTANT: If warning lamps illuminate, change


machine operating method immediately. If this lamp
remains illuminated, stop the engine and determine
the cause of the problem. See the Maintenance
Section - Chapter 6 in this manual or contact your
dealer.

WARNING: Hot coolant can spray out if the


radiator cap is removed. To remove the
radiator cap:
Let the system cool, turn to first notch, then
wait until all pressure is released.
Scalding can result from fast removal of
radiator cap. Check and service engine
cooling system according to maintenance
instructions. Failure to comply may result in
death or injury.

Figure 21

BS07M776

ENGINE OIL PRESSURE LAMP (RED)


The engine oil pressure lamp (3) will illuminate if the
engine oil pressure drops abnormally while the
engine is running. Stop the engine immediately and
check engine oil.
See the Maintenance Section- Chapter 6 for
checking oil level.

BS07M779

Figure 23

BATTERY CHARGE LAMP (RED)


The battery charge lamp (5) will illuminate if the
charging system is experiencing a malfunction. This
lamp will illuminate briefly when the engine is turned
on and should turn off once the engine is running.
Check the charging system if this indicator remains
illuminated after the engine has started.

Figure 22

BS07M777

COOLANT TEMPERATURE LAMP (RED)


If the coolant temperature rises abnormally, the
coolant temperature lamp (4) will illuminate. Run the
machine at low idle until the coolant temperature
drops to a normal range.
Reduce engine RPM to idle, and stop operation until
engine coolant temperature reaches a safe operating
temperature range.
See the Maintenance Section - Chapter 6 for
checking coolant level.
87722071 NA

Issued 01-08

Bur

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BS07M780

Figure 24

Figure 25

BS07M781

LOW FUEL WARNING LAMP (RED)

HIGH SPEED LAMP (YELLOW)

If fuel is low, a warning lamp will illuminate. Stop the


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

The high speed indicator lamp will be illuminated


when the travel speed is switched to high (2nd)
speed. The travel speed selector switch is located on
the grip of the right travel lever. The speed will
automatically return to low (1st) when the starter key
is switched off.

BS07M778

ENGINE AIR FILTER LAMP (RED)


The engine air filter lamp will illuminate if the air
cleaner filter is restricted. If the lamp illuminates, stop
the machine immediately and clean or replace the air
filter.
See Maintenance Section- Chapter 6 for additional
information.

3-12

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


SWITCHES
10

3
4

9
1

7
6
5
8

TRAVEL SPEED SELECT SWITCH


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

Figure 26

BS07M782

1. STARTER KEY SWITCH


2. TRAVEL SPEED SELECT
SWITCH
3. HORN SWITCH
4. DECELERATION SELECTOR
SWITCH
5. WORK LAMP SWITCH

6. HEATER SWITCH
(CANOPY)
7. WIPER AND WASHER
SWITCH
8. TRAVEL ALARM
SELECT SWITCH
9. SWING/REMOTE
CONTROL SWITCH
10. NIBBLER AND
BREAKER SWITCH

Figure 27

BS07M672

Figure 28

BS07M783

WARNING: Use low speed when operating


on a slope or loading/unloading from a truck
or trailer. Sudden changes in ground level
can cause accidents. Failure to comply could
result in injury or death.
Select low speed when travelling on rough or soft
ground, in confined spaces, loading or unloading
from a trailer, or when tractive force is required.
Select high when moving on flat, level ground.

BS07M784

Figure 29

IGNITION KEY SWITCH

HORN SWITCH

Use the ignition key (1) to start and stop the engine.
See page 3-9 for additional information.

The horn switch (3) is located on the top of the right


control. Always sound the horn before star ting
engine or moving the machine.

87722071 NA

Issued 01-08

Bur

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 30

BS07M785

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

S E L E C TO R

SWITCH

Press the deceleration switch (4) during engine


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

Figure 33

BS07M778

WIPER AND WASHER SWITCH


Use the washer/wiper switch (7) to spray washer fluid
or turn on the windshield wipers. The switch has four
settings.
Wash: (left): Sprays washer fluid
Off: Stop
On: Operates wipers only
Wash (right) Operates washer fluid and wipers
NOTE: Do not use the washer for more than 20
seconds continually or without washer fluid, as the
washer tank motor may be damaged.

BS07M786

Figure 31

WORK LAMP SWITCH


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

Figure 34

BS07M779

TRAVEL ALARM SELECT SWITCH (OPTIONAL)


The travel alar m (8) will sound when travel is
engaged.

BS07M787

Figure 32

HEATER SWITCH (OPTIONAL)


Use the heater switch (6) to turn the optional heater
on or off. The switch has three settings: OFF, (L) low
fan speed, and (H) high fan speed.
3-14

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


LEVERS

1
5
4
Figure 35

BS07M790

SWING REMOTE CONTROL BUTTON

Figure 37

BS08A065

To operate the boom swing function, press the button


(9) on the top of the left control lever. Operate to left
for left boom swing or right for right boom swing. To
switch from the boom swing function, return the
control lever to neutral position, keeping your finger
off the swing control button.

1.
2.
3.
4.
5.

SAFETY LOCK LEVER


RIGHT/LEFT CONTROL LEVER
TRAVEL LEVER WITH PEDALS
THROTTLE LEVERS
DOZER CONTROL LEVER

Figure 38

BS06H080

Figure 36

BS07M791

NIBBLER AND BREAKER OPERATING BUTTON


(OPTIONAL)
Nibbler and breaker (10) functions are an optional
feature. These switches are located on the grip of the
left control lever.
The breaker button when pushed is on, when
released breaker operation stops.
The nibbler closes when button (A) is pressed. The
nibbler will open when button (B) is pressed.

1. FUNCTION CANCELLATION LEVER IN


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

HYDRAULIC FUNCTION CANCELLATION LEVER


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

87722071 NA

Issued 01-08

Bur

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS


OPERATING CONTROL LEVERS

Left Hand Operator Control Lever (ISO/SAE


Pattern)

Figure 39

UPW00100006E11

Figure 41

DC04D562

WARNING: Hydraulic controls are designed


for and set to an ISO operating pattern.
Changing the control pattern will effect the
operation of the machine controls. Make
certain patterns match machine movement.
Failure to comply could result in injury or
death.

Figure 40

BS07N561

LH CONTROL LEVER
2

3-16

Arm Out

Arm In

Swing Left

Swing Right

RH CONTROL LEVER
1

Boom Down

Boom Up

Bucket In

Bucket Out

The Left Hand Operator Control Lever is located at


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

FORWARD - Variable speed ARM out.


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

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


BHL PATTERN

Right Hand Operator Control Lever (ISO/SAE


Pattern)

DC04D563

Figure 42

BS07N561

LH CONTROL LEVER
1

Boom Down

Boom Up

Swing Left

Swing Right

RH CONTROL LEVER
2

Arm Out

Arm In

Bucket In

Bucket Out

In the BHL multi control shifting the boom and arm


functions are opposite the ISO system.

The Right Hand Operator Control Lever is located at


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

FORWARD - Variable Speed BOOM down.


BACKWARD - Variable speed BOOM up.
LEFT - Variable speed BUCKET in (Digging).
RIGHT - Variable speed BUCKET out (Dump).
CENTER - Neutral position.

Figure 43

UPX00200006E01

87722071 NA

Figure 44

Issued 01-08

Bur

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS


NOTE: An optional Pattern Control Change Valve is
available. Contact your dealer for more information. If
your Excavator already has this valve installed use
the following instructions (BHL Pattern) regarding its
operation.

PATTERN CONTROL CHANGE (BHL PATTERN)


To change the machines control pattern from ISO
(SAE) to (BHL) pattern, proceed as follows:

1. Place the attachment on the ground, throttle


control in low idle, and turn the key switch off.

Figure 46

BS07N621

1. PATTERN CHANGER VALVE

3. Open the right compartment door, locate the


pattern changer lever (2).

3
4
DC04C344

Figure 45

1. HYDRAULIC FUNCTION CANCELLATION LEVER


IN LOCKED (UP) POSITION

2. Place the hydraulic function cancellation lever in


the lock (UP) position before leaving the cab.
Figure 47

BS07N564

4. Loosen wing bolt (3), and change the lever


position to the desired pattern.
5. Hand tighten the wing bolt (3) securely. Do not
use tools to tighten.
6. Close compartment cover.
7. Carefully operate the control levers to make
certain functions match the pattern selected.
Practice in an open area to become familiar with
the new pattern.
WARNING: Check machines control pattern
for conformance to pattern on decal-card in
cab. If pattern does not match decal-card on
cab door holder, flip decal-card on holder to
match the machines control pattern before
operating machine. Failure to comply could
result in injury or death.

3-18

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


WARNING: Whenever a change is made to
the machines control pattern, also change
the pattern decal card in the cab to match the
new pattern. Failure to comply could result in
injury or death.

LEFT HAND OPERATOR CONTROL LEVER


(BHL PATTERN)

Figure 48

DC04D565

DC04D567

1. ISO/SAE PATTERN DECAL CARD

Figure 50

Slowly operate Left Hand control to make sure it


matches BHL pattern and to familiarize yourself with
the new control pattern.

RIGHT HAND OPERATOR CONTROL LEVER


(BHL PATTERN)

Figure 49

DC04D566

1. BHL PATTERN DECAL CARD

DC04D568

Figure 51

Slowly operate Right Hand control to make sure it


matches BHL pattern and to familiarize yourself with
the new control pattern.

87722071 NA

Issued 01-08

Bur

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS


LEFT AND RIGHT TRAVEL LEVERS AND
PEDALS

Figure 53

BS07N624

1. Push both levers forward (or press the front of


the pedals) to travel forward.
2. Pull both levers towards you (or press the near
side of pedals) to move in reverse.
3. Release both levers in the center position to stop
movement and place the machine in neutral.

2
1
Figure 52

BS07N623

1. TRAVEL MOTOR
2. DOZER BLADE

The travel levers and pedals are located in front of


operator seat. They are used to move the left or right
track of the machine either forward or backward.

FORWARD - Variable speed forward track


movement.

BACKWARD - Variable speed reverse track


movement.

CENTER - Neutral position.


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

Figure 54

BS07N625

THROTTLE CONTROL LEVER


The throttle control lever is located to the right of the
operators seat and is used to control engine speed.
(A) LOW (low idling) - Push the throttle fully forward
to set the engine in low idle.
(B) HIGH (high idling) - Pull the throttle fully
backward to set the engine in high idle.

WARNING: Always know the position of the


travel motors before starting movement.
Failure to comply could result in injury or
death.

3-20

Issued 01-08

Bur

87722071 NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS


HOUR METER

Figure 55

BS07N626

DOZER CONTROL LEVER

BS07M792

Use the dozer control lever to move the dozer up or


down.
(C) Dozer Up - Pull the lever back.
(D) Dozer Down - Push the lever forward.

Figure 56

The Hour Meter indicates the total time that the


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

When traveling, raise the dozer blade to its maximum


height.

87722071 NA

Issued 01-08

Bur

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-22

Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS
TABLE OF CONTENTS
BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
STARTING AND STOPPING MACHINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starting Machine Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
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 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
4-14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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
4-19

Issued 01-08

Bur

87722071 NA

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

4-2

Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE


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

16. Before undertaking any travel or 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.
87722071 NA

Issued 01-08

Bur

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 operators 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.

4-4

Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS


EMERGENCY ENGINE SHUT DOWN
Use this emergency shut down measure ONLY when
the key switch fails to shut down the engine.

STARTING AND STOPPING MACHINE


ENGINE IN COLD CLIMATES
STARTING ENGINE
1. Move throttle control to 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.
4. Turn key to the START position and release as
soon as engine starts. Key will automatically
return to the ON position.

1
Figure 2

DC04C344

1. ENGINE EMERGENCY STOP CONTROL

1. Pull out the engine emergency stop control


located at the lower right hand side of the
operators seat until engine stops.
2. Before restarting engine,
engine stop control in.

push

emergency

IMPORTANT: Release Key after 20 seconds of


cranking if engine does not start.
Wait at least 2 minutes before attempting to start
engine again to allow starter motor to cool.
NOTE:

After starting the engine, use the auto warm up


system described in Machine Warm Up in this
chapter, and warm the engine and hydraulic oil.

If engine fails to start after 3 attempts, inspect fuel


system and correct any problem.

When cranking engine, the absence of blue or


white smoke from the exhaust
Stopping the Machine

BS07M861

Figure 3

1. Move machine to a firm, level area and place the


attachment in the hydraulic oil check position.
2. Move throttle control to LO position. Allow
engine to idle for 5 minutes.
3. Turn key switch to OFF position.

87722071 NA

Issued 01-08

Bur

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS


STARTING MACHINE ENGINE WITH BOOSTER
CABLES

3
CONNECTING BOOSTER CABLE

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.
1. Move vehicle or machine to be used for boosting
as close to the batter y box of the disabled
machine as possible.
CAUTION: Do not allow the vehicle or machine used
for boosting to touch metal to metal with the disabled
machine. This could short circuit electrical systems
and cause extensive damage to the CPU and other
components.

4
1

4
Figure 4

DC04D588

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE


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

CAUTION: Use only vehicles or machines with 24V


DC electrical system to boost start this machine.

3. Locate and connect one end of the booster cable


to the positive (+) terminal on the battery of the
disabled machine.

2. Make certain key switch of disabled machine is in


the OFF position before proceeding with booster
cable connection.

4. Connect other end of positive booster cable to


positive (+) terminal of battery being used for
boosting.

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.

5. Locate and connect second cable to the negative


(-) te r minal of th e ba tte r y being used fo r
boosting.
6. Connect other end of negative (-) cable to the
upper frame of disabled machine as far away
from battery as possible.
STARTING BOOSTING MACHINE ENGINE
1. Start engine boosting machine in normal manner
according to climate conditions.
2. Allow 5 minutes or more to provide partial charge
to the discharged batteries.
STARTING DISABLED MACHINE ENGINE
1. Start engine of disabled machine in normal
manner according to climate conditions.

WARNING: The negative (-) cable, when


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

4-6

Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS


DISCONNECTING BOOSTER CABLES

MACHINE WARM UP

4
4

1
Figure 5

DC04D588

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE


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

After disabled machine engine is running, follow


these steps to disconnect the cables.
1. Disconnect the negative (-) cable from disabled
machine upper frame.
2. Disconnect negative (-) cable from battery used
for boosting.
3. Disconnect positive (+) cable from battery used
for boosting.

WARNING: While operating the machine


with cold hydraulic oil, the operator may
experience slow or unexpected movement of
functions. Damage to the hydraulic
components may result due to the cold oil not
providing adequate lubrication.
Auto warm up should be utilized when ever
machine is started in climate temperatures
below 10C (50F) 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.

4. Disconnect positive (+) cable from terminal of


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

87722071 NA

Issued 01-08

Bur

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS


CHECK MONITOR PANEL

Figure 6

BS07M798

Check all gauges and indicators on the monitor after starting the engine. Make certain the water temperature (1) is
in the normal range, fuel (2) is adequate, and other indicator lamps are not illuminated or indicating any engine
abnormalities.
Warming Hydraulic Oil
CAUTION: Check clearance between bucket and
cab before operation. Slowly cycle bucket, check for
interference with arm and cab, particularly if a lifting
eye is welded on bucket bottom. Exercise care when
operating the bucket near the cab.
a. Move throttle control to HI idle position.

Figure 8

DC04D474

DC04D473

Figure 7

b. Perform bucket dig operation and hold over


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

4-8

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


minutes each.
WARNING: While operating the machine
with cold hydraulic oil, the operator may
experience slow or unexpected movement of
functions.
Damage to the hydraulic components may
result due to the cold oil not providing
adequate lubrication.
Auto Warm Up should be utilized anytime
machine is started in climate temperature
below 10C (50F) to stabilize machine
control response. Cold oil can cause erratic
machine operation. Failure to comply could
result in injury or death.
Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL DECAL
OPERATING PATTERN
The operating and travel controls of this machine are
factory set at ISO/SAE standard operating patterns.
OPERATING PATTERN DECAL
The illustrations are a repres entation of the
CONTROLS decal located inside the right side
window of the operator cab. Study this decal and
understand the directions each control can be
operated and the functions associated with each
movement of particular control. Detailed instructions
for each control and its functions are explained on
the following pages of this chapter. Should this decal
become damaged or missing, install a new decal.
WARNING: Check and make sure that
operations pattern control matches the decal
provided inside the right side window. Failure
to comply could result in injury or death.

BS07M796

Figure 9

BS07M797

Figure 10

WARNING: If your machine is set to the


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

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4-9

CHAPTER 4 - OPERATING INSTRUCTIONS

BASIC OPERATION OF HYDRAULIC CONTROLS


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

FUNCTION CANCELLATION LEVER


1. Unlocked Position

WARNING: Normal positioning of the


machine for the purpose of determining
Front, Rear, Forward, Reverse are with the
travel motors located behind the operators
cab. Failure to comply could result in injury or
death.
WARNING: Always know the location of
travel motors before operating any hydraulic
controls. Failure to comply could result in
injury or death.

Figure 11

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 Operators
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

BS07M800

Figure 14

For fast travel speed, depress and release the travel


speed select switch once before operating the travel
controls. This puts the travel motors in FAST (1)
travel speed and the lamp for FAST on the gauge
cluster display will illuminate.
Figure 12

DC04D477

With the travel motors positioned behind the cab:


a. Push both travel levers or press the pedals
toward front of machine and machine will
travel FORWARD.

To return to SLOW travel speed, stop travel and


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

Figure 13

DC04D478

b. Pull both travel levers or press the pedals


toward operator seat and machine will travel
in REVERSE.
c. Return both travel levers to NEUTRAL
(center) position and machine will stop
travelling.
NOTE: The distance the travel levers are pushed or
pulled determines travel speed of the machine.
EXAMPLE:
Travel levers are pulled or pushed to full stroke machine will travel at top speed.
Travel levers are pulled or pushed to mid position machine will travel at 1/2 speed.

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4-11

CHAPTER 4 - OPERATING INSTRUCTIONS


TURNING THE MACHINE

Figure 18

DC04D482
DC04D479

Figure 15

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 19

DC04D483
DC04D480

Figure 16

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 20

DC04D484
DC04D481

Figure 17

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 IN A NARROW SPACE

IMPORTANT:
A. Climbing ability of a machine can change
depending upon shoe type, engine lubrication,
etc.
B. When approaching or descending a slope,
operate the travel levers slowly.
C. For braking, slowly return travel levers or
pedals to the neutral (center) position. Brakes
are engaged automatically.
D. The travel operation for 2 hours or more may
cause the failure of the travel motors due to
the rise of the operating temperature. Dont
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 -20C
(-4F), the travel lever or pedal action may be
heavier than normal. This is due to the
viscosity of the hydraulic oil in frigid climates.
TRAVEL SAFETY
a. Know the position of the travel motor before
beginning travel.
b. Travel on firm, level surfaces as much as
possible.

Figure 21

BS07N682

BOOM IN FOLDED POSITION

T h e b oo m m ay b e fo l d e d i n a s s h ow n i n t h e
illustration. Folding the boom in will decrease the
swing radius of the machine.
Canopy swing radius with folded boom:
1690 m (66.5 in.)
Cab swing radius with folded boom:
2170 m (85.4 in.)
OPERATING THE MACHINE IN WATER

c. When traveling on rough terrain, travel in


SLOW speed with engine at a low idle.
d. Travel with the travel motors in the back of the
machine for long distance travel.
e. When traveling or operating machine on snow
or icy surfaces, clean track shoes frequently to
prevent clogging.

f. Keep a safe distance from stationary objects


and electrical power lines.
g. Be aware of load capacities of bridges and
road shoulders. Reinforce if necessary.
h. Use decking or planks to protect road
surfaces as much as possible. Be careful
when turning or counter rotating machine on
asphalt pavement.
i. Do not allow large or heavy objects to strike
travel motors.
j. Do not travel over large objects such as
boulders, rock, etc.
k. The machine can sink on soft ground or mud.
Avoid these areas.

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1
BS07M851

Figure 22

If necessary to travel or operate machine in a river or


other water, the bed must be firm and water current
slow. Water must not be deeper than indicated in the
illustration.
NOTE: If the machine is operated while the swing
bearing is submerged in water, then the swing
bearing, swing pinion, and the swivel joint may wear
out prematurely. Immediate replacement of grease in
grease bath and flushing of the swing bearing is
required. See Maintenance Section.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS


MACHINE ATTACHMENT AND SWING - ISO/SAE
PATTERN
The following operation instructions are to be used
with hoe bucket attachment only. If other attachments
are being used, consult the operators manual for the
particular attachment.
WARNING: Read, understand and follow all
safety precautions during all operations of
this machine and its attachment.
1. Boom Operation
Operation of the Boom is performed by pushing and
p u l l i n g t h e R i g h t C o n t r o l L eve r fo r wa r d a n d
backward. Boom speed is determined by how far the
lever is activated.

DC04D485

Figure 23

a. Pulling right control lever BACK raises boom.

Figure 25

DC04D487

a. Pushing the left control lever FORWARD


moves the arm out.

Figure 26

DC04D488

b. Pulling the left control lever BACK brings arm


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

DC04D486

Figure 24

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.

Figure 27

DC04D489

a. Moving the right control lever to the LEFT


operates the bucket in (digging).
DC04D491

Figure 29

a. Moving the left control lever to the LEFT swing


machine to the left.

Figure 28

DC04D490

b. Moving the right control lever to the RIGHT


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

DC04D492

Figure 30

b. Moving the left control lever to the RIGHT


swings the machine to the right.
c. Returning control to the Neutral (center)
position stops swing.

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4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY


CLEANING SAND & SOIL FROM BUCKET

USE ARM IN ACTION

BS07M852

Figure 31

Operate the bucket at shallow depths and use the


arm in action to fill the bucket. Setting the bucket too
deep will decrease the machines efficiency. Always
point bucket teeth in the direction the machine will be
digging to reduce digging resistance and the
possibility of bucket teeth damage.

Figure 33

BS07M854

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.

OPERATE BOOM SMOOTHLY


DITCH DIGGING

DC04E075

Figure 32

Always begin and end boom operation slowly with


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

Figure 34

BS07M855

For efficient ditch digging, position the machine


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

The attachment will provide maximum digging force


when the arm and boom are at 90 - 110 of each
other.
USING THE DOZER

4-16

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CHAPTER 4 - OPERATING INSTRUCTIONS


OFFSET DIGGING

Figure 35

BS07M856

For back filling and leveling work after digging, use


the dozer to push the soil back into the ditch or to
level ground.
Do not push or pull material with the bucket like a
bulldozer when using the machine to level material.
1. Scrape the soil at its upper surface with the
dozer.
2. Use the dozer to back fill a trench.
3. Adjust the height of dozer with the dozer control
lever to avoid over loading the engine.
4. Never travel with front attachment touching the
ground. Severe structural damage could occur.
LOADING

BS07M858

Figure 37

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.

Figure 36

BS07M857

1. Operating efficiency can be improved by


positioning the dump truck so the swing distance
is kept to a minimum. Always have a good field
of view.
2. Start at the front side of the dump body and work
toward the back.

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4-17

CHAPTER 4 - OPERATING INSTRUCTIONS


MACHINE OPERATION IN ADVERSE WEATHER
CONDITIONS

4. Make certain that the engine coolant mixture is


sufficient to keep the machine safe.

OPERATION IN EXTREME COLD

5. If the machine becomes overheated, idle the


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

1. Follow procedures at the beginning of this


chapter as starting the engine may be difficult
due to extremely cold temperature.
2. Use an engine oil, hydraulic oil, and diesel fuel
d e s i g n e d fo r u s e i n c o l d c l i m a t e s . S e e
Maintenance Section for reference. Keep
batteries fully charged.
3. Make certain to perform machine warm-up
procedures as described at the beginning of this
chapter to prevent premature wear or damage to
pumps, motors, and other components.
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
5C (9F) lower than the machine may experience
during operation, storage or transport.
5. Keep battery terminals free of ice and snow. Ice
and snow could cause the terminals to short
circuit and cause extensive damage to the
machine system. Check the battery electrolyte
(acid) level frequently and fill as necessary with
distilled water. If the machine will be left outside
overnight, removing the batteries and storing in a
warm area is recommended.

WARNING: Do not drain the cooling system


when the engine is hot. Allow time to cool all
engine parts. Failure to comply could result in
injury or death.
6. Check the battery electrolyte (acid) level
frequently and fill as necessary with distilled
water.
7. Keep a close watch on the gauges for warning
icons during operation. Avoid unnecessary low
speed running of the engine during operation.
OPERATION IN HIGH ALTITUDES
1. Due to low atmospheric pressure at high
altitudes, a decrease in engine power will be
experienced. Be aware of this fact when placing
machine under heavy load in high altitudes
climates.
2. Keep close watch on the engine temperature
gauge to avoid overheating of the engine.
OPERATION IN SANDY AND DUSTY AREAS
1. Check the engine air cleaner elements frequently
in sandy or dusty conditions.
2. When air cleaner restriction lamp illuminates,
change filters immediately regardless of time
intervals.
3. Service fuel filter, water separator, engine oil and
filters, and all hydraulic filters frequently.
4. Keep the radiator, oil cooler, inter-cooler, and air
conditioning condenser clean.

OPERATION IN EXTREME HEAT


1. Use an engine oil, hydraulic oil and fuel designed
for use in hot climates. See Maintenance Section
for reference. Also keep batteries fully charged.
2. Clean radiator, oil cooler and debris screen often
t o p r eve n t d a m a g e o r ove r h e a ti n g o f t h e
machine.
CAUTION: Do not allow dirt and debris to
accumulate in the radiator fins, oil cooler fins or
debris screen, as this may cause a fire.

OPERATION AT SEASHORE OR SALTY CLIMATE


1. Thoroughly wash machine daily to help avoid
corrosion of machined areas, electr ical
components and cylinder rods.
2. Frequently check all mounting hardware for
proper tightness. Torque to proper value to aid in
preventing salt from entering the machine
systems.

3. Keep all belts properly tensioned.

4-18

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CHAPTER 4 - OPERATING INSTRUCTIONS


OPERATION IN HUMID CLIMATE

BUCKET SELECTION GUIDE

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

Bucke t se lection is extremely impo r tant to a


machines productivity, durability, and stability.
Choosing an excessively large bucket can reduce
productivity due to slower than normal cycle times.
Using an oversized or overly wide bucket in severe
conditions such as mining, will lead to durability
problems for both the machine and bucket involved.

Undercarriage life varies upon the operation method.


Use the following guides to increase the life of the
machines undercarriage.

Stability will be adversely affected using a bucket that


is unnecessarily large.

1. Select the track shoe that best suits the


machines application. If in doubt, consult with
your dealer when selecting track shoes.

If the buckets used locally var y in weight from


recommended buckets, it will be necessary to adjust
the bucket capacity accordingly. A heavier bucket
must correspond to a reduced capacity.

2. Do not allow the tracks to slip during operation. If


this occurs, reduce load until slipping stops.
3. Avoid sudden starts, accelerations, abrupt speed
changes, high speeds on rough terrains, sharp
turns, and sudden stops.
4. Always operate machine in straight lines
whenever possible. Avoid short radius when
turning. Make turns with the largest possible
radius.
5. Prior to operation, clear boulders and obstacles
to prevent damage to track shoes.
6. Always operate machine parallel to the incline of
the slope. Operating machine across the incline
of the slope will not only shorten the machines
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.

87722071 NA

Issued 01-08

Bur

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

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

HYDRAULIC BREAKER

4. Basic Operation

1. Selection of the Hydraulic Breaker

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.

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 Precautions 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

Figure 38

BS06H080

1. FUNCTION CANCELLATION LEVER

a. Start machine and place the hydraulic function


cancellation lever in UNLOCKED (down)
position.

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.

Figure 39

BS07HM859

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.

4-20

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CHAPTER 4 - OPERATING INSTRUCTIONS


MACHINE SET-UP
SETTING SELECTOR VALVE

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.

Operation

OFF

Breaker stops operating

Depress button B

Breaker starts operating

Nibbler
Button section

Figure 41

BS07N621

1. SELECTOR VALVE
2. COVER

Breaker
Button section

Figure 40

BS07HM860

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

Machines equipped with a nibbler breaker


attachment must have the selector valve (1) set to
the correct position for the breaker or nibbler
operation.
NOTE: Make sure to relieve hydraulic system and
tank pressure as instructed in RELEASING
HYDRAULIC SYSTEM AND TANK PRESSURE in
Chapter 6.
Lower the attachment to the ground and stop the
engine. Set the cancellation lever in the locked
position.
SELECTOR VALVE SHIFTING POSITION
TO TANK

TO C/V

TO TANK

TO ATT TO C/V

B : USE BREAKER
UPM00700003ES1

TO ATT

N : USE NIBBLER
Figure 42

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.
87722071 NA

Issued 01-08

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4-21

CHAPTER 4 - OPERATING INSTRUCTIONS


GETTING THE MOST OUT OF YOUR BREAKER

WARNING: Read, understand and follow all


safety precautions and operating procedures
found in this manual before operating the
machine or any attachment. Failure to
comply could result in injury or death.

A. BREAKER PROPER POSITIONING

Figure 43

BS07M864

a. Use a 24 mm Allen wrench to loosen bolt (3).


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

Figure 45

DC03M065

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

BS07M865

Figure 44

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

Attachment Hydraulic Oil Shut off valve


NOTE: Make sure to switch the position of the stop
valves to the CLOSED position before removing the
attachment.
The valve is used to shut off the flow of hydraulic oil
when changing attachment. Use a 19 mm hex to
open and close valves.

4-22

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 operators 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.

Issued 01-08

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87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS


E. EXCAVATING AND TRENCHING

C. BREAKING OVERSIZE ROCKS

Figure 46

DC03M066

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.

DC03M068

Figure 48

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:

D. SURFACE ROCK DEMOLITION

1. Make sure to adjust the proper hydraulic flow


according to the breaker specifications.
2. Place tool against material to be broken at 90
angle to work surface.
3. Use the boom, arm, and bucket controls to press
firmly against surface, keeping perpendicularity
while operating the breaker.
4. As material breaks, stop breaker quickly to
prevent idle strokes.
5. Reposition breaker if material does not break
after 15 seconds of operation.
Figure 47

DC03M067

Use the breaker just as if it were a hand held breaker,


or a plain hammer and chisel. Adjust the breakers
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.

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.

87722071 NA

Issued 01-08

Bur

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS


D. CYLINDERS

SAFETY PRECAUTIONS
The following safety precautions should be used in
conjunction with other safety precautions found in
this manual.
WARNING: Read, understand and follow all
safety precautions and operating procedures
found in this manual before operating the
machine or any attachment.
A. USE FOR INTENDED PURPOSE

Figure 51

DC04E063

DO NOT OPERATE boom, arm or bucket cylinders


at stroke ends when using a breaker attachment.
Doing this can cause undue stress on the cylinder
rods and result in damage.
E. AVOID CONTINUOUS OPERATION

DC04E061

Figure 49

Use the attachment only for its intended purpose. If


not used in accordance with the manufacturers
instructions, the excessive pressure exerted on the
boom, arm and frame structure of the machine will
cause premature failure of the components.
B. PASSENGERS
Never allow passengers on the attachment or
machine.
Figure 52

DC04E064

C. PROTECTIVE EQUIPMENT

Operate the nibbler/breaker in one (1) minute


intervals. Operation for longer than one (1) minute at
a time can cause high oil temperatures and damage
the accumulators, cylinder seals and possibly pump
damage.

DC04E062

Figure 50

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.
4-24

Issued 01-08

Bur

87722071 NA

CHAPTER 4 - OPERATING INSTRUCTIONS


I. DO NOT LIFT

F. HOSE SURGE

Figure 53

DC04E065

DC04E068

Should the hydraulic hoses begin to surge or vibrate


abnormally during operation of a Breaker or Nibbler,
immediately stop operation and contact an
authorized dealer for assistance. This problem often
is a result of damaged accumulators and can also
result in valve failure.

Never use optional attachment to lift or transport


objects or materials. Doing so can cause extensive
damage to the attachment, the machine structures or
cause injury or death due to slipping or dropping of
load due to improper attachment.
J. WORKING RANGES

G. DO NOT USE DROPPING FORCE

Figure 54

DC04E066

Figure 56

Never use the dropping force of the attachment to


break or drive objects. This will cause extensive
damage to the attachment and machine structure.

DC04E069

Figure 57

Never operate an optional attachment over the sides


of the machine. Only operate over the front or rear of
the tracks.

H. DO NOT USE SWING FORCE

Figure 55

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.
87722071 NA

Issued 01-08

Bur

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS

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

c. Obtain any permits required from proper


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

Machine with Canopy

Machine with Cab

Figure 58

BS08A059/BS0A060

4-26

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CHAPTER 4 - OPERATING INSTRUCTIONS


2. Loading the Machine
WARNING: Never attempt to load or unload
machine without ramps. Failure to comply
could result in injury or death.
a. Apply parking brakes on tractor and trailer and
chock trailer wheels before attempting to load
or unload machine.

b. Lower ramps of trailer.


c. Start the machine.
d. Set travel speed to LOW - 1st speed.
e. Move throttle control to low idle position.
f. Raise the attachment and slowly move
machine up trailer ramps and over rear axles
of trailer.
g. Slowly move machine completely onto trailer
until in proper transport position.
h. Slowly swing machine 180 until attachment is
toward rear of trailer.
i. Slowly lower boom until attachment rests on
trailer bed.

Figure 59

DC04C344

1. FUNCTION CANCELLATION LEVER

k. Place hydraulic function cancellation lever in


the LOCKED (up) position.
l. Turn machine OFF, remove key and lock all
doors, filler caps and access panels.
IMPORTANT: Place a cover over the exhaust pipe of
the machine and secure to avoid water entering the
engine.

j. Do not have bucket and arm cylinder at full


stroke during transport as this may cause
damage to cylinders.

87722071 NA

Issued 01-08

Bur

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS


Securing Machine to Trailer

BS07N631

Figure 60

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 61

DC04D581

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.

4-28

Issued 01-08

Bur

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CHAPTER 4 - OPERATING INSTRUCTIONS


LIFTING MACHINE
The following procedures are for lifting the machine,
without modification. These procedures do not take
into account modifications made to the machine that
affect machine weight or center of gravity.
LIFTING MACHINE WITH ATTACHMENT
INSTALLED
WARNING: Always use proper lifting
equipment and devices. Use of improper
lifting equipment could allow the load to shift
or fall causing severe damage, serious injury
or death.
a. Install lift eyes/shackles at holes provided at
both ends of the dozer blade. Locate lift areas.
b. Attach cables or wire ropes with a capacity
rating sufficient to lift the machine, at lifting
locations.

BS07A061

Figure 63

BS08A062

Figure 64

1
Figure 62

DC04D582

1. HARDWOOD OR STEEL BLOCK

c. Place hardwood or steel block between cables


and crawler frame.
\

WARNING: Place a hardwood or steel block


between cables and crawler frame to prevent
damage to the tracks from cables during
lifting. Failure to comply could result in
machine damage.

d. Slowly raise the lift apparatus to check with


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

87722071 NA

Issued 01-08

Bur

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE

Figure 65

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.

4-30

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.

Issued 01-08

Bur

87722071 NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS


TABLE OF CONTENTS
FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5


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

Issued 01-07

Bur

87722071 NA

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

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87722071 NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS


SWING BEARING

REQUIRED FLUIDS/LUBRICANTS AND


CAPACITIES
ENGINE
Type of Oil . . . . . . . . . . . . . . Engine Oil SAE 15W30
Capacity:
Engine Oil with filter change . . 6.7 liters (1.8 gal)
NOTE: See ENGINE OIL LEVEL in Chapter 6 for proper
oil filling and/or checking engine oil level.
HYDRAULIC
Type of Oil . . . . . . . . . . . . . . . . . Hydraulic Oil AW 46
Capacity:
Hydraulic Tank. . . . . . . . . . . . .38 liters (10.0 gal)
Hydraulic System . . . . . . . . . .48 liters (12.7 gal)

Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2


Capacity . . . As required (1 place - swing 90 x 4)
NOTE: See SWING BEARING LUBRICATION in
Chapter 6 for proper lubrication.

TRACK TENSION ADJUSTMENT


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

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

NOTE:
1. See HYDRAULIC OIL LEVEL in Chapter 6 for
proper filling and/or checking hydraulic oil level.
TRAVEL MOTOR REDUCTION UNIT
Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil
Capacity 0.7 liters (0.18 gal) Each x 2

ENGINE COOLANT MIXTURE


Expected Minimum Temp.

Long Life Coolant

-14.5C (5.9F)

30% mixed

-34C (-29.2F)

50% mixed

NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL


in Chapter 6 for proper filling and/or checking oil level.

Capacity:
Cooling System . . . . . . . . . . . . . . 4.6 liters (1.22 gal)

UPPER ROLLERS
Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil
Capacity . . . . . . . . . . . . .45 cc (2.7 cu. in.) Each
IDLERS
Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil
Capacity . . . . . . . . . . . . 80 cc (4.8 cu. in.) Each

NOTE: See ENGINE COOLANT CHANGE in


Chapter 6 for proper coolant filling and/or coolant
level check.

FUEL TANK
Type of Fuel . . . . . . . . . . . . . Diesel Fuel grade No. 2
Capacity . . . . . . . . Fuel Tank - 38 liters (10 gal)

OPERATING LEVER JOINT


Type of Oil . . . . . . . . . . . . . . . . . . . . EP Grease EP/2
Capacity . . . . . . . . . . . . As required in each joint

NOTE: See FUEL LEVEL in Chapter 6 for proper


filling and/or checking the fuel level.

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

UPPER ATTACHMENT PINS


Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2
Capacity . . . . . . . . . . . . .As required in each pin
NOTE: See ATTACHMENT LUBRICATION
Chapter 6 for proper lubrications.
87722071 NA

Issued 01-08

Bur

in
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


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.

5-4

Issued 01-08

Bur

87722071 NA

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
-30C~15C
(-22F~59F)

FRIGID
-20C~30C
(-4F~86F)

FRIGID-WARM
-25C~40C
(-13F~104F)

WARM
-5C~40C
(23F~104F)

VERY HOT
5C~55C
(41F~131F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT

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

FRIGID
-30C~30C
(-22F~86F)

WARM
-5C~40C
(23F~104F)

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

SAE10W30

SAE15W40*

SAE15W50

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

CLIMATE ZONE

LUBRICANT

FUEL

LUBRICANT

FRIGID
-15C ~ -25C
(5F ~ -13F)

WARM
-5C ~ -15C
(23F ~ 5F)

VERY HOT
-5C and Above
(23F 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)
-34C (-29.2F)

FLUID
ENGINE COOLANT
(50% MIXTURE)

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

USE OF BIO-DEGRADABLE OILS


87722071 NA

Issued 01-08

Bur

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS


When you use Bio-degradable Oil (BIO OIL), refer to the following information:
1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is
recommended, as the vegetable based oil has a maximum usage temperature of 80C (176F). 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.

5-6

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS


TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6


Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DAILY INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Alternator/Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

50 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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


Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect and Adjust Fan/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dozer Pin Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Greasing the Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom, Arm, and Attachment Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Inner Element
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Return Filter (Breaker Use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Issued 01-08

Bur

87722071 NA

6-28
6-29

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Clean and Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
Replacing the Inner Element
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Replacing Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
Repairing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
Check Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
Check Starter and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
1500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Check Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Hydraulic Suction Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
Pilot Valve and Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
Upper and Lower Roller - Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
Upper Roller Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
Change Swing Gear Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
Intake and Exhaust Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48
Replacing the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49
Replacing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49
Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50
Rubber Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51
Rubber Track Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51
Rubber Track Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53
Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55
Releasing Lock on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55
Removing Gears from Travel Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55
Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56
Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56
Lowering Bucket Attachment on a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57

6-2

Issued 01-08

Bur

87722071 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.

87722071 NA

Issued 01-08

Bur

DC04B670

Figure 3

Use caution and wear the proper safety equipment


when working around hot areas. Never change oils,
engine coolant or filters immediately after a machine
has been stopped. Allow machine to cool down
before performing maintenance procedure.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


PREVENT CONTAMINATION

WARM ENGINE OIL


Engine should have a temperature between 20C 40C (68F - 104F) 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
operators console to inform the operator that the
machine will be inoperable for inspection and
maintenance. This tag will help prevent accidental
starting of the machine.
INSPECT WASTE OILS AND FILTERS

IMPORTANT: Never allow a hydraulic line or


component to become contaminated. Always use
proper caps and plugs.
SEALS AND O-RINGS
Always replace seals and O-rings with new parts.
Never reuse a seal or O-ring during reassembly of
components. Make sure to lubricate all new seals
with the appropriate oil before installation.
STOP ENGINE
DO NOT attempt any maintenance with engine
running. Always stop the engine and allow machine
to cool.
WEAR SAFETY EQUIPMENT
Wear hard hat, safety goggles or face shield, work
gloves, safety shoes, and well fitting work clothes
when perfor ming inspection and maintenance
procedures on this machine.

DC04B672

Figure 5

Before disposal, inspect all waste oils, fluids, and


filters for debris and foreign material. Cut open the oil
filters to determine any abnormal wear.

CLEANING PARTS
Use only approved cleaning solvents and proper
equipment to clean parts.
WARNING: Never use gasoline, diesel fuel
or other flammable solvents to clean parts.
Always clean parts in a well ventilated area.
Failure to comply could result in injury or
death.

6-4

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


WELDING SAFETY

STEPS AND HAND HOLDS

1. Turn key switch to OFF position.


2. Remove negative (-) cable from battery terminal.
3. Attach the welder ground cable within 1 m (39
in.) from component being welded.
4. Do not clamp the welder ground cable close to or
in location where ground could be separated by
bearings or seals.
WARNING: Disconnect batteries before
welding on this machine. Connect welder
ground cable within 1 m (39 in.) of area to be
welded. Failure to comply could result in
machine damage, injury or death.

1. Inspect daily all mounting steps and hand holds


on the machine to make sure they are clean and
in safe working condition.
2. Repair or replace all damaged parts or
components before allowing any operation of the
machine.
IMPORTANT: Use steps and handholds when
mounting and dismounting the machine. Keep steps,
handholds, and step rails clean and in safe working
condition free of grease, oil, mud, ice, and snow.

FRAME STRUCTURE
1. Carefully inspect the entire frame structure for
signs of damage, broken welds, etc.
NOTE: Remove any excessive grease from the
attachment pin connecting areas to inspect welding.
2. Repair or replace all frame components found to
be damaged before allowing any operation of the
machine.
3. In cases where welding is required, consult your
authorized dealer for proper procedures. Use
only certified welding personnel familiar with
structural welding methods to perform repairs
requiring welding. Never allow current to flow
through a joint such as between a pin, bushing,
bearing, seal and/or between upper and lower
structures.

87722071 NA

Issued 01-08

Bur

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM


IMPORTANT: Before performing any work on the
hydraulic system, there should be no pressure in any
of the circuits.

1
2

WARNING: Never change oils or filters on a


machine that has just finished working. Allow
machine to cool until oils and fluids are warm,
not hot. Release hydraulic tank pressure
before
working
with
any
hydraulic
components. Failure to comply could result in
machine damage, injury or death.
1. Keep all non-authorized personnel clear of the
machine. Park the machine on firm, level ground,
lower the bucket/attachment to the ground and
stop the engine.

Figure 8

BS08A247

5. Make certain the hydraulic oil temperature is


below 40 C (104 F).
6. Open the door to the hydraulic tank (1) and
secure in place with strut.

BS07M861

7. Press the rubber cap (2) on the top of the


hydraulic tank 5 to 7 times.

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 40C (104 F).
Failure to comply with this warning could
result in injury or death.

6-6

Issued 01-08

Bur

87722071 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.

87722071 NA

Issued 01-08

Bur

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

As Required
(AR)

Every 8
hours

Every 50
hours

Every 250
hours

Every 500 hours

Every 1000
hours

Every 1500
hours

6-8

6-15

Fan and air conditioning drive belt

6-28

Air filter

6-31

Fuel tank filter

AR

8-11

Bolt and nut torque

AR

Rubber track (if equipped)

6-10

Grease bucket, boom, arm cylinder, dozer

6-11

Engine oil level

6-12

Coolant level

6-12

Radiator

6-12

Electrical connections

6-13

Water separator

6-13

Fuel tank level

6-14

Hydraulic reservoir level

6-15

Hydraulic lines

Fan/alternator belt tension

Rubber crawler belt

6-17

Attachment

6-17

Drain fuel tank sediment

6-18

Engine oil and filter

Run-in

6-19

Rubber track

Run-in

6-23

Fan/alternator belt tension

50

7-4

Battery check

50

Hydraulic return filter

6-26

Fan/alternator belt tension

6-27

Swing reduction gear

6-27

Boom, arm cylinder, dozer

6-28

Engine air cleaner element

6-29

Hydraulic return filter (Breaker attachment)

8-11

Bolt and nut torque

6-30

Fuel water separator

6-31

Fuel filter

6-32

Engine air cleaner elements

6-33

Travel reduction gear

Drain

AR

6-15

Engine oil and filter

AR

Run-in

6-16

6-24

Lubricate

AR
AR

6-19

6-25

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL
NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

50
50
50
50

Run-in

50
250
250

Run-in

250
250
250
250
250
500
500
500

Run-in

500

6-34

Radiator coolant

1000

6-36

Hydraulic return filters

1000

RM

Valve clearances

1000

RM

Starter/generator

1000

RM

Injector Timing

1500

Issued 01-08

Bur

87722071 NA

Every 2000
hours

Every 5000
hours

6-38

Hydraulic suction strainer

2000

6-40

Pilot valve

2000

6-41

Solenoid in-line filter

2000

Drain

Lubricate

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL
NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-43

Travel reduction gears

2000

6-44

Idler oil change

2000

RM

Swing gear grease

RM

Intake and exhaust

6-47

Hydraulic oil

2000
2000
5000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine
performance and protection.
NOTE: RM = See Repair Manual or contact Authorized Dealer

87722071 NA

Issued 01-08

Bur

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION AND MAINTENANCE


The following procedures are to be performed every 8 hours or daily, before starting the machine.
DOZER PIN GREASE POINTS
WARNING: Be cautious of hot fluids and
surfaces. Wear goggles, safety shoes, hard
hat, work clothes, and work gloves to perform
inspection and maintenance on this machine.

3
1
2
3

GREASE MACHINE AND ATTACHMENTS

Figure 11

BS07N035

1. DOZER CYLINDER ROD PIN (1)


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

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

BS07M861

During the initial 50 hours of operation during the


run-in period, grease bucket, boom, arm cylinder and
dozer every 8 hours. After the initial run-in period,
grease every 50 hours.

8
10

1. Move the machine to firm level ground and place


the bucket/attachment on the ground. Turn the
engine off.

11
6
5
9

Figure 12

BS07N033

1
2

Figure 10

BS07N028

1.
2.
3.
4.

4.
5.
6.
7.
8.
9.
10.
11.

BOOM FOOT PIN (1)


BOOM CYLINDER FOOT PIN (3)
BOOM CYLINDER ROD PIN (1)
ARM CYLINDER FOOT PIN (1)
ARM CYLINDER ROD PIN (1)
BOOM/ARM CONNECTING PIN (2)
BUCKET CYLINDER FOOT PIN (1)
BUCKET CYLINDER ROD PIN (1)

BUCKET CYLINDER ROD PIN


IDLER LINK/ARM CONNECTING PIN
BUCKET LINK PIN
ARM/BUCKET CONNECTING PIN

2. Clean the grease fitting before greasing. Replace


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

6-10

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


ENGINE OIL LEVEL

12

14

2
13
Figure 13

BS07N634

(5) BOOM CYLINDER FOOT PIN


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

(14) SWING BRACKET/FRAME CONNECTING PIN

IMPORTANT: Dispose of all waste in accordance


with environmental regulations.
WARNING: The machine and attachment
should not be moved when greasing.
Personal injury may result. Move attachment
to a different position, stop the engine and
lubricate the attachment again. Repeat this
procedure until the front attachment is
completely lubricated.

Figure 14

BS07N039

1. OIL DIPSTICK
2. FILLER CAP

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


should be changed at 50 hour run-in period and
at every 250 hours thereafter.
2. Raise the engine cover.
3. Pull engine dipstick out, clean it with a clean, dry,
lint free cloth. Reinsert into engine. Pull out again
to visually inspect the engine oil level on dipstick.
4. If necessary to add oil, remove oil filler cap and
fill engine oil to proper level.
NOTE: After adding oil, check oil level again, replace
filler cap and dipstick and close engine cover.

87722071 NA

Issued 01-08

Bur

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


ENGINE ELECTRICAL

ENGINE COOLANT LEVEL

2
3

1
4
Figure 16

DC04C292

Figure 15

BS07M872

1.
2.
3.
4.

RESERVOIR CAP
RADIATOR CAP
RADIATOR
RESERVOIR

1. Check coolant level every 8 hours. Coolant


should be changed at 1000 hours. The coolant
reservoir tank is located on the right side of the
engine compartment.
2. Proper coolant level is between FULL and LOW
marks.
3. If necessary to add coolant, remove reservoir
cap and fill to proper level with fresh coolant
mixture.

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.

4. If no coolant is shown in reservoir, check coolant


level in radiator. Fill radiator with proper coolant
mixture and replace cap. Then refill reservoir to
proper level. Inspect hoses and connections for
leaks.
WARNING: Never remove radiator cap
when engine is hot. Allow engine to cool
before removing radiator cap.

6-12

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


FUEL LEVEL

DRAIN WATER SEPARATOR

2
Figure 17

BS07M675

1. FUEL LEVEL GAUGE

1. Turn the ignition switch key ON and the fuel


gauge in the cluster will indicate the fuel tank
level.
2. To refuel the machine, remove the fuel tank cap.
Do not remove the fuel screen (if equipped) for
fueling. Refill fuel tank to full mark to reduce air
volume (condensation). Failure to do so could
create problems such as r usting and fuel
freezing, as well as other associated problems.

87722071 NA

Issued 01-08

Bur

BS07N030

Figure 18

1. Inspect water separator every 8 hours. Drain and


clean at 500 hours.
2. Visually inspect separator. If red ring (1) sinks to
bottom of case, no water is present.
3. When ring is floating, drain water and sediment.
4. Open valve (2) and drain until clean fuel is
discharged.
5. Repair or replace damaged hoses and lines
before any operation.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


HYDRAULIC OIL LEVEL
WARNING: Gasses from hydraulic tank may
be hot. Wear personal safety equipment.
Failure to comply could result in injury or
death.

2
3

Figure 19

BS07M861

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. 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.

Figure 21

BS07N635

1.
2.
3.
4.

CAP SCREW & WASHER


COVER PLATE
O-RING
SIGHT GAUGE

B. Slowly remove the mounting bolts (1) from the


cover plate.

1
2

C. Add hydraulic oil, filling hydraulic tank to the


proper level.
D. Clean and inspect the O-ring. Replace O-ring
if damaged. Lubricate the O-ring with
hydraulic oil and install the O-ring.
E. Install cover plate, cap screws and washers.
Tighten the cap screws to torque specification.
Refer to Torque Specification Table in the
Specifications Section.

Figure 20

BS08A247

1. COVER
2. AIR RELEASE BUTTON

A. Release all pressure from hydraulic tank. (See


releasing hydraulic pressure for additional
infor mation.)Depress air release button
several times to release hydraulic tank
pressure.

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.

6-14

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


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

HYDRAULIC OIL LEAKS

DC04C300

Figure 23

CHECK CRAWLER BELTS

Figure 22

DC04C287

Keep crawler belts free of dirt and imbedded rock for


maximum traction. Visually check for cracking,
separating, exposed core or other damage. Check
tension after the first 50 hours of initial operation.

WARNING: Never use your hand to check


for leaks. High pressure fluid leaks will
penetrate the skin and cause severe injury.
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.

87722071 NA

Issued 01-08

Bur

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


INSPECT ALTERNATOR/FAN BELT CONDITION
Visually check the belt every day. Belt tension should
be checked after the first 50 hours of run in time and
every 250 hours thereafter.

3
2

Figure 24

BS07N031

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

WARNING: Rotating parts can cause


extreme injury. Stop engine before servicing.
Keep away from fan and belt when engine is
running. Failure to comply could result in
injury or death.
Check belt for insufficient tension, wear, and
damage. A loose belt can cause battery charge
failure, engine overheating, or abnormal belt wear. If
too much tension is applied to the belt, the bearings
or belt may be prematurely damaged.
A belt is considered used when it has been on a
running engine for 5 minutes or more.
To check tension apply a force of 98 N (22 lb) to the
center of the belt and measure the deflection.

6-16

New belt tension

Used belt tension

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

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

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE:
DRAIN FUEL TANK SEDIMENT

ATTACHMENT LUBRICATION

2
3

1
2

Figure 25

BS07N028

1.
2.
3.
4.

BUCKET CYLINDER ROD PIN (1)


IDLER LINK/ARM CONNECTING PIN (1)
BUCKET LINK PIN (1)
ARM/BUCKET CONNECTING PIN (1)

During the first 50 hours of operation, grease


attachment every 8 hours. After the initial run-in
period, grease every 50 hours.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Place the cancellation lever in the
locked position. Keep all unauthorized personnel
clear of the area.
2. Clean the grease fitting before greasing. Replace
any damaged grease fitting.
3. Lubricate with a grease gun through the grease
fittings shown. Wipe off any grease that leaks out
of the pin connection.
IMPORTANT: Dispose of all waste in accordance
with environmental regulations.
WARNING: The machine and attachment
should not be moved when greasing.
Personal injury may result. Move attachment
to a different position, stop the engine and
lubricate the attachment again. Repeat this
procedure until the front attachment is
completely lubricated.

Figure 26

BS07N128

1. FUEL TANK
2. DRAIN PLUG

WARNING: Do not smoke or allow any open


flame near by when draining fuel. Stop
engine. Thoroughly clean up any spilled fuel.
Failure to comply could result in injury or
death.
Draining water and sediment is most effectively
performed in the morning. Turn the upper structure of
the machine so the drain plug (2) is midway between
the crawler belts.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Place the cancellation lever in the
locked position. Keep all unauthorized personnel
clear of the area.
2. Place a suitable container under the drain plug
(2) to catch the discharged fuel.
3. Slowly loosen the drain plug (2) to drain water
and sediment. When clean fuel begins to flow,
tighten the drain plug.
4. Check for fuel leakage after tightening drain plug.
If fuel is leaking, stop the engine, and consult
your authorized dealer for repair.

87722071 NA

Issued 01-08

Bur

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


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

ENGINE OIL LEVEL

Figure 28

BD07N032

1. OIL FILTER
2. FILTER WRENCH

7. Use the filter wrench provided with the machine,


and turn counter clockwise to remove the oil
filter.

Figure 27

BS07N029

1.
2.
3.
4.
5.

DRAIN CAP
COVER
DIPSTICK
OIL FILL CAP
DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a


new machine, then at every 250 hours thereafter.
1. 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 covers
4. Locate the engine oil drain plug and place an
empty oil container [7 L (2 gal) capacity] under
the plug. Attach the quick drain hose (5), and
drain the oil into the container.
5. Remove engine oil drain plug and let the engine
oil drain out completely.

6-18

Figure 29

BD07N040

8. To install the oil filter, apply a thin coat of engine


oil to the gasket (A) of the new oil filter, fill the
filter partially with engine oil and then secure the
filter by tightening 2/3 of a complete turn by hand
after the gasket comes in contact with the oil filter
head.
NOTE: Check the waste oil. If there are metal flakes
in the oil, contact your dealer. DO NOT reuse the oil
filter.
9. Clean oil drain plug and install it. Tighten
securely.
10. Fill with the specified amount of oil through filler
port (4) and install oil filler cap.
11. Before starting the engine, check oil level using
the dipstick (3). The level should be between the
L and H limits as shown. Start and run the engine
for five minutes. Stop the engine and recheck the
oil level after 30 minutes. Add oil if necessary.
12. Install under cover (2) to its original position.

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


TRACKS AND COMPONENTS
Check rubber track tension every 50 hours.

Figure 32

BS07N042

Figure 30

DC04C300

Abrasion on the rubber crawler belt varies depending


on working conditions. Frequently check for wear
and tension, particularly on a new crawler belt as
there will be an initial stretch during the first 30 hours
of operation.

3. Move the upper structure at 90 to the crawler


frame. Operate the attachment placing it on the
ground as illustrated and gradually lower the
boom to lift one side of the machine. Support the
lower travel structure with a safety support (1).

1. Visually inspect track shoes for signs of


excessive wear or damage.

BS07N043

1.
2.
3.
4.
Figure 31

BS07N041

2. Keep all unauthorized personnel clear of the


area. Move the rubber crawler belt so the joining
ends (M mark) comes to the upper center
position.

Figure 33

CRAWLER FRAME
LOWER ROLLER
RUBBER BELT
IRON SHOE

4. Measure the clearance in the center of the track,


between the bottom of the track frame and the
track shoe surface.
Measure Clearance (A)
Rubber belt 70 - 80 mm (2.76 - 3.15 in.)
Iron shoe: 115 - 130 mm (4.53 - 5.12 in.)
If track tension is not within the specifications, make
adjustments to the track.
NOTE: If working on firm, hard ground, more track
tension is recommended. If working on loose gravel
or stone, lower track tension is recommended.

87722071 NA

Issued 01-08

Bur

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING: Grease in track tensioning


mechanism is under extreme pressure and
can penetrate skin causing severe injury.
Keep face and body away from grease fitting
area. Never loosen grease fitting more than
one (1) complete turn. If grease does not
release after one (1) turn of the fitting, call
your authorized dealer for assistance. Failure
to comply could result in injury or death.

Figure 34

DC04C307

Figure 36

BS07N045

1.
2.
A.
B.

GREASE FITTING
GREASE CYLINDER
GREASE FILL
PRESSURE

INCREASING TRACK TENSION

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 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


REMOVING RUBBER CRAWLER BELT

ADJUSTING FOR LESS TENSION

1
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.

Figure 40

BS07N042

1. Keep all unauthorized personnel clear of the


area. Park the machine on a hard, level surface.
Move the upper structure at a 90 to the crawler
frame. Operate the attachment placing it on the
ground as illustrated and gradually lower the
boom to lift one side of the machine. Support the
lower travel structure with a safety support (1).

1
Figure 39

BS07N047

3. After grease has been released, tighten the


grease fitting.
Torque to: 73.5 14.7 Nm (54.2 10.8 lbf ft).
Move the machine forward and backward to
confirm the correct tension of the crawler belt. If
necessary, adjust again.

87722071 NA

Issued 01-08

Bur

BS07N046

Figure 41

2. Gradually loosen the grease fitting to release


grease under pressure. Loosen the grease fitting
(1) less than one turn. Grease will flow from the
fitting (2).

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


Replacing the Rubber Crawler Belt

1
1
BS07N049

Figure 42

3. Insert three steel pipes into the bottom front


rubber crawler belt, then slowly rotate the
sprocket backward by moving the track.
4. Stop the rotation when the rubber crawler belt
separates from the idler wheel. Shut off the
engine.
5. Slide the crawler belt over the steel pipes to
remove.

Figure 43

BS07N042

1. Keep all unauthorized personnel clear of the


area. Park the machine on a hard, level surface.
Move the upper structure at a 90 to the crawler
frame. Operate the attachment placing it on the
ground as illustrated and gradually lower the
boom to lift one side of the machine. Shut off the
engine. Support the lower travel structure with a
safety support (1).

1
Figure 44

BS07N049

2. Engage the rubber crawler belt with the sprocket


and hang it on the idler.
3. Insert three steel pipes into the bottom front
r ubber crawler belt then slowly rotate the
sprocket backward. When the rubber crawler belt
separates from the idler wheel, stop the rotation.
Shut off the engine.
4. Slide the rubber crawler belt over the steel pipes
to install it.

6-22

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


INSPECT 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.

5
2
4
1

7
3

Figure 45

BS07N050

1.
2.
3.
4.
5.
6.
7.

Figure 46

BS07N031

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

WARNING: Rotating parts can cause


extreme injury. Stop engine before servicing.
Keep away from fan and belt when engine is
running. Failure to comply could result in
injury or death.
Check belt for insufficient tension, wear, and
damage. A loose belt can cause battery charge
failure, engine overheating, or abnormal belt wear. If
too much tension is applied to the belt, the bearings
or belt may be prematurely damaged.

5. Stop the rotation of the sprocket to confirm the


rubber crawler belt is securely engaged to the
sprocket, idler, and lower rollers. See illustration.
6. Check the tension on the belt and make any
adjustments necessary.
7. If tension is correct, lower the machine to the
ground.

ADJUSTING BELT
1. Slightly loosen attaching bolt (1) and adjusting
bolt (2).
2. Loosen adjusting bolt (3) adjust the fan belt to
the correct tension, and tighten bolts (1) and (2).
3. After adjustment, run the engine at low idle for
approximately 5 minutes, then recheck the
tension of belt.
New Belt Tension

Used Belt Tension

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

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

NOTE: A used belt refers to a belt that has been run


5 minutes or more.

87722071 NA

Issued 01-08

Bur

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


HYDRAULIC RETURN FILTER

1
2
3
6
1

4
5

BS07M861

Figure 47

Replace the hydraulic return filter when the machine


is new at 50 hours during the run-in period. The
hydraulic return filter should be replaced every 1000
hours thereafter.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
2. Make certain to remove all hydraulic pressure
from the system.
WARNING: Hydraulic fluid is under extreme
pressure. Make certain all pressure is
released in the hydraulic system. Failure to
comply could result in injury or death.
3. Open the cover to the hydraulic tank and secure
with the strut.
4. Clean any dirt from the filter area to avoid
contaminating the hydraulic system.

Figure 48

BS07N636

5. Press the valve (several times: 5 to 7 times)


together with the breather cap (8), and bleed the
hydraulic oil tank of the remaining pressure.
6. Remove bolt (1), spring washer (2) and cover (3)
from the upper surface of the tank.
7. Take the spring (4), valve (5) and element (6) out
of the tank.
8. Replace O-ring (7) fitted on the face of cover (3).
9. Clean the parts taken out with light oil.
10. Install element by reversing the disassembly
procedure.
11. Install cover (3).
Tightening torque: 23.52 Nm {171.4 lbfft}
12. Start and run the engine at idle. Move the
machine controls to remove air from the system.
Then place the machine in position to check the
oil level.
Stop the engine and check the oil level adding
oil, if need.
13. Close the cover on the hydraulic oil tank and
lock.

6-24

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE


ENGINE OIL LEVEL

4
2

Figure 50

BD07N032

1. OIL FILTER
2. FILTER WRENCH

7. Use the filter wrench provided with the machine,


and turn counter clockwise to remove the oil
filter.

2
3

Figure 49

BS07N029

1. DRAIN CAP
2. COVER
3. DIPSTICK

4. OIL FILL CAP


5. DRAIN HOSE

Change oil and oil filter at 50 hour run-in period for a


new machine, then at every 250 hours thereafter.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
2. Raise the engine cover. Remove the dipstick to
allow oil to run more freely.
3. Remove bolts and engine belly pan covers
4. Locate the engine oil drain plug and place an
empty oil container [7 L (2 gal) capacity] under
the plug. Attach the quick drain hose (5), and
drain the oil into the container.
5. Remove engine oil drain plug and let the engine
oil drain out completely.
6. After draining oil, remove drain hose, and tighten
drain cap (1) securely. Remove any spilled oil.
87722071 NA

Issued 01-08

Bur

BD07N040

Figure 51

8. To install the oil filter, apply a thin coat of engine


oil to the gasket (A) of the new oil filter, fill the
filter partially with engine oil and then secure the
filter by tightening 2/3 of a complete turn by hand
after the gasket comes in contact with the oil filter
head.
NOTE: Do not reuse the oil filter.
9. Clean oil drain plug and install it. Tighten
securely.
10. Check drained oil for any metal shavings, flakes,
or particles. Contact your dealer if any debris is
found.
11. Fill with the specified amount of oil through filler
port (4) and install oil filler cap.
12. Before starting the engine, check oil level using
the dipstick (3). The level should be between the
L and H limits as shown. Start and run the engine
for five minutes. Stop the engine and recheck the
oil level after 30 minutes. Add oil if necessary.
13. Install cover (2) to its original position.
6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


INSPECT AND ADJUST FAN/ALTERNATOR BELT
Check and adjust the fan/alternator belt every 250
hours.

Adjusting Belt
1. Slightly loosen attaching bolt (1) and adjusting
bolt (2).
2. Loosen adjusting bolt (3) adjust the fan belt to
the correct tension, and tighten bolts (1) and (2).

3. After adjustment, run the engine at low idle for


approximately 5 minutes, then recheck the
tension of belt.

New Belt Tension

Used Belt Tension

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

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

NOTE: A used belt refers to a belt that has been run


5 minutes or more.
Figure 52

BS07N031

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

BOLT AND NUT TORQUE


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

WARNING: Rotating parts can cause


extreme injury. Stop engine before servicing.
Keep away from fan and belt when engine is
running. Failure to comply could result in
injury or death.
Check belt for insufficient tension, wear, and
damage. A loose belt can cause battery charge
failure, engine overheating, or abnormal belt wear. If
too much tension is applied to the belt, the bearings
or belt may be prematurely damaged.

6-26

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87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


DOZER PIN GREASE POINTS

BOOM, ARM, AND ATTACHMENT GREASE


POINTS

3
7

10

11
6
5
9
Figure 53

BS07N035

Figure 55

BS07N033

1. DOZER CYLINDER ROD PIN (1)


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

4.
5.
6.
7.
8.
9.
10.
11.

When machine is new, during the first 50 hours of


operation, grease attachment, boom, arm, and boom
swing every 8 hours. After the initial run-in period,
grease every 250 hours.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

BOOM FOOT PIN (1)


BOOM CYLINDER FOOT PIN (3)
BOOM CYLINDER ROD PIN (1)
ARM CYLINDER FOOT PIN (1)
ARM CYLINDER ROD PIN (1)
BOOM/ARM CONNECTING PIN (2)
BUCKET CYLINDER FOOT PIN (1)
BUCKET CYLINDER ROD PIN (1)

BOOM SWING GREASE POINTS

2. Clean the grease fitting before greasing. Replace


any damaged grease fitting.

15

3. Lubricate with a grease gun through the grease


fittings shown. Wipe off any grease that leaks out
of the pin connection.

12

IMPORTANT: Dispose of all waste in accordance


with environmental regulations.

14

GREASING THE SWING BEARING

13
BS07N034

12.
13.
14.
15.

Figure 56
SWING CYLINDER FOOT PIN (1)
SWING CYLINDER ROD PIN (1)
SWING BRACKET/FRAME CONNECTING PIN (2
SLEWING GEAR (1)

1. Park the machine on a firm, level surface with


both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
Figure 54

BS07N130

Grease the swing bearing by adding grease to each


fitting (4 locations) until grease comes out fittings.
WARNING: Do not swing the machine while
greasing the swing bearing.
87722071 NA

Issued 01-08

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2. Clean the grease fitting before greasing. Replace


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

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


CLEANING AND REPLACING ENGINE AIR
FILTER
Clean the air filter element every 250 hours. After
cleaning six times or at six month intervals, the
element should be replaced at 500 hours. If any
damage is visible to the filter, replace it regardless of
machine time or scheduled maintenance.

BS07N637

6. After cleaning, use a light to check the inside of


the element for tearing, pinholes, or packing
d a m a g e. R e p l a c e w i t h a n ew e l e m e n t , i f
necessary.
7. Set outer element (1) in the housing.
8. Install the cover on two clamp (2) positions,
directing the mark "TOP" on the cover to the inlet
side

1 3

Figure 57
Figure 59

BS07N664

IMPORTANT: When cleaning outer element, do not


remove inner element to prevent dust from entering
the air intake.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

9. The TOP position mark should face up. Make


certain to avoid interference with the intake hose.
Incline the air filter casing approximately 15 to
the engine side.
REPLACING THE INNER ELEMENT
(IF EQUIPPED)

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


cover.

1 3

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


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

Figure 60

BS07N637

10. The inner element is an optional part. To replace,


remove the inner element (3).
11. Install new inner element (3) and outer element
(1). Replace cover. Make certain the O-ring seal
is correctly positioned.
BS07N132

Figure 58

5. To clean the outer element (1), blow compressed


air (less than 0.3 MPa {43 psi}) up and down
along the folds of the filter element interior to
remove clogged dust or other contaminants.

6-28

IMPORTANT: For machines equipped with double


elements, the inner element must be replaced
together with the outer element. Do not clean inner
element. Replace only with a new element.

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


HYDRAULIC RETURN FILTER (BREAKER USE)

1
2
3
6

4
5

Figure 61

BS07M861

Replace the hydraulic return filter at 250 hours if you


are using a breaker/nibbler attachment.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
WARNING: Hydraulic fluid is under extreme
pressure. Make certain all pressure is
released in the hydraulic system. Failure to
comply could result in injury or death.
2. Remove all pressure from the hydraulic system.
3. Open the cover to the hydraulic tank and secure
with the strut.
4. Clean any dirt from the filter area to avoid
contaminating the hydraulic system.

BS08A248

Figure 62

5. Press the valve (several times: 5 to 7 times)


together with the breather cap (8), and bleed the
hydraulic oil tank of the remaining pressure.
6. Remove bolt (1), spring washer (2) and cover (3)
from the upper surface of the tank.
7. Take the spring (4), valve (5) and element (6) out
of the tank.
8. Replace O-ring (7) fitted on the face of cover (3).
9. Clean the parts taken out with light oil.
10. Install element by reversing the disassembly
procedure.
11. Install cover (3).
Tightening torque: 23.52 Nm {171.4 lbfft}
12. Start and run the engine at idle. Move the
machine controls to remove air from the system.
Then place the machine in a level position to
check the oil level. Stop the engine and check
the oil level, adding oil if necessary.
13. Close the cover on the hydraulic oil tank and
lock.

87722071 NA

Issued 01-08

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6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE


CLEAN AND DRAIN WATER SEPARATOR
Check the water separator every 8 hours. Clean and
Drain the engine water separator every 500 hours.

2
7
4
8

5
1
6

9
1

1.
2.
3.
4.
5.
6.
7.
8.
9.
A.
B.
C.
D.

5
8
6
3
BS07N135

Figure 64

BS07N136

AIR BREATHER PLUG


HANDLE (FUEL VALVE)
DRAIN VALVE
ELEMENT
RING (RED)
SPRING
O-RING
CASE
RING
IN
OUT
FUEL VALVE CLOSED
FUEL VALVE OPEN

Figure 63

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. Visually inspect separator. If red ring (1) sinks to
bottom of case, no water is present.
3. When ring is floating, drain water and sediment.
4. Open valve (2) and drain until clean fuel is
discharged.
5. The components of the water separator must be
removed to clean. Take care not to lose red ring
and spring. Do not use gasoline to clean the filter
elements. Wipe off any spilled fuel.

Figure 65

BS07N137

6. Push the handle (2) of the water separator


upward to the CLOSE position (C).
7. Loosen the ring (9) to remove the case (8) and
drain water out.
8. When the water is drained, clean the element (4)
inside and out. Replace the O-ring with a new
one.
9. Install the element (4) to the water separator
body. Place the O-r ing 7 on the case (8),
reassemble, then tighten.
10. Push the handle (2) downward to set at OPEN.
11. After draining water and cleaning, bleed air from
the fuel system.

6-30

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87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


REPLACING FUEL FILTER
The fuel filter should be replaced at 500 hours. The
fuel filter should not be reused. It must be replaced.

BD07N040

Figure 66

BS07N398

WARNING: Engine and components stay


hot after operating. Allow machine to cool
before servicing. Failure to comply could
result in injury or death.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

Figure 67

5. Apply a thin coating of grease to the seal of the


new oil filter. Install and tighten by hand, turning
about 2/3 of a turn after the seal contacts the
engine.
6. Start and run the engine at idle for 5 minutes to
check for leaks.
7. Close the engine door and install the cover
located under the engine.
IMPORTANT: Dispose of all hazardous waste
properly
according
to
local
environmental
regulations.

2. Allow the machine to cool. Open the engine door


and remove the lower cover.
3. Place the filter wrench on the filter cartridge (1),
and remove the filter.
4. Wipe off any dirt on the seal face of filter base to
avoid contamination.

87722071 NA

Issued 01-08

Bur

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


CLEANING AND REPLACING ENGINE AIR
FILTER
Clean the air filter element every 250 hours. After
cleaning six times or at six month intervals, the
element should be replaced at 500 hours. If any
damage is visible to the filter, replace it regardless of
machine time or scheduled maintenance.

1 3

Figure 70

BS07N664

7. The TOP position mark should face up. Make


certain to avoid interference with the intake hose.
Incline the air filter casing approximately 15 to
the engine side.
REPLACING THE INNER ELEMENT
(IF EQUIPPED)
BS07N637

Figure 68

IMPORTANT: When cleaning outer element, do not


remove inner element to prevent dust from entering
the air intake.

1 3

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


cover. Remove the air cleaner outer element (1)
from the housing.
2. Clean the inside of air cleaner housing.

Figure 71

BS07N131

8. The inner element is an optional part. To replace,


remove the inner element (3).
9. Install new inner element (3) and outer element
(1). Replace cover. Make certain the O-ring seal
is correctly positioned.
BS07N132

Figure 69

3. To clean the outer element (1), blow compressed


air (less than 0.3 MPa {43 psi}) up and down
along the folds of the filter element interior to
remove clogged dust or other contaminants.

IMPORTANT: For machines equipped with double


element, the inner element must be replaced
together with the outer element. Do not clean inner
element. Replace only with a new element.

4. After cleaning, use a light to check the inside of


the element for tearing, pinholes, or packing
damage. Replace with a new element every 500
hours or anytime damage is evident.
5. Set outer element (1) in the housing.
6. Install the cover on two clamp (2) positions,
directing the mark "TOP" on the cover to the inlet
side
6-32

Issued 01-08

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87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


TRAVEL REDUCTION GEAR
The travel reduction gear oil should be changed at
500 hours for a new machine. Change the travel
reduction gear oil every 2000 hours thereafter.

2
3

BS07N670

1
Figure 72

BS07N668

Figure 74

5. After oil has been drained out completely, clean


DRAIN plug. Use teflon tape on DRAIN plug for
additional sealing and install plug. Tighten
securely.

1. DRAIN PORT
2. FILL PORT

6. Add engine oil through the oil FILL opening (2)


until oil starts flowing out of the port (3).

1. Park the machine on a firm, level surface with


both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

7. Clean oil FILL plug. Use teflon tape on plug for


additional sealing and install plug. Tighten plug
securely.

2. When parking the machine, make certain the


drain port (1) is at the bottom.

8. Check drained oil for any metal particles. If


contaminant are present, contact your dealer.
WARNING: Travel reduction gear is under
pressure. Keep your face and body clear of
drains. Never attempt to service a hot
machine. Allow the machine to cool before
performing any service. Heat increases travel
reduction gear oil pressure. Loosen plug
slowly and wear face protection. Failure to
comply could result in injury or death.

Figure 73

BS07N669

3. Stop engine and place an empty container under


the drain plug.
4. Remove oil FILL and DRAIN plugs to drain oil
into the container.

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Issued 01-08

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6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE


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

6. To drain radiator, place a rag or paper towel on


the radiator cap and slowly remove it to release
the pressure.
7. Drain the radiator with drain hose.
8. After draining, install the drain plug (2). Fill the
cooling system with system cleaner according to
cleaner container instructions.

11

3
Figure 76

BS07N142

9. Operate the engine at a speed slightly faster


than low idling (5) to raise the coolant
temperature to 80 C (176 F) or within white
range on the temperature gauge for coolant
t e m p e r a t u r e . O p e r a t e t h e e n g i n e fo r
approximately 10 minutes.

2
UPW00400091J01

1. RADIATOR HOSE CLAMP


2. RADIATOR CAP

Figure 75
3. RADIATOR HOSE

10. Stop the engine. Allow the system to cool.


Loosen the radiator cap slowly. After ensuring
that the pressure has been released, push the
cap down and hold while turning to remove.
Loosen the radiator drain plug (2). Flush the
radiator (3) with clean water until the water runs
clear.

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.

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

2. Open the engine cover and secure it with strut.

12. Stop the engine. Allow the engine to cool. Check


the coolant level. The reservoir tank (4) water
level should be between FULL and LOW. Adjust
level to specifications.

3. Check the hoses for leakage due to loose


clamps, or cracked and worn hoses.
4. Tighten any loose clamps.
5. Replace any hoses that are damaged. See
replacing radiator hoses for further information.

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

WARNING: Use extreme caution when


removing the radiator cap. The coolant is
under high pressure when hot. Never remove
the radiator cap when system is hot. Allow
sufficient time for machine to cool down.
Failure to comply could result in injury or
death.
6-34

Issued 01-08

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87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


REPAIRING HOSES

CHECK VALVE CLEARANCES

1. Drain coolant into clean container for reuse if not


changing coolant.
2. Clean the areas where the new hose will be
connected.
3. Remove the clamps (if reusing old clamps) from
the old hose and install them to the new hose.
4. Coat the inside ends of the new radiator hose
with grease and install. Tighten clamps securely.

Check and adjust the engine valve clearance every


1000 hours of engine operation. Contact your Case
Dealers Service Department for assistance.
CHECK STARTER AND GENERATOR
Have the starter and generator checked every 1000
hours of engine operation. Contact your Case
Dealers Service Department for assistance.

5. Fill radiator with coolant.


6. Install radiator cap, start engine, and bring
engine temperature to about 90C (194F).
7. Run engine at low idle, check for leaks and repair
as needed.
8. Install radiator lower cover and close engine
cover.
NOTE: Refer to LUBRICATION, FILTERS, AND
FLUIDS section for proper engine coolant and
capacity.
9. Inspect radiator cap for proper fit and pressure,
and replace if needed.

87722071 NA

Issued 01-08

Bur

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


HYDRAULIC RETURN FILTER

1
2
3
1

4
5

BS07M861

Figure 77

Replace the hydraulic return filter at 250 hours if you


are using a breaker/nibbler attachment.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
WARNING: Hydraulic fluid is under extreme
pressure. Make certain all pressure is
released in the hydraulic system. Failure to
comply could result in injury or death.
2. Release all pressure from the hydraulic system.
3. Open the cover to the hydraulic tank and secure
with the strut.

Figure 78

BS08A248

4. Clean any dirt from the filter area to avoid


contaminating the hydraulic system.

5. Press the valve (several times: 5 to 7 times)


together with the breather cap (8), and bleed the
hydraulic oil tank of the remaining pressure.
6. Remove bolt (1), spring washer (2) and cover (3)
from the upper surface of the tank.
7. Take the spring (4), valve (5) and element (6) out
of the tank.
8. Replace O-ring (7) fitted on the face of cover (3).
9. Clean the parts taken out with light oil.
10. Install element by reversing the disassembly
procedure.
11. Install cover (3).
Tightening torque: 23.52 Nm {171.4 lbfft}
12. Start and run the engine at idle. Move the
machine controls to remove air from the system.
Then place the machine in level position to check
the oil level. Stop the engine and check the oil
level, adding oil, if necessary.
13. Close the cover on the hydraulic oil tank and
lock.

6-36

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1500 HOUR MAINTENANCE


CHECK INJECTION TIMING
Have the injection timing checked every 1500 hours
of engine operation. Contact your Case Dealers
Service Department for assistance

87722071 NA

Issued 01-08

Bur

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE


HYDRAULIC SUCTION STRAINER CLEANING

The hydraulic tank suction strainer should be


cleaned when the engine hour meter registers 2000
hours and every 2000 hours there after.

3
4

6
1

Figure 79

BS07M861

WARNING: Do not perform any service work


on a machine that is hot. Allow the machine
and components to cool before performing
any work on fluids and oils. Failure to comply
could result in injury or death.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

Figure 81

BS07N665

5. Loosen the four cap screws (2) and lock washers


( 3 ) . R e m ove c ove r ( 4 ) . B e c a r e f u l n o t t o
accidently drop bolts or nuts into the tank during
this procedure.

WARNING: Hydraulic fluid is under extreme


pressure. Make certain all pressure is
released in the hydraulic system. Failure to
comply could result in injury or death.

2. Open the cover to the hydraulic tank and secure


with the strut.

1
Figure 82

BS07N667

6. Remove strainer (5) and clean with light oil or by


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

BS07N146

Figure 80

3. Release all pressure from the hydraulic system.


Press the valve 5 to 7 times together with the
breather cap (1).
4. Clean any dirt from the filter area to avoid
contaminating the hydraulic system.
6-38

Issued 01-08

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87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2
3
4
5

Figure 83

BS07N667

8. Insert strainer (5) into suction tube. Install cover


(4) with cap screws (2) and lock washers (3).
Torque to: 23.51.98 Nm (171.4 lbf ft).
9. Start the engine and operate at low idle for 5 to 7
minutes. Operate each cylinder and swing.
Retur n the machine to the hydraulic level
checking position. Stop the engine and check the
hydraulic oil. If level is low, add oil.

87722071 NA

Issued 01-08

Bur

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


PILOT VALVE AND SOLENOID VALVE
Clean the pilot valve filter and solenoid filter when the
hour meter registers 2000 hours.

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
3
Figure 85

BS07N147

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


remove the cover.
BS07M861

Figure 84

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.

4. Disconnect the hose (1) connected to P port on


the pilot valve (4), then remove connector with
filter (2).
5. After removal, put a plug into the bore to prevent
entry of foreign matter.
6. Wear face protection, wash the filter with
cleaning solvent. Use compressed air to remove
any material.

WARNING: Hydraulic fluid is under extreme


pressure. Make certain all pressure is
released in the hydraulic system. Failure to
comply could result in injury or death.
2. Release all pressure to the hydraulic system.

6-40

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

7a

7b 7c

7d 7e

8
7

BS07N149

Figure 87

7a.CASE
7b.STRAINER

7c.LABEL
7d.O-RING
7e.FITTING
Figure 86

BS07N148

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


necessary.
8. After cleaning, install to the original position in
reverse order. See torque charts.
9. Remove the in-line filter (7) of solenoid valve (6)
for cleaning.
10. Remove the right-hand guard (8).
11. After removal of the hose, remove the in-line filter
assembly (7) from the tee installed on the
solenoid valve (6). After removal, the oil holes of
tee and hose should be plugged.

87722071 NA

Issued 01-08

Bur

12. Remove the case (7a) and the fitting (7e), and
then remove strainer (7b) with screwdriver.
13. Spray light oil or air on the strainer (7b) to clean.
Clean the inside of the case (7a). Check the
O-ring (7d) for damage, if it is damaged, replace
it with new one.
14. Install the strainer (7b) on the fitting (7e) with
screwdriver, and fit in the in-line filter case (7a).
Tightening torque: 59 to 79 Nm {43 to 58 lbfft}
15. Remove the plug, install the in-line filter
assembly (7) on the solenoid valve (6), and then
install hose (1).

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

12
12
99
11

12

13

10
9
Figure 89

BS07N150

18. Dust tends to accumulate on the inside elbow (9)


(cur ved area). Clean par ts to avoid
contamination (projected portion).
19. Check the O-ring (12) for damage, and replace, if
damaged.
UPW00400107J01

Figure 88

16. Remove the elbow with filter (9) of pilot valve


(10) for cleaning.
17. Remove the floor mat and floor plate. Disconnect
the hose (11) connected to P port on the pilot
valve (10). Remove the elbow (9). After removal,
put a plug into the bore to prevent entry of
foreign matter.

6-42

20. After cleaning, install to the original position in


the reverse order of disassembly. Refer to
torque charts for tightening hose (11).
21. Reinstall the floor mat and floor plate.

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


TRAVEL REDUCTION GEAR
The travel reduction gear oil should be changed at
500 hours for a new machine. Change the travel
reduction gear oil every 2000 hours thereafter.

2
3

BS07N670

1
Figure 90

BS07N668

Figure 92

5. After oil has been drained out completely, clean


DRAIN plug. Use teflon tape on DRAIN plug for
additional sealing and install plug. Tighten
securely.

1. DRAIN PORT
2. FILL PORT

6. Add engine oil through the oil FILL opening (2)


until oil starts flowing out of the port (3).

1. Park the machine on a firm, level surface with


both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.

7. Clean oil FILL plug. Use teflon tape on plug for


additional sealing and install plug. Tighten plug
securely.

2. When parking the machine, make certain the


drain port (1) is at the bottom.

8. Check drained oil for any metal particles. If


contaminants are present, contact your dealer.
WARNING: Travel reduction gear is under
pressure. Keep your face and body clear of
drains. Never attempt to service a hot
machine. Allow the machine to cool before
performing any service. Heat increases travel
reduction gear oil pressure. Loosen plug
slowly and wear face protection. Failure to
comply could result in injury or death.

Figure 91

BS07N669

3. Stop engine and place an empty container under


the drain plug.
4. Remove oil FILL and DRAIN plugs to drain oil
into the container.

87722071 NA

Issued 01-08

Bur

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


UPPER AND LOWER ROLLER - IDLER OIL
CHANGE

1. Park the machine on a firm, level surface with


both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
2. Loosen the rubber crawler shoe. Loosen the cap
screws (1) of the lower roller about one turn.
3. Start up the engine and lift up the side of the
machine with the boom and arm.

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


Stop the engine.

Figure 93

BS07N259

1.
2.
3.
4.
5.
6.

TRAVEL MOTOR
SPROCKET
LOWER ROLLER
CRAWLER BELT
UPPER ROLLER
IDLER

Idlers must be removed from the crawler frame to


change the gear oil. Refer to the oil and grease
specification for the required volume.
WARNING: Do not perform any service work
on a machine that is hot. Allow the machine
and components to cool before performing
any work on fluids and oils. Failure to comply
could result in injury or death.

WARNING: Grease in track tensioning


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

Figure 95

BS07N261

5. Remove the capscrews (1) with washers (2)


which install the lower roller to the crawler frame
at two positions. Remove the lower roller (3).
6. Remove the feeding port plug (4) with allen
wrench, and discharge the old engine oil.
7. Fill with the specified volume (35 cc or 2.1 cu.in)
of engine oil through the feeding port.
8. Apply sealing (teflon) tape to thread on the plug
(4), and securely tighten it. Thoroughly wipe off
oil adhered to periphery.
9. Apply Loctite #262 to thread on the capscrews
(1), and temporarily install the lower roller (3) to
the crawler frame.
10. Remove the safety support which supports the
machine, then tighten the capscrew (1).
Tightening torque: 208 21 Nm {153 15 lbfft}
11. 11.Lift up the machine to adjust the crawler shoe
tension referring to Adjusting Track Tension.

BS07N260

Figure 94

1.
6-44

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


IDLER OIL CHANGE

3
2
1
6
5
3

Figure 96

BD07N262

BS07N263

WARNING: Check and adjustment for track


tension requires the machine to be lifted off
the ground one track at a time. Unexpected
lowering of the machine could result in injury
or death. Do not operate the boom while
adjusting the crawler belt. Failure to comply
could result in injury or death.
1. This is a two person procedure. If you doubt your
ability to perfor m this procedure, call your
authorized dealer. See procedure for removing
and installing crawler belt in this section.
2. Remove the rubber crawler belt. Place a safety
support under the machine.
3. Remove the idler (1) and adjuster (2) from the
crawler frame.
Weight of idler + Idler Adjuster =
approximately. 40 kg (88 lb)

Figure 97

NOTE: Check the drained waste oil. If there are


metal flakes in the oil, contact your Case Dealer. DO
NOT reuse the oil filter.
6. Apply sealing (teflon) tape to the threads on the
plug (3), and securely tighten it. Wipe off any
remaining oil.
7. Apply grease to the sliding face (A) on the piston
(4) and cylinder (5) of the idler adjuster (2).
8. Install the idler so that the fill - drain port plug (3)
of idler and the grease fitting (6) of idler adjuster
(2) are facing to outside.
9. Install the rubber crawler belt.
10. Adjust the tension on the rubber crawler belt.
Refer to procedure for adjusting belt tension.
Raise the machine off the safety support, remove
the safety support and slowly lower the machine
to the ground.

4. Remove the fill drain plug (3) with Allen wrench


to drain old gear oil.
5. Fill the idler with (80 cc {4.8 cu.in.}) of the
specified oil through the fill drain port.

87722071 NA

Issued 01-08

Bur

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


UPPER ROLLER OIL CHANGE

CHANGE SWING GEAR GREASE


If the machine is operated in a water depth close to
the swing gear grease bearing, the water may
become mixed with the grease and cause it to
deteriorate. Continued operation with deteriorated
grease will cause damage to the gears and bearing.
Contact your dealer for service and inspection.

This procedure should be completed by a qualified


service professional.

INTAKE AND EXHAUST VALVE CHECK

5
Figure 98

BD07N264

To ensure the seal of the exhaust and intake valves,


contact your dealer for service and inspection. this
procedure should be completed by a qualified
service professional.

The crawler belts must be removed to service the


idlers. See procedure for removing and installing
crawler belts in this section.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
2. Loosen the rubber crawler belt (6).
3. Raise the rubber crawler belt with a hydraulic
jack (5).

2 3

BS07N265

Figure 99

4. Loosen the nuts (2) and the bolts (3) used to


assemble the upper roller (1) to the machine and
remove it.
5. Remove the oil fill - drain port plug (4) with an
Allen wrench, and drain old gear oil.
6. Fill the upper roller with 45 cc {2.7 cu.in} of the
specified oil through the fill - drain port.
7. Apply sealing (teflon) tape to the threads on the
plug (4) and securely tighten it. Thoroughly wipe
off any remaining oil.
8. Install the roller in reverse order of disassembly.
Apply thread lock sealant (Three Bond #1324) on
thread of the bolts (3), tighten the screws.
Tightening torque: 667 Nm {485 lbfft}
6-46

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE


CHANGE HYDRAULIC OIL

2
3
4

6
6

BS07N269

Figure 100

BS07N268

WARNING: Allow machine to cool. Release


hydraulic pressure before servicing any
hydraulic component. Hydraulic fluid is under
extreme pressure and can cause severe
injury. Failure to comply could result in injury
or death.
1. Park the machine on a firm, level surface with
both attachments resting on the ground. Turn the
engine off. Keep all unauthorized personnel clear
of the area.
2. Park the machine so the drain plug (1) on the
hydraulic oil tank comes midway between both
crawlers. Make certain all pressure is removed
from the hydraulic system.
3. Remove the right side guard.
4. Open the cover on the hydraulic tank with the
engine key, and secure open with the strut.
5. Clean dirt from the filter to avoid contaminating
the hydraulic system.
6. Press the valve 5 to 7 times together with the
breather cap (8), and bleed the remaining
pressure from the hydraulic oil tank.

87722071 NA

Issued 01-08

Bur

7. Place a container (40 L {11 gal.}) beneath the


drain plug (1). Remove the drain plug (1) with a
27 mm wrench and drain the remaining oil.
8. Tighten the drain plug (1).
Tightening torque 73.5 5 Nm (54.2 3.7 lbf. ft.)
9. Loosen the four bolts (2) and lock washers (3).
Remove cover (4).
10. Check O-ring for damage, and replace if
necessary.
NOTE: Use caution not to drop bolts or nuts inside
hydraulic tank. Do not allow fluid to come in contact
with skin.
11. Fill the hydraulic oil tank with hydraulic oil at
filling por t (F) according to machine
specifications.
12. Install cover (4) with bolts (2) and lock washers
(3).
Tightening torque:
23.5 2 Nm (17 1.4 lbf. ft.)
13. Install the right side guard.
14. After starting the engine, run at low idle. Perform
several telescopic movements of each cylinder
and the swing operation. Return the machine to
the hydraulic oil level check position, and check
the oil level.

6-47

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.

2
Figure 103

BS07N272

6. SAFETY BLOCK
7. HAMMER
8. PUNCHING TOOL

1. Using a hammer and punch, hammer out the


locking pin. Take care not to damage the rubber
lock pin (3).

Figure 101

BS07N269

WARNING: When replacing a bucket tooth


or side cutters, securely block the bucket to
avoid injury.
Replace the bucket tooth if small holes appear on the
tooth point or when the edge lines of the tooth point
are worn.

1
2

3. Clean the surface of the adapter nose (1) with a


putty knife to remove any adhered soil.
4. Fit the tooth point (2) onto the adapter nose (1).
5. Push the rubber lock pin (3) in the hole of the
adapter nose (1).
6. Drive the locking pin (4) until it is aligned with the
point face.

5
Figure 102

BS07N271

1.
2.
3.
4.
5.

6-48

Figure 104

BS07N273

2. Inspect the locking pin (4) and rubber lock pin


(3). Replace them if the locking pin (4) is too
shor t or the r ubber lock pin (3) is in poor
condition.

ADAPTER
TOOTH POINT
RUBBER LOCK PIN
LOCKING PIN
ADAPTER NOSE

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


REPLACING THE SIDE CUTTERS

REPLACING BUCKET

7
8

1
Figure 105

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: 11512 Nm {84.68.7 lbfft}
4. After tightening the nuts, spot-weld them.

3
2
BS07N276

Figure 107

4
3
Figure 106

DC04C362

1.
2.
3.
4.

WARNING: When replacing a bucket tooth


or side cutters, securely block the bucket to
avoid injury. Do not insert fingers to align pin
bores. Align visually or with a tool. Failure to
comply could result in injury or death.
1. Carefully operate the boom and the arm to
remove load from the pins.
2. Roll O-rings (1) onto the bucket boss. After
removing the pins, place them back in the
original position.

NUTS
SIDE CUTTER
BOLT
TOOTH POINT

3. Remove the lock ring (2) and lock pin (3),


remove the pins (4) and (5) in order to remove
the bucket (6).
IMPORTANT: Keep pins free of sand, dirt or other
contaminants when removed. Do not damage the
dust seals (9) on both ends of the arm.

87722071 NA

Issued 01-08

Bur

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


INSTALLING BUCKET

9
2

7
8

3
5

4
4
5
6

BS07N277

6
Figure 108

1. Clean each pin and pin hole and grease


sufficiently.
2. Move the bucket cylinder to match the pin bores
or the bucket (6) and bucket link (8) with each
other, then insert the pin (4).
3. Raise the boom and slightly raise the bucket
from the ground.

BS07N278

4. Align bucket (6) with the pin hole of arm (7)


moving arm (7), and insert pin (5).
5. Insert pin (3) and fit lock ring (2).
Fit O-ring (1) to the normal position.
6. Apply grease on the grease nipples for
respective pin until the grease comes out
through the gap between pins and bore.
WARNING: When replacing a bucket tooth
or side cutters, securely block the bucket to
avoid injury. Do not insert fingers to align pin
bores. Align visually or with a tool. Failure to
comply could result in injury or death.

6-50

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


RUBBER CRAWLER TRACK
Rubber track offers many benefits over metal track,
but must be used in accordance to the
m a nu fa c t u r e r s s p e c i f i c a t i o n s. T h e m a c h i n e
guarantee does not cover improper operation at job
sites. Do not operate the machine over objects such
as steel plates, steel pipes, concrete rod, stones and
r o ck s w i t h s h a r p e d g e s. O b s e r ve o p e r a t i n g
conditions and characteristics of rubber track to gain
optimum performance.
RUBBER TRACK OPERATION
BS07N287

Figure 111

DO NOT operate or travel over river beds with stones


of different sizes. Rubber crawler belts may be
damaged or come off the rollers. The service life of
the rubber crawler belts will be reduced if the belt is
not maintained with the correct tension.

Figure 109

BS07N292

TRACK COMPARISON

BS07N288

Figure 112

DO NOT operate on oil contaminated surfaces. Oil


will damage the rubber crawler belts.

Figure 110

BS07N286

DO NOT operate in gravel mixed land, rugged and


solid rock bed, over iron scraps, or edges of iron
plates such as concrete rebar.

BS07N287

Figure 113

DO NOT operate near open fires, or on steel plates


exposed to the sun or use in asphalt leveling. Heat
will damage rubber crawler belts.
When storing the machine for long periods, indoor
storage is recommended. Rubber crawler belts can
be damaged if exposed for long periods of time to
harsh environments in a non-operational mode.

87722071 NA

Issued 01-08

Bur

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BS07N290

Figure 114

DO NOT operate the crawler belt on the ground if the


other track has been lifted. The additional weight
may damage the track or cause the track to come off.

BS07N291

Figure 118

BS07N296

Avoid changing direction of the machine on ground


with a difference in level of 20 cm (8 in.) or more.
Travel at right angles over ground when there is a
significant difference in level.

Figure 116

Use care not to damage the track with the machine


attachment.
Do not apply side load force or side impact on the
bucket or attachment during operation.
If the machine is raised with the bucket, lower
machine slowly.
6-52

I f m a c h i n e i s o p e ra t e d i n s a l t y o r c o r r o s i ve
conditions, the bonding of the rubber to the metal
core can be damaged. Clean the belts after use. The
normal temperature operating range for rubber
crawler belts is between -25 to 55 C (-13 to 131 F).

Figure 115

Use caution when operating on ice or snow. Rubber


belts can easily slip. Avoid making sudden turns on
concrete. Avoid sudden direction changes, as this
may cause premature wear on the crawler belts.

BS07N294

Figure 117

BS07N295

Figure 119

BS07N297

When moving up a slope, avoid changing direction of


the machine when the machine is at a point between
the level ground and the slope.

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


RUBBER TRACK INSPECTION

2
3
4

Figure 120

BS07N298

Do not travel on a slope with one side of the machine


lifted. Always travel with both sides level to avoid
damage to the track.

Figure 122

BS07N280

1.
2.
3.
4.
5.

LOWER ROLLER
RUBBER CRAWLER BELT
LUG
STEEL CORD
METAL CORE

Repair or replace rubber crawler belt if it is damaged.


Contact your dealer for assistance in replacing belts
or refer to the machine Repair Manual.
HEIGHT OF LUG

Figure 121

BS07N299

Do not change direction of the machine with the


rubber crawler on high spots as illustrated. This can
cause the rubber crawler belt to be damaged or
come off.

4
BS07N281

Figure 123

Replace the belt with a new one if the height of the


lug is below (A) 5 mm (0.2 in.). The low height of lug
will decrease traction.
If the lug wears and the steel cord (4) in the belt is
exposed over two links, replace the belt.

87722071 NA

Issued 01-08

Bur

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


RUBBER TRACK METAL CORE

STEEL CORD DAMAGE

1
2
4

5
3
Figure 124

BS07N282

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

Figure 126

BS07N284

1.
2.
3.
4.
A.

LOWER ROLLER
METAL CORE
RUBBER
STEEL CORD
INTERFERENCE WITH ROLLER

Depending on the usage of the rubber crawler belt,


there occasionally may be peeling of the metal core
(2). Peeling occurs on the inner side due to contact
with the rollers (1), idlers, and sprockets. The lug side
(outer side of belt) may appear undamaged.
IMPORTANT: Unapproved or prohibited operation of
the machine can cause damage to the rubber crawler
belt. The warranty is not applicable for any damage
due to prohibited or unapproved usage of the rubber
track or the use of it with improper tension.

BS07N283

Figure 125

Repair the belt if a crack approximately 60 mm (2.4


in) is seen between the lug of the rubber belt. Repair
immediately if the steel cord (4) is exposed even
though the crack is minimal.

Figure 127

BS07N285

Cracked rubber belts showing metal core (2) must be


replaced with new belts.
Minute cracks will not effect performance, and it is
not necessary to replace belt.

6-54

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


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

WARNING: Read and understand all safety


precautions
and
procedures
before
attempting any operation, inspection,
maintenance, or repair of this machine, any
attachment or any of its systems. Failure to
comply could result in injury or death.
WARNING: The
following
procedures
should only be performed by an experienced
service technician familiar with this machine.
Failure to comply could result in injury or
death.
RELEASING LOCK ON TRAVEL MOTOR

Figure 130

BS07N669

3. Place a pan under the travel motor to drain oil.


Slowly remove upper plug, then remove drain
plug to drain reduction unit oil.
Plug Opposing flat - 6 mm (0.24).

Figure 128

BS07N300

The travel motors of a disabled machine are locked


by the hydraulic control valve and by the mechanical
brake system. If the machine is locked and unable to
run, it can be moved by releasing the travel motor
lock by one of the following methods.

WARNING: Travel reduction gear is under


pressure. Keep your face and body clear of
drains. Never attempt to service a hot
machine. Allow the machine to cool before
performing any service. Heat increases travel
reduction gear oil pressure. Loosen plug
slowly and wear face protection.
5

2
1

REMOVING GEARS FROM TRAVEL REDUCTION


UNIT

5
6
2
4
14 3

BXPX00900004E01

Figure 131

4. Insert a flat blade screwdriver into gap between


the body (1) and snap ring (3), and remove the
snap ring.
5. Remove the cover (2).
6. Use care when removing cover, as ball (5) will
fall. Clean ball if contaminated.

Figure 129

BS07N674

1. Place blocks at front and rear of tracks to prevent


machine from moving when brakes are released.
2. Lower attachment to the ground.
87722071 NA

Issued 01-08

Bur

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


ASSEMBLING THE TRAVEL MOTOR

2
5

5
3

6
6

2
4
14 3
Figure 132

BS07N674

NOTE: The crawler belt is now free to rotate.


7. Install drain plug (4) and refill unit with the
previously drained oil. Tow the machine to
desired location for further service.
IMPORTANT: Avoid spills. Dispose of all hazardous
waste in accordance with government laws and
regulations.
ASSEMBLING THE TRAVEL MOTOR

Figure 134

XPX00900005E01

2. To prevent the ball (5) from falling from sun gear


(6), coat the ball (5) with a light coat of grease.
3. Lubricate the O-ring (14) with grease and fit into
groove of cover (2). Install cover (2).
4. Use care not to damage O-ring.
5. Replace the O-ring at drain plug (4) with a new
one. Install the drain plug (4).
6. Add the specified gear oil through the oil fill plug
until oil starts flowing out of the oil level plug.

5
6
2
4
14 3
BS07N674

Figure 133

1. After all repairs are compete, assemble the travel


motor units.

6-56

Issued 01-08

Bur

87722071 NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


LOWERING BUCKET ATTACHMENT ON A
DISABLED MACHINE

BS07N384

Figure 135

BS07N380

WARNING: Keep all unauthorized personnel


away from the bucket/attachment and
excavator boom.
The weight of the bucket or attachment may
cause unexpected m ovem ent of
bucket/attachment, arm and boom during the
procedure.
B l o ck th e bu cke t /a tt a ch m e n t t o avo i d
u n ex p e c t e d m o ve m e n t . R e l e a s e t h e
pressure in the hydraulic lines slowly until
pressure is completely released.
Control the bucket/attachment movement by
slowly removing the lock.

Figure 136

To lower the bucket position, proceed carefully as


follows: When the bucket is in digging position (A)
(bucket cylinder completely extended, (see figure)
disconnect hose head (H) side. When the bucket is in
dump position (B) (bucket cylinder completely
retracted), disconnect the hose rod (R) side
IMPORTANT: Do not allow the hydraulic line or
components to become contaminated. This could
cause severe system damage to the hydraulic
system. Contact your dealer to obtain the proper
caps and plugs to be used.
IMPORTANT: Clean up all spilled oil. Dispose of any
hazardous waste in compliance with local
environmental regulations.

Do not enter the area under


bucket/attachment while lowering. Failure to
comply could result in injury or death.
The following procedure is to be used only in an
emergency if the machine is disabled. Proceed with
extreme caution. Keep all unauthorized personnel
away from the bucket/attachment and excavator
boom.
Block the bucket/attachment to avoid unexpected
movement. Release the pressure in the hydraulic
lines slowly until pressure is completely released.
Control the bucket/attachment movement by slowly
removing the lock.

87722071 NA

Issued 01-08

Bur

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS


LOWERING THE ARM

Figure 138

BS07N386
BS07N385

Figure 137

WARNING: Make certain the area around


the machine is clear of people and objects
before attempting these procedures. Failure
to comply could result in injury or death.

Gradually loosen the hose of rod side connected to


the arm (R).

LOWERING THE BOOM


G ra d u a l l y l o o s e n t h e h o s e o f h e a d ( H ) s i d e
connected to the boom cylinder.
Stop lowering the attachment at 30 - 40 cm (12 - 16
in.) above ground level to allow for moving the
machine.
1. Tighten the hose fitting.
2. After moving the machine to the service area,
slowly loosen the hose fitting to lower the
attachment to the ground.
3. Contact your dealer for machine repairs.

6-58

Issued 01-08

Bur

87722071 NA

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL
TABLE OF CONTENTS
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Starter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 01-08

Bur

87722071 NA

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

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

Issued 01-08

Bur

87722071 NA

CHAPTER 7 - ELECTRICAL
ELECTRICAL COMPONENTS

FUSIBLE STARTER LINK


.

FUSES
.

Figure 1

BS07N387

WARNING: Make certain the starter switch


is in the OFF position before replacing fuses.
Fuses protect the electrical system from excess
current. Replace a blown fuse or any fuse generating
white powder on it.
Always replace fuses with a fuse of the same
capacity. The spare fuses are stored in the back side
of the fuse box cover.
AMPS

FUNCTION

30A

WIPER, HEATER

30A

RELAY, SOLENOID

30A

WORK LAMP

10A

HORN, CAB LIGHT

30A

ENGINE STOP SOLENOID

10A

BATTERY RELAY,
CLUSTER GAUGE

NO.

87722071 NA

Issued 01-08

Bur

BS07N388

Figure 2

If the electrical power does not come on when the


starter key switch is in the on position, the fusible link
may be the cause. Inspect and replace the red
fusible link (1).
The fusible link protects the electrical system from
current over load. The fusible link functions like a
fuse.
WARNING: 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.

7-3

CHAPTER 7 - ELECTRICAL
BATTERIES
Perform complete battery service on a new machine
after the first 50 hours of engine operation. Then,
check electrolyte (acid) every 50 hours.

WARNING:

Figure 4

BS07N390

Wear safety clothes, goggles or face shield,


gloves and safety shoes when working with
batteries.
Work in a well ventilated area.
Battery electrolyte (acid) is corrosive. If it
comes in contact with skin, eyes or clothing,
flush with large amount of water and seek
immediate medical attention.
Battery electrolyte (acid) produces hydrogen
gas that is highly explosive. Keep away
sparks, fire or flames and do not smoke when
working with batteries. Failure to comply
could result in injury or death.
BS07N389

1.
2.
3.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.

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

Figure 3

1. Park the machine on a firm, level surface with


both attachments resting on the ground. Turn the
engine off. Place the cancellation lever in the
locked position. Keep all unauthorized personnel
clear of the area.
2. The battery is located under the floor plate.
Remove the floor mat and remove the battery
cover.

Figure 5

BS07N391

3. Remove battery cell caps (1) and visually inspect


electrolyte (acid) level. Proper level is 10 - 15
mm (0.4 in. - 0.6 in.) above cell plates.
4. If necessary, fill each cell to proper level with
DISTILLED WATER ONLY.
5. Remove cables from terminals and clean with
hot water. Coat each terminal with a thin layer of
petroleum jelly. Clean cables in the same
manner and reinstall onto battery.
6. If cables are found to be in poor condition,
replace with new parts immediately.
7-4

Issued 01-08

Bur

87722071 NA

CHAPTER 7 - ELECTRICAL
ALTERNATOR
WARNING:
Prevent Battery Explosion:
Batteries give hydrogen gases that can
explode and cause personal injury.
Keep sparks, open flames and cigarettes
away from the batteries.
Keep metallic articles away from batteries.
Keep all ventilation caps tightly secured.
Never check charge by placing metal articles
across battery terminals.
Leave battery box open to improve ventilation
when charging.

Ask your Dealer to check the Alternator.


Make sure that the terminal protectors are correctly
installed.
Do not use steam cleaning equipment or a cleaning
solvent to clean the alternator.
STARTER MOTOR
Ask your Dealer to check the Starter Motor.
Make sure that the terminal protectors are correctly
installed.

NOTE: Battery life can be shortened by over


charging and over discharging of the battery.
Replace any battery that will not hold charge or is
difficult to charge.
7. Use a hydrometer to check the specific gravity of
each cell. Compare readings to the chart below.
NOTE: Use
hydrometer
manufacturers instruction.

according

to

its

ATMOSPHERIC TEMPERATURE
CHARGE
20C (68F)

0C (32F)

-10C (14F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

8. When disconnecting batteries, remove the


negative (-) cable first. When connecting
batteries, connect the negative (-) cable last.
9. When the battery requires charging:
a. Disconnect battery cables from terminals.
b. Remove all cell caps.
c. Check for proper electrolyte (acid) level.
d. Connect charger leads to the proper battery
terminals.
NOTE: Make certain not to cross Positive (+) and
negative (-) terminals when connecting charger.
e. Stop charge if battery overheats.
f. Periodically check the specific gravity of the
batteries with a hydrometer. Stop charging
batteries when 100% charged.

87722071 NA

Issued 01-08

Bur

7-5

CHAPTER 7 - ELECTRICAL
WORK LAMPS

4
3

Figure 7

BS07N393

Figure 6

BS07N392

A 55W bulb is used for the work lamps.

WARNING: Do not touch a lighted bulb.


Shut off lamp and allow it to cool. Make
certain work lamp switch is in the OFF
position. Failure to comply could cause
machine damage or injury.

NOTE: The service life of a bulb is shortened if oil or


grease is on the bulb at the time of installation. When
replacing the bulb, hold it at the flange area. Do not
touch the bulb glass with your fingers. Wipe the bulb
with a clean cloth after installation.

7-6

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.

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS
TABLE OF CONTENTS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Canopy Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Capacities Canopy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10


TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capscrews and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuts and Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 01-08

Bur

87722071 NA

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

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS
CANOPY MACHINE DIMENSIONS

Figure 1

BS08A063

CAB MACHINE DIMENSIONS

Figure 2

BS08A064

87722071 NA

Issued 01-08

Bur

8-3

CHAPTER 8 - SPECIFICATIONS
SPEED AND GRADEABILITY
Rubber Crawler Belt
8.7 min (8.7 RPM)

Swing Speed

Travel Speed

Steel Crawler Belt


1

Low
(1st)

High
(2nd)

Low
(1st)

High
(2nd)

2.5 km/h
(1.6 mph)

4.5 km/h
(2.8 mph)

2.5 km/h
(1.6 mph)

4.5 km/h
(2.8 mph)

Gradeability

58% (30)

ENGINE
Model
Type
Number of cylinders - Bore X Stroke
Total Displacement
Output Rating
Maximum Torque
Starting Motor
Generator

YANMAR 3TNV88-SYB
Water cooled, 4 cycle type swirl chamber type diesel engine
3 - 88 mm X 90 mm (3 - 3.46 in. X 3.54 inch)
1.642 liters (100.2 cubic inch)
21.2 kW (2400 min1)
29 PS (2400 RPM)
98.4 Nm (1440 min1)
72.6 lbf ft (1440 RPM)
12 V (1.7 kW)
12 V (55 A)

HYDRAULIC COMPONENTS
Hydraulic Pump
Hydraulic Motor

Variable displacement axial piston pump


Axial piston

Hydraulic Motor with Reducer (Travel)

2 - Axial piston, 2-speed motor

Control Valve

10- spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer)


Return Filter

Double action cylinder


Filter type with bypass valve (30 microns)

SIDE DIGGING AND DOZER


Type

Boom swing by hydraulic cylinder

Boom Swing Angle Right

60

Boom Swing Angle Left

70

Dozer Blade Travel (Up/Down)

8-4

540/440 (21.3/17.3)

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS
CRAWLER TYPE
Length between
center of idler and
center of travel motor
mm (ft - in)

Width
mm (inch)

Type

Ground Pressure
kPa (psi)
Canopy - Cab

Rubber Belt

300 mm (11.8 in)

1700 mm (67 inch)

32 (4.6)

33 (4.8)

Steel Belt

300 mm (11.8 in)

1700 mm (67 inch)

33 (4.8)

34 (4.9)

BUCKET TYPE
Heaped Capacity
m3 (cubic yard)

Bucket

0.11 (0.144)

Outer Width
with side cutter
600 mm (23.6 in.)

Outer Width
without side cutter
554 mm (21.8 in.)

Number of
teeth
4

Weight
Kg (lbs.)
89 (196)

MACHINE WEIGHTS

Rubber Crawler Belt

Steel Crawler Belt

Canopy

Cab

Canopy

Cab

3580 kg (7900 lb)

3720 kg (8205 lb)

3730 kg (8160 lb)

3840 kg (8465 lb)

* With 165 lb (75 kg) operator, 137 lb (62 kg) bucket, full fuel and standard equipment

87722071 NA

Issued 01-08

Bur

8-5

CHAPTER 8 - SPECIFICATIONS
LIFT CAPACITIES CANOPY MODEL
4 ft. 4 in (1.32 m) Arm
Lift capacities calculated using 11.8 in (300 mm) shoes 196 lb (89 kg) bucket, blade down.
Load
(Lift Point)
Height

5 ft (1.5 m)
END - SIDE

7.5 ft (2.3 m)
END - SIDE

10 ft (3.0 m)
END - SIDE

+ 10 ft
(3.0 m)
+7.5 ft
(2.3 m)

12.5 ft (3.8 m)
END - SIDE
1190 lb
540 kg

1120 lb
510 kg

1380 lb
620 kg

1380 lb
620 kg

1280 lb
580 kg

1100 lb
500 kg

+5 ft
(1.52 m)

2760 lb
1250 kg

2380 lb
1080 kg

1830 lb
830 kg

1510 lb
680 kg

1480 lb
670 kg

1050 lb
470 kg

+2.5 ft
(0.8 m)

3760 lb
1700 kg

2180 lb
990 kg

2270 lb
1030 kg

1420 lb
640 kg

1690 lb
760 kg

1000 lb
450 kg

Ground
Level

2550 lb
1150 kg

2550 lb
1150 kg

4020 lb
1820 kg

2120 lb
960 kg

2520 lb
1140 kg

1360 lb
610 kg

1820 lb
820 kg

970 lb
440 kg

-2.5 ft
(-0.8 m)

4080 lb
1850 kg

4080 lb
1850 kg

3830 lb
1740 kg

2120 lb
960 kg

2520 lb
1140 kg

1340 lb
610 kg

1800 lb
810 kg

960 lb
430 kg

-5.0 ft
(-1.52 m)

5790 lb
2620 kg

4550 lb
2060 kg

3290 lb
1490 kg

2150 lb
970 kg

2210 lb
1000 kg

1360 lb
620 kg

-7.5 ft
(-2.3 m)

3470 lb
1570 kg

3470 lb
1570 kg

2110 lb
950 kg

2110 lb
950 kg

15 ft (4.6 m)
END - SIDE

1390 lb
630 kg

750 lb
340 kg

* Rated loads are hydraulic limits rather than tipping load limits

LIFT CAPACITIES CAB MODEL


4 ft. 4 in (1.32 m) Arm
Lift capacities calculated using 11.8 in (300 mm) shoes (196 lb (89 kg) bucket, blade down
Load
(Lift Point)
Height

5 ft (1.5 m)
END - SIDE

7.5 ft (2.3 m)
END - SIDE

10 ft (3.0 m)
END - SIDE

12.5 ft (3.8 m)
END - SIDE

+ 10 ft
(3.0 m)

1190 lb
540 kg

1190 lb
540 kg

+7.5 ft
(2.3 m)

1280 lb
580 kg

1160 lb
530 kg

+5 ft
(1.52 m)

2760 lb
1250 kg

2510 lb
1140 kg

1830 lb
830 kg

1600 lb
720 kg

1480 lb
670 kg

1120 lb
500 kg

+2.5 ft
(0.8 m)

3760 lb
1700 kg

2310 lb
1050 kg

2270 lb
1030 kg

1500 lb
680 kg

1690 lb
760 kg

1070 lb
480 kg

Ground
Level

2550 lb
1150 kg

2550 lb
1150 kg

4020 lb
1820 kg

2250 lb
1020 kg

2520 lb
1140 kg

1450 lb
650 kg

1820 lb
820 kg

1040 lb
470 kg

-2.5 ft
(-0.8 m)

4080 lb
1850 kg

4080 lb
1850 kg

3830 lb
1740 kg

2250 lb
1020 kg

2520 lb
1140 kg

1430 lb
650 kg

1800 lb
810 kg

1030 lb
460 kg

-5.0 ft
(-1.52 m)

5790 lb
2620 kg

4800 lb
2180 kg

3290 lb
1490 kg

2280 lb
1030 kg

2210 lb
1000 kg

1450 lb
660 kg

-7.5 ft
(-2.3 m)

3470 lb
1570 kg

3470 lb
1570 kg

2110 lb
950 kg

2110 lb
950 kg

15 ft (4.6 m)
END - SIDE

1390 lb
630 kg

800 lb
360 kg

* Rated loads are hydraulic limits rather than tipping load limits

8-6

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS
LIFT CAPACITIES CAB MODEL
3 ft. 11 in (1.2 m) Arm
Lift capacities calculated using 11.8 in (300 mm) shoes (196 lb (89 kg) bucket, blade down, 551 lb (250 kg)
additional counterweight
Load
(Lift Point)
Height

5 ft (1.5 m)
END - SIDE

7.5 ft (2.3 m)
END - SIDE

10 ft (3.0 m)
END - SIDE

12.5 ft (3.8 m)
END - SIDE

+ 10 ft
(3.0 m)

1190 lb
540 kg

1190 lb
540 kg

+7.5 ft
(2.3 m)

1280 lb
580 kg

1280 lb
580 kg

+5 ft
(1.52 m)

2760 lb
1250 kg

2760 lb
1250 kg

1830 lb
830 kg

1830 lb
830 kg

1480 lb
670 kg

1320 lb
600 kg

+2.5 ft
(0.8 m)

3760 lb
1700 kg

2710 lb
1230 kg

2270 lb
1030 kg

1780 lb
800 kg

1690 lb
760 kg

1270 lb
580 kg

Ground
Level

2550 lb
1150 kg

2550 lb
1150 kg

4020 lb
1820 kg

2650 lb
1200 kg

2520 lb
1140 kg

1720 lb
780 kg

1820 lb
820 kg

1240 lb
560 kg

-2.5 ft
(-0.8 m)

4080 lb
1850 kg

4080 lb
1850 kg

3830 lb
1740 kg

2650 lb
1200 kg

2520 lb
1140 kg

1700 lb
770 kg

1800 lb
810 kg

1230 lb
560 kg

-5.0 ft
(-1.52 m)

5790 lb
2620 kg

5590 lb
2530 kg

3290 lb
1490 kg

2690 lb
1220 kg

2210 lb
1000 kg

1720 lb
780 kg

-7.5 ft
(-2.3 m)

3470 lb
1570 kg

3470 lb
1570 kg

2110 lb
950 kg

2110 lb
950 kg

15 ft (4.6 m)
END - SIDE

1390 lb
630 kg

960 lb
430 kg

* Rated loads are hydraulic limits rather than tipping load limits

87722071 NA

Issued 01-08

Bur

8-7

CHAPTER 8 - SPECIFICATIONS
CANOPY TYPE MACHINE WORKING RANGES
A
A

F
J

Figure 3

UPV00600003ES1

Units: m (ft-in)
Machine equipped with 0.11 m3 (0.144 yd.3) Bucket
WORKING RANGES

8-8

Standard Arm
1.32 m (51.9 in)

Long Arm
1.59 m (62.6 in)

Bucket
0.11 m3 (0.144 cu. yd.)

Bucket
0.11 m3 (0.144 cu. yd.)

Maximum digging reach

5240 mm (17 ft. 2 in.)

5500 mm (18 ft. 1 in.)

Maximum digging reach at ground level

5110 mm (16 ft. 9 in.)

5370 mm (17 ft. 7in.)

Maximum digging depth

3080 mm (10 ft. 1 in.)

3350 mm (11 ft. 0 in.)

Maximum digging height

4980 mm (16 ft. 4 in.)

5160 mm (16 ft. 11 in.)

Maximum dumping clearance

3580 mm (11 ft. 9 in.)

3760 mm (12 ft. 4 in.)

Minimum dumping clearance

1410 mm (4 ft. 8 in.)

1150 mm (3 ft. 9 in.)

Maximum vertical wall digging depth

2390 mm (7 ft. 10 in.)

2650 mm (8 ft. 8 in.)

Minimum swing radius

2040 mm (6 ft. 8 in.)

2070 mm (6 ft. 10 in.)

Height at minimum swing radius

3780 mm (12 ft. 5 in.)

3780 mm (12 ft. 5 in.)

8-ft. level digging depth

2600 mm (8 ft. 6 in.)

2920 mm (9 ft. 7 in.)

Horizontal digging stroke at ground level -stroke

2370 mm (7 ft. 9 in.)

2770 mm (9 ft. 1 in.)

Horizontal digging stroke at ground level - minimum

1670 mm (5 ft. 6 in.)

1530 mm (5 ft. 0 in.)

Dozer blade - Above

540 mm (1 ft. 9 in.)

540 mm (1 ft. 9 in.)

Dozer blade - Below

440 mm (1 ft. 5 in.)

440 mm (1 ft. 5 in.)

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS
CAB TYPE MACHINE WORKING RANGES

A
A

Figure 4

UPV00600004ES1

Units: m (ft-in)
Machine equipped with 0.11 m3 (0.144 yd.3) Bucket
WORKING RANGES

Standard Arm
1.32 m (51.9 in)

Long Arm
1.59 m (62.6 in)

Bucket
0.11 m3 (0.144 cu. yd.)

Bucket
0.11 m3 (0.144 cu. yd.)

Maximum digging reach

5240 mm (17 ft. 2 in.)

5500 mm (18 ft. 1 in.)

Maximum digging reach at ground level

5110 mm (16 ft. 9 in.)

5370 mm (17 ft. 7in.)

Maximum digging depth

3080 mm (10 ft. 1 in.)

3350 mm (11 ft. 0 in.)

Maximum digging height

4370 mm (14 ft. 4 in.)

4490 mm (14 ft. 9 in.)

Maximum dumping clearance

3040 mm (10 ft. 0 in.)

3150 mm (10 ft. 4 in.)

Minimum dumping clearance

1140 mm (3 ft. 9 in.)

870 mm (2 ft. 10 in.)

Maximum vertical wall digging depth

2390 mm (7 ft. 10 in.)

2650 mm (8 ft. 8 in.)

Minimum swing radius

2560 mm (8 ft. 5 in.)

2570 mm (8 ft. 5 in.)

Height at minimum swing radius

3460 mm (11 ft. 4 in.)

3470 mm (11 ft. 5 in.)

8-ft. level digging depth

2600 mm (8 ft. 6 in.)

2920 mm (9 ft. 7 in.)

Horizontal digging stroke at ground level -stroke

2370 mm (7 ft. 9 in.)

2770 mm (9 ft. 1 in.)

Horizontal digging stroke at ground level - minimum

1670 mm (5 ft. 6 in.)

1530 mm (5 ft. 0 in.)

Dozer blade - Above

540 mm (1 ft. 9 in.)

540 mm (1 ft. 9 in.)

Dozer blade - Below

440 mm (1 ft. 5 in.)

440 mm (1 ft. 5 in.)

87722071 NA

Issued 01-08

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 Operators Manual
before operating this machine. Rules for safe
operation of equipment should be followed at
all times. Failure to comply could result in
injury or death.

8-10

5. Capacities apply to the machine as originally


manufactured and normally equipped by the
manufacturer.
IMPORTANT: The operator must consider the weight
of any device utilized for lifting to properly calculate
the total lifting capacity of the machine. Example:
1. If the excavator uses the same bucket size
indicated in the Lifting Chart, and a lifting cable,
etc. weighing 100 kg (220 lbs) is used for lifting,
then you have to subtract this additional 100 kg
(220 lbs) from every value indicated in the Lifting
Chart accordingly.
2. If a bucket is changed for a larger bucket, which
weight is more than the bucket indicated in the
Lifting Chart, then you have to subtract this
additional weight from every value indicated in
the Lifting Chart accordingly.
3. If a bucket is changed for a smaller bucket, which
weight is less than the bucket indicated in the
Lifting Chart, then you can add this additional
weight to every value indicated in the Lifting
Chart accordingly.

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS
The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
CAP SCREWS AND NUTS
METRIC COARSE THREAD STANDARD
TIGHTENING TORQUE VALUES
Make certain to tighten all Capscrews & Nuts to proper torque values.
Metric Coarse Thread Standard Tightening Torque Values
4.8 T

Classification
NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M6

P=1

0.45 0.05
(3.2 0.4)

0.38 0.04
(2.7 0.3)

0.98 0.1
(7.1 0.7)

0.83 0.08
(6.0 0.6)

1.77 0.18
(12.8 1.3)

1.5 0.15
(10.8 1.1)

M8

P=1.25

1.09 0.11
(7.9 0.8)

0.92 0.09
(6.6 0.7)

2.4 0.2
(17.3 1.4)

2.0 0.2
(14.4 1.4)

4.3 0.4
(31.0 2.9)

3.6 0.4
(26.0 2.9)

M10

P=1.5

2.2 0.2
(15.9 1.4)

1.83 0.18
(13.2 1.3)

4.7 0.5
(33.9 3.6)

4.0 0.4
(28.9 2.9)

8.5 0.9
(61.3 6.5)

7.2 0.7
(52.0 5.1)

M12

P=1.75

3.7 0.4
(26.7 2.9)

3.2 0.3
(23.1 2.2)

8.1 0.8
(58.5 5.8)

6.8 0.7
(49.1 5.1)

14.6 1.5
(105 10.8)

12.3 1.2
(88.8 8.7)

M14

P=2

5.9 0.6
(42.6 4.3)

5.0 0.5
(36.1 3.6)

12.8 1.3
(92.5 9.4)

10.8 1.1
(78.0 7.9)

23 2
(166 14)

19.5 1.9
(140 14)

M16

P=2

9.0 0.9
(64.9 6.5)

7.6 0.7
(54.8 5.1)

19.5 2.0
(140 14.4)

16.4 1.6
(118 11.5)

35 4
(252 28.9)

29 3
(209 21.6)

M18

P=2.5

12.4 1.2
(89.6 8.7)

10.5 1.0
(75.8 7.2)

27 3
(195 22)

23 2
(166 14)

49 5
(354 36)

41 4
(296 29)

M20

P=2.5

17.5 1.7
(126 12.3)

14.7 1.4
(106 10.1)

38 4
(274 29)

32 3
(231 22)

68 7
(491 51)

57 6
(412 43)

M22

P=2.5

23 2
(166 14)

19.6 2
(142 14)

51 5
(368 36)

43 4
310 29)

92 9
(663 65)

77 7
(555 58)

M24

P=3

30 3
(217 22)

24 3
(173 22)

65 7
(469 51)

53 5
(383 36)

118 12
(852 87)

96 10
(693 72)

M27

P=3

44 4
(318 29)

36 3
(260 22)

96 10
(693 72)

78 8
(563 58)

173 17
(1250 120)

140 14
(1010 100)

M30

P=3.5

60 6
(433 43)

50.5 5
(361 36)

131 13
(946 94)

110 11
(794 79)

235 24
(1700 170)

198 20
(1430 140)

M33

P=3.5

81 8
(585 58)

68 7
(491 51)

176 18
(1270 130)

148 15
(1070 110)

317 32
(2290 200)

266 27
(1920 200)

M36

P=4

105 10
(758 72)

88 9
(636 65)

227 23
(1640 170)

190 19
(1370 140)

409 41
(2960 300)

343 34
(2480 250)

TORQUE VALUE UNIT: kgf (ft-lbs)

87722071 NA

Issued 01-08

Bur

8-11

CHAPTER 8 - SPECIFICATIONS
METRIC FINE THREAD STANDARD TIGHTENING
TORQUE VALUES
Tighten all Capscrews & Nuts to proper torque values.
Metric Fine Thread Standard Tightening Torque Values
4.8 T

Classification
NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M8

P=1

1.15 0.11
(8.3 0.8)

0.97 0.1
(7.0 0.7)

2.5 0.2
(18.0 1.4)

2.1 0.2
(15.2 1.4)

4.5 0.4
(32.5 2.9)

3.8 0.4
(27.4 2.9)

M10

P=1.25

2.3 0.2
(16.6 1.4)

1.91 0.19
(13.8 1.4)

4.9 0.5
(35.4 3.6)

4.2 0.4
(30.3 2.9)

8.9 0.9
(64.2 6.5)

7.5 0.7
(54.2 5.1)

M12

P=1.25

4.0 0.4
(28.9 2.9)

3.4 0.3
(24.5 2.2)

8.7 0.9
(62.8 6.5)

7.3 0.7
(52.7 5.1)

15.7 1.6
(113 13)

13.2 1.3
(95.3 9.4)

M16

P=1.5

9.4 0.9
(67.9 6.5)

7.9 0.8
(57.0 5.8)

20 2
(144 14)

17.2 1.7
(124 12)

37 4
(267 29)

31 3
(224 22)

M20

P=1.5

19 9
(137 14)

15.8 1.6
(114 14)

41 4
(296 29)

34 3
(246 22)

74 7
(535 51)

62 6
(448 43)

M24

P=2

32 3
(231 22)

27 3
(195 22)

70 7
(506 51)

58 6
(419 43)

126 12
(910 87)

105 10
(758 72)

M30

P=2

65 6
(469 43)

54 5
(390 36)

142 14
(1030 100)

118 12
(852 87)

255 26
(1840 190)

212 21
(1530 150)

M36

P=3

109 11
(787 79)

91 9
(657 65)

238 23
(1720 170)

198 20
(1430 140)

428 43
(3090 310)

357 36
(2580 260)

TORQUE VALUE UNIT: kgf (ft-lbs)

ORS JOINT (O-RING SEALING TYPE)


ORS Joint (O-ring Sealing Type)

Hose mouth
ring and
Coupling

8-12

NOMINAL SIZE

OPPOSING FLATS
mm

TORQUE VALUE
kgfm (ft-lbs)

1 - 14 UNS

30 - 32

14 1.4 (101 10)

1 - 3/16 12 UN

36 - 41

18 1.8 (130 13)

1 - 7/16 12 UN

41 - 46

21 2.1 (152 15)

Issued 01-08

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

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS
NUTS AND SLEEVES
Nuts and Sleeves

MANUFACTURERS
NAME

WORKING PRESSURE
kgf/cm2 (psi)

350 (4980)
Travel line only

NIPPON A.M.C.

350 (4980)
Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS

TUBE SIZE
O.D. X THICKNESS
mm (in)

OPPOSING FLATS
mm
Dimension B

TORQUE VALUE
kgfm (ft-lbs)

10 X 1.5
(0.394 X 0.059)

19

4.5 0.5 (33 4)

15 X 2.0
(0.591 X 0.079)

27

15 2 (108 14)

18 X 2.5
(0.709 X 0.098)

32

18 2 (130 14)

22 X 3.0
(0.866 X 0.118)

36

22 2 (159 14)

28 X 4.0
(1.10 X 0.157)

41

28 3 (203 22)

35 X 5.0
(1.38 X 0.20)

55

35 4.5 (253 29)

N2 (NYLON) TUBE FITTING JOINTS

Flare Type Fitting Joints

N2 (Nylon) Tube Fitting Joints

Overtightening of flare type (Union Nut Type) metal


joints may cause damage to nuts, seat surfaces, and
prevent optimum sealing resulting in oil leaks.
NOMINAL SIZE
(PIPE THREAD)

TORQUE VALUE

1/4

2.5 0.3 (18.1 1.8)

3/8

5 0.5 (36.2 3.6)

1/2

6 0.6 (43.4 4.3)

3/4

12 1.2 (86.8 8.7)

14 1.4 (101 10)

1-1/4

17 1.7 (123 12)

1-1/2

21 2.1 (152 15)

42 4.2 (304 30)


Unit: kgfm (ft.-lbs)

87722071 NA

Issued 01-08

Bur

1. Clean Tube and make sure certain tube end is


trimmed smooth.
2. Insert tube into fitting until tube end is securely
seated in fitting body.
3. Tighten the nut by hand.
4. Use a spanner wrench, securely tighten nut by
turning 1-1/4 turns.

8-13

CHAPTER 8 - SPECIFICATIONS
WEIGHT OF MATERIALS TABLE
lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Material (Loose Weight)

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted & broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

8-14

Issued 01-08

Bur

87722071 NA

CHAPTER 8 - SPECIFICATIONS
UNITS OF PRESSURE

SOME CONVERSION UNITS


UNITS OF WEIGHT

Units of Pressure
From

Units of Weight
From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

Into

Multiply by

psi

14.223

Pa
(Pascal)

9.807

Atm

0.06805

Bars

UNITS OF LENGTH
psi

kg/cm

Units of Length
From

Into

Multiply by

Divide by

meters

feet

3.28

mm

inches

25.4

inches

mm

25.4

0.06895
2

0.0703

Pa
(Pascal)

6894.76

psi

145.04

MPa
(MegaPascal)

UNITS OF VOLUME

UNITS OF POWER

Units of Volume
From

Units of Power

Into

Multiply by

From

Into

Multiply by

Gal
(US Liquid)

0.264

HP

kW

0.7457

in3

61.02

kW

HP

1.341

yard3

0.00131

quarts

1.0567

ounces
(US)

33.81

m3

0.765

in3

46656

ft3

27

cm3

764554.9

liters

764.555

Liters

UNITS OF FLOW
Units of Flow
Into

From

Multiply by

Lit/min
Gal/min
(US liquid)

Liter/min

3.79

Lit/sec

0.0631

cm3/min

3785.4

ft3/min

0.1337

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

Yard3

UNITS OF TORQUE
Units of Torque
From

Nm

lbf-ft

87722071 NA

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgfm

0.1382552

Nm

1.35582

lbf-in

12

Issued 01-08

Bur

8-15

CHAPTER 8 - SPECIFICATIONS

NOTES

8-16

Issued 01-08

Bur

87722071 NA

CHAPTER 9 - INDEX

Chapter 9

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

B
Back Filling & Leveling with Front Attachment .. 4-16
Basic Operation of Hydraulic Controls ............... 4-10
Before Operating the Hydraulic Breaker ............ 4-20
Before Operating the Machine ............................. 4-3
Boom Operation ................................................ 4-14
Bucket ................................................................ 6-48
Bucket Operation ............................................... 4-15
Bucket Selection Guide ..................................... 4-19
Burn Prevention ................................................... 2-8

C
Cab Dome Light ................................................... 3-5
Cab Door Latch ................................................... 3-3
Cab Machine Dimensions .................................... 8-3
Canopy Machine Dimensions .............................. 8-3
Cleaning Parts ..................................................... 6-4
Cleaning Sand & Soil from Bucket .................... 4-16
Components & Controls Nomenclature ............... 3-9
Connecting Booster Cable ................................... 4-6
Control Decal ....................................................... 4-9
Counter Rotating Machine ................................. 4-12

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

Emergency Engine Shut Down ............................ 4-5


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

F
Fire Extinguisher .................................................. 2-8
Fire Prevention .................................................... 2-8
Flare Type Fitting Joints .................................... 8-13
Issued 01-08

G
General Information ..............................................1-1
Ground Transportation .......................................4-26
Guidelines for Attachment Lubrication .................6-7
Guidelines to Replace Ground Tools ...................6-7

H
Hand Signals ......................................................2-26
Hazardous Chemical Precautions ........................2-8
Hot Surface & Fluids ............................................6-3
How to Handle Life Hammer ................................2-9
Hydraulic Breaker ...............................................4-20
Hydraulic Oil Leaks .................................. 6-15, 6-16
Hydraulic Oil Level .............................................6-14

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

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

L
Lifting Capacities ................................................8-10
Lifting Machine ...................................................4-29
Lifting Machine With Attachment Installed .........4-29
Locking/Unlocking Cab Door ................................3-3

87722071 NA

Frame Structure ...................................................6-5


Fuel Handling Precautions ...................................2-8
Fuel Level ...........................................................6-13

Bur

Machine Access Compartments and Doors .........3-7


Machine Attachment and Swing .........................4-14
Machine Components ..........................................1-3
Machine Dimensions ............................................8-3
Machine Electrical ..............................................6-17
Machine Operation in Adverse Weather Conditions .
4-18
Machine Storage ................................................4-30
Machine Travel Controls ....................................4-11
Machine Warm Up ................................................4-7
Maintenance Precautions .....................................2-7
Manual Warm Up .................................................4-7
Metric Coarse Thread Standard Tightening Torque
Values ..........................................................8-11
9-1

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

N
N2 (Nylon) Tube Fitting Joints ........................... 8-13
Nibbler/Breaker .................................................. 4-21
Nuts & Sleeves .................................................. 8-13

O
Opening and Closing Door Glass ........................ 3-4
Opening and Closing Windshield ........................ 3-4
Operate Boom Smoothly ................................... 4-16
Operating Both Travel Levers Together ............ 4-11
Operating Pattern ................................................ 4-9
Operating Pattern Decal ...................................... 4-9
Operating Precautions ......................................... 2-6
Operating the machine ........................................ 4-3
Operating the Machine in Water ........................ 4-13
Operating the Shovel ......................................... 4-17
Operation at Seashore or Salty Climate ............ 4-18
Operation in Extreme Cold ................................ 4-18
Operation in Extreme Heat ................................ 4-18
Operation in High Altitudes ................................ 4-18
Operation in Humid Climate .............................. 4-19
Operation in Sandy and Dusty Areas ................ 4-18
Operator Cab Nomenclature ............................... 3-9
Operator Precautions .......................................... 2-5
Operator Seat Adjustments ................................. 3-6
Operators Compartment Controls and Accessories .
3-8
ORS Joint (O-ring Sealing Type ........................ 8-12

P
Personal Safety ................................................... 2-3
Practices to Improve Efficiency ......................... 4-16
Prevent Contamination ........................................ 6-4

R
Releasing Hydraulic System Pressure ................ 6-6
Removing and Storing Lower Front Window ....... 3-4
Removing Machine from Storage ...................... 4-30
Removing the Bucket ........................................ 6-54
Required Filters ................................................... 5-4
Required Fluids/Lubricants and Capacities ......... 5-3
Right Hand Operator Console and Monitor ......... 3-9
Right, Left, Front, and Rear of the Machine ........ 1-2
Roll-Over Protective Structure (If equipped) ........ 2-8
9-2

S
Safety Area ...........................................................2-3
Safety Rules .........................................................2-3
Seals & O-Rings ...................................................6-4
Seat Belt ...............................................................3-6
Seat Belt Precautions ...........................................2-9
Seat Height Adjustment ........................................3-6
Securing Machine to Trailer ...............................4-28
Selection of the Hydraulic Breaker .....................4-20
Specific Precautions to this Machine ....................2-9
Starter Motor ........................................................7-5
Starting & Stopping Machine Engine with
Temperature above 0C (32F) .....................4-4
Starting & Stopping Machine Engine with
Temperature below 0C (32F) ......................4-5
Starting and Stopping Precautions .......................2-5
Starting Boosting Machine Engine .......................4-6
Starting Disabled Machine Engine .......................4-6
Starting Engine ............................................. 4-4, 4-5
Starting Machine Engine with Booster Cable .......4-6
Steps and Handrails ...........................................6-17
Stop Engine ..........................................................6-4
Stopping Engine - Normal Conditions .......... 4-4, 4-5
Swing Operation .................................................4-15

T
Torque Specifications .........................................8-11
Track Links .........................................................6-21
Tracks and Components ....................................6-19
Transportation ....................................................4-26
Transporting Precautions .....................................2-8
Travel Safety ......................................................4-13

U
Units of Flow .......................................................8-15
Units of Length ...................................................8-15
Units of Power ....................................................8-15
Units of Pressure ................................................8-15
Units of Torque ...................................................8-15
Units of Volume ..................................................8-15
Units of Weight ...................................................8-15
Use Arm in Action ...............................................4-16
Use of Optional Attachment ...............................4-19
Utility Safety .........................................................2-4

W
Warm Engine Oil ..................................................6-4
Warming of Hydraulic Oil ......................................4-8
Warming Up of Engine .........................................4-7
Wear Safety Equipment .......................................6-4
Weight of Materials Table ...................................8-14
Issued 01-08

Bur

87722071 NA

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

87722071 NA

Issued 01-08

Bur

9-3

CHAPTER 9 - INDEX

9-4

Issued 01-08

Bur

87722071 NA