CX36B Tier 4 Op S Manual PDF

OPERATOR’S 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:
❷ Is instructed in safe and proper use of the machine.
❷ Reads and understands the Manual(s) pertaining to the machine.
❷ Reads and understands ALL Safety Decals on the machine.
❷ Clears the area of other persons.
❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job
site.
It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and
maintenance.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects,
and other reproductive harm.
Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
TECHNICAL MANUALS
Manuals are available from your Dealer for the operation, service, and repair of your machine.
Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for
Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.
Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your
machine so your Dealer can provide the correct manuals for your machine.
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..
TABLE OF CONTENTS
GENERAL INFORMATION
To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CHAPTER 4
OPERATING INSTRUCTIONS
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
Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CHAPTER 6
MAINTENANCE AND ADJUSTMENTS
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 Issued 01-08 Bur I

1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Bur 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 Issued 01-08 Bur 1-1

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.
6 6
4 3
5 5
2
DC03H142 Figure 1
1. FRONT 3. RIGHT HAND SIDE 5. TRAVEL REDUCTION GEARS (TRAVEL MOTORS)

2. REAR 4. LEFT HAND SIDE 6. IDLER WHEELS
1-2 Issued 01-08 Bur 87722071 NA

MACHINE COMPONENTS
32 33
30
31
36 15
34 16
17
8
35 18
12
37
13 19
3
14 5
11 4
29 6
20 1
7
28
27
24
25 2
26 10
23 21
22 9
BS07M601 Figure 2
MACHINE COMPONENTS
1. ENGINE 11. SWING CYLINDER 21. SWIVEL JOINT 31. BOOM CYLINDER
2. OIL FILTER 12. CONTROL VALVE 22. TRAVEL MOTOR 32. ARM CYLINDER
3. RADIATOR 13. TRAVEL LEVER 23. SWING BEARING 33. WORK LAMP
4. RESERVOIR TANK 14. SAFETY LOCK LEVER 24. IDLER ASSEMBLY 34. ARM
5. AIR CLEANER 15. CANOPY 25. LOWER ROLLER 35. LINK
6. MUFFLER 16. CONTROL LEVER 26. UPPER ROLLER 36. BUCKET CYLINDER
7. FUEL TANK 17. DOZER CONTROL LEVER 27. RUBBER CRAWLER BELT 37. BUCKET
8. HYDRAULIC TANK 18. THROTTLE LEVER 28. DOZER BLADE
9. HYDRAULIC PUMP 19. MONITOR PANEL 29. DOZER CYLINDER
10. SWING MOTOR 20. BATTERY 30. BOOM
87722071 NA Issued 01-08 Bur 1-3

IDENTIFICATION NUMBERS
MODEL, SERIAL NUMBER, AND YEAR OF ENGINE
MANUFACTURE
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.
BS07M603 Figure 4
ENGINE
➤
Make and Model
➤
Serial Number
BS07N400 Figure 3
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 Issued 01-08 Bur 87722071 NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS
CHAPTER 2
SAFETY, DECALS, AND HAND SIGNALS
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Boom and Arm Movement - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Safety Controls - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Hot Surfaces - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Pressurized Fluids and Lubricants - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Counterweight Swing Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
track Tension Adjuster - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Keep Clear of Working Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Battery - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Safety Lock Lever - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Seat Belt - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Falling Front Window - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Hydraulic Oil Check Position - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Stop Engine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Confirm Attachment Movement- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Do Not Operate This Machine- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Issued 01-08 Bur 87722071 NA 2-1

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

SAFETY RULES
PERSONAL SAFETY
WARNING: This safety alert symbol
If Safety Decals on this machine are ISO two panel
indicates important safety messages in this
Pictorial, decals are defined as follows:
manual. When you see this symbol, carefully
read the message that follows and be alert to • The first panel indicates the nature of the
the possibility of death or serious injury. hazard.
M171C • The second panel indicates the appropriate
Most accidents involving machine operating and avoidance of the hazard.
maintenance can be avoided by following basic • Background color is YELLOW
safety rules and precautions. Read and understand
all the safety messages in this manual, the safety Prohibition symbols such as and STOP if
manual and the safety signs on the machine before used, are RED.
you operate or service the machine. See your dealer
if you have any questions. SAFETY AREA
BS06H091 Figure 1 BC02N198 Figure 2
1. OPERATOR’S MANUAL STORAGE SPACE 1. WORKING AREA

2. SAFETY AREA
READ THIS MANUAL COMPLETELY and make The safety area is the space necessary for the
sure you understand the controls. All equipment has machine to operate at the maximum range of the
a limit. Make sure you understand the speed, brakes, tool. The area is a full 360 ° swing plus 6 feet (2
steering, stability, and load characteristics of this meters).
machine before you start to operate this machine.
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

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. RH99G001 Figure 3
ALWAYS have all local utility companies mark the CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU
location of their lines. PERFORM ANY MACHINE OPERATION
Know the utility color code (U.S.A. and Canada):
In U.S.A. and Canada call one of many “One Call
System Director” services. If you do not know the Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
local number, call the national number (U.S.A. and Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow
Canada only): 1-888-258-0808. Communication, Telephone, Television. . Orange
IMPORTANT: Check with local authorities for laws, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
regulations and/or strict penalties requiring you to Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown
locate and avoid existing utilities. 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

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 points of support when getting on and off the
and know how to use each. 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. • Do not jump off the machine.
• Know and use the protective equipment that is to • Do not dismount while the machine is in motion.
be worn when operating this machine. Hard hats, • Foreign material or grease on the steps and hand
protective glasses, protective shoes, gloves, rails can cause an accident. Keep the steps and
reflector type vests, respirators and ear protection hand rails clean.
are examples of the type of equipment that may
be required. STARTING AND STOPPING PRECAUTIONS
• Certain protective equipment should be replaced • Walk around the machine and warn all personnel
and renewed upon age and wear. Old or damaged who may be servicing the machine or are in the
hard hats may not provide the same level of machine path prior to starting. Do not start until all
protection as a new hard hat. Faded and soiled personnel are clearly away from the machine.
vests are no longer as highly visible as new vests. Sound the horn, if equipped, before starting.
See the manufacturer’s recommendation. • Walk around the machine’s tool, attachment, or
• Do not rush. Walk, do not run. furthermost contact point to view operation danger
area from the work site personnel view and angle.
• Know and use the hand signals required for
particular jobs and know who has the • Check that the parking device is applied, place the
responsibility for signaling. transmission in neutral or park as specified by the
manufacturer before starting the machine.
GENERAL • Adjust, secure and latch the seat and fasten the
• It is the responsibility of the operator to read and seat belt before starting the machine.
understand the Operator’s Manual and other
information provided and use the correct
• Start and operate the machine only from the
operator’s seat.
operating procedure. Machines should be
operated only by qualified operators. • Do not bypass the machine’s neutral-start system.
The neutral-start system must be repaired if it
• DO NOT OPERATE this machine or perform malfunctions.
maintenance work if you have not had appropriate
training and read and fully understand the • Use booster cables only in the recommended
instructions and warnings in this manual. manner. Improper use can result in battery
explosion or unexpected machine motion.
• Wear the seat belt to maximize the protection Ventilate the battery area before using booster
capability of a ROPS (Roll Over Protective
cables. Make sure that using booster cables will
Structure) when the machine is so equipped.
not interfere or harm electronic processing or
• Inspect the ROPS and seat belt mounting bolts on computer devices.
a daily basis to ensure their integrity.
• DO NOT OPERATE the engine in an enclosed
• Do not permit riders on the machine if there is no area without adequate ventilation.
manufacturer’s designated place for a rider.
• Park the machine on level ground whenever
• DO NOT use the bucket or attachment to lift possible and apply the parking brake. On grades,
persons or carry riders on the machine. park the machine with the wheels or track
securely blocked.
• Make sure that all protective guards, canopies,
doors, etc. are in place and secure. • Before leaving the operator’s station, lower the
equipment to the ground, shut off the engine and
• Remove all loose object stored in the machine. place the function cancellation lever into the
Remove all objects which do not belong in or on
locked or up position.
the machine and its equipment.
• Remove the starter key or disconnect switch when
leaving the machine parked or unattended.
87722071 NA Issued 01-08 Bur 2-5

OPERATING PRECAUTIONS • On machines with independently operated wheel

• Check brakes, steering and other machine control brakes, lock the brake pedals together when
devices in accordance with the manufacturer’s roading to provide equalized brake application.
instructions prior to starting operation. Observe all • Use the recommended transport devices when
gauges or warning instruments for proper roading the machine.
operation. Operate all controls to insure proper
operation. If any malfunctions are found, remove • Use the approved drawbar and / or attachment
the starter key or disconnect switch key. Place a point when using the machine for towing. If a
DO NOT OPERATE tag on the machine until the cable or chain is used, keep people away from the
malfunction is corrected. tow line.
• If a failure that causes loss of control such as • Before you operate at night, check that all lamps
steering, service brakes or engine occurs, stop illuminate.
the machine motion as quickly as possible, • If your machine has a cab make sure that all
remove the starter key or disconnect switch key. windows are clean and that the windshield wipers
Place a DO NOT OPERATE tag on the machine and washers work correctly.
and keep it securely parked until the malfunction
is corrected or the machine can be safely towed. • Engine exhaust fumes can cause death. If you
operate this machine in an enclosed area, make
• Understand the machine limitations and keep the sure there is ventilation to replace the exhaust
machine under control. fumes with fresh air.
• Operate and drive the machine with care and at • Check all controls in a clear area and make sure
speed compatible with conditions. Use extra the machine is operating correctly.
caution when operating over rough ground, on
slopes, and when turning. • Dust, fog, smoke, etc., can decrease your vision
and cause an accident. Stop the machine or
• Note and avoid all hazards and obstructions such decrease the speed until you can see.
as ditches, underground lines, trees, cliffs,
overhead electrical wires or areas where there is • Contact with high voltage power lines,
danger of a slide. underground cables, etc., can cause serious
injury or death from electrocution.
• Carry loads in recommended positions for
maximum stability. • Before you drive or operate in an area with high
voltage lines, cables, or a power station, tell the
• Never lift loads in excess of capacity. power or utility company what you are going to do.
• Use the recommended machine ballast and You MUST HAVE THE POWER DISCONNECTED
counterweighting. OR KEEP A SAFE WORKING DISTANCE from the
lines, cables, or power station. Keep all parts of
• Know and understand the job site traffic flow the machine a safe distance away from the power
patterns and obey signalmen, road signs and source. You must also know any federal,
flagmen. state/provincial, or local safety codes or
• Know and understand that job site conditions may regulations that apply to the job site.
change on an hourly basis. Hills of dirt, debris or • If a part of the machine touches high voltage
obstructions may grow and change from the time power:
you began the day. It is your responsibility to
monitor the changes and keep the machine, tools 1. Warn other workers NOT TO TOUCH THE
and attachments, etc. a safe distance. MACHINE and to stay away from the machine.
• Watch for bystanders and never allow anyone to 2. If you can break contact, reverse the operation
be under or to reach through the machine and its that caused contact with the high voltage power,
equipment while operating. and move the machine away from the danger
area. If you cannot break contact stay in the
• Select a gear that will prevent excessive speed machine until the utility company de-energizes
when going downhill. Do not coast downhill. the line and tells you that the power is off.
• When roading a machine, know and use the • If you have extreme conditions, such as a fire,
signaling devices required on the machine. etc., and you are forced to leave the machine, do
Provide an escort for roading where required. 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.
2-6 Issued 01-08 Bur 87722071 NA

• 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 the machine in motion or the engine operating. If
people around you. the engine must be in operation to make certain
adjustments, place the transmission in neutral,
• You must make a judgment if weather, road, or apply the parking brake, place the equipment in a
earth conditions will permit safe operation on a
safe position, securely block the tracks and use
hill, ramp, or rough ground.
extreme caution.
• Stay away from hazardous areas such as ditches,
overhangs, etc. Walk around the work area before
• Securely block the machine or any component
that may fall before working on the machine or
you start and look for hazards.
component. If possible, use a back up or
• Be alert and always know the location of all secondary blocking device, also.
workers in your area. Keep all other persons
completely away from your machine. Injury or
• To prevent unexpected movement, securely block
working elements when repairing or changing
death can result if you do not follow these
working tool parts such as cutting edges.
instructions.
• Never make repairs on pressurized components,
• Develop fluid and smooth operating techniques fluid, gas or mechanical until the pressure has
and maintain the surface condition where the
been relieved according to the manufacturer’s
machine travels in order to control vibration
instructions.
transfer to the operator.
• Use extreme caution when removing radiator
MAINTENANCE PRECAUTIONS caps, drain plugs, grease fittings or pressure taps.
• Do not attempt repairs unless trained. Refer to Park the machine and let it cool down before
manuals and experienced repair personnel for opening a pressurized tank.
help. • Release all pressure before working on systems
which have an accumulator. Use a piece of
cardboard, newspaper, or wood to check for
pressurized leaks to prevent fluid penetrating the
skin. Pressurize accumulators with the proper gas
according to manufacturer’s recommendations.
• When absolutely necessary to tow the machine,
do not exceed the recommended towing speed.
Be sure the towing machine has sufficient braking
capacity to stop the towed load. If the towed
machine cannot be braked, a tow bar must be
used or two towing machines must be used. - one
in front pulling and one in the rear to act as a
brake. Avoid towing over long distances.
DC04E084 Figure 4
• Observe proper maintenance procedures.
• Before beginning any inspection or maintenance
procedures, secure a “DO NOT OPERATE” tag to • Whenever servicing or replacing hardened pins,
the operator’s console to inform the operator that etc., use a brass drift or other suitable material
the machine will be inoperable for inspection and between the hammer and pin. Alternate: Use a
maintenance. This tag will prevent accidental brass hammer, drift or suitable material on the pin,
starting of the machine. etc.
• Wear protective glasses and other required safety • Keep the brakes and steering systems in good
equipment when servicing or repairing the operating condition.
machine. • Replace all missing, illegible or damaged safety
• Wear gloves to protect hands when handling 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

FUEL HANDLING PRECAUTIONS • Hot coolant can spray out if the radiator cap is
• Do not smoke or permit open flames while fueling removed. To remove the radiator cap, let the
or near fueling operations. cooling system cool, turn to the first notch, wait
until the pressure is released, then remove the
• Never remove the fuel cap or refuel gasoline radiator cap.
engine powered machines with the engine
running or hot. Never allow fuel to spill on hot HAZARDOUS CHEMICAL PRECAUTIONS
machine components. Never allow fuel to
contaminate the environment.
• If you are exposed to or come in contact with
hazardous chemicals you can be seriously
• To avoid spilling fuel, maintain control of the fuel injured. The fluids, lubricants, paints, adhesives,
filler nozzle when filling the tank. coolants, etc., used with your machine can be
hazardous.
• Do not fill the fuel tank completely to the top. Allow
room for expansion. • Material Safety Data Sheets (MSDS) provide
information about the chemical substances within
• Clean up spilled fuel immediately and dispose of a product, safe handling procedures, first aid
contaminated material in an environmentally
measures and procedures to be taken when the
correct manner.
product is accidentally spilled or released. MSDS
• Tighten the fuel tank cap securely. Should the fuel are available from your dealer.
cap be lost, replace it only with the original
manufacturers approved cap. Use of a
• Before you service your machine, check the
MSDS for each fluid, lubricant, etc., used in this
non-approved cap without proper venting may
machine. This information indicates what the risks
result in pressurization of the tank.
are and how to service the machine safely. Follow
• Never use fuel for cleaning purposes. this information when servicing the machine.
• Use the correct fuel grade for the operating • Before you service this machine and before you
season. dispose of the old fluids and lubricants, always
remember the environment. DO NOT put oil or
BURN PREVENTION fluids into the ground or into containers that can
leak.
WARNING: BATTERY ACID CAUSES • Check with your local environmental or recycling
SEVERE BURNS. Batteries contain sulfuric center or your dealer for correct disposal
acid. Avoid contact with skin, eyes or information.
clothing.
Antidote: EXTERNAL - Flush with water. TRANSPORTING PRECAUTIONS
Antidote: INTERNAL - Drink large quantities 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
of water or milk. necessary for transporting this machine on a road or
DO NOT induce vomiting. Seek medical highway.
attention immediately.
EYES - Flush with water for 15 minutes and ROLL-OVER PROTECTIVE STRUCTURE (IF
seek medical attention immediately. EQUIPPED)
M144B 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.
WARNING: BATTERIES PRODUCE Unauthorized modifications such as welding, drilling,
EXPLOSIVE GASES. Keep sparks, flame, cutting, or adding attachments can weaken the
cigars and cigarettes away. Ventilate when structure and reduce your protection. Replace ROPS
charging or using in enclosed area. Always if it is subjected to roll-over or damage. Do not
wear eye protection when working near attempt to repair.
batteries. Wash hands after handling. KEEP
OUT OF REACH OF CHILDREN. FIRE EXTINGUISHER
It is recommended that you have a fire extinguisher
• When the battery electrolyte is frozen, the battery on your machine. Contact your dealer for the type
can explode if, you try to charge the battery, or and location of a fire extinguisher on this machine.
you try to jump start and run the engine. To
prevent the battery electrolyte from freezing, try to FIRE PREVENTION
keep the battery at full charge. If you do not follow
these instructions, you or others in the area can Remove all trash or debris from the machine each
be injured day. Check the engine area and exhaust system
2-8 Issued 01-08 Bur 87722071 NA

SEAT BELT PRECAUTIONS SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or tool as low as possible while
moving the machine around the job site.
1
• Never smoke while refueling.
• Do not use tractive force of the machine for
loading the bucket attachment nor to push or pull
any objects.
• Do not use swinging force of the machine for
operations.
• Do not perform “hammering” operation with the
2 bucket.
• Do not use this machine for anything other than its
BC02N375 Figure 5 intended purpose.
1. RIGHT HAND BELT STRAP • DO NOT OPERATE bucket and arm cylinders to
2. LATCH MECHANISM stroke end repeatedly.
1. Insert the metal end of the right-hand belt strap • Do not over exert the machine’s capacities.
into the latch mechanism on the left-hand side of
the seat.
• Never pull standing objects toward the machine.
2. To unlatch the seat belt, press the red button on • Do not use the long reach attachment for general
the left-hand side latch mechanism. 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
DC04D572 Figure 6
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

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 and STOP if used are RED.
2-10 Issued 01-08 Bur 87722071 NA

BOOM AND ARM MOVEMENT - CAUTION

Located on seat stand cover - Part Number YN20T01013P1
BS08A058/BS07M647 Figure 7
HYDRAULIC OIL - WARNING

Located on hydraulic tank- Part Number PW20T01007P1
BS07M639/PW20T01007P1 Figure 8
87722071 NA Issued 01-08 Bur 2-11

SAFETY CONTROLS - WARNING

Located on seat stand cover - Part Number YN20T01016P1
HOT SURFACES - CAUTION

Located on engine door hinge - Part Number YN20T01220P1
BS07M640/YN20T01220P1 Figure 10
2-12 Issued 01-08 Bur 87722071 NA

PRESSURIZED FLUIDS AND LUBRICANTS - WARNING

Located on radiator duct - Part Number PW20T01094P1
BS07M444/PW20T01094P1 Figure 11
ENGINE STOP - CAUTION

Located on hood support- Part Number YN20T01012P1
BS07M444/BS07M448 Figure 12
87722071 NA Issued 01-08 Bur 2-13

COUNTERWEIGHT SWING AREA - DANGER

Located on radiator cover- Part Number PE2T01014P1
BS07M646/BS06J055 Figure 13
ENGINE STOP - CAUTION

Located on engine radiator- Part Number YN20T01009P1
BS07M606BS07M649 Figure 14
2-14 Issued 01-08 Bur 87722071 NA

BOOSTER CABLE - WARNING

Located on battery box cover- Part Number YN20T01338P1
TRACK TENSION ADJUSTER - WARNING

Located on crawler frame - Part Number 243T6110
87722071 NA Issued 01-08 Bur 2-15

KEEP CLEAR OF WORKING AREA - DANGER

Located on both sides of arm- Part Number PE20T01012P1
BS07M652/UPX00100013E01 Figure 17
DOZER BLADE - CAUTION

Located on seat stand cover- Part Number PY20T01077P1
2-16 Issued 01-08 Bur 87722071 NA

BATTERY - DANGER
Located on battery box cover- Part Number PY20T01069P1
BS07M652/PY20T01069P1 Figure 19
ELECTRICAL LINE SAFETY - DANGER

Located on seat stand cover- Part Number YN20T01006P1
BS08A058//BS07M654 Figure 20
87722071 NA Issued 01-08 Bur 2-17

SELECTOR VALVE - CAUTION

Located on seat stand cover- Part Number PE20T01016P1
BS07M607/UPX00100022E01 Figure 21
SAFETY LOCK LEVER - WARNING

BS08A058/UPX00100017E01 Figure 22
2-18 Issued 01-08 Bur 87722071 NA

FOOT PEDAL- CAUTION

BS07M607/UPX00100018E01 Figure 23
SEAT BELT - WARNING

Located on seat stand cover- Part Number PE20T01027P1
BS07M607/UPX00100019E01 Figure 24
87722071 NA Issued 01-08 Bur 2-19

WINDOW LOCK - CAUTION

Located on inside front window- Part Number YN20T01416P1
BS07M655/UPX00100026E01 Figure 25
FALLING FRONT WINDOW - CAUTION

Located on inside front window - Part Number PM20T01035P1
BS07M655/UPX00100021E01 Figure 26
2-20 Issued 01-08 Bur 87722071 NA

CAB DOOR - WARNING

Located inside cab door - Part Number PV20T01008P1
BS07M657/UPX00100023 Figure 27
HYDRAULIC OIL CHECK POSITION - NOTICE

Located on seat stand cover- Part Number 243P3379
BS08A058/UPX00100017E01 Figure 28
87722071 NA Issued 01-08 Bur 2-21

CAP AND KEY COVER - CAUTION

Located near fuel fill cap - Part Number PW20T01090P1
BS07M610/UPX00100028E01 Figure 29
STOP ENGINE - DANGER

Located on inside of side cover- Part Number YN20T01214P1
BS07M605/UPX00100031E01 Figure 30
2-22 Issued 01-08 Bur 87722071 NA

CONFIRM ATTACHMENT MOVEMENT- WARNING

Located on inside of right window (cab). Located on ceiling (canopy) - Part Number YN20T01039P1
BS07M656/UPX00100032E01 Figure 31
DO NOT OPERATE THIS MACHINE- WARNING

Located on inside of right window (cab). Located on ceiling (canopy) - Part Number PE20T01028P1
BS07M656/UPW00100075E01 Figure 32
87722071 NA Issued 01-08 Bur 2-23

CALIFORNIA PROPOSITION 65 - WARNING

Located on inside right window (cab). Located on ceiling (canopy) - Part Number 2432T6457
BS07M656UPJ00010005E01 Figure 33
CALIFORNIA PROPOSITION 65 - WARNING

Located on inside right window (cab). Located on ceiling (canopy) - Part Number YN20T01495P1
BS07M656UPJ00010006E01 Figure 34
2-24 Issued 01-08 Bur 87722071 NA

HOT PARTS (OPTIONAL CAB WITH AIR CONDITIONING)

Located on compressor - Part Number PH20T01102P1
BS07M656/BS07N559 Figure 35
87722071 NA Issued 01-08 Bur 2-25

HAND SIGNALS
IMPORTANT: When operating the machine, never MOVE LOAD IN HORIZONTALLY
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.
The following is a compilation of the Hand Signals to
be used when a flagman is required for Excavator
Operation. All personnel associated with the
operation of the excavator should know these signals
and their meaning before attempting to operate this
machine.
RAISE LOAD VERTICALLY DC04E040 Figure 38

Face Machine Operator, extend right arm toward
operator with hand facing operator and move hand in
direction of movement required.
MOVE LOAD OUT HORIZONTALLY
DC04E038 Figure 36
Face Machine Operator, raise right forearm vertical,
with index finger pointing up and move hand in a
small circular motion.
LOWER LOAD VERTICALLY DC04E041 Figure 39

Face Machine Operator, extend right arm toward
operator with back of hand facing operator and move
hand in direction of movement required.
RAISE BOOM
DC04E039 Figure 37
Face Machine Operator, extend right arm down,
point index finger down and move hand in small
circular motion.
DC04E042 Figure 40
Face Machine Operator, extend right ar m out
horizontally from shoulder, make a fist with thumb up.
LOWER BOOM
2-26 Issued 01-08 Bur 87722071 NA
ARM IN
DC04E043 Figure 41
Face Machine Operator, extend right ar m out DC04E046 Figure 44
horizontally from shoulder, make a fist with thumb Face Machine Operator, bend at elbows with arms
down. facing operator, make fists and point thumbs in
toward each other.
SWING LEFT
ARM OUT
DC04E044 Figure 42
Face Machine Operator, extend right ar m out DC04E047 Figure 45
horizontally from shoulder, make a fist with index Face Machine Operator, bend at elbows with arms
finger pointing in swing direction. facing operator, make fists and point thumbs out
away from each other.
SWING RIGHT
COUNTER ROTATE LEFT
DC04E045 Figure 43
Fa c e M a c h i n e O p e ra t o r, ex t en d l e f t a r m o u t DC04E048 Figure 46
horizontally from shoulder, make a fist with index Face machine Operator, place right hand on top of
finger pointing in swing direction. 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.
87722071 NA Issued 01-08 Bur 2-27

COUNTER ROTATE RIGHT CLOSE BUCKET (BUCKET IN OR DIG)
DC04E049 Figure 47 DC04E052 Figure 50

Face Machine Operator, place left hand on top of Face Machine Operator, hold left hand in, closed and
hard hat, bend right arm at elbow to the left, make a stationary, hold right hand in, make a fist with index
fist with right hand with index finger pointing out and finger pointing toward left hand and move right hand
rotate hand in a forward circular motion. in a small forward circular motion.
TRAVEL FORWARD. OPEN BUCKET (BUCKET OUT OR DUMP)
Face Machine Operator, bend both elbows in, make Face Machine Operator, hold left hand in, open and
fists and rotate fists one over the other in a reverse stationary, hold right hand in, make fist with index
circular motion finger pointing toward left hand and move right hand
in small forward circular motion.
TRAVEL REVERSE
TURN LEFT
DC04E051 Figure 49
DC04E054 Figure 52
Face Machine Operator, bend both elbows in, make
fists and rotate fists one over the other in a forward Face Machine Operator, raise right forearm up, make
circular motion. fist with right hand and hold stationary, bend left arm
in, make fist with left hand and rotate left fist in a
small reverse circular motion.
2-28 Issued 01-08 Bur 87722071 NA
TURN RIGHT STOP
DE04E055 Figure 53 DC04E058 Figure 56

Face Machine Operator, raise left forearm up, make 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
fist with left hand and hold stationary, bend right hand horizontally from shoulder with hand open and facing
arm in, make fist with right hand and rotate right fist in down, move arm in a horizontal motion back and
a small forward circular motion. forth.
MOVE THIS MUCH EMERGENCY STOP

Face Machine Operator, raise both forearms up, Face Machine Operator, raise both ar ms out
hands open and facing each other, move hands in horizontally from shoulders with hands open and
laterally indicating how far to go. facing down, move arms in a horizontal motion back
and forth.
MOVE SLOWLY
STOP ENGINE
DC04E057 Figure 55
Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t DC04E060 Figure 58
horizontally toward right shoulder with hand open Face Machine Operator, right arm at side, draw left
and facing down, point right index finger up toward thumb or index finger across throat.
open left hand and rotate right hand in a reverse
circular motion. (Raise Load Slowly is illustrated).
87722071 NA Issued 01-08 Bur 2-29
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Opening Right Window Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Seat Front and Rear Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Engine Door Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Window Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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

NOTES
3-2 Issued 01-08 Bur 87722071 NA

OPERATOR CAB AND OPERATOR SEAT

LOCKING/UNLOCKING CAB DOOR CAB DOOR LATCH
1 1
2 2
3 3
BS07M259 Figure 1 BS07M259 Figure 2
1. DOOR CATCH 1. The cab door can be latched in an open position

2. HANDLE by opening door until it is locked in place by the
3. KEY door latch (1) located on the cab.
Use the ignition switch key to lock or unlock cab door.

Insert key fully into door lock and turn to lock and WARNING: Never use the lever for door
unlock cab door. Use this key to open other machine latch release as a handle to mount and/or
locking compartments. dismount from the machine. Failure to
comply could result in injury or death.
BS07M660 Figure 3
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

OPENING AND CLOSING WINDSHIELD REMOVING AND STORING LOWER FRONT

WINDOW
Front window (upper) can be stored in ceiling.
IMPORTANT: Make sure to properly lock the window
frame in place, or the wiper lock may not function
properly, and the wiper may be damaged because
the wiper moves when the wiper motor switch is
turned on. 1 1
DC04D662 Figure 6
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.
2. Securely store the removed lower front window
UPW00200038J01 Figure 4 in the holder in the rear of cab behind the
operator’s seat.
1. Pull lock lever down (1) on front window upper
section to unlock the window. 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.
1 OPENING RIGHT WINDOW GLASS
1
BS07M661 Figure 5
1. LOCK LEVER
2. Hold handles on left and right sides of the front

window. Lift the front window up and slide
BS07M663 Figure 7
overhead all the way to the back. The window 1. LOCK
will automatically lock when in position.
1. Open cab door by releasing lock and sliding the
window.
WARNING: Special attention must be paid
not to injure hands and others when the front 2. Close the door glass sliding it to LOCK position,
window is closed. Always make sure to then lock it.
properly lock the front window in place to
avoid injury. Failure to comply could result in
injury or death.
3-4 Issued 01-08 Bur 87722071 NA

CAB DOME LIGHT DOCUMENT POUCH
BS06H100 Figure 8 BS06H091 Figure 9
CAB DOME LIGHT DOCUMENT POUCH
1. Turn Cab Dome Light ON by pushing the Dome 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

Light Switch downward. compartment is a pouch located on the back of the
operator’s seat. Keep the Operator and Parts Manual
2. Turn OFF by pushing switch all the way up.
for this machine in this location at all times for quick,
easy reference.
87722071 NA Issued 01-08 Bur 3-5

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
1
DC04D529 Figure 11
1 1. BUCKLE
2. RED BUTTON
1. Sit on the operator’s seat and adjust the seat

position so that the operator’s back closely
BS07666 Figure 10 contacts with the seat back.
SEAT FRONT & REAR ADJUSTMENT LEVER 2. Draw out the right side seat belt and fasten it to
the buckle located on the left side.
• Move the seat adjustment lever to the right. Adjust
the seat forward or backward to the desired NOTE: If the belt stops while you’re pulling it out,
position. release the tension and continue pulling it out.
• Release lever to lock the seat in position. 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
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 Bur 87722071 NA

MACHINE ACCESS COMPARTMENTS AND DOORS

ENGINE DOOR COVER
2
1 4
DC04D529 Figure 12 BS07M668 Figure 14
1. LOCK 2. RIGHT HAND SIDE COVER

2. RELEASE 3. ENGINE DOOR
4. LEFT HAND SIDE COVER
A lock is provided for the engine doors. Use the
ignition key to open and lock the engine doors. 2. Secure the cover in open position with the strut.
3. To close, return the strut to the storage position,
and close cover. Lock the compar tment by
turning the key in a counter clockwise direction.
WARNING: Secure the engine doors in open

position with strut when servicing. Failure to
comply could result in injury or machine
damage.
WINDOW WASHER TANK
1 2
BS07M668 Figure 13
1. KEY CYLINDER
1. After releasing the lock, remove the key and

open cover.
3 1
BS07M670 Figure 15
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 Bur 3-7

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES
2 6 7 8 1
19 5 9 4 20
3 14
15
13
12
10
17
18
11
16
BS07M671 Figure 16
COMPONENTS
6. BOOM SWING (OPERATING

1. RIGHT OPERATING LEVER 11. WORK LIGHT SWITCH 16. OPERATOR’S SEAT
PEDAL)
7. OPTION PEDAL 17. WIPER SWITCH
2. LEFT OPERATING LEVER 12. THROTTLE LEVER
(NIBBLER AND BREAKER) (CAB MODEL)
18. HEATER SWITCH
3. SAFETY LOCK LEVER 8. HORN SWITCH 13. STARTER SWITCH
(OPTIONAL)
9. TRAVEL SPEED SELECT 14. DECELERATION SWITCH
4. RIGHT TRAVEL LEVER 19. LEFT TRAVEL PEDAL
SWITCH (OPTIONAL)
15. DOZER BLADE
5. LEFT TRAVEL LEVER 10. MONITOR PANEL 20. RIGHT TRAVEL PEDAL
OPERATING LEVER
3-8 Issued 01-08 Bur 87722071 NA

OPERATOR CAB NOMENCLATURE RIGHT HAND CONSOLE AND MONITOR

This chapter points out locations of operator controls KEY SWITCH
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.
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 BS07M672 Figure 17
and function of the components and controls of this KEY SWITCH
machine.
The Key Switch is located on the right hand operator
All personnel associated with this machine should
console and has 4 operating functions.
read and understand this information BEFORE
beginning any work with or on this equipment.
OFF - When key is turned to this position, the
e n g i n e s t o p s a n d e l e c t r i c a l p owe r t o t h e
machine’s electrical system is stopped after
approximately 3 seconds.
ON - When key is in the “ON” position, electrical
power is supplied to all the machine’s electrical
systems.
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.
87722071 NA Issued 01-08 Bur 3-9

MONITOR
BS07M673 Figure 18
1. ENGINE COOLANT TEMPERATURE GAUGE 5. BATTERY CHARGE LAMP (RED)

2. FUEL LEVEL GAUGE 6. LOW FUEL WARNING LAMP (RED)
3. ENGINE OIL PRESSURE LAMP (RED) 7. AIR CLEANER LAMP (RED)
4. COOLANT TEMPERATURE LAMP (RED) 8. HIGH TRAVEL SPEED LAMP - 2ND (YELLOW)
GAUGES

1. BLUE: COLD CONDITION 1. WHITE: OPERATING CONDITION
2. WHITE: OPERATING CONDITION 2. RED: REFILL
3. RED: OVER HEATING
FUEL GAUGE
COOLANT TEMPERATURE GAUGE
Indicates the amount of fuel in fuel tank. F: Indicates
Indicates the temperature of the engine coolant and a full tank. Refuel when the indicator is approaching
operates when the starter key switch is turned to the empty with diesel fuel only. Do not allow the machine
ON position. The temperature is normal in the white to run out of fuel.
range. If the indicator enters the red range, let the
engine low idle until the coolant temperature
indicator moves back into the white range.
If the indicator is in the blue range, warm up engine
and hydraulic oil.
3-10 Issued 01-08 Bur 87722071 NA
WARNING LAMPS
WARNING: Do not perform any
IMPORTANT: If warning lamps illuminate, change
maintenance on a hot engine. Allow the
machine operating method immediately. If this lamp
engine to cool before inspection or
remains illuminated, stop the engine and determine
maintenance. Failure to comply may result in
the cause of the problem. See the Maintenance
death or injury.
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.
BS07M776 Figure 21
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.
BS07M777 Figure 22
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

LOW FUEL WARNING LAMP (RED) HIGH SPEED LAMP (YELLOW)
If fuel is low, a warning lamp will illuminate. Stop the The high speed indicator lamp will be illuminated
engine and add fuel. Do not allow the machine to run when the travel speed is switched to high (2nd)
out of fuel. 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

SWITCHES
10 2 3
4
9
7 BS07M783 Figure 28
6
TRAVEL SPEED SELECT SWITCH
5
Use the travel speed select switch (2) to change
travel speeds. When the machine is turned off, the
8 travel speed is automatically set to low (1st).
BS07M782 Figure 26 WARNING: Use low speed when operating

6. HEATER SWITCH on a slope or loading/unloading from a truck
1. STARTER KEY SWITCH
(CANOPY) or trailer. Sudden changes in ground level
2. TRAVEL SPEED SELECT 7. WIPER AND WASHER can cause accidents. Failure to comply could
SWITCH SWITCH result in injury or death.
8. TRAVEL ALARM
3. HORN SWITCH
SELECT SWITCH Select low speed when travelling on rough or soft
4. DECELERATION SELECTOR 9. SWING/REMOTE ground, in confined spaces, loading or unloading
SWITCH CONTROL SWITCH from a trailer, or when tractive force is required.
10. NIBBLER AND
5. WORK LAMP SWITCH
BREAKER SWITCH Select high when moving on flat, level ground.
IGNITION KEY SWITCH HORN SWITCH
Use the ignition key (1) to start and stop the engine. The horn switch (3) is located on the top of the right
See page 3-9 for additional information. control. Always sound the horn before star ting
engine or moving the machine.
87722071 NA Issued 01-08 Bur 3-13

BS07M785 Figure 30
BS07M778 Figure 33
D E C E L E R AT I O N S E L E C TO R SWITCH
(OPTIONAL) WIPER AND WASHER SWITCH
Press the deceleration switch (4) during engine Use the washer/wiper switch (7) to spray washer fluid
rotation to change the engine to low speed. Press or turn on the windshield wipers. The switch has four
again to release the deceleration function. Fuel settings.
efficiency and noise generation can be aided by Wash: (left): Sprays washer fluid
using this switch. Turning the ignition switch off will
automatically release the deceleration function. 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.
BS07M779 Figure 34
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
LEVERS
2 3 2
1
5
BS07M790 Figure 35
SWING REMOTE CONTROL BUTTON BS08A065 Figure 37
To operate the boom swing function, press the button 1. SAFETY LOCK LEVER
(9) on the top of the left control lever. Operate to left 2. RIGHT/LEFT CONTROL LEVER
for left boom swing or right for right boom swing. To 3. TRAVEL LEVER WITH PEDALS
switch from the boom swing function, return the 4. THROTTLE LEVERS
control lever to neutral position, keeping your finger 5. DOZER CONTROL LEVER
off the swing control button.
BS06H080 Figure 38
1. FUNCTION CANCELLATION LEVER IN

LOCKED (UP) POSITION
BS07M791 Figure 36 2. FUNCTION CANCELLATION LEVER IN
UNLOCK (DOWN) POSITION
NIBBLER AND BREAKER OPERATING BUTTON
(OPTIONAL) HYDRAULIC FUNCTION CANCELLATION LEVER
Nibbler and breaker (10) functions are an optional A hydraulic function cancellation lever is provided on
feature. These switches are located on the grip of the the left control console to avoid activation of any
left control lever. unwanted hydraulic function. When the function
cancellation lever is placed in the unlock (down)
The breaker button when pushed is on, when
position, the alarm will sound intermittently for one
released breaker operation stops.
(1) second and the hydraulic system becomes active.
The nibbler closes when button (A) is pressed. The Before leaving the cab, shut down the engine, and
nibbler will open when button (B) is pressed. 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

OPERATING CONTROL LEVERS Left Hand Operator Control Lever (ISO/SAE

Pattern)
UPW00100006E11 Figure 39
DC04D562 Figure 41
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.
death.
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.
BS07N561 Figure 40
• FORWARD - Variable speed ARM out.
LH CONTROL LEVER RH CONTROL LEVER • BACKWARD - Variable speed ARM in.
2 E Arm Out 1 A Boom Down • LEFT - Variable speed left SWING.
F Arm In B Boom Up • RIGHT - Variable speed right SWING.
G Swing Left 3 C Bucket In
4 • CENTER - Neutral position.
H Swing Right D Bucket Out
3-16 Issued 01-08 Bur 87722071 NA

BHL PATTERN Right Hand Operator Control Lever (ISO/SAE

Pattern)
DC04D563 Figure 44
The Right Hand Operator Control Lever is located at
the top front of the right hand operator console. Its
BS07N561 Figure 42 purpose is to allow the operator to control operations
of the boom and bucket. Operating speed of function
LH CONTROL LEVER RH CONTROL LEVER is variable from stop to full stroke depending on how
far lever is operated. The right hand operator control
1 E Boom Down 2 A Arm Out has the following basic operational functions.
F Boom Up B Arm In
• FORWARD - Variable Speed BOOM down.
4 G Swing Left 3 C Bucket In
• BACKWARD - Variable speed BOOM up.
H Swing Right D Bucket Out
• LEFT - Variable speed BUCKET in (Digging).
In the BHL multi control shifting the boom and arm • RIGHT - Variable speed BUCKET out (Dump).
functions are opposite the ISO system.
• CENTER - Neutral position.
UPX00200006E01 Figure 43
87722071 NA Issued 01-08 Bur 3-17

NOTE: An optional Pattern Control Change Valve is

available. Contact your dealer for more information. If
your Excavator already has this valve installed use
the following instructions (BHL Pattern) regarding its
operation. 2
PATTERN CONTROL CHANGE (BHL PATTERN)
To change the machine’s control pattern from ISO
(SAE) to (BHL) pattern, proceed as follows:
1. Place the attachment on the ground, throttle 1
control in low idle, and turn the key switch off.
1 BS07N621 Figure 46
1. PATTERN CHANGER VALVE
3. Open the right compartment door, locate the

pattern changer lever (2).
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.
BS07N564 Figure 47
4. Loosen wing bolt (3), and change the lever
position to the desired pattern.
5. Hand tighten the wing bolt (3) securely. Do not
use tools to tighten.
6. Close compartment cover.
7. Carefully operate the control levers to make
certain functions match the pattern selected.
Practice in an open area to become familiar with
the new pattern.
WARNING: Check machine’s control pattern

for conformance to pattern on decal-card in
cab. If pattern does not match decal-card on
cab door holder, flip decal-card on holder to
match the machine’s control pattern before
operating machine. Failure to comply could
result in injury or death.
3-18 Issued 01-08 Bur 87722071 NA

LEFT HAND OPERATOR CONTROL LEVER

WARNING: Whenever a change is made to (BHL PATTERN)
the machine’s control pattern, also change
the pattern decal card in the cab to match the
new pattern. Failure to comply could result in
injury or death.
DC04D565 Figure 48
DC04D567 Figure 50
1. ISO/SAE PATTERN DECAL CARD
Slowly operate Left Hand control to make sure it
matches BHL pattern and to familiarize yourself with
1 the new control pattern.
RIGHT HAND OPERATOR CONTROL LEVER
(BHL PATTERN)
DC04D566 Figure 49
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

LEFT AND RIGHT TRAVEL LEVERS AND

PEDALS
BS07N624 Figure 53
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
BS07N623 Figure 52
1. TRAVEL MOTOR
2. DOZER BLADE
The travel levers and pedals are located in front of BS07N625 Figure 54
operator seat. They are used to move the left or right
track of the machine either forward or backward. THROTTLE CONTROL LEVER
• FORWARD - Variable speed forward track The throttle control lever is located to the right of the
movement. operator’s seat and is used to control engine speed.
• BACKWARD - Variable speed reverse track (A) LOW (low idling) - Push the throttle fully forward
movement. to set the engine in low idle.
• CENTER - Neutral position. (B) HIGH (high idling) - Pull the throttle fully
backward to set the engine in high idle.
The travel functions described are with the travel
motor located behind the cab.
WARNING: Always know the position of the

travel motors before starting movement.
death.
3-20 Issued 01-08 Bur 87722071 NA

HOUR METER
BS07N626 Figure 55
DOZER CONTROL LEVER BS07M792 Figure 56

Use the dozer control lever to move the dozer up or The Hour Meter indicates the total time that the
down. engine has run. It meters the time continuously as
(C) Dozer Up - Pull the lever back. long as the engine is running. Use the hour meter as
reference for machine maintenance.
(D) Dozer Down - Push the lever forward.
When traveling, raise the dozer blade to its maximum
height.
87722071 NA Issued 01-08 Bur 3-21

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Function Cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Turning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Machine Attachment and Swing - ISO/SAE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Operate Boom Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Ditch Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Using the dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Offset Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Issued 01-08 Bur 87722071 NA 4-1

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

BEFORE OPERATING THE MACHINE 16. Before undertaking any travel or working
operations during hours of darkness, make sure
WARNING: Do not attempt to operate this the lighting and signaling equipment is fully
machine unless you have first read and operative.
understand the safety messages and
instructions appearing in this manual. OPERATING THE MACHINE
CE-NA000
Before operating this machine, be sure to do the WARNING: Check all controls and safety
following: devices in a safe, open area before starting
work.
1. Check the level of all fluids (engine oil, hydraulic
CE-NA000
fluid, and coolant) and make sure that the fluids
an d lubr ican ts ar e suita ble for p reva iling When operating the machine, be sure to do the
conditions. See Chapter 6 - Maintenance and following:
Adjustments. 1. When starting the engine, be sure to use the
2. Carry out the daily maintenance operations. correct procedure for the prevailing weather
conditions. See Star ting The Engine in this
3. Inspect the machine, look for any signs of chapter.
possible leakage and check the hoses. Tighten
or replace as necessar y. See Chapter 6 - 2. Regularly consult the hourmeter to ensure that
Maintenance and Adjustments. all ser vicing operations are carried out
punctually. See Chapter 6 - Maintenance and
4. See run-in period if the machine is new or if the Adjustments.
engine has been reconditioned.
3. If you use your machine in particularly harsh
5. Check the track assemblies. conditions (dusty or corrosive atmosphere), the
6. Clean the steps and access handles. Grease, oil, ser vicing inter vals should be reduced
mud or ice (in winter) on the steps and access accordingly.
handles can causes accidents. Make sure they 4. Take note of the locations of hoses/cables before
are kept clean at all times. starting work.
7. Clean or replace any decals which are illegible. 5. Do not work near overhead high-voltage electric
See Decals in Chapter 2 - Safety and Decals. lines without checking beforehand that all
8. Make sure that the engine hood and the side necessary measures have been taken to respect
doors are properly closed and latched. the safest distances: See the decal on this
machine for safe working distances.
9. Secure the cab door in either fully closed or fully
opened position. 6. When working on a public highway, use standard
traffic signals and take into consideration the
10. Remove any obstructions which hinder visibility. working range of the upperstructure and its
Clean the windshield, the windows and the rear attachments. Local regulations stipulate the
view mirrors. number, type and location of reflector strips.
11. Check that no tools or other items have been left 7. Never operate the working or travel controls
on the machine (the undercarr iage or the unless you are properly seated in the operator's
upperstructure) or in the operator's compartment. seat with the seat belt correctly fastened.
12. Make sure no one is on or under the machine. 8. Modify your driving to suit the type of work and
The operator must be alone on the machine. working conditions.
13. Make sure nobody is standing in the machine 9. Do not allow anyone within the machine's
working area. operating radius. Stop all operations until
14. Find out about current safety measures in use on everyone has cleared the area.
the work site. 10. Operate all controls gradually to ensure smooth
15. Work out a convenient means of escape from the machine operation.
m ac h i ne ( be p ro a c t i ve an d d et er m i n e an 11. See Operating in Water if the machine will be
emergency exit) in the event of the cab door standing in water during use.
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 12. See Transporting the Machine in this chapter
hammer. when driving the machine onto a trailer.
87722071 NA Issued 01-08 Bur 4-3

13. See Lifting Procedures for the Machine in this STARTING AND STOPPING MACHINE
chapter when it is necessary to lift the machine. ENGINE
14. In some configurations, the working range of the
attachment allows the tool to interfere with the STARTING ENGINE
machine. Always maintain a safe minimum 1. Sit comfortably in the operator’s seat, making
distance between the tool and the machine. certain you can reach all the pedals and controls.
Fasten the seat belt.
15. Never use the attachment for sweeping the
ground to level out rubble or push objects (this 2. Move throttle control to “LO” position.
creates transversal stress on the attachment).
3. Insert key into key switch and turn to the “ON”
16. Avoid running the engine in a confined space. If position.
there is no alternative, proper ventilation must be
4. Sound horn to warn personnel that the machine
provided at all times.
is being started.
17. Dust, smoke or mist can reduce visibility and
5. Turn key to the START position and release as
cause an accident. Reduce speed or come to a
soon as engine starts. Key will automatically
complete stop until visibility has improved.
return to the ON position.
18. In the event of an operation problem or failure,
move the machine to a safe place, lower the CAUTION: Release Key after 20 seconds of
attachment to the ground, shut down the engine cranking if engine does not start.
and remove the key switch. Locate the problem, Wait at least 2 minutes before attempting to start
and take the necessary steps to warn others not engine again to allow starter motor to cool.
to attempt to operate the machine.
19. Do not stop the engine without taking prevailing NOTE: If engine fails to start after 3 attempts,
weather conditions into consideration. See inspect fuel system and correct any problem found.
Stopping the Engine. When cranking engine, the absence of “blue” or
“white” smoke from the exhaust indicates no fuel is
20. See Parking the Machine when you park the reaching the engine cylinders.
machine.
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.
BS07M794 Figure 1
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

EMERGENCY ENGINE SHUT DOWN STARTING AND STOPPING MACHINE

Use this emergency shut down measure ONLY when ENGINE IN COLD CLIMATES
the key switch fails to shut down the engine.
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 IMPORTANT: Release Key after 20 seconds of
DC04C344 Figure 2 cranking if engine does not start.
Wait at least 2 minutes before attempting to start
1. ENGINE EMERGENCY STOP CONTROL
engine again to allow starter motor to cool.
1. Pull out the engine emergency stop control NOTE:
located at the lower right hand side of the
operator’s seat until engine stops. • After starting the engine, use the auto warm up
system described in Machine Warm Up in this
2. Before restarting engine, push emergency chapter, and warm the engine and hydraulic oil.
engine stop control in.
• 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
1
2
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

STARTING MACHINE ENGINE WITH BOOSTER

CABLES
3
CONNECTING BOOSTER CABLE 2 1
WARNING: Improper booster cable

connections can cause an explosion resulting
in personal injury.
Always follow the correct procedures when
connecting and disconnecting the booster
cables. 4
1. Move vehicle or machine to be used for boosting
as close to the batter y box of the disabled
1 2 3 4
machine as possible. DC04D588 Figure 4
1. POSITIVE (+) TERMINAL OF DISABLED MACHINE

CAUTION: Do not allow the vehicle or machine used 2. POSITIVE (+) TERMINAL OF BATTERY BEING USED
for boosting to touch metal to metal with the disabled FOR BOOSTING
machine. This could short circuit electrical systems 3. NEGATIVE (-) TERMINAL OF BATTERY BEING USED
and cause extensive damage to the CPU and other FOR BOOSTING
4. UPPER FRAME OF DISABLED MACHINE
components.
3. Locate and connect one end of the booster cable
CAUTION: Use only vehicles or machines with 24V
to the positive (+) terminal on the battery of the
DC electrical system to boost start this machine.
disabled machine.
2. Make certain key switch of disabled machine is in 4. Connect other end of positive booster cable to
the OFF position before proceeding with booster positive (+) terminal of battery being used for
cable connection. boosting.
WARNING: Wear hard hat, approved safety 5. Locate and connect second cable to the negative
glasses or face shield, gloves and other (-) te r minal of th e ba tte r y being used fo r
safety equipment when working with boosting.
batteries. Failure to comply could result in 6. Connect other end of negative (-) cable to the
injury or death. upper frame of disabled machine as far away
from battery as possible.
WARNING: AVOID ACID BURNS
Battery electrolyte is an acid and can cause STARTING BOOSTING MACHINE ENGINE
injury or blindness if it contacts with skin or 1. Start engine boosting machine in normal manner
eyes. according to climate conditions.
Wear eye protection and protective clothing
when handling or servicing batteries. 2. Allow 5 minutes or more to provide partial charge
to the discharged batteries.
If electrolyte contacts skin or eyes, flush
affected areas immediately with clean water
STARTING DISABLED MACHINE ENGINE
and seek medical attention. Failure to comply
could result in injury or death. 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

DISCONNECTING BOOSTER CABLES MACHINE WARM UP
WARNING: While operating the machine

3 with cold hydraulic oil, the operator may
2 1 experience slow or unexpected movement of
functions. Damage to the hydraulic
components may result due to the cold oil not
providing adequate lubrication.
Auto warm up should be utilized when ever
machine is started in climate temperatures
below 10°C (50°F) to stabilize machine
4 control response. Cold oil can cause erratic
machine operation. Failure to comply could
4 3 2 1 result in injury or death.
DC04D588 Figure 5
MANUAL WARM UP
1. POSITIVE (+) TERMINAL OF DISABLED MACHINE
2. POSITIVE (+) TERMINAL OF BATTERY USED FOR 1. Warming Up Engine
BOOSTING a. Allow the engine to run for 5 minutes under no
3. NEGATIVE (-) TERMINAL OF BATTERY USED FOR load conditions with throttle control at “LO” idle
BOOSTING
position.
4. UPPER FRAME OF DISABLED MACHINE
After disabled machine engine is running, follow b. During warm up, visually and audibly inspect
these steps to disconnect the cables. engine for abnor mal conditions such as
unusual exhaust color, excessive vibrations
1. Disconnect the negative (-) cable from disabled and excessive or unusual noises.
machine upper frame.
2. Disconnect negative (-) cable from battery used c. Should problem areas be noticed, stop
for boosting. engine, locate and repair problem areas
before restating or operating the machine.
3. Disconnect positive (+) cable from battery used
for boosting.
4. Disconnect positive (+) cable from terminal of
disabled machine.
CAUTION: When disconnecting booster cables
always disconnect negative (-) cable first from frame
of disabled machine.
87722071 NA Issued 01-08 Bur 4-7

CHECK MONITOR PANEL
1 2 3 4
BS07M798 Figure 6
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.
DC04D474 Figure 8
d. Operate the boom and arm controls for 5 to 10
DC04D473 Figure 7
minutes each.
b. Perform bucket dig operation and hold over
relief for 10 to 15 seconds, then operate WARNING: While operating the machine
bucket dump and hold over relief for 10 to 15 with cold hydraulic oil, the operator may
seconds. Repeat the operations for 5 to 10 experience slow or unexpected movement of
minutes. functions.
Damage to the hydraulic components may
c. Move throttle control to mid position. result due to the cold oil not providing
adequate lubrication.
Auto Warm Up should be utilized anytime
machine is started in climate temperature
below 10°C (50°F) to stabilize machine
control response. Cold oil can cause erratic
machine operation. Failure to comply could
4-8 Issued 01-08 Bur 87722071 NA

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 BS07M796 Figure 9

operations pattern control matches the decal
provided inside the right side window. Failure
to comply could result in injury or death.
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
BS07M797 Figure 10
87722071 NA Issued 01-08 Bur 4-9

BASIC OPERATION OF HYDRAULIC CONTROLS

The following instructions are aimed at providing an FUNCTION CANCELLATION LEVER
operator with the basic function of each hydraulic 1. Unlocked Position
control. Use these instructions, and practice with a
machine in a safe, clear area in order to operate
safely and efficiently. 2
WARNING: Normal positioning of the
machine for the purpose of determining
Front, Rear, Forward, Reverse are with the
travel motors located behind the operator’s 1
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. BS06H080 Figure 11
1. UNLOCKED POSITION
2. LOCKED POSITION
Before any hydraulic operation is possible the

Function Cancellation lever must be placed in the
UNLOCKED (down) position. Placing the Function
Cancellation Lever in the UNLOCKED (down)
position also positions the left hand Operator’s
Console in its operating and lock position.
2. Locked Position
Before leaving the operator cab, place the Function
Cancellation Lever in the LOCKED (up) position by
pulling lever up. With Function Cancellation Lever in
the LOCKED (up) position, no hydraulic operation is
possible and this allows easy access in and out of
the operator seat.
WARNING: Always place the Function

Cancellation Lever in the Locked (up)
position before leaving cab to prevent any
operation of hydraulic controls. Failure to
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.
4-10 Issued 01-08 Bur 87722071 NA

MACHINE TRAVEL CONTROLS TRAVEL SPEED SELECT SWITCH

This machine incorporates several travel controls for
the convenience of the operator. Each track can be
operated independently to turn the machine or
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.
DC04D477 Figure 12 To return to SLOW travel speed, stop travel and
With the travel motors positioned behind the cab: depress and release travel speed select switch once.
a. Push both travel levers or press the pedals IMPORTANT: Use FAST travel speed on firm, level
toward front of machine and machine will surfaces only. Do not travel continuously for more
travel FORWARD. than two hours. Stop for a period of 10 minutes at low
idle speed before resuming travel.
DC04D478 Figure 13
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.
87722071 NA Issued 01-08 Bur 4-11

TURNING THE MACHINE
DC04D482 Figure 18
DC04D479 Figure 15 d. Pull right travel lever toward operator seat to
a. Push the left travel lever toward front of turn machine to the RIGHT in reverse motion
machine to turn machine to the RIGHT in
COUNTER ROTATING MACHINE
forward motion.
DC04D483 Figure 19
DC04D480 Figure 16
a. Pull left travel lever BACK and push right
b. Pull the left travel lever back toward operator
travel lever FORWARD to counter rotate
seat to turn machine to the LEFT in reverse
machine to the LEFT.
motion.
DC04D484 Figure 20
DC04D481 Figure 17
b. Pull right travel lever BACK and push left
c. Push the right travel lever toward front of
travel lever FORWARD to counter rotate
machine to turn machine to the LEFT in
machine to the RIGHT.
forward motion.
NOTE: All functions explained with use of travel
levers can also be performed using the travel pedals.
4-12 Issued 01-08 Bur 87722071 NA

IMPORTANT: OPERATING IN A NARROW SPACE

A. Climbing ability of a machine can change
depending upon shoe type, engine lubrication,
etc.
B. When approaching or descending a slope,
operate the travel levers slowly.
C. For braking, slowly return travel levers or
pedals to the neutral (center) position. Brakes
are engaged automatically.
D. The travel operation for 2 hours or more may
cause the failure of the travel motors due to
the rise of the operating temperature. Don’t
travel continuously for more than 2 hours.
S t o p fo r 1 0 m i nu t e s a t l ow i d l e b e fo r e
resuming travel. BS07N682 Figure 21
E. In extremely cold conditions, below -20°C BOOM IN FOLDED POSITION
(-4°F), the travel lever or pedal action may be 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
“heavier” than normal. This is due to the illustration. Folding the boom in will decrease the
viscosity of the hydraulic oil in frigid climates. swing radius of the machine.
TRAVEL SAFETY Canopy swing radius with folded boom:
a. Know the position of the travel motor before 1690 m (66.5 in.)
beginning travel. Cab swing radius with folded boom:
b. Travel on firm, level surfaces as much as 2170 m (85.4 in.)
possible.
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 3 2
prevent clogging.
4
f. Keep a safe distance from stationary objects
and electrical power lines.
g. Be aware of load capacities of bridges and
road shoulders. Reinforce if necessary. 1
h. Use decking or planks to protect road BS07M851 Figure 22
surfaces as much as possible. Be careful
If necessary to travel or operate machine in a river or
when turning or counter rotating machine on
other water, the bed must be firm and water current
asphalt pavement.
slow. Water must not be deeper than indicated in the
i. Do not allow large or heavy objects to strike illustration.
travel motors.
j. Do not travel over large objects such as NOTE: If the machine is operated while the swing
boulders, rock, etc. bearing is submerged in water, then the swing
bearing, swing pinion, and the swivel joint may wear
k. The machine can sink on soft ground or mud.
out prematurely. Immediate replacement of grease in
Avoid these areas.
grease bath and flushing of the swing bearing is
required. See Maintenance Section.
87722071 NA Issued 01-08 Bur 4-13

MACHINE ATTACHMENT AND SWING - ISO/SAE

PATTERN
The following operation instructions are to be used
with hoe bucket attachment only. If other attachments
are being used, consult the operator’s manual for the
particular attachment.
WARNING: Read, understand and follow all

safety precautions during all operations of
this machine and its attachment.
1. Boom Operation
Operation of the Boom is performed by pushing and
p u l l i n g t h e R i g h t C o n t r o l L eve r fo r wa r d a n d DC04D487 Figure 25
backward. Boom speed is determined by how far the a. Pushing the left control lever FORWARD
lever is activated. moves the arm out.
DC04D485 Figure 23 DC04D488 Figure 26

a. Pulling right control lever BACK raises boom. 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.
4-14 Issued 01-08 Bur 87722071 NA

Bucket Operation Swing Operation

IMPORTANT: Check clearance between bucket and Swing operation is performed by moving the Left
cab before operation. Slowly cycle bucket, check for Control Lever to the right and left. Swing speed is
interference with arm and cab, particularly if a lifting determined by the amount the lever is moved.
eye is welded on bucket bottom. Exercise care when
operating the bucket near the cab. WARNING: Make certain area is clear of
obstacles and persons before beginning
Operation of the Bucket is performed by moving the swing operation of the machine. Sound horn
Right Control Lever to the right or left. before beginning swing operation. Failure to
NOTE: Use swing flashers during swing operations.
DC04D489 Figure 27
a. Moving the right control lever to the LEFT
operates the bucket in (digging).
DC04D491 Figure 29
a. Moving the left control lever to the LEFT swing
machine to the left.
DC04D490 Figure 28
b. Moving the right control lever to the RIGHT
operates the bucket out (dumping).
DC04D492 Figure 30
c. Returning the right control lever to Neutral
(center) position, stops operation of the b. Moving the left control lever to the RIGHT
bucket. swings the machine to the right.
c. Returning control to the Neutral (center)
position stops swing.
87722071 NA Issued 01-08 Bur 4-15

PRACTICES TO IMPROVE EFFICIENCY

USE ARM IN ACTION CLEANING SAND & SOIL FROM BUCKET
BS07M852 Figure 31
Operate the bucket at shallow depths and use the BS07M854 Figure 33
arm in action to fill the bucket. Setting the bucket too Operate arm to a near level position and bring the
deep will decrease the machine’s efficiency. Always bucket to a dumping position. If sand and soil do not
point bucket teeth in the direction the machine will be fall out, move the bucket lever right and left a few
digging to reduce digging resistance and the times.
possibility of bucket teeth damage.
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 BS07M855 Figure 34
smooth careful movement of the control lever. Do not For efficient ditch digging, position the machine
perform sudden starts and stops of the boom as this parallel to the ditch to be dug using smooth bucket
creates unnecessary stress on the machine and its and arm motions. For wide ditch digging, dig both
components. 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 Issued 01-08 Bur 87722071 NA

OFFSET DIGGING
BS07M856 Figure 35
For back filling and leveling work after digging, use
the dozer to push the soil back into the ditch or to
level ground.
Do not push or pull material with the bucket like a
bulldozer when using the machine to level material.
1. Scrape the soil at its upper surface with the
dozer.
2. Use the dozer to back fill a trench.
3. Adjust the height of dozer with the dozer control
lever to avoid over loading the engine. BS07M858 Figure 37
To operate the boom swing function, press the button
4. Never travel with front attachment touching the on the top of the left control lever. Operate the control
ground. Severe structural damage could occur. lever to the left for left boom swing or right for right
boom swing.
LOADING
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
BS07M857 Figure 36
1. Operating efficiency can be improved by
positioning the dump truck so the swing distance
is kept to a minimum. Always have a good field
of view.
2. Start at the front side of the dump body and work
toward the back.
87722071 NA Issued 01-08 Bur 4-17

MACHINE OPERATION IN ADVERSE WEATHER 4. Make certain that the engine coolant mixture is
CONDITIONS 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
1. Follow procedures at the beginning of this
OFF and check coolant level. If after filling to
chapter as starting the engine may be difficult
proper level the machine continues to overheat,
due to extremely cold temperature.
stop engine, allow to cool, drain and flush entire
2. Use an engine oil, hydraulic oil, and diesel fuel cooling system and refill with the proper mixture
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 of fresh, clean coolant.
Maintenance Section for reference. Keep
batteries fully charged. WARNING: Do not drain the cooling system
when the engine is hot. Allow time to cool all
3. Make certain to perform machine warm-up engine parts. Failure to comply could result in
procedures as described at the beginning of this injury or death.
chapter to prevent premature wear or damage to
pumps, motors, and other components. 6. Check the battery electrolyte (acid) level
frequently and fill as necessary with distilled
NOTE: In extremely frigid climates, covering the water.
radiator is a method to aid the machine warm-up. If
necessary to maintain operating temperature, cover 7. Keep a close watch on the gauges for warning
the outer edges of the radiator, leaving an opening in icons during operation. Avoid unnecessary low
the center part of the cover thus avoiding fan speed running of the engine during operation.
overloading. Keep a close watch on the gauge for
warning icons during operation. It may be necessary OPERATION IN HIGH ALTITUDES
to use a coolant heater, fuel heater, engine heater 1. Due to low atmospheric pressure at high
jacket, and/or additional battery power to aid engine altitudes, a decrease in engine power will be
starting. experienced. Be aware of this fact when placing
4. Make certain that the engine coolant mixture is machine under heavy load in high altitudes
sufficient to keep the machine safe. Take into climates.
consideration wind chill factors when mixing 2. Keep close watch on the engine temperature
coolant ratios. gauge to avoid overheating of the engine.
NOTE: Mix coolant to a protection temperature of
5°C (9°F) lower than the machine may experience OPERATION IN SANDY AND DUSTY AREAS
during operation, storage or transport. 1. Check the engine air cleaner elements frequently
in sandy or dusty conditions.
5. Keep battery terminals free of ice and snow. Ice
and snow could cause the terminals to short 2. When air cleaner restriction lamp illuminates,
circuit and cause extensive damage to the change filters immediately regardless of time
machine system. Check the battery electrolyte intervals.
(acid) level frequently and fill as necessary with
3. Service fuel filter, water separator, engine oil and
distilled water. If the machine will be left outside
filters, and all hydraulic filters frequently.
overnight, removing the batteries and storing in a
warm area is recommended. 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 OPERATION AT SEASHORE OR SALTY CLIMATE
for use in hot climates. See Maintenance Section 1. Thoroughly wash machine daily to help avoid
for reference. Also keep batteries fully charged. corrosion of machined areas, electr ical
components and cylinder rods.
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 2. Frequently check all mounting hardware for
machine. proper tightness. Torque to proper value to aid in
preventing salt from entering the machine
CAUTION: Do not allow dirt and debris to
systems.
accumulate in the radiator fins, oil cooler fins or
debris screen, as this may cause a fire.
3. Keep all belts properly tensioned.
4-18 Issued 01-08 Bur 87722071 NA

OPERATION IN HUMID CLIMATE BUCKET SELECTION GUIDE

1. In climates with high humidity, thoroughly wash Bucke t se lection is extremely impo r tant to a
the machine daily and coat all bare surfaces with machine’s productivity, durability, and stability.
an oil based lubricant to help prevent corrosion.
Choosing an excessively large bucket can reduce
2. Operate the A/C with the cab doors and windows productivity due to slower than normal cycle times.
closed.
Using an oversized or overly wide bucket in severe
conditions such as mining, will lead to durability
LONGER UNDERCARRIAGE LIFE
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 Stability will be adversely affected using a bucket that
machine’s undercarriage. is unnecessarily large.
1. Select the track shoe that best suits the If the buckets used locally var y in weight from
machine’s application. If in doubt, consult with recommended buckets, it will be necessary to adjust
your dealer when selecting track shoes. 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. If the material density (weight) exceeds guidelines
specifications then the bucket capacity must be
3. Avoid sudden starts, accelerations, abrupt speed reduced.
changes, high speeds on rough terrains, sharp
turns, and sudden stops. If the machine is to continuously dig rock, wasted
shale, river cobble or other severe applications the
4. Always operate machine in straight lines narrowest bucket possible should be utilized. This
whenever possible. Avoid short radius when will allow the greatest possible penetration and
turning. Make turns with the largest possible minimal twisting of the attachment (boom and arm).
radius. Bucket capacity is not to be the prime consideration
5. Prior to operation, clear boulders and obstacles for severe applications.
to prevent damage to track shoes. If a machine is used in a spoil pile operation, which
6. Always operate machine parallel to the incline of causes a large radius dump cycle, applicable loads
the slope. Operating machine across the incline may have to be adjusted down by 5% from the Lift
of the slope will not only shorten the machine’s Chart Values.
undercarr iage life, but the machine could
unexpectedly slide down hill, and/or roll over. USE OF OPTIONAL ATTACHMENTS
If a machine is equipped with optional attachments,
7. Do not force the machine to carry out work that
applicable bucket sizes and suspended loads must
exceeds its working capability.
be reduced in direct proportion to the weight or
8. It is very important that inspections and combined weight of these attachments. Failure to
maintenance schedules be followed as indicated consider the added weight of such attachments will
in the Maintenance Section. Work conditions cause stability problems. Additionally the weights of
may require these scheduled times to be such attachments must be considered when the Lift
significantly shorter. Chart is referred to before lifting a load.
9. DO NOT OPERATE machine with loose track IMPORTANT:
shoes, and maintain proper track tension
The operator must consider the weight of any device
adjustment at all times during operation.
utilized for lifting to properly calculate the total lifting
capacity of the machine.
87722071 NA Issued 01-08 Bur 4-19

HYDRAULIC BREAKER 4. Basic Operation

1. Selection of the Hydraulic Breaker WARNING: Read, understand and follow all
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 safety precautions and operation procedures
excavator, it is necessary to match stability, hydraulic found in this manual before operating the
pressure, and the oil flow for each breaker. To select machine or any attachment. Failure to
hydraulic breakers, contact your dealer. comply could result in injury or death.
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 1
MAINTENANCE FOR NIBBLER/BREAKER in the
MAINTENANCE AND ADJUSTMENT Section.
Thoroughly read the Hydraulic Breaker Operation
Manual and SAFETY PRECAUTIONS from this
Section, as well as the Safety Precaution’s Section in
this manual to avoid damaging the machine or
hydraulic breaker during operation. Select the
appropr iate hydraulic flow for the breaker by BS06H080 Figure 38
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
1. FUNCTION CANCELLATION LEVER
NIBBLER/BREAKER BASIC M AC H I N E
OPERATION in this section.
a. Start machine and place the hydraulic function
3. Hydraulic Oil Level Check and Contamination cancellation lever in UNLOCKED (down)
Prevention 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.
BS07HM859 Figure 39
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 Issued 01-08 Bur 87722071 NA

MACHINE SET-UP
SETTING SELECTOR VALVE
2
BS07HM860 Figure 40
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. BS07N621 Figure 41
1. SELECTOR VALVE
2. COVER
Breaker
Machines equipped with a nibbler breaker
Button section Operation attachment must have the selector valve (1) set to
the correct position for the breaker or nibbler
OFF Breaker stops operating operation.
Depress button B Breaker starts operating
NOTE: Make sure to relieve hydraulic system and
Nibbler tank pressure as instructed in RELEASING
HYDRAULIC SYSTEM AND TANK PRESSURE in
Chapter 6.
Button section Operation
Lower the attachment to the ground and stop the
Depress button A Nibbler closes
engine. Set the cancellation lever in the locked
Depress button B Nibbler opens position.
SELECTOR VALVE SHIFTING POSITION

IMPORTANT: Operation of Breaker or Nibbler longer
than one (1) minute intervals could cause premature
wear or damage to the attachment and the machine. TO TANK TO TANK
If material is not breaking, reposition breaker or
nibbler and repeat operation in one (1) minute
intervals. TO C/V TO ATT TO C/V TO ATT
WARNING: Never leave the operator cab

with engine running. Failure to comply could
B : USE BREAKER N : USE NIBBLER
NIBBLER/BREAKER UPM00700003ES1 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.

safety precautions and operation procedures
found in this manual before operating the
machine or any attachment. Failure to
87722071 NA Issued 01-08 Bur 4-21

GETTING THE MOST OUT OF YOUR BREAKER

3 2 safety precautions and operating procedures
machine or any attachment. Failure to
A. BREAKER PROPER POSITIONING

4
1
BS07M864 Figure 43
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).
DC03M065 Figure 45
Always position the breaker perpendicular to the
1 2 material you intend to break. The breaker can be
vertical, horizontal, or anywhere in between, as long
as the tool is perpendicular to the surface and the
pressure applied is in the same direction of the tool.
B. APPLIED PRESSURE ON BREAKER
The breaker must have sufficient pressure between
the tool and the surface of the material intended to
break in order to allow the shock wave to flow
through the tool and to the material being broken.
BS07M865 Figure 44
The applied pressure has to be constantly adjusted
1. EXCAVATOR ARM by combining the boom, arm, and bucket functions
2. PLUG
so that the breaker follows the tool at all times during
ATTACHMENT HYDRAULIC OIL VALVE POSITIONS
breaker operation.
A. CLOSED
B. OPEN When the excavator boom is lowered, it normally
follows a curved path, which changes the original
Attachment Hydraulic Oil Shut off valve perpendicular position of the breaker. It is very
important to keep adjusting the operator’s controls to
NOTE: Make sure to switch the position of the stop
maintain constant perpendicularity between the
valves to the CLOSED position before removing the
breaker and the surface of the material being broken.
attachment.
In addition, the applied pressure should be sufficient
The valve is used to shut off the flow of hydraulic oil to avoid the breaker tool from bouncing on the rock
when changing attachment. Use a 19 mm hex to rather than transmitting the shock wave into it. The
open and close valves. applied pressure should not lift the machine high off
the ground, since the excavator can drop suddenly,
as the breaker breaks through the material, and
harmful shock loads will be transmitted through the
entire machine.
4-22 Issued 01-08 Bur 87722071 NA

C. BREAKING OVERSIZE ROCKS E. EXCAVATING AND TRENCHING
DC03M066 Figure 46 DC03M068 Figure 48

Do not attempt breaking oversize boulders from the Lay back side walls a bit at the time so that they do
center. It is much more efficient to break these type not interfere with the breaker housing. To lessen the
of rocks from the edges. Also, do not break into opportunity for side loading, approach each wall from
smaller pieces than necessary. There is a direct the opposite side by positioning the excavator
relationship between the size of the boulders and the perpendicular to the trench.
size of the breaker. It is inefficient to break large
F. RULES TO REMEMBER
rocks with small breakers and vice versa.
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.
DC03M067 Figure 47 6. Do not bend or pry with the breaker tool while
Use the breaker just as if it were a hand held breaker, operating.
or a plain hammer and chisel. Adjust the breaker’s 7. DO NOT OPERATE breaker with attachment
position according to the work to be done, and take cylinders at full extension.
small bites at a time. The only difference between a
hand held breaker and the hydraulic excavator 8. DO NOT OPERATE breaker submerged in
breaker is the size of the rocks that can be broken. water.
Do not try to break too much at one time. 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
SAFETY PRECAUTIONS D. CYLINDERS

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

safety precautions and operating procedures
machine or any attachment.
A. USE FOR INTENDED PURPOSE
DC04E063 Figure 51
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 manufacturer’s
instructions, the excessive pressure exerted on the
boom, arm and frame structure of the machine will
cause premature failure of the components.
B. PASSENGERS
Never allow passengers on the attachment or
machine.
C. PROTECTIVE EQUIPMENT DC04E064 Figure 52
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

F. HOSE SURGE I. DO NOT LIFT
DC04E065 Figure 53
DC04E068 Figure 56
Should the hydraulic hoses begin to surge or vibrate
abnormally during operation of a Breaker or Nibbler, Never use optional attachment to lift or transport
immediately stop operation and contact an objects or materials. Doing so can cause extensive
authorized dealer for assistance. This problem often damage to the attachment, the machine structures or
is a result of damaged accumulators and can also cause injury or death due to slipping or dropping of
result in valve failure. load due to improper attachment.
G. DO NOT USE DROPPING FORCE J. WORKING RANGES

Never use the dropping force of the attachment to Never operate an optional attachment over the sides
break or drive objects. This will cause extensive of the machine. Only operate over the front or rear of
damage to the attachment and machine structure. the tracks.
H. DO NOT USE SWING FORCE
DC04E067 Figure 55
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

TRANSPORTATION
GROUND TRANSPORTATION c. Obtain any permits required from proper
1. Machine Preparation gover nment agencies for machine
transportation.
a. Know the total weight, length, width and height
of the machine being transported. d. Use only a trailer with a rated capacity
sufficient to transport the machine.
b. Know route to be traveled. Investigate
bridges, overpasses, height of road signs on e. Make certain trailer has ramps or a ramp is
route. available for loading and unloading the
machine.
Machine with Canopy
Machine with Cab
BS08A059/BS0A060 Figure 58
4-26 Issued 01-08 Bur 87722071 NA

2. Loading the Machine
WARNING: Never attempt to load or unload

machine without ramps. Failure to comply
a. Apply parking brakes on tractor and trailer and
chock trailer wheels before attempting to load 1
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.
DC04C344 Figure 59
f. Raise the attachment and slowly move
machine up trailer ramps and over rear axles 1. FUNCTION CANCELLATION LEVER
of trailer.
k. Place hydraulic function cancellation lever in
g. Slowly move machine completely onto trailer the LOCKED (up) position.
until in proper transport position.
l. Turn machine OFF, remove key and lock all
h. Slowly swing machine 180° until attachment is doors, filler caps and access panels.
toward rear of trailer.
IMPORTANT: Place a cover over the exhaust pipe of
i. Slowly lower boom until attachment rests on
the machine and secure to avoid water entering the
trailer bed.
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

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.
DC04D581 Figure 61
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 87722071 NA

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
DC04D582 Figure 62
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. BS08A062 Figure 64
e. Lift machine carefully, keeping sway to a
minimum. Place machine in desired location.
87722071 NA Issued 01-08 Bur 4-29

MACHINE STORAGE
BS07M870 Figure 65
MACHINE IN STORAGE POSITION
PREPARE MACHINE CARE DURING STORAGE

Perform the following procedures to prepare the Every 30 days during storage, it will be necessary to
machine for long term storage. start and run the machine to circulate the fluids
through the systems. Before starting, clean cylinder
1. Perform all inspection and maintenance
rods and after running, re-grease cylinder rods.
proce dure s as de scr ibed in Mainte nance
Section. Make certain fluid levels are correct.
NOTE: Run and operate machine for approximately
2. Thoroughly clean the machine, inspect for 1 hour to allow all fluids to circulate well and reach
damaged or worn parts and components and normal operating temperatures.
replace or repair all damaged or worn parts.
REMOVING MACHINE FROM STORAGE
IMPORTANT: Protect CPU and all electrical
components from water and steam when cleaning 1. Perform all inspection and maintenance
the machine. procedures as described in the Maintenance
Section before bringing machine out of storage
3. Completely fill fuel tank with fresh, clean fuel to for normal operation.
aid in preventing condensation of moisture inside 2. Remove drain plugs from the travel motors and
the fuel tank. Make sure to use an anti-algae swing gear reduction units to drain off any
additive in the fuel tank. moisture which may have accumulated during
4. Move machine to an indoor location for storage. storage.
5. Park the machine with belts/tracks on top of 3. Carefully inspect all hydraulic hoses after long
wood if possible with the exposed piston rods of periods of storage for signs of deterioration.
the cylinders retracted as much as possible. 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. WARNING: Hydraulic fluid or grease injected
8. Remove batteries and store in a well ventilated, into your skin can cause severe injury or
warm area. death. Keep your hands and body away from
any pressurized leak. Use cardboard or paper
to check for a leak. If fluid is injected into your
skin, see a doctor immediately and have the
fluid removed. Failure to comply with this
warning could result in injury or death.
4-30 Issued 01-08 Bur 87722071 NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS
CHAPTER 5
LUBRICATION, FILTERS, AND FLUIDS
TABLE OF CONTENTS
FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Upper Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
USE OF BIO-DEGRADABLE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Issued 01-07 Bur 87722071 NA 5-1

NOTES
5-2 Issued 01-07 Bur 87722071 NA

FLUIDS AND FILTERS

REQUIRED FLUIDS/LUBRICANTS AND SWING BEARING
CAPACITIES
Type of Oil . . . . . . . . . . . . . . . . . . . EP Grease EP/2
ENGINE Capacity . . . As required (1 place - swing 90° x 4)
Type of Oil . . . . . . . . . . . . . . Engine Oil SAE 15W30
NOTE: See SWING BEARING LUBRICATION in
Capacity: Chapter 6 for proper lubrication.
Engine Oil with filter change . . 6.7 liters (1.8 gal)
NOTE: See ENGINE OIL LEVEL in Chapter 6 for proper TRACK TENSION ADJUSTMENT
oil filling and/or checking engine oil level.
HYDRAULIC Capacity . . . . . . . . . . . . . . As required (2 places)
Type of Oil . . . . . . . . . . . . . . . . . Hydraulic Oil AW 46
NOTE: See TRACK TENSION in Chapter 6 for
Capacity: proper procedures in injecting grease.
Hydraulic Tank. . . . . . . . . . . . .38 liters (10.0 gal)
Hydraulic System . . . . . . . . . .48 liters (12.7 gal)
RADIATOR
NOTE: Coolant . . . . . . . . . Ethylene-glycol Coolant Solution

1. See HYDRAULIC OIL LEVEL in Chapter 6 for
proper filling and/or checking hydraulic oil level.
ENGINE COOLANT MIXTURE
TRAVEL MOTOR REDUCTION UNIT Expected Minimum Temp. Long Life Coolant
Type of Oil . . . . . . . . . . . . . . . . SAE 90 GL4 Gear Oil
-14.5°C (5.9°F) 30% mixed
Capacity 0.7 liters (0.18 gal) Each x 2
-34°C (-29.2°F) 50% mixed
NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL
in Chapter 6 for proper filling and/or checking oil level.
Capacity:
UPPER ROLLERS Cooling System . . . . . . . . . . . . . . 4.6 liters (1.22 gal)
NOTE: See ENGINE COOLANT CHANGE in
Capacity . . . . . . . . . . . . .45 cc (2.7 cu. in.) Each Chapter 6 for proper coolant filling and/or coolant
level check.
IDLERS
Capacity . . . . . . . . . . . . 80 cc (4.8 cu. in.) Each 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 NOTE: See FUEL LEVEL in Chapter 6 for proper
Capacity . . . . . . . . . . . . As required in each joint filling and/or checking the fuel level.
NOTE: See CONTROL LEVER JOINT

LUBRICATION in chapter 6 for proper lubrications.
UPPER ATTACHMENT PINS

Capacity . . . . . . . . . . . . .As required in each pin
NOTE: See ATTACHMENT LUBRICATION in

Chapter 6 for proper lubrications.
87722071 NA Issued 01-08 Bur 5-3

REQUIRED FILTERS
NOTE: Refer to the Parts Manual for the correct part Engine
numbers to order.
• Engine Oil Filter
HYDRAULIC
• Air Cleaner Inner Element
• Return Filter Element for Standard Machine
• Air Cleaner Outer Element
• Return Filter Element for Breaker and N&B
• Tank Suction Strainer FUEL
• Tank Breather Filler Element • Engine Fuel Filter
• Pilot Line 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

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

HYDRAULIC OIL FRIGID FRIGID FRIGID-WARM WARM VERY HOT
(ANTI-WEAR, ANTIOXIDANT, -30°C~15°C -20°C~30°C -25°C~40°C -5°C~40°C 5°C~55°C
AND NON-FOAMING) (-22°F~59°F) (-4°F~86°F) (-13°F~104°F) (23°F~104°F) (41°F~131°F)
ISOVG22 ISOVG32 ISOVG32S ISOVG46 ISOVG68

FRIGID WARM VERY HOT
-30°C~30°C -5°C~40°C 30°C and Above
ENGINE OIL (-22°F~86°F) (23°F~104°F) (86°F and Above)
A.P.I. CLASSIFICATION FOR SERVICE CD
SAE10W30 SAE15W40* SAE15W50
*Note: All engines shipped from factory with SAE15W40 engine oil.

FRIGID WARM VERY HOT
-15°C ~ -25°C -5°C ~ -15°C -5°C and Above
(5°F ~ -13°F) (23°F ~ 5°F) (23°F and Above)
FUEL
WINTERIZED
ASTM D975 No.1 ASTM D975 No.2 ASTM D975 No.2
LUBRICANT For Swing Motor Reduction Unit and Travel Motor Reduction Units
ENGINE OIL
A.P.I. Classification for Service CD - SAE15W40
(For General Purpose Lubrication)
LUBRICANT GENERAL LUBRICATION SWING GEAR SUMP (BATH)

Extreme Pressure Multi Purpose N.L.G.I. No. 2 Lithium Base
GREASE Grease No.2 with
EP Type Grease MOS2 Grease
FLUID ANTIFREEZE (LLC)

-34°C (-29.2°F)
ENGINE COOLANT
Mixture ratio should protect to 5°C (9°F) lower than the coldest temperature the machine
(50% MIXTURE)
will experience. Take into consideration Wind Chill Factors.
USE OF BIO-DEGRADABLE OILS

87722071 NA Issued 01-08 Bur 5-5
When you use Bio-degradable Oil (BIO OIL), refer to the following information:
1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is
recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The
degradation of vegetable based oil occurs more rapidly and causes reduced service life.
2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, it is required to
flush the hydraulic system that was filled with mineral oil twice, before adding bio oil.
3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction
of BIO OIL compared to that mineral oil.
4. For further information about recommended Bio-degradable oil, please contact local dealer.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Check Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Inspect Alternator/Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
50 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Inspect Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Inspect and Adjust Fan/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Bolt and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Dozer Pin Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Greasing the Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Boom, Arm, and Attachment Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Replacing the Inner Element
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Hydraulic Return Filter (Breaker Use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Issued 01-08 Bur 87722071 NA 6-1

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
Check Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
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
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

GENERAL INFORMATION
GENERAL SAFETY
safety precautions contained in this manual DISPOSAL OF HAZARDOUS WASTE
before performing any inspection or Dispose of waste oils, fluids, lubricants, filters, and
maintenance procedures on this machine, its other hazardous waste properly.
system or components. Failure to comply
IMPORTANT: Dispose of all hazardous waste in
accordance with government environmental
WARNING: Wear goggles, safety shoes, regulations, laws, and codes.
hard hat, work clothes and work gloves to
perform inspection and maintenance on this KEEP MACHINE CLEAN
machine. Failure to comply could result in
injury or death.
DC04B669 Figure 2
Thoroughly clean machine before perfor ming
DC04B668 Figure 1 inspection and maintenace procedures. It is easier
1. It is recommended that an inspection and and safer to locate problems, perform maintenance
maintenance schedule be developed and and also reduce r isk of hydraulic s ystem
maintained on a regular basis for this machine. contamination when machine is clean.
Developing and maintaining such a schedule
helps to keep the machine in optimum operating HOT SURFACE & FLUIDS
condition.
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
DC04B670 Figure 3
schedule to perform machine maintenance at more
frequent intervals based on the work conditions. Use caution and wear the proper safety equipment
when working around hot areas. Never change oils,
3. Use only oils, fluids, lubricants, filters and engine coolant or filters immediately after a machine
replacement parts supplied by your authorized has been stopped. Allow machine to cool down
dealer to keep machine in optimum operating before performing maintenance procedure.
condition.
87722071 NA Issued 01-08 Bur 6-3

WARM ENGINE OIL PREVENT CONTAMINATION

Engine should have a temperature between 20°C -
40°C (68°F - 104°F) before the oil is changed. If
necessary, run engine until the oil is warm within the
recommended oil change temperature.
TAG-OUT MACHINE
DC04B673 Figure 6
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.
IMPORTANT: Never allow a hydraulic line or
DC04B671 Figure 4
component to become contaminated. Always use
Before beginning any inspection or maintenance proper caps and plugs.
procedures, secure a DO NOT OPERATE tag to the
operator’s console to inform the operator that the SEALS AND O-RINGS
machine will be inoperable for inspection and
Always replace seals and O-rings with new parts.
maintenance. This tag will help prevent accidental
Never reuse a seal or O-ring during reassembly of
starting of the machine.
components. Make sure to lubricate all new seals
with the appropriate oil before installation.
INSPECT WASTE OILS AND FILTERS
STOP ENGINE
DO NOT attempt any maintenance with engine
running. Always stop the engine and allow machine
to cool.
WEAR SAFETY EQUIPMENT

Wear hard hat, safety goggles or face shield, work
gloves, safety shoes, and well fitting work clothes
when perfor ming inspection and maintenance
procedures on this machine.
CLEANING PARTS
DC04B672 Figure 5
Before disposal, inspect all waste oils, fluids, and Use only approved cleaning solvents and proper
filters for debris and foreign material. Cut open the oil equipment to clean parts.
filters to determine any abnormal wear.
WARNING: Never use gasoline, diesel fuel
or other flammable solvents to clean parts.
Always clean parts in a well ventilated area.
death.
6-4 Issued 01-08 Bur 87722071 NA

WELDING SAFETY STEPS AND HAND HOLDS

1. Turn key switch to OFF position. 1. Inspect daily all mounting steps and hand holds
on the machine to make sure they are clean and
2. Remove negative (-) cable from battery terminal.
in safe working condition.
3. Attach the welder ground cable within 1 m (39
2. Repair or replace all damaged parts or
in.) from component being welded.
components before allowing any operation of the
4. Do not clamp the welder ground cable close to or machine.
in location where ground could be separated by
IMPORTANT: Use steps and handholds when
bearings or seals.
mounting and dismounting the machine. Keep steps,
handholds, and step rails clean and in safe working
WARNING: Disconnect batteries before condition free of grease, oil, mud, ice, and snow.
welding on this machine. Connect welder
ground cable within 1 m (39 in.) of area to be
welded. Failure to comply could result in
machine damage, injury or death.
FRAME STRUCTURE
1. Carefully inspect the entire frame structure for
signs of damage, broken welds, etc.
NOTE: Remove any excessive grease from the
attachment pin connecting areas to inspect welding.
2. Repair or replace all frame components found to
be damaged before allowing any operation of the
machine.
3. In cases where welding is required, consult your
authorized dealer for proper procedures. Use
only certified welding personnel familiar with
structural welding methods to perform repairs
requiring welding. Never allow current to flow
through a joint such as between a pin, bushing,
bearing, seal and/or between upper and lower
structures.
87722071 NA Issued 01-08 Bur 6-5

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 BS08A247 Figure 8
stop the engine. 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.
7. Press the rubber cap (2) on the top of the
hydraulic tank 5 to 7 times.
1
2
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
BS07M861 Figure 7 damage, injury or death.
2. Turn the ignition switch key to the ON position.
Pilot control switch must be on.
3. Operate the control levers from right to left and

front to rear approximately a dozen times. Turn
the ignition key to the OFF position.
4. Set the safety lock lever to LOCKED position.
WARNING: Hydraulic fluid or grease injected

into your skin can cause severe injury or
death. Keep your hands and body away from
any pressurized leak. Use cardboard or paper
to check for a leak. If fluid is injected into your
skin, see a doctor immediately and have the
fluid removed. Failure to comply with this
warning could result in injury or death.
WARNING: Before carrying out any service

work on the hydraulic system, it is necessary
to allow the system to cool (the temperature
should not be more than 40°C (104° F).
Failure to comply with this warning could
6-6 Issued 01-08 Bur 87722071 NA

GUIDELINES TO REPLACE GROUND TOOLS GUIDELINES FOR ATTACHMENT LUBRICATION

It is very important to keep bucket teeth and side Lubricate attachment pins according to the intervals
cutters properly tightened. Loose or missing bolts will indicated in the Maintenance Chart. Use extreme
increase loads and eventually cause tool failure. pressure multipur pose grease No. 2 EP type.
Extended operation with loose hardware can cause Lubr icate all points until grease purges. The
the bolts to stretch and wear on the support mounting lubrication intervals are based on an average duty
holes. Heating of hardware and support mounting cycle. Average duty cycle is defined as Most typical
holes will cause the same effect. Follow these digging application, road construction in natural bed
general guidelines to insure proper tightness of clay, digging 50% - 60% of the daily work schedule
hardware on bucket teeth and side cutters.
New pins and bushings, including new machines and
• When installing new cutting edges, end bits, side repairs require special break-in procedures. While
cutters, and bucket teeth, make sure that all both pin and bushing have a special ground finish,
supporting surfaces are free of dirt, paint, debris, they still have to be mated to each other to eliminate
rust, scale or weld splatter. All mating surfaces the machining high points.
must be clean and flat to insure that maximum
Because of these high spots, it is recommended that
clamping force is obtained.
the front attachment or the repaired area be
• Make sure that all bolts and nut threads are clean lubricated a minimum of once every eight (8) hours
and dry. DO NOT APPLY ANY TYPE OF for the first 50 hours for a standard machine working
LUBRICANT. in an average duty cycle. This lubrication procedure
will reduce the possibility of a premature pin or
• When installing end bits, start at the center and bushing failure during the break-in period.
work toward the outside edges.
While grease grooves in the bushings allow grease
• Always torque bolts according to specifications. to move around the bushing, it does not insure that
• For best results, strike all head bolts with a heavy grease gets on all of the bushing surfaces. Any load
hammer to seat them properly before final torque. 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
WARNING: Wear safety glasses whenever
the volume of grease that a power system does,
striking metal objects with a hammer. Failure
there is a greater possibility of bushing galling,
unless the standard lubr ication procedure is
• When new parts are used, the mating surfaces will modified. No matter how much grease is pumped
seat more uniformly and the bolts torque will be into the pin bushing cavity with a hand grease gun,
less than the standard value after a short period of the grease will tend to escape to the outside before
operation. Make sure to check all bolts for proper filling the grease cavity. Therefore, to avoid this
tightness on new parts after eight (8) hours of situation, the front attachment has to be repositioned
operation. during the lubrication process, to move the load area
and allow the grease to cover the entire grease
• Lower maintenance costs by replacing, turning, or cavity between the pin and bushing.
rotating cutting edges before they reach their wear
limits.
• When finding loose bolts, check bolts for
elongation and support mount holes for wear.
Replace bolts and repair any wear on support
mounting hole if needed. Torque bolts according
to specifications.
87722071 NA Issued 01-08 Bur 6-7

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART
NEW MACHINE
Intervals in hours
Service intervals
Lubricate
Service points
Replace
INITIAL
Check
Clean
Drain
page
6-15 Fan and air conditioning drive belt AR

6-28 Air filter AR
As Required
6-31 Fuel tank filter AR AR
(AR)
8-11 Bolt and nut torque AR
6-19 Rubber track (if equipped) AR
6-10 Grease bucket, boom, arm cylinder, dozer Run-in 8
6-11 Engine oil level 8
6-12 Coolant level 8
6-12 Radiator 8
6-12 Electrical connections 8
Every 8
hours 6-13 Water separator 8
6-13 Fuel tank level 8
6-14 Hydraulic reservoir level 8
6-15 Hydraulic lines 8
6-16 Fan/alternator belt tension 8
6-15 Rubber crawler belt 8
6-17 Attachment 50
6-17 Drain fuel tank sediment 50
6-18 Engine oil and filter Run-in 50
Every 50
6-19 Rubber track Run-in 50
hours
7-4 Battery check 50
6-24 Hydraulic return filter Run-in 50
6-25 Engine oil and filter 250
6-27 Swing reduction gear Run-in 250
Every 250
hours 6-27 Boom, arm cylinder, dozer 250
6-28 Engine air cleaner element 250
6-29 Hydraulic return filter (Breaker attachment) 250
8-11 Bolt and nut torque 250
6-30 Fuel water separator 500
6-31 Fuel filter 500
Every 500 hours
6-32 Engine air cleaner elements 500
6-33 Travel reduction gear Run-in 500
6-34 Radiator coolant 1000
Every 1000 6-36 Hydraulic return filters 1000
hours
RM Valve clearances 1000
RM Starter/generator 1000
Every 1500
RM Injector Timing 1500
hours
6-8 Issued 01-08 Bur 87722071 NA

NEW MACHINE
Intervals in hours
Service intervals
Lubricate
Service points
Replace
INITIAL
Check
Clean
Drain
page
6-38 Hydraulic suction strainer 2000
6-40 Pilot valve 2000
6-41 Solenoid in-line filter 2000
Every 2000
6-43 Travel reduction gears 2000
hours
6-44 Idler oil change 2000
RM Swing gear grease 2000
RM Intake and exhaust 2000
Every 5000
6-47 Hydraulic oil 5000
hours
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

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 3
hat, work clothes, and work gloves to perform 1
inspection and maintenance on this machine.
2
GREASE MACHINE AND ATTACHMENTS 3
1 2 BS07N035 Figure 11
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
BS07M861 Figure 9
During the initial 50 hours of operation during the 7
run-in period, grease bucket, boom, arm cylinder and 4 8
dozer every 8 hours. After the initial run-in period,
grease every 50 hours. 10
1. Move the machine to firm level ground and place
the bucket/attachment on the ground. Turn the
11
engine off.
6
5
9
BS07N033 Figure 12
4. BOOM FOOT PIN (1)

3 4 5. BOOM CYLINDER FOOT PIN (3)
1 6. BOOM CYLINDER ROD PIN (1)
7. ARM CYLINDER FOOT PIN (1)
2
8. ARM CYLINDER ROD PIN (1)
9. BOOM/ARM CONNECTING PIN (2)
10. BUCKET CYLINDER FOOT PIN (1)
11. BUCKET CYLINDER ROD PIN (1)
BS07N028 Figure 10
1. BUCKET CYLINDER ROD PIN

2. IDLER LINK/ARM CONNECTING PIN
3. BUCKET LINK PIN
4. 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

ENGINE OIL LEVEL

12
5
14
13
BS07N634 Figure 13
(5) BOOM CYLINDER FOOT PIN
(12) SWING CYLINDER FOOT PIN
(13) SWING CYLINDER ROD PIN
(14) SWING BRACKET/FRAME CONNECTING PIN 1
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. BS07N039 Figure 14
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

ENGINE COOLANT LEVEL ENGINE ELECTRICAL
DC04C292 Figure 16
BS07M872 Figure 15 1. Visually and manually inspect all engine
electrical wiring, connectors and components for
1. RESERVOIR CAP
signs of damage and malfunction.
2. RADIATOR CAP
3. RADIATOR 2. Repair or replace all damaged or malfunctioning
4. RESERVOIR wiring, connectors and components before
resuming operation of the machine.
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 WARNING: Operating the machine with
engine compartment. damaged or malfunctioning electrical
components can cause serious damage to
2. Proper coolant level is between FULL and LOW
the machine and serious injury to personnel.
marks.
Repair or replace faulty components
3. If necessary to add coolant, remove reservoir immediately.
cap and fill to proper level with fresh coolant
mixture.
4. If no coolant is shown in reservoir, check coolant
level in radiator. Fill radiator with proper coolant
mixture and replace cap. Then refill reservoir to
proper level. Inspect hoses and connections for
leaks.
WARNING: Never remove radiator cap

when engine is hot. Allow engine to cool
before removing radiator cap.
6-12 Issued 01-08 Bur 87722071 NA

FUEL LEVEL DRAIN WATER SEPARATOR
2
BS07M675 Figure 17 BS07N030 Figure 18
1. FUEL LEVEL GAUGE 1. Inspect water separator every 8 hours. Drain and
clean at 500 hours.
1. Turn the ignition switch key ON and the fuel
2. Visually inspect separator. If red ring (1) sinks to
gauge in the cluster will indicate the fuel tank
bottom of case, no water is present.
level.
3. When ring is floating, drain water and sediment.
2. To refuel the machine, remove the fuel tank cap.
Do not remove the fuel screen (if equipped) for 4. Open valve (2) and drain until clean fuel is
fueling. Refill fuel tank to full mark to reduce air discharged.
volume (condensation). Failure to do so could 5. Repair or replace damaged hoses and lines
create problems such as r usting and fuel before any operation.
freezing, as well as other associated problems.
87722071 NA Issued 01-08 Bur 6-13

HYDRAULIC OIL LEVEL

WARNING: Gasses from hydraulic tank may
be hot. Wear personal safety equipment.
death.
1
1
2 2
BS07M861 Figure 19
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. 4
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 BS07N635 Figure 21
[122-176° F]) 1. CAP SCREW & WASHER
2. COVER PLATE
3. Refill if oil level is below L.
3. O-RING
4. To add hydraulic oil, open the right side cover 4. SIGHT GAUGE
and support with strut.
B. Slowly remove the mounting bolts (1) from the
cover plate.
1
C. Add hydraulic oil, filling hydraulic tank to the
2 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.
F. Check all hydraulic controls for proper
BS08A247 Figure 20 functionality before operating the machine.
1. COVER
2. AIR RELEASE BUTTON WARNING: Never operate the machine with
faulty control or function. Make all necessary
A. Release all pressure from hydraulic tank. (See repairs before allowing any operation. Failure
releasing hydraulic pressure for additional to comply could result in machine damage,
infor mation.)Depress air release button injury or death.
several times to release hydraulic tank
pressure.
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

IMPORTANT: Always use clean hydraulic oil. Use

caution to avoid contamination during filling.
HYDRAULIC OIL LEAKS
DC04C300 Figure 23
CHECK CRAWLER BELTS

Keep crawler belts free of dirt and imbedded rock for
maximum traction. Visually check for cracking,
DC04C287 Figure 22 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

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.
BS07N031 Figure 24
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.
New belt tension Used belt tension

8 - 12 mm 10-14 mm
(8/16 - 7/16 in) (3/8 - 1/2 in)
6-16 Issued 01-08 Bur 87722071 NA

50 HOUR MAINTENANCE:
ATTACHMENT LUBRICATION DRAIN FUEL TANK SEDIMENT
3 4
1
2
BS07N028 Figure 25
1. BUCKET CYLINDER ROD PIN (1)

2. IDLER LINK/ARM CONNECTING PIN (1)
3. BUCKET LINK PIN (1)
4. ARM/BUCKET CONNECTING PIN (1)
During the first 50 hours of operation, grease

attachment every 8 hours. After the initial run-in
1
period, grease every 50 hours.
both attachments resting on the ground. Turn the BS07N128 Figure 26
engine off. Place the cancellation lever in the 1. FUEL TANK
locked position. Keep all unauthorized personnel 2. DRAIN PLUG
clear of the area.
WARNING: Do not smoke or allow any open
flame near by when draining fuel. Stop
3. Lubricate with a grease gun through the grease engine. Thoroughly clean up any spilled fuel.
fittings shown. Wipe off any grease that leaks out Failure to comply could result in injury or
of the pin connection. death.
IMPORTANT: Dispose of all waste in accordance Draining water and sediment is most effectively
with environmental regulations. performed in the morning. Turn the upper structure of
the machine so the drain plug (2) is midway between
WARNING: The machine and attachment the crawler belts.
should not be moved when greasing. 1. Park the machine on a firm, level surface with
Personal injury may result. Move attachment both attachments resting on the ground. Turn the
to a different position, stop the engine and engine off. Place the cancellation lever in the
lubricate the attachment again. Repeat this locked position. Keep all unauthorized personnel
procedure until the front attachment is clear of the area.
completely lubricated. 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

ENGINE OIL LEVEL 6. After draining oil, remove drain hose, and tighten
drain cap (1) securely. Remove any spilled oil.
1
2
BD07N032 Figure 28
1. OIL FILTER
2. FILTER WRENCH
1
7. Use the filter wrench provided with the machine,
and turn counter clockwise to remove the oil
filter.
2
3
5
BS07N029 Figure 27
1. DRAIN CAP
BD07N040 Figure 29
2. COVER 8. To install the oil filter, apply a thin coat of engine
3. DIPSTICK oil to the gasket (A) of the new oil filter, fill the
4. OIL FILL CAP filter partially with engine oil and then secure the
5. DRAIN HOSE
filter by tightening 2/3 of a complete turn by hand
Change oil and oil filter at 50 hour run-in period for a after the gasket comes in contact with the oil filter
new machine, then at every 250 hours thereafter. head.
1. Park the machine on a firm, level surface with NOTE: Check the waste oil. If there are metal flakes
both attachments resting on the ground. Turn the in the oil, contact your dealer. DO NOT reuse the oil
engine off. Keep all unauthorized personnel clear filter.
of the area. 9. Clean oil drain plug and install it. Tighten
2. Raise the engine cover. Remove the dipstick to securely.
allow oil to run more freely.
10. Fill with the specified amount of oil through filler
3. Remove bolts and engine belly pan covers port (4) and install oil filler cap.
4. Locate the engine oil drain plug and place an 11. Before starting the engine, check oil level using
empty oil container [7 L (2 gal) capacity] under the dipstick (3). The level should be between the
the plug. Attach the quick drain hose (5), and L and H limits as shown. Start and run the engine
drain the oil into the container. for five minutes. Stop the engine and recheck the
oil level after 30 minutes. Add oil if necessary.
5. Remove engine oil drain plug and let the engine
oil drain out completely. 12. Install under cover (2) to its original position.
6-18 Issued 01-08 Bur 87722071 NA

TRACKS AND COMPONENTS

Check rubber track tension every 50 hours.
BS07N042 Figure 32
3. Move the upper structure at 90° to the crawler
DC04C300 Figure 30 frame. Operate the attachment placing it on the
Abrasion on the rubber crawler belt varies depending ground as illustrated and gradually lower the
on working conditions. Frequently check for wear boom to lift one side of the machine. Support the
and tension, particularly on a new crawler belt as lower travel structure with a safety support (1).
there will be an initial stretch during the first 30 hours
of operation.
2
1. Visually inspect track shoes for signs of 1
excessive wear or damage.
3 4
BS07N043 Figure 33
1. CRAWLER FRAME
2. LOWER ROLLER
3. RUBBER BELT
4. IRON SHOE
BS07N041 Figure 31
4. Measure the clearance in the center of the track,
2. Keep all unauthorized personnel clear of the between the bottom of the track frame and the
area. Move the rubber crawler belt so the joining track shoe surface.
ends (M mark) comes to the upper center
Measure Clearance (A)
position.
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

2
DC04C307 Figure 34 1
WARNING: Grease in track tensioning
mechanism is under extreme pressure and
can penetrate skin causing severe injury.
BS07N045 Figure 36
Keep face and body away from grease fitting
area. Never loosen grease fitting more than 1. GREASE FITTING
2. GREASE CYLINDER
one (1) complete turn. If grease does not
A. GREASE FILL
release after one (1) turn of the fitting, call B. PRESSURE
your authorized dealer for assistance. Failure
to comply could result in injury or death. INCREASING TRACK TENSION
BS07N044 Figure 35
BS07N046 Figure 37
5. Grease in track tensioning mechanism is under 6. To increase track tension, inject extreme
extreme pressure and can penetrate skin pressure No. 2 grease into idler adjustment
causing severe injury. Keep face and body away grease fitting (1) with a grease gun until proper
from grease fitting area. Never loosen grease tension is reached.
fitting more than one (1) complete turn. If grease IMPORTANT: If the adjustment to the track cannot
does not release after one (1) turn of the fitting, be maintained, the grease cylinder may need repair.
call your authorized dealer for assistance. Contact your authorized dealer.
6-20 Issued 01-08 Bur 87722071 NA

ADJUSTING FOR LESS TENSION REMOVING RUBBER CRAWLER BELT
BS07N046 Figure 38 BS07N042 Figure 40

1. Gradually loosen the grease fitting to release 1. Keep all unauthorized personnel clear of the
grease under pressure. Do not loosen the grease area. Park the machine on a hard, level surface.
fitting (1) more than one turn. Move the upper structure at a 90° to the crawler
2. If the grease does not release adequately, move frame. Operate the attachment placing it on the
the machine forward and backward. 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
BS07N047 Figure 39
3. After grease has been released, tighten the
BS07N046 Figure 41
grease fitting.
Torque to: 73.5 ± 14.7 Nm (54.2 ± 10.8 lbf ft). 2. Gradually loosen the grease fitting to release
Move the machine forward and backward to grease under pressure. Loosen the grease fitting
confirm the correct tension of the crawler belt. If (1) less than one turn. Grease will flow from the
necessary, adjust again. fitting (2).
87722071 NA Issued 01-08 Bur 6-21

Replacing the Rubber Crawler Belt
BS07N049 Figure 42
3. Insert three steel pipes into the bottom front BS07N042 Figure 43
rubber crawler belt, then slowly rotate the 1. Keep all unauthorized personnel clear of the
sprocket backward by moving the track. area. Park the machine on a hard, level surface.
4. Stop the rotation when the rubber crawler belt Move the upper structure at a 90° to the crawler
separates from the idler wheel. Shut off the frame. Operate the attachment placing it on the
engine. ground as illustrated and gradually lower the
boom to lift one side of the machine. Shut off the
5. Slide the crawler belt over the steel pipes to engine. Support the lower travel structure with a
remove. safety support (1).
BS07N049 Figure 44
2. Engage the rubber crawler belt with the sprocket
and hang it on the idler.
3. Insert three steel pipes into the bottom front
r ubber crawler belt then slowly rotate the
sprocket backward. When the rubber crawler belt
separates from the idler wheel, stop the rotation.
Shut off the engine.
4. Slide the rubber crawler belt over the steel pipes
to install it.
6-22 Issued 01-08 Bur 87722071 NA

INSPECT FAN BELT CONDITION

1 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.
2 6
3
5
2
4

3 extreme injury. Stop engine before servicing.
injury or death.
BS07N050 Figure 45
1. LOWER ROLLER
2. RUBBER CRAWLER BELT Check belt for insufficient tension, wear, and
3. SPROCKET damage. A loose belt can cause battery charge
4. IDLER failure, engine overheating, or abnormal belt wear. If
5. LUG
6. METAL CORE
7. TRAVEL MOTOR
5. Stop the rotation of the sprocket to confirm the ADJUSTING BELT
rubber crawler belt is securely engaged to the 1. Slightly loosen attaching bolt (1) and adjusting
sprocket, idler, and lower rollers. See illustration. bolt (2).
6. Check the tension on the belt and make any 2. Loosen adjusting bolt (3) adjust the fan belt to
adjustments necessary. the correct tension, and tighten bolts (1) and (2).
7. If tension is correct, lower the machine to the
3. After adjustment, run the engine at low idle for
ground.
approximately 5 minutes, then recheck the
tension of belt.
New Belt Tension Used Belt Tension

8 - 12 mm 10 - 14 mm
(8/16 - 7/16 inch) (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

HYDRAULIC RETURN FILTER

1
2
3
6 7
1
2
4
BS07M861 Figure 47 8
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.
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. BS07N636 Figure 48
3. Open the cover to the hydraulic tank and secure
5. Press the valve (several times: 5 to 7 times)
with the strut.
together with the breather cap (8), and bleed the
4. Clean any dirt from the filter area to avoid hydraulic oil tank of the remaining pressure.
contaminating the hydraulic system.
6. Remove bolt (1), spring washer (2) and cover (3)
from the upper surface of the tank.
7. Take the spring (4), valve (5) and element (6) out
of the tank.
8. Replace O-ring (7) fitted on the face of cover (3).
9. Clean the parts taken out with light oil.
10. Install element by reversing the disassembly
procedure.
11. Install cover (3).
Tightening torque: 23.5±2 N•m {17±1.4 lbf•ft}
12. Start and run the engine at idle. Move the
machine controls to remove air from the system.
Then place the machine in position to check the
oil level.
Stop the engine and check the oil level adding
oil, if need.
13. Close the cover on the hydraulic oil tank and
lock.
6-24 Issued 01-08 Bur 87722071 NA

250 HOUR MAINTENANCE

ENGINE OIL LEVEL
4 1
2
BD07N032 Figure 50
1. OIL FILTER
2. FILTER WRENCH
7. Use the filter wrench provided with the machine,

1 and turn counter clockwise to remove the oil
filter.
3
5
BS07N029 Figure 49 BD07N040 Figure 51

1. DRAIN CAP 4. OIL FILL CAP
2. COVER 5. DRAIN HOSE
8. To install the oil filter, apply a thin coat of engine
3. DIPSTICK oil to the gasket (A) of the new oil filter, fill the
filter partially with engine oil and then secure the
Change oil and oil filter at 50 hour run-in period for a filter by tightening 2/3 of a complete turn by hand
new machine, then at every 250 hours thereafter. after the gasket comes in contact with the oil filter
1. Park the machine on a firm, level surface with head.
both attachments resting on the ground. Turn the NOTE: Do not reuse the oil filter.
of the area. 9. Clean oil drain plug and install it. Tighten
securely.
2. Raise the engine cover. Remove the dipstick to
allow oil to run more freely. 10. Check drained oil for any metal shavings, flakes,
or particles. Contact your dealer if any debris is
3. Remove bolts and engine belly pan covers found.
4. Locate the engine oil drain plug and place an 11. Fill with the specified amount of oil through filler
empty oil container [7 L (2 gal) capacity] under port (4) and install oil filler cap.
the plug. Attach the quick drain hose (5), and
drain the oil into the container. 12. Before starting the engine, check oil level using
the dipstick (3). The level should be between the
5. Remove engine oil drain plug and let the engine L and H limits as shown. Start and run the engine
oil drain out completely. for five minutes. Stop the engine and recheck the
6. After draining oil, remove drain hose, and tighten oil level after 30 minutes. Add oil if necessary.
drain cap (1) securely. Remove any spilled oil. 13. Install cover (2) to its original position.
87722071 NA Issued 01-08 Bur 6-25

INSPECT AND ADJUST FAN/ALTERNATOR BELT Adjusting Belt

Check and adjust the fan/alternator belt every 250 1. Slightly loosen attaching bolt (1) and adjusting
hours. bolt (2).
2. Loosen adjusting bolt (3) adjust the fan belt to
3 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
2 tension of belt.
New Belt Tension Used Belt Tension
1 8 - 12 mm 10 - 14 mm
(8/16 - 7/16 inch) (3/8- 1/2 inch)
NOTE: A used belt refers to a belt that has been run

5 minutes or more.
BS07N031 Figure 52
1. ATTACHING BOLT BOLT AND NUT TORQUE
2. ADJUSTING BOLT When the hour meter registers 250 hours, check all
3. ADJUSTING BOLT machine bolts and nuts for proper torque. See charts
in Chapter 8 - Specifications.
extreme injury. Stop engine before servicing.
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
6-26 Issued 01-08 Bur 87722071 NA

DOZER PIN GREASE POINTS BOOM, ARM, AND ATTACHMENT GREASE

POINTS
3
1 4 7
8
2
10
3
11
6
5
9
BS07N035 Figure 53
1. DOZER CYLINDER ROD PIN (1) BS07N033 Figure 55

2. DOZER CYLINDER FOOT PIN (1)
4. BOOM FOOT PIN (1)
3. DOZER FOOT PIN (2)
5. BOOM CYLINDER FOOT PIN (3)
6. BOOM CYLINDER ROD PIN (1)
When machine is new, during the first 50 hours of
7. ARM CYLINDER FOOT PIN (1)
operation, grease attachment, boom, arm, and boom 8. ARM CYLINDER ROD PIN (1)
swing every 8 hours. After the initial run-in period, 9. BOOM/ARM CONNECTING PIN (2)
grease every 250 hours. 10. BUCKET CYLINDER FOOT PIN (1)
1. Park the machine on a firm, level surface with 11. BUCKET CYLINDER ROD PIN (1)
BOOM SWING GREASE POINTS
of the area.
15
3. Lubricate with a grease gun through the grease 12
IMPORTANT: Dispose of all waste in accordance 14
with environmental regulations.
GREASING THE SWING BEARING
13
BS07N034 Figure 56
12. SWING CYLINDER FOOT PIN (1)

13. SWING CYLINDER ROD PIN (1)
14. SWING BRACKET/FRAME CONNECTING PIN (2
15. SLEWING GEAR (1)

of the area.
BS07N130 Figure 54 2. Clean the grease fitting before greasing. Replace
Grease the swing bearing by adding grease to each any damaged grease fitting.
fitting (4 locations) until grease comes out fittings. 3. Lubricate with a grease gun through the grease
WARNING: Do not swing the machine while
greasing the swing bearing.
87722071 NA Issued 01-08 Bur 6-27

CLEANING AND REPLACING ENGINE AIR 6. After cleaning, use a light to check the inside of
FILTER the element for tearing, pinholes, or packing
Clean the air filter element every 250 hours. After 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
cleaning six times or at six month intervals, the necessary.
element should be replaced at 500 hours. If any 7. Set outer element (1) in the housing.
damage is visible to the filter, replace it regardless of
8. Install the cover on two clamp (2) positions,
machine time or scheduled maintenance.
directing the mark "TOP" on the cover to the inlet
side
2 1 3
BS07N637 Figure 57
BS07N664 Figure 59
IMPORTANT: When cleaning outer element, do not
9. The TOP position mark should face up. Make
remove inner element to prevent dust from entering
certain to avoid interference with the intake hose.
the air intake.
Incline the air filter casing approximately 15° to
1. Park the machine on a firm, level surface with the engine side.
engine off. Keep all unauthorized personnel clear REPLACING THE INNER ELEMENT
of the area. (IF EQUIPPED)
2. Release the two clamps (2) from the air cleaner
cover. 2 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.
BS07N637 Figure 60
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 IMPORTANT: For machines equipped with double
5. To clean the outer element (1), blow compressed elements, the inner element must be replaced
air (less than 0.3 MPa {43 psi}) up and down together with the outer element. Do not clean inner
along the folds of the filter element interior to element. Replace only with a new element.
remove clogged dust or other contaminants.
6-28 Issued 01-08 Bur 87722071 NA

HYDRAULIC RETURN FILTER (BREAKER USE)

1
2
3
6
1 7
2
4
BS07M861 Figure 61
8
Replace the hydraulic return filter at 250 hours if you
are using a breaker/nibbler attachment.
of the area.

2. Remove all pressure from the hydraulic system.
with the strut.
BS08A248 Figure 62
4. Clean any dirt from the filter area to avoid
contaminating the hydraulic system. 5. Press the valve (several times: 5 to 7 times)
hydraulic oil tank of the remaining pressure.
of the tank.
procedure.
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.
lock.
87722071 NA Issued 01-08 Bur 6-29


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
5 8
1
6
9
1. AIR BREATHER PLUG
2. HANDLE (FUEL VALVE)
3. DRAIN VALVE
4. ELEMENT
2 5. RING (RED)
4 6. SPRING
7. O-RING
5 8. CASE
9. RING
8 A. IN
6 B. OUT
C. FUEL VALVE CLOSED
3 D. FUEL VALVE OPEN
BS07N135 Figure 63
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. BS07N137 Figure 65
5. The components of the water separator must be 6. Push the handle (2) of the water separator
removed to clean. Take care not to lose red ring upward to the CLOSE position (C).
and spring. Do not use gasoline to clean the filter 7. Loosen the ring (9) to remove the case (8) and
elements. Wipe off any spilled fuel. 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 Issued 01-08 Bur 87722071 NA

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 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
BS07N398 Figure 66 engine.
6. Start and run the engine at idle for 5 minutes to
WARNING: Engine and components stay check for leaks.
hot after operating. Allow machine to cool 7. Close the engine door and install the cover
before servicing. Failure to comply could located under the engine.
IMPORTANT: Dispose of all hazardous waste
1. Park the machine on a firm, level surface with properly according to local environmental
both attachments resting on the ground. Turn the regulations.
of the area.
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

CLEANING AND REPLACING ENGINE AIR

FILTER
Clean the air filter element every 250 hours. After
cleaning six times or at six month intervals, the
element should be replaced at 500 hours. If any
damage is visible to the filter, replace it regardless of
machine time or scheduled maintenance.
2 1 3
BS07N664 Figure 70
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 1 3
2
remove inner element to prevent dust from entering
the air intake.
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.
BS07N131 Figure 71
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.
IMPORTANT: For machines equipped with double
BS07N132 Figure 69 element, the inner element must be replaced
3. To clean the outer element (1), blow compressed together with the outer element. Do not clean inner
air (less than 0.3 MPa {43 psi}) up and down element. Replace only with a new element.
along the folds of the filter element interior to
remove clogged dust or other contaminants.
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 Bur 87722071 NA

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 Figure 74
5. After oil has been drained out completely, clean
1 “DRAIN” plug. Use teflon tape on DRAIN plug for
additional sealing and install plug. Tighten
BS07N668 Figure 72 securely.
1. DRAIN PORT 6. Add engine oil through the oil FILL opening (2)
2. FILL PORT
until oil starts flowing out of the port (3).
7. Clean oil FILL plug. Use teflon tape on plug for
additional sealing and install plug. Tighten plug
securely.
of the area.
8. Check drained oil for any metal particles. If
2. When parking the machine, make certain the
contaminant are present, contact your dealer.
drain port (1) is at the bottom.
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
BS07N669 Figure 73
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 6-33


REPLACING ENGINE COOLANT 6. To drain radiator, place a rag or paper towel on
The engine coolant should be replaced every 1000 the radiator cap and slowly remove it to release
hours. Check the coolant level every 8 hours as part the pressure.
of daily maintenance. 7. Drain the radiator with drain hose.
8. After draining, install the drain plug (2). Fill the
11 cooling system with system cleaner according to
cleaner container instructions.
3
BS07N142 Figure 76
9. Operate the engine at a speed slightly faster
4
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 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.
UPW00400091J01 Figure 75
Loosen the radiator drain plug (2). Flush the
1. RADIATOR HOSE CLAMP 3. RADIATOR HOSE radiator (3) with clean water until the water runs
2. RADIATOR CAP clear.
1. Park the machine on a firm, level surface with 11. Install the radiator drain plug (2). Fill the radiator
both attachments resting on the ground. Turn the 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 %
engine off. Keep all unauthorized personnel clear COOLANT. Start and run the engine to fully
of the area. 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
3. Check the hoses for leakage due to loose level should be between FULL and LOW. Adjust
clamps, or cracked and worn hoses. level to specifications.
4. Tighten any loose clamps. 13. Check the system for leaks and repair. Close the
engine door.
5. Replace any hoses that are damaged. See
replacing radiator hoses for further information.
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.
death.
6-34 Issued 01-08 Bur 87722071 NA

REPAIRING HOSES CHECK VALVE CLEARANCES

1. Drain coolant into clean container for reuse if not Check and adjust the engine valve clearance every
changing coolant. 1000 hours of engine operation. Contact your Case
Dealer’s Service Department for assistance.
2. Clean the areas where the new hose will be
connected.
CHECK STARTER AND GENERATOR
3. Remove the clamps (if reusing old clamps) from Have the starter and generator checked every 1000
the old hose and install them to the new hose. hours of engine operation. Contact your Case
4. Coat the inside ends of the new radiator hose Dealer’s Service Department for assistance.
with grease and install. Tighten clamps securely.
5. Fill radiator with coolant.
6. Install radiator cap, start engine, and bring
engine temperature to about 90°C (194°F).
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

HYDRAULIC RETURN FILTER

1
2
3
6
1 7
2
4
BS07M861 Figure 77
8
Replace the hydraulic return filter at 250 hours if you
are using a breaker/nibbler attachment.
of the area.

2. Release all pressure from the hydraulic system.
with the strut.
BS08A248 Figure 78
contaminating the hydraulic system. 5. Press the valve (several times: 5 to 7 times)
hydraulic oil tank of the remaining pressure.
of the tank.
procedure.
Then place the machine in level position to check
the oil level. Stop the engine and check the oil
level, adding oil, if necessary.
lock.
6-36 Issued 01-08 Bur 87722071 NA


CHECK INJECTION TIMING
Have the injection timing checked every 1500 hours
of engine operation. Contact your Case Dealer’s
Service Department for assistance
87722071 NA Issued 01-08 Bur 6-37


HYDRAULIC SUCTION STRAINER CLEANING
The hydraulic tank suction strainer should be 2
cleaned when the engine hour meter registers 2000 3
hours and every 2000 hours there after.
4
1
2
BS07M861 Figure 79
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 BS07N665 Figure 81
could result in injury or death. 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.
of the area.

comply could result in injury or death. 7
with the strut.
1
BS07N667 Figure 82
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).
contaminating the hydraulic system.
6-38 Issued 01-08 Bur 87722071 NA
2
3
4
5
BS07N667 Figure 83
8. Insert strainer (5) into suction tube. Install cover
(4) with cap screws (2) and lock washers (3).
Torque to: 23.5±1.98 Nm (17±1.4 lbf ft).
9. Start the engine and operate at low idle for 5 to 7
minutes. Operate each cylinder and swing.
Retur n the machine to the hydraulic level
checking position. Stop the engine and check the
hydraulic oil. If level is low, add oil.
87722071 NA Issued 01-08 Bur 6-39

PILOT VALVE AND SOLENOID VALVE

Clean the pilot valve filter and solenoid filter when the
hour meter registers 2000 hours. 4 5
The P port of right and left pilot valves (for operation
and travel) and the solenoid valve are equipped with 2
a connector with a filter. Dirt that adheres on the filter
will decrease oil flow.
1
2 3
3
BS07N147 Figure 85
3. Loosen 2 bolts (3) on the operating box to
remove the cover.
BS07M861 Figure 84
4. Disconnect the hose (1) connected to P port on
the pilot valve (4), then remove connector with
WARNING: Do not perform any service work filter (2).
on a machine that is hot. Allow the machine
and components to cool before performing 5. After removal, put a plug into the bore to prevent
any work on fluids and oils. Failure to comply entry of foreign matter.
could result in injury or death. 6. Wear face protection, wash the filter with
1. Park the machine on a firm, level surface with cleaning solvent. Use compressed air to remove
both attachments resting on the ground. Turn the any material.
of the area.

2. Release all pressure to the hydraulic system.
6-40 Issued 01-08 Bur 87722071 NA

7a 7b 7c 7d 7e
8
7a.CASE
6 7b.STRAINER
7c.LABEL
7d.O-RING
7e.FITTING
12. Remove the case (7a) and the fitting (7e), and
BS07N148 Figure 86
then remove strainer (7b) with screwdriver.
7. Check the O-ring (5) for damage, and replace if
13. Spray light oil or air on the strainer (7b) to clean.
necessary.
Clean the inside of the case (7a). Check the
8. After cleaning, install to the original position in O-ring (7d) for damage, if it is damaged, replace
reverse order. See torque charts. it with new one.
9. Remove the in-line filter (7) of solenoid valve (6) 14. Install the strainer (7b) on the fitting (7e) with
for cleaning. screwdriver, and fit in the in-line filter case (7a).
Tightening torque: 59 to 79 N•m {43 to 58 lbf•ft}
10. Remove the right-hand guard (8).
15. Remove the plug, install the in-line filter
11. After removal of the hose, remove the in-line filter assembly (7) on the solenoid valve (6), and then
assembly (7) from the tee installed on the install hose (1).
solenoid valve (6). After removal, the oil holes of
tee and hose should be plugged.
87722071 NA Issued 01-08 Bur 6-41

12
12
99
11 P 12
13
10
9
BS07N150 Figure 89
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.
20. After cleaning, install to the original position in
UPW00400107J01 Figure 88
the reverse order of disassembly. Refer to
16. Remove the elbow with filter (9) of pilot valve torque charts for tightening hose (11).
(10) for cleaning.
21. Reinstall the floor mat and floor plate.
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 Issued 01-08 Bur 87722071 NA

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 Figure 92
5. After oil has been drained out completely, clean
1 DRAIN plug. Use teflon tape on DRAIN plug for
additional sealing and install plug. Tighten
BS07N668 Figure 90 securely.
1. DRAIN PORT 6. Add engine oil through the oil FILL opening (2)
2. FILL PORT
until oil starts flowing out of the port (3).
7. Clean oil FILL plug. Use teflon tape on plug for
additional sealing and install plug. Tighten plug
securely.
of the area.
8. Check drained oil for any metal particles. If
2. When parking the machine, make certain the
contaminants are present, contact your dealer.
drain port (1) is at the bottom.

reduction gear oil pressure. Loosen plug
slowly and wear face protection. Failure to
BS07N669 Figure 91
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

UPPER AND LOWER ROLLER - IDLER OIL 1. Park the machine on a firm, level surface with
CHANGE both attachments resting on the ground. Turn the
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).
1 Stop the engine.
2
3
4 3 4
6 5
BS07N259 Figure 93 1 1
1. TRAVEL MOTOR
2. SPROCKET
2 2
3. LOWER ROLLER
4. CRAWLER BELT
5. UPPER ROLLER
6. IDLER
Idlers must be removed from the crawler frame to BS07N261 Figure 95

change the gear oil. Refer to the oil and grease 5. Remove the capscrews (1) with washers (2)
specification for the required volume. which install the lower roller to the crawler frame
at two positions. Remove the lower roller (3).
WARNING: Do not perform any service work 6. Remove the feeding port plug (4) with allen
on a machine that is hot. Allow the machine wrench, and discharge the old engine oil.
and components to cool before performing 7. Fill with the specified volume (35 cc or 2.1 cu.in)
any work on fluids and oils. Failure to comply of engine oil through the feeding port.
could result in injury or death. 8. Apply sealing (teflon) tape to thread on the plug
(4), and securely tighten it. Thoroughly wipe off
oil adhered to periphery.
WARNING: Grease in track tensioning
mechanism is under extreme pressure and 9. Apply Loctite #262 to thread on the capscrews
can penetrate skin. Keep face and body away (1), and temporarily install the lower roller (3) to
from grease fitting area. Do not loosen the crawler frame.
grease fitting more than one turn. Failure to 10. Remove the safety support which supports the
comply could result in injury or death. machine, then tighten the capscrew (1).
Tightening torque: 208 ± 21 Nm {153 ± 15 lbf•ft}
11. 11.Lift up the machine to adjust the crawler shoe
tension referring to Adjusting Track Tension.
BS07N260 Figure 94
1.
6-44 Issued 01-08 Bur 87722071 NA

IDLER OIL CHANGE
2
1
6
5
4
3
BD07N262 Figure 96
BS07N263 Figure 97
WARNING: Check and adjustment for track NOTE: Check the drained waste oil. If there are
tension requires the machine to be lifted off metal flakes in the oil, contact your Case Dealer. DO
the ground one track at a time. Unexpected NOT reuse the oil filter.
lowering of the machine could result in injury 6. Apply sealing (teflon) tape to the threads on the
or death. Do not operate the boom while plug (3), and securely tighten it. Wipe off any
adjusting the crawler belt. Failure to comply remaining oil.
7. Apply grease to the sliding face (A) on the piston
1. This is a two person procedure. If you doubt your (4) and cylinder (5) of the idler adjuster (2).
ability to perfor m this procedure, call your 8. Install the idler so that the fill - drain port plug (3)
authorized dealer. See procedure for removing of idler and the grease fitting (6) of idler adjuster
and installing crawler belt in this section. (2) are facing to outside.
2. Remove the rubber crawler belt. Place a safety 9. Install the rubber crawler belt.
support under the machine.
10. Adjust the tension on the rubber crawler belt.
3. Remove the idler (1) and adjuster (2) from the Refer to procedure for adjusting belt tension.
crawler frame. Raise the machine off the safety support, remove
Weight of idler + Idler Adjuster = the safety support and slowly lower the machine
approximately. 40 kg (88 lb) 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

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
6 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.
1 2 3 INTAKE AND EXHAUST VALVE CHECK

To ensure the seal of the exhaust and intake valves,
5 contact your dealer for service and inspection. this
procedure should be completed by a qualified
BD07N264 Figure 98 service professional.
The crawler belts must be removed to service the
idlers. See procedure for removing and installing
crawler belts in this section.
of the area.
2. Loosen the rubber crawler belt (6).
3. Raise the rubber crawler belt with a hydraulic
jack (5).
1 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: 66±7 N•m {48±5 lbf•ft}
6-46 Issued 01-08 Bur 87722071 NA


CHANGE HYDRAULIC OIL
2
3
4
BS07N269
BS07N268 Figure 100
7. Place a container (40 L {11 gal.}) beneath the
drain plug (1). Remove the drain plug (1) with a
WARNING: Allow machine to cool. Release 27 mm wrench and drain the remaining oil.
hydraulic pressure before servicing any 8. Tighten the drain plug (1).
hydraulic component. Hydraulic fluid is under Tightening torque 73.5 ± 5 Nm (54.2 ± 3.7 lbf. ft.)
extreme pressure and can cause severe
injury. Failure to comply could result in injury 9. Loosen the four bolts (2) and lock washers (3).
or death. Remove cover (4).
1. Park the machine on a firm, level surface with 10. Check O-ring for damage, and replace if
both attachments resting on the ground. Turn the necessary.
of the area. NOTE: Use caution not to drop bolts or nuts inside
hydraulic tank. Do not allow fluid to come in contact
2. Park the machine so the drain plug (1) on the with skin.
hydraulic oil tank comes midway between both
crawlers. Make certain all pressure is removed 11. Fill the hydraulic oil tank with hydraulic oil at
from the hydraulic system. filling por t (F) according to machine
specifications.
3. Remove the right side guard.
12. Install cover (4) with bolts (2) and lock washers
4. Open the cover on the hydraulic tank with the (3).
engine key, and secure open with the strut. Tightening torque:
5. Clean dirt from the filter to avoid contaminating 23.5 ± 2 Nm (17 ± 1.4 lbf. ft.)
the hydraulic system. 13. Install the right side guard.
6. Press the valve 5 to 7 times together with the 14. After starting the engine, run at low idle. Perform
breather cap (8), and bleed the remaining several telescopic movements of each cylinder
pressure from the hydraulic oil tank. and the swing operation. Return the machine to
the hydraulic oil level check position, and check
the oil level.
87722071 NA Issued 01-08 Bur 6-47

SPECIAL PROCEDURES
BUCKET
WARNING: Wear goggles, safety shoes,

hard hat, work clothes, and work gloves to
7
perform inspection and maintenance on this
machine. Failure to comply could result in
injury or death.
ABRASION OR DAMAGE ON TOOTH POINTS
8
AND SIDE CUTTERS 6
Check for wear and/or looseness of bucket tooth
points. Tooth point life cannot be determined only by 2
the number of operating hours.
BS07N272 Figure 103
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).
BS07N269 Figure 101
WARNING: When replacing a bucket tooth

or side cutters, securely block the bucket to
avoid injury. 2
Replace the bucket tooth if small holes appear on the
tooth point or when the edge lines of the tooth point
are worn. BS07N273 Figure 104
2. Inspect the locking pin (4) and rubber lock pin

3 4 (3). Replace them if the locking pin (4) is too
shor t or the r ubber lock pin (3) is in poor
condition.
3. Clean the surface of the adapter nose (1) with a
putty knife to remove any adhered soil.
1
4. Fit the tooth point (2) onto the adapter nose (1).
2
5. Push the rubber lock pin (3) in the hole of the
adapter nose (1).
5 6. Drive the locking pin (4) until it is aligned with the
point face.
BS07N271 Figure 102
1. ADAPTER
2. TOOTH POINT
3. RUBBER LOCK PIN
4. LOCKING PIN
5. ADAPTER NOSE
6-48 Issued 01-08 Bur 87722071 NA

REPLACING THE SIDE CUTTERS REPLACING BUCKET
1
BS07N274 Figure 105
1. Remove all sand and soil adhering around the
bolts. Use an acetylene torch to cut off the bolts,
then remove the side cutter.
2. Clean the mounting face and install a new side
cutter. When replacing the side cutter, replace
the bolts and nuts with new ones.
3. Tightening torque: 115±12 Nm {84.6±8.7 lbf•ft}
4. After tightening the nuts, spot-weld them.
3
2
2 9 4 5
BS07N276 Figure 107
2
1 avoid injury. Do not insert fingers to align pin
4 bores. Align visually or with a tool. Failure to
3 1. Carefully operate the boom and the arm to
DC04C362 Figure 106 remove load from the pins.
1. NUTS 2. Roll O-rings (1) onto the bucket boss. After
2. SIDE CUTTER removing the pins, place them back in the
3. BOLT original position.
4. 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

INSTALLING BUCKET
9
2
7
8
3 9
5
4
4
5
6 6
BS07N278
BS07N277 Figure 108 4. Align bucket (6) with the pin hole of arm (7)
1. Clean each pin and pin hole and grease moving arm (7), and insert pin (5).
sufficiently. 5. Insert pin (3) and fit lock ring (2).
2. Move the bucket cylinder to match the pin bores Fit O-ring (1) to the normal position.
or the bucket (6) and bucket link (8) with each 6. Apply grease on the grease nipples for
other, then insert the pin (4). respective pin until the grease comes out
3. Raise the boom and slightly raise the bucket through the gap between pins and bore.
from the ground.
avoid injury. Do not insert fingers to align pin
bores. Align visually or with a tool. Failure to
6-50 Issued 01-08 Bur 87722071 NA

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.
BS07N292 Figure 109

TRACK COMPARISON
BS07N288 Figure 112

DO NOT operate on oil contaminated surfaces. Oil
will damage the rubber crawler belts.
BS07N286 Figure 110

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


DO NOT operate the crawler belt on the ground if the 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
other track has been lifted. The additional weight conditions, the bonding of the rubber to the metal
may damage the track or cause the track to come off. 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).
BS07N291 Figure 115

Use caution when operating on ice or snow. Rubber
belts can easily slip. Avoid making sudden turns on BS07N296 Figure 118
concrete. Avoid sudden direction changes, as this Avoid changing direction of the machine on ground
may cause premature wear on the crawler belts. 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.
BS07N294 Figure 116

Use care not to damage the track with the machine
attachment. BS07N297 Figure 119
Do not apply side load force or side impact on the When moving up a slope, avoid changing direction of
bucket or attachment during operation. the machine when the machine is at a point between
If the machine is raised with the bucket, lower the level ground and the slope.
machine slowly.
6-52 Issued 01-08 Bur 87722071 NA

RUBBER TRACK INSPECTION
2 5
BS07N298 Figure 120

4
Do not travel on a slope with one side of the machine BS07N280 Figure 122
lifted. Always travel with both sides level to avoid 1. LOWER ROLLER
damage to the track. 2. RUBBER CRAWLER BELT
3. LUG
4. STEEL CORD
5. METAL CORE
Repair or replace rubber crawler belt if it is damaged.
Contact your dealer for assistance in replacing belts
or refer to the machine Repair Manual.
HEIGHT OF LUG
BS07N299 Figure 121

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

STEEL CORD DAMAGE RUBBER TRACK METAL CORE
5
3
If the steel cords (B) are over one half broken in one 1. LOWER ROLLER
row, replace the crawler belt. 2. METAL CORE
3. RUBBER
4. STEEL CORD
CRACKED CRAWL ER BELT A. 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.
4 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

2
Repair the belt if a crack approximately 60 mm (2.4
in) is seen between the lug of the rubber belt. Repair
immediately if the steel cord (4) is exposed even
though the crack is minimal.
BS07N285 Figure 127

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

MOVING A DISABLED MACHINE

WARNING: Block front and rear tracks to
WARNING: Read and understand all safety prevent movement. Support the attachment
precautions and procedures before securely. Failure to comply could result in
attempting any operation, inspection, injury or death.
maintenance, or repair of this machine, any
attachment or any of its systems. Failure to
WARNING: The following procedures

should only be performed by an experienced
service technician familiar with this machine.
death.
RELEASING LOCK ON TRAVEL MOTOR
BS07N669 Figure 130

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).

BS07N300 Figure 128
The travel motors of a disabled machine are locked reduction gear oil pressure. Loosen plug
by the hydraulic control valve and by the mechanical slowly and wear face protection.
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. 2 5
REMOVING GEARS FROM TRAVEL REDUCTION 1

UNIT
3
5 BXPX00900004E01 Figure 131

4. Insert a flat blade screwdriver into gap between
6 the body (1) and snap ring (3), and remove the
snap ring.
2
5. Remove the cover (2).
4 6. Use care when removing cover, as ball (5) will
14 3 fall. Clean ball if contaminated.
BS07N674 Figure 129
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

ASSEMBLING THE TRAVEL MOTOR

1 2
5
6 3
6
2
4
14 3 XPX00900005E01 Figure 134
2. To prevent the ball (5) from falling from sun gear
BS07N674 Figure 132
(6), coat the ball (5) with a light coat of grease.
NOTE: The crawler belt is now free to rotate.
3. Lubricate the O-ring (14) with grease and fit into
7. Install drain plug (4) and refill unit with the groove of cover (2). Install cover (2).
previously drained oil. Tow the machine to
desired location for further service. 4. Use care not to damage O-ring.
IMPORTANT: Avoid spills. Dispose of all hazardous 5. Replace the O-ring at drain plug (4) with a new
waste in accordance with government laws and one. Install the drain plug (4).
regulations. 6. Add the specified gear oil through the oil fill plug
until oil starts flowing out of the oil level plug.
ASSEMBLING THE TRAVEL MOTOR
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

LOWERING BUCKET ATTACHMENT ON A

DISABLED MACHINE
BS07N384 Figure 136

To lower the bucket position, proceed carefully as
BS07N380 Figure 135 follows: When the bucket is in digging position (A)
(bucket cylinder completely extended, (see figure)
WARNING: Keep all unauthorized personnel disconnect hose head (H) side. When the bucket is in
away from the bucket/attachment and dump position (B) (bucket cylinder completely
excavator boom. retracted), disconnect the hose rod (R) side
The weight of the bucket or attachment may IMPORTANT: Do not allow the hydraulic line or
cause unexpected m ovem ent of components to become contaminated. This could
bucket/attachment, arm and boom during the cause severe system damage to the hydraulic
procedure. system. Contact your dealer to obtain the proper
B l o ck th e bu cke t /a tt a ch m e n t t o avo i d caps and plugs to be used.
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 IMPORTANT: Clean up all spilled oil. Dispose of any
pressure is completely released. hazardous waste in compliance with local
environmental regulations.
Control the bucket/attachment movement by
slowly removing the lock.
Do not enter the area under
bucket/attachment while lowering. Failure to
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

LOWERING THE ARM
BS07N386 Figure 138

BS07N385 Figure 137 LOWERING THE BOOM
WARNING: Make certain the area around 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

the machine is clear of people and objects connected to the boom cylinder.
before attempting these procedures. Failure Stop lowering the attachment at 30 - 40 cm (12 - 16
to comply could result in injury or death. in.) above ground level to allow for moving the
machine.
Gradually loosen the hose of rod side connected to 1. Tighten the hose fitting.
the arm (R). 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fusible Starter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Issued 01-08 Bur 87722071 NA 7-1

NOTES
7-2 Issued 01-08 Bur 87722071 NA

ELECTRICAL COMPONENTS FUSIBLE STARTER LINK

.
FUSES
.
BS07N387 Figure 1
BS07N388 Figure 2
If the electrical power does not come on when the
starter key switch is in the on position, the fusible link
WARNING: Make certain the starter switch may be the cause. Inspect and replace the red
is in the OFF position before replacing fuses. fusible link (1).
Fuses protect the electrical system from excess The fusible link protects the electrical system from
current. Replace a blown fuse or any fuse generating current over load. The fusible link functions like a
white powder on it. fuse.
Always replace fuses with a fuse of the same
capacity. The spare fuses are stored in the back side
of the fuse box cover. WARNING: Never replace a faulty fuse with
a higher amperage fuse. Never use a jumper
in place of a fuse. Never splice accessories
NO. AMPS FUNCTION
directly into fuse terminals.
1 30A WIPER, HEATER
2 30A RELAY, SOLENOID
3 30A WORK LAMP
4 10A HORN, CAB LIGHT
5 30A ENGINE STOP SOLENOID
BATTERY RELAY,
6 10A
CLUSTER GAUGE
87722071 NA Issued 01-08 Bur 7-3

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:
BS07N390 Figure 4
1. CAP
2. TERMINAL
3. TERMINAL COVER
Wear safety clothes, goggles or face shield, A. INDICATOR
gloves and safety shoes when working with B. AIR VENT HOLE
C. BLUE
batteries.
D. RED
Work in a well ventilated area. E. WHITE
Battery electrolyte (acid) is corrosive. If it F. UPPER LIMIT
comes in contact with skin, eyes or clothing, G. LOWER LIMIT
H. GOOD CONDITION
flush with large amount of water and seek I. REFILLING REQUIRED
immediate medical attention. J. CHARGING REQUIRED
Battery electrolyte (acid) produces hydrogen .
gas that is highly explosive. Keep away 2

sparks, fire or flames and do not smoke when 1
working with batteries. Failure to comply
BS07N389 Figure 3
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. BS07N391 Figure 5
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

ALTERNATOR
WARNING: Ask your Dealer to check the Alternator.
Prevent Battery Explosion: Make sure that the terminal protectors are correctly
Batteries give hydrogen gases that can installed.
explode and cause personal injury.
Do not use steam cleaning equipment or a cleaning
Keep sparks, open flames and cigarettes solvent to clean the alternator.
away from the batteries.
Keep metallic articles away from batteries. STARTER MOTOR
Keep all ventilation caps tightly secured. Ask your Dealer to check the Starter Motor.
Never check charge by placing metal articles
across battery terminals. Make sure that the terminal protectors are correctly
installed.
Leave battery box open to improve ventilation
when charging.
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 according to its
manufacturer’s instruction.
ATMOSPHERIC TEMPERATURE
CHARGE
20°C (68°F) 0°C (32°F) -10°C (14°F)
100% 1.26 1.27 1.28
90% 1.24 1.25 1.26
80% 1.22 1.23 1.24
75% 1.21 1.22 1.23
8. When disconnecting batteries, remove the

negative (-) cable first. When connecting
batteries, connect the negative (-) cable last.
9. When the battery requires charging:
a. Disconnect battery cables from terminals.
b. Remove all cell caps.
c. Check for proper electrolyte (acid) level.
d. Connect charger leads to the proper battery
terminals.
NOTE: Make certain not to cross Positive (+) and
negative (-) terminals when connecting charger.
e. Stop charge if battery overheats.
f. Periodically check the specific gravity of the
batteries with a hydrometer. Stop charging
batteries when 100% charged.
87722071 NA Issued 01-08 Bur 7-5

WORK LAMPS .
1
4
3 2
5
6 7
BS07N393 Figure 7
BS07N392 Figure 6 1. Park the machine on a firm, level surface with
A 55W bulb is used for the work lamps.
of the area.
WARNING: Do not touch a lighted bulb. 2. Disconnect the electrical connector, then remove
Shut off lamp and allow it to cool. Make the work lamp from the machine with a wrench.
certain work lamp switch is in the OFF 3. Remove screw (1), then remove rim (2) and lens
position. Failure to comply could cause (3) from the casing (4).
machine damage or injury.
4. Remove spring (6) that secures the socket (5).
5. Remove the bulb (7) from the socket (5) and
NOTE: The service life of a bulb is shortened if oil or replace the bulb with a new one.
grease is on the bulb at the time of installation. When 6. Assemble the work lamp using the reverse order.
replacing the bulb, hold it at the flange area. Do not
touch the bulb glass with your fingers. Wipe the bulb NOTE: If the replacement bulb does not light, check
with a clean cloth after installation. the fuse.
7-6 Issued 01-08 Bur 87722071 NA

CHAPTER 8 - SPECIFICATIONS
CHAPTER 8
SPECIFICATIONS
TABLE OF CONTENTS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Canopy Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Cab Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Lift Capacities Canopy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Lift Capacities CaB Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Capscrews and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Nuts and Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Issued 01-08 Bur 87722071 NA 8-1

NOTES
8-2 Issued 01-08 Bur 87722071 NA

GENERAL SPECIFICATIONS
CANOPY MACHINE DIMENSIONS
BS08A063 Figure 1
CAB MACHINE DIMENSIONS
BS08A064 Figure 2
87722071 NA Issued 01-08 Bur 8-3

SPEED AND GRADEABILITY
Rubber Crawler Belt Steel Crawler Belt

1
Swing Speed 8.7 min (8.7 RPM)
Low High Low High
(1st) (2nd) (1st) (2nd)
Travel Speed
2.5 km/h 4.5 km/h 2.5 km/h 4.5 km/h
(1.6 mph) (2.8 mph) (1.6 mph) (2.8 mph)
Gradeability 58% (30°)
ENGINE
Model YANMAR 3TNV88-SYB

Type Water cooled, 4 cycle type swirl chamber type diesel engine
Number of cylinders - Bore X Stroke 3 - 88 mm X 90 mm (3 - 3.46 in. X 3.54 inch)
Total Displacement 1.642 liters (100.2 cubic inch)
21.2 kW (2400 min1)
Output Rating 29 PS (2400 RPM)
98.4 Nm (1440 min1)
Maximum Torque 72.6 lbf ft (1440 RPM)
Starting Motor 12 V (1.7 kW)
Generator 12 V (55 A)
HYDRAULIC COMPONENTS
Hydraulic Pump Variable displacement axial piston pump

Hydraulic Motor Axial piston
Hydraulic Motor with Reducer (Travel) 2 - Axial piston, 2-speed motor
Control Valve 10- spool multiple control valve
Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder
Return Filter 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) 540/440 (21.3/17.3)
8-4 Issued 01-08 Bur 87722071 NA

CRAWLER TYPE
Length between Ground Pressure

Width center of idler and
Type kPa (psi)
mm (inch) center of travel motor Canopy - Cab
mm (ft - in)
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
Weight
Heaped Capacity Outer Width Outer Width Number of Kg (lbs.)
Bucket
m3 (cubic yard) with side cutter without side cutter teeth
0.11 (0.144) 600 mm (23.6 in.) 554 mm (21.8 in.) 4 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

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 5 ft (1.5 m) 7.5 ft (2.3 m) 10 ft (3.0 m) 12.5 ft (3.8 m) 15 ft (4.6 m)

(Lift Point) END - SIDE END - SIDE END - SIDE END - SIDE END - SIDE
Height
+ 10 ft 1190 lb 1120 lb
(3.0 m) 540 kg 510 kg
+7.5 ft 1380 lb 1380 lb 1280 lb 1100 lb
(2.3 m) 620 kg 620 kg 580 kg 500 kg
+5 ft 2760 lb 2380 lb 1830 lb 1510 lb 1480 lb 1050 lb
(1.52 m) 1250 kg 1080 kg 830 kg 680 kg 670 kg 470 kg
+2.5 ft 3760 lb 2180 lb 2270 lb 1420 lb 1690 lb 1000 lb 1390 lb 750 lb
(0.8 m) 1700 kg 990 kg 1030 kg 640 kg 760 kg 450 kg 630 kg 340 kg
Ground 2550 lb 2550 lb 4020 lb 2120 lb 2520 lb 1360 lb 1820 lb 970 lb
Level 1150 kg 1150 kg 1820 kg 960 kg 1140 kg 610 kg 820 kg 440 kg
-2.5 ft 4080 lb 4080 lb 3830 lb 2120 lb 2520 lb 1340 lb 1800 lb 960 lb
(-0.8 m) 1850 kg 1850 kg 1740 kg 960 kg 1140 kg 610 kg 810 kg 430 kg
-5.0 ft 5790 lb 4550 lb 3290 lb 2150 lb 2210 lb 1360 lb
(-1.52 m) 2620 kg 2060 kg 1490 kg 970 kg 1000 kg 620 kg
-7.5 ft 3470 lb 3470 lb 2110 lb 2110 lb
(-2.3 m) 1570 kg 1570 kg 950 kg 950 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

Height
+ 10 ft 1190 lb 1190 lb
(3.0 m) 540 kg 540 kg
+7.5 ft 1280 lb 1160 lb
(2.3 m) 580 kg 530 kg
+5 ft 2760 lb 2510 lb 1830 lb 1600 lb 1480 lb 1120 lb
(1.52 m) 1250 kg 1140 kg 830 kg 720 kg 670 kg 500 kg
-5.0 ft 5790 lb 4800 lb 3290 lb 2280 lb 2210 lb 1450 lb
(-1.52 m) 2620 kg 2180 kg 1490 kg 1030 kg 1000 kg 660 kg
-7.5 ft 3470 lb 3470 lb 2110 lb 2110 lb
(-2.3 m) 1570 kg 1570 kg 950 kg 950 kg
8-6 Issued 01-08 Bur 87722071 NA

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

Height
+ 10 ft 1190 lb 1190 lb
(3.0 m) 540 kg 540 kg
+7.5 ft 1280 lb 1280 lb
(2.3 m) 580 kg 580 kg
+5 ft 2760 lb 2760 lb 1830 lb 1830 lb 1480 lb 1320 lb
(1.52 m) 1250 kg 1250 kg 830 kg 830 kg 670 kg 600 kg
-5.0 ft 5790 lb 5590 lb 3290 lb 2690 lb 2210 lb 1720 lb
(-1.52 m) 2620 kg 2530 kg 1490 kg 1220 kg 1000 kg 780 kg
-7.5 ft 3470 lb 3470 lb 2110 lb 2110 lb
(-2.3 m) 1570 kg 1570 kg 950 kg 950 kg
87722071 NA Issued 01-08 Bur 8-7

CANOPY TYPE MACHINE WORKING RANGES
A
A’
C G
H
D
E
XY
K L
J
F
B
UPV00600003ES1 Figure 3
Standard Arm Long Arm

Units: m (ft-in) 1.32 m (51.9 in) 1.59 m (62.6 in)
Machine equipped with 0.11 m3 (0.144 yd.3) Bucket
WORKING RANGES Bucket Bucket
0.11 m3 (0.144 cu. yd.) 0.11 m3 (0.144 cu. yd.)
A Maximum digging reach 5240 mm (17 ft. 2 in.) 5500 mm (18 ft. 1 in.)
A’ Maximum digging reach at ground level 5110 mm (16 ft. 9 in.) 5370 mm (17 ft. 7in.)
B Maximum digging depth 3080 mm (10 ft. 1 in.) 3350 mm (11 ft. 0 in.)
C Maximum digging height 4980 mm (16 ft. 4 in.) 5160 mm (16 ft. 11 in.)
D Maximum dumping clearance 3580 mm (11 ft. 9 in.) 3760 mm (12 ft. 4 in.)
E Minimum dumping clearance 1410 mm (4 ft. 8 in.) 1150 mm (3 ft. 9 in.)
F Maximum vertical wall digging depth 2390 mm (7 ft. 10 in.) 2650 mm (8 ft. 8 in.)
G Minimum swing radius 2040 mm (6 ft. 8 in.) 2070 mm (6 ft. 10 in.)
H Height at minimum swing radius 3780 mm (12 ft. 5 in.) 3780 mm (12 ft. 5 in.)
J 8-ft. level digging depth 2600 mm (8 ft. 6 in.) 2920 mm (9 ft. 7 in.)
K Horizontal digging stroke at ground level -stroke 2370 mm (7 ft. 9 in.) 2770 mm (9 ft. 1 in.)
L Horizontal digging stroke at ground level - minimum 1670 mm (5 ft. 6 in.) 1530 mm (5 ft. 0 in.)
X Dozer blade - Above 540 mm (1 ft. 9 in.) 540 mm (1 ft. 9 in.)
Y Dozer blade - Below 440 mm (1 ft. 5 in.) 440 mm (1 ft. 5 in.)
8-8 Issued 01-08 Bur 87722071 NA

CAB TYPE MACHINE WORKING RANGES
A
A’
C
H
D
E
X
Y
K L
F
J
B
UPV00600004ES1 Figure 4
Standard Arm Long Arm

Units: m (ft-in) 1.32 m (51.9 in) 1.59 m (62.6 in)
Machine equipped with 0.11 m3 (0.144 yd.3) Bucket
WORKING RANGES Bucket Bucket
0.11 m3 (0.144 cu. yd.) 0.11 m3 (0.144 cu. yd.)
A Maximum digging reach 5240 mm (17 ft. 2 in.) 5500 mm (18 ft. 1 in.)
A’ Maximum digging reach at ground level 5110 mm (16 ft. 9 in.) 5370 mm (17 ft. 7in.)
B Maximum digging depth 3080 mm (10 ft. 1 in.) 3350 mm (11 ft. 0 in.)
C Maximum digging height 4370 mm (14 ft. 4 in.) 4490 mm (14 ft. 9 in.)
D Maximum dumping clearance 3040 mm (10 ft. 0 in.) 3150 mm (10 ft. 4 in.)
E Minimum dumping clearance 1140 mm (3 ft. 9 in.) 870 mm (2 ft. 10 in.)
F Maximum vertical wall digging depth 2390 mm (7 ft. 10 in.) 2650 mm (8 ft. 8 in.)
G Minimum swing radius 2560 mm (8 ft. 5 in.) 2570 mm (8 ft. 5 in.)
H Height at minimum swing radius 3460 mm (11 ft. 4 in.) 3470 mm (11 ft. 5 in.)
J 8-ft. level digging depth 2600 mm (8 ft. 6 in.) 2920 mm (9 ft. 7 in.)
K Horizontal digging stroke at ground level -stroke 2370 mm (7 ft. 9 in.) 2770 mm (9 ft. 1 in.)
L Horizontal digging stroke at ground level - minimum 1670 mm (5 ft. 6 in.) 1530 mm (5 ft. 0 in.)
X Dozer blade - Above 540 mm (1 ft. 9 in.) 540 mm (1 ft. 9 in.)
Y Dozer blade - Below 440 mm (1 ft. 5 in.) 440 mm (1 ft. 5 in.)
87722071 NA Issued 01-08 Bur 8-9

LIFTING CAPACITIES
1. Do not attempt to lift any load that exceeds the 5. Capacities apply to the machine as originally
rated values at their specified load radius and manufactured and normally equipped by the
height. manufacturer.
2. Lifting capacities assume a machine standing on IMPORTANT: The operator must consider the weight
a level, firm, and uniform supporting surface. of any device utilized for lifting to properly calculate
Operator must make allowance for job conditions the total lifting capacity of the machine. Example:
such as soft or uneven ground, out of level
1. If the excavator uses the same bucket size
conditions, side loads, sudden stopping of loads,
indicated in the Lifting Chart, and a lifting cable,
hazardous conditions, inexperienced personnel,
etc. weighing 100 kg (220 lbs) is used for lifting,
weight of various other buckets, lifting slings,
then you have to subtract this additional 100 kg
attachment, etc.
(220 lbs) from every value indicated in the Lifting
3. Rating at bucket lift hook. Chart accordingly.
4. The rated loads are in compliance with SAE 2. If a bucket is changed for a larger bucket, which
Hydraulic Excavator Lift Capacity Standard weight is more than the bucket indicated in the
J1097. They do not exceed 87% of hydraulic Lifting Chart, then you have to subtract this
lifting capacity or 75% of tipping load. Rated additional weight from every value indicated in
loads marked with asterisk (*) are limited by the Lifting Chart accordingly.
hydraulic capacity rather than tipping load.
3. If a bucket is changed for a smaller bucket, which
WARNING: Operator should be fully weight is less than the bucket indicated in the
acquainted with the Operator’s Manual Lifting Chart, then you can add this additional
before operating this machine. Rules for safe weight to every value indicated in the Lifting
operation of equipment should be followed at Chart accordingly.
all times. Failure to comply could result in
injury or death.
8-10 Issued 01-08 Bur 87722071 NA

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

Classification 4.8 T 7T 10.9 T
NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
0.45 ± 0.05 0.38 ± 0.04 0.98 ± 0.1 0.83 ± 0.08 1.77 ± 0.18 1.5 ± 0.15
M6 P=1
(3.2 ± 0.4) (2.7 ± 0.3) (7.1 ± 0.7) (6.0 ± 0.6) (12.8 ± 1.3) (10.8 ± 1.1)
1.09 ± 0.11 0.92 ± 0.09 2.4 ± 0.2 2.0 ± 0.2 4.3 ± 0.4 3.6 ± 0.4
M8 P=1.25
(7.9 ± 0.8) (6.6 ± 0.7) (17.3 ± 1.4) (14.4 ± 1.4) (31.0 ± 2.9) (26.0 ± 2.9)
2.2 ± 0.2 1.83 ± 0.18 4.7 ± 0.5 4.0 ± 0.4 8.5 ± 0.9 7.2 ± 0.7
M10 P=1.5
(15.9 ± 1.4) (13.2 ± 1.3) (33.9 ± 3.6) (28.9 ± 2.9) (61.3 ± 6.5) (52.0 ± 5.1)
3.7 ± 0.4 3.2 ± 0.3 8.1 ± 0.8 6.8 ± 0.7 14.6 ± 1.5 12.3 ± 1.2
M12 P=1.75
(26.7 ± 2.9) (23.1 ± 2.2) (58.5 ± 5.8) (49.1 ± 5.1) (105 ± 10.8) (88.8 ± 8.7)
5.9 ± 0.6 5.0 ± 0.5 12.8 ± 1.3 10.8 ± 1.1 23 ± 2 19.5 ± 1.9
M14 P=2
(42.6 ± 4.3) (36.1 ± 3.6) (92.5 ± 9.4) (78.0 ± 7.9) (166 14) (140 ± 14)
9.0 ± 0.9 7.6 ± 0.7 19.5 ± 2.0 16.4 ± 1.6 35 ± 4 29 ± 3
M16 P=2
(64.9 ± 6.5) (54.8 ± 5.1) (140 ± 14.4) (118 ± 11.5) (252 ± 28.9) (209 ± 21.6)
12.4 ± 1.2 10.5 ± 1.0 27 ± 3 23 ± 2 49 ± 5 41 ± 4
M18 P=2.5
(89.6 ± 8.7) (75.8 ± 7.2) (195 ± 22) (166 ± 14) (354 ± 36) (296 ± 29)
17.5 ± 1.7 14.7 ± 1.4 38 ± 4 32 ± 3 68 ± 7 57 ± 6
M20 P=2.5
(126 ± 12.3) (106 ± 10.1) (274 ± 29) (231 ± 22) (491 ± 51) (412 ± 43)
23 ± 2 19.6 ± 2 51 ± 5 43 ± 4 92 ± 9 77 ± 7
M22 P=2.5
(166 ± 14) (142 ± 14) (368 ± 36) 310 ± 29) (663 ± 65) (555 ± 58)
30 ± 3 24 ± 3 65 ± 7 53 ± 5 118 ± 12 96 ± 10
M24 P=3
(217 ± 22) (173 ± 22) (469 ± 51) (383 ± 36) (852 ± 87) (693 ± 72)
44 ± 4 36 ± 3 96 ± 10 78 ± 8 173 ± 17 140 ± 14
M27 P=3
(318 ± 29) (260 ± 22) (693 ± 72) (563 ± 58) (1250 ± 120) (1010 ± 100)
60 ± 6 50.5 ± 5 131 ± 13 110 ± 11 235 ± 24 198 ± 20
M30 P=3.5
(433 ± 43) (361 ± 36) (946 ± 94) (794 ± 79) (1700 ± 170) (1430 ± 140)
81 ± 8 68 ± 7 176 ± 18 148 ± 15 317 ± 32 266 ± 27
M33 P=3.5
(585 ± 58) (491 ± 51) (1270 ± 130) (1070 ± 110) (2290 ± 200) (1920 ± 200)
105 ± 10 88 ± 9 227 ± 23 190 ± 19 409 ± 41 343 ± 34
M36 P=4
(758 ± 72) (636 ± 65) (1640 ± 170) (1370 ± 140) (2960 ± 300) (2480 ± 250)
TORQUE VALUE UNIT: kgf (ft-lbs)
87722071 NA Issued 01-08 Bur 8-11

METRIC FINE THREAD STANDARD TIGHTENING

TORQUE VALUES
Tighten all Capscrews & Nuts to proper torque values.
Metric Fine Thread Standard Tightening Torque Values

Classification 4.8 T 7T 10.9 T
NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
1.15 0.11 0.97 ± 0.1 2.5 ± 0.2 2.1 ± 0.2 4.5 ± 0.4 3.8 ± 0.4
M8 P=1
(8.3 ± 0.8) (7.0 ± 0.7) (18.0 ± 1.4) (15.2 ± 1.4) (32.5 ± 2.9) (27.4 ± 2.9)
2.3 ± 0.2 1.91 ± 0.19 4.9 ± 0.5 4.2 ± 0.4 8.9 ± 0.9 7.5 ± 0.7
M10 P=1.25
(16.6 ± 1.4) (13.8 ± 1.4) (35.4 ± 3.6) (30.3 ± 2.9) (64.2 ± 6.5) (54.2 ± 5.1)
4.0 ± 0.4 3.4 ± 0.3 8.7 ± 0.9 7.3 ± 0.7 15.7 ± 1.6 13.2 ± 1.3
M12 P=1.25
(28.9 ± 2.9) (24.5 ± 2.2) (62.8 ± 6.5) (52.7 ± 5.1) (113 ± 13) (95.3 ± 9.4)
9.4 ± 0.9 7.9 ± 0.8 20 ± 2 17.2 ± 1.7 37 ± 4 31 ± 3
M16 P=1.5
(67.9 ± 6.5) (57.0 ± 5.8) (144 ± 14) (124 ± 12) (267 ± 29) (224 ± 22)
19 ± 9 15.8 ± 1.6 41 ± 4 34 ± 3 74 ± 7 62 ± 6
M20 P=1.5
(137 ± 14) (114 ± 14) (296 ± 29) (246 ± 22) (535 ± 51) (448 ± 43)
32 ± 3 27 ± 3 70 ± 7 58 ± 6 126 ± 12 105 ± 10
M24 P=2
(231 ± 22) (195 ± 22) (506 ± 51) (419 ± 43) (910 ± 87) (758 ± 72)
65 ± 6 54 ± 5 142 ± 14 118 ± 12 255 ± 26 212 ± 21
M30 P=2
(469 ± 43) (390 ± 36) (1030 ± 100) (852 ± 87) (1840 ± 190) (1530 ± 150)
109 ± 11 91 ± 9 238 ± 23 198 ± 20 428 ±43 357 ± 36
M36 P=3
(787 ± 79) (657 ± 65) (1720 ± 170) (1430 ± 140) (3090 ± 310) (2580 ± 260)
TORQUE VALUE UNIT: kgf (ft-lbs)
ORS JOINT (O-RING SEALING TYPE)
ORS Joint (O-ring Sealing Type)
OPPOSING FLATS TORQUE VALUE WORKING PRESSURE

NOMINAL SIZE
mm kgfm (ft-lbs) kgf/cm2 (psi)
1 - 14 UNS 30 - 32 14 ± 1.4 (101 ± 10)
Hose mouth
350 (4980)
ring and 1 - 3/16 12 UN 36 - 41 18 ± 1.8 (130 ± 13)
385 (5475) Power Boost
Coupling 1 - 7/16 12 UN 41 - 46 21 ± 2.1 (152 ± 15)
8-12 Issued 01-08 Bur 87722071 NA

NUTS AND SLEEVES
Nuts and Sleeves
TUBE SIZE OPPOSING FLATS

MANUFACTURER’S WORKING PRESSURE TORQUE VALUE
O.D. X THICKNESS mm
NAME kgf/cm2 (psi) kgfm (ft-lbs)
mm (in) Dimension B
10 X 1.5
19 4.5 ± 0.5 (33 ± 4)
(0.394 X 0.059)
15 X 2.0
27 15 ± 2 (108 ± 14)
(0.591 X 0.079)
350 (4980) 18 X 2.5
NIPPON A.M.C. 32 18 ± 2 (130 ± 14)
Travel line only (0.709 X 0.098)
22 X 3.0
36 22 ± 2 (159 ± 14)
(0.866 X 0.118)
28 X 4.0
41 28 ± 3 (203 ± 22)
(1.10 X 0.157)
350 (4980) 35 X 5.0
IHARA KOATSU 55 35 ± 4.5 (253 ± 29)
Travel line only (1.38 X 0.20)
FLARE TYPE FITTING JOINTS 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 TORQUE VALUE
(PIPE THREAD)
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. Clean Tube and make sure certain tube end is
1”
trimmed smooth.
1-1/4” 17 ± 1.7 (123 ± 12) 2. Insert tube into fitting until tube end is securely
1-1/2” 21 ± 2.1 (152 ± 15) seated in fitting body.
3. Tighten the nut by hand.
2” 42 ± 4.2 (304 ± 30) 4. Use a spanner wrench, securely tighten nut by
Unit: kgfm (ft.-lbs) turning 1-1/4 turns.
87722071 NA Issued 01-08 Bur 8-13

WEIGHT OF MATERIALS TABLE

Material (Loose Weight) lb/yrd3 kg/m3
Wood chips 700 420
Peat, dry 750 440
Cinders 950 560
Peat, wet 1170 690
Top soil 1600 950
Coal 1780 1050
Caliche 2100 1250
Earth, loam 2100 1250
Shale 2250 1330
Sand, dry 2400 1420
Clay, dry 2500 1480
Earth, dry 2550 1510
Limestone, broken or crush 2600 1540
Earth, wet 2700 1600
Clay, wet 2800 1660
Rock, granite, blasted & broken 2800 1660
Sand, moist 2850 1690
Sand and gravel, dry 2900 1720
Sand, wet 3100 1840
Sand and gravel, wet 3400 2020
8-14 Issued 01-08 Bur 87722071 NA

SOME CONVERSION UNITS UNITS OF PRESSURE
UNITS OF WEIGHT Units of Pressure

From Into Multiply by
Units of Weight
psi 14.223
kg/cm2 Pa
kg lb 2.2 9.807
(Pascal)
lb kg 0.454
Atm 0.06805
Bars 0.06895
UNITS OF LENGTH
psi 2
kg/cm 0.0703
Units of Length Pa
6894.76
From Into Multiply by Divide by (Pascal)
meters feet 3.28 - MPa psi 145.04

(MegaPascal)
mm inches - 25.4
inches mm 25.4 - UNITS OF VOLUME
UNITS OF POWER Units of Volume

Units of Power
Gal
From Into Multiply by 0.264
(US Liquid)
HP kW 0.7457 in3 61.02
kW HP 1.341 Liters yard3 0.00131
quarts 1.0567
UNITS OF FLOW
ounces
33.81
(US)
Units of Flow
m3 0.765
in3 46656
Lit/min 3.79
Yard3 ft3 27
Gal/min Lit/sec 0.0631
cm3 764554.9
(US liquid) cm3/min 3785.4
liters 764.555
ft3/min 0.1337
ft3/min 0.0353
Gal/min 0.264
Liter/min
Gal/sec 0.004403
yard3/min 0.001308
UNITS OF TORQUE
Units of Torque
lbf-ft 0.738
kgf 0.1019716
N·m
lbf-ft 0.737561
lbf-in 8.85075
kgfm 0.1382552
lbf-ft N·m 1.35582
lbf-in 12
87722071 NA Issued 01-08 Bur 8-15

NOTES
8-16 Issued 01-08 Bur 87722071 NA

CHAPTER 9 - INDEX
Chapter 9
INDEX
A Frame Structure ...................................................6-5
Alternator ............................................................. 7-5 Fuel Handling Precautions ...................................2-8
Arm Operation ................................................... 4-14 Fuel Level ...........................................................6-13
Attachment Lubrication ...................................... 6-17
G
B General Information ..............................................1-1
Back Filling & Leveling with Front Attachment .. 4-16 Ground Transportation .......................................4-26
Basic Operation of Hydraulic Controls ............... 4-10 Guidelines for Attachment Lubrication .................6-7
Before Operating the Hydraulic Breaker ............ 4-20 Guidelines to Replace Ground Tools ...................6-7
Before Operating the Machine ............................. 4-3
Boom Operation ................................................ 4-14 H
Bucket ................................................................ 6-48 Hand Signals ......................................................2-26
Bucket Operation ............................................... 4-15 Hazardous Chemical Precautions ........................2-8
Bucket Selection Guide ..................................... 4-19 Hot Surface & Fluids ............................................6-3
Burn Prevention ................................................... 2-8 How to Handle Life Hammer ................................2-9
Hydraulic Breaker ...............................................4-20
C Hydraulic Oil Leaks .................................. 6-15, 6-16
Cab Dome Light ................................................... 3-5 Hydraulic Oil Level .............................................6-14
Cab Door Latch ................................................... 3-3
Cab Machine Dimensions .................................... 8-3 I
Canopy Machine Dimensions .............................. 8-3 Identification Numbers ..........................................1-4
Cleaning Parts ..................................................... 6-4 Inspect Waste Oils and Filters ..............................6-4
Cleaning Sand & Soil from Bucket .................... 4-16
K
Components & Controls Nomenclature ............... 3-9
Keep Machine Clean ............................................6-3
Connecting Booster Cable ................................... 4-6
Key Switch ............................................................3-9
Control Decal ....................................................... 4-9
Counter Rotating Machine ................................. 4-12
L
Lifting Capacities ................................................8-10
D
Lifting Machine ...................................................4-29
Decals ................................................................ 2-10
Lifting Machine With Attachment Installed .........4-29
Disposal of Hazardous Waste ............................. 6-3
Locking/Unlocking Cab Door ................................3-3
Document Pouch ................................................. 3-5
M
E
Machine Access Compartments and Doors .........3-7
Emergency Engine Shut Down ............................ 4-5
Machine Attachment and Swing .........................4-14
Engine ................................................................. 1-4
Machine Components ..........................................1-3
Engine Coolant Level ........................................ 6-12
Machine Dimensions ............................................8-3
Engine Coolant Tank & Engine Air Cleaner Access
Doors ............................................................. 3-7 Machine Electrical ..............................................6-17
Engine Electrical ................................................ 6-12 Machine Operation in Adverse Weather Conditions .
4-18
Engine Fluid Leaks ............................................ 6-12
Machine Storage ................................................4-30
Engine Oil Level ....................................... 6-18, 6-25
Machine Travel Controls ....................................4-11
F Machine Warm Up ................................................4-7
Fire Extinguisher .................................................. 2-8 Maintenance Precautions .....................................2-7
Fire Prevention .................................................... 2-8 Manual Warm Up .................................................4-7
Flare Type Fitting Joints .................................... 8-13 Metric Coarse Thread Standard Tightening Torque
Values ..........................................................8-11
87722071 NA Issued 01-08 Bur 9-1
CHAPTER 9 - INDEX
Metric Fine Thread Standard Tightening Torque S

Values ......................................................... 8-12 Safety Area ...........................................................2-3
Model, Serial Number, and Year of Manufacture 1-4 Safety Rules .........................................................2-3
Monitor ............................................................... 3-10 Seals & O-Rings ...................................................6-4
Mounting and Dismounting Precautions .............. 2-5 Seat Belt ...............................................................3-6
Seat Belt Precautions ...........................................2-9
N
Seat Height Adjustment ........................................3-6
N2 (Nylon) Tube Fitting Joints ........................... 8-13
Securing Machine to Trailer ...............................4-28
Nibbler/Breaker .................................................. 4-21
Selection of the Hydraulic Breaker .....................4-20
Nuts & Sleeves .................................................. 8-13
Specific Precautions to this Machine ....................2-9
Starter Motor ........................................................7-5
O
Starting & Stopping Machine Engine with
Opening and Closing Door Glass ........................ 3-4
Temperature above 0°C (32°F) .....................4-4
Opening and Closing Windshield ........................ 3-4
Starting & Stopping Machine Engine with
Operate Boom Smoothly ................................... 4-16 Temperature below 0°C (32°F) ......................4-5
Operating Both Travel Levers Together ............ 4-11 Starting and Stopping Precautions .......................2-5
Operating Pattern ................................................ 4-9 Starting Boosting Machine Engine .......................4-6
Operating Pattern Decal ...................................... 4-9 Starting Disabled Machine Engine .......................4-6
Operating Precautions ......................................... 2-6 Starting Engine ............................................. 4-4, 4-5
Operating the machine ........................................ 4-3 Starting Machine Engine with Booster Cable .......4-6
Operating the Machine in Water ........................ 4-13 Steps and Handrails ...........................................6-17
Operating the Shovel ......................................... 4-17 Stop Engine ..........................................................6-4
Operation at Seashore or Salty Climate ............ 4-18 Stopping Engine - Normal Conditions .......... 4-4, 4-5
Operation in Extreme Cold ................................ 4-18 Swing Operation .................................................4-15
Operation in Extreme Heat ................................ 4-18
Operation in High Altitudes ................................ 4-18 T
Operation in Humid Climate .............................. 4-19 Torque Specifications .........................................8-11
Operation in Sandy and Dusty Areas ................ 4-18 Track Links .........................................................6-21
Operator Cab Nomenclature ............................... 3-9 Tracks and Components ....................................6-19
Operator Precautions .......................................... 2-5 Transportation ....................................................4-26
Operator Seat Adjustments ................................. 3-6 Transporting Precautions .....................................2-8
Operator’s Compartment Controls and Accessories . Travel Safety ......................................................4-13
3-8
ORS Joint (O-ring Sealing Type ........................ 8-12 U
Units of Flow .......................................................8-15
P Units of Length ...................................................8-15
Personal Safety ................................................... 2-3 Units of Power ....................................................8-15
Practices to Improve Efficiency ......................... 4-16 Units of Pressure ................................................8-15
Prevent Contamination ........................................ 6-4 Units of Torque ...................................................8-15
Units of Volume ..................................................8-15
R
Units of Weight ...................................................8-15
Releasing Hydraulic System Pressure ................ 6-6
Use Arm in Action ...............................................4-16
Removing and Storing Lower Front Window ....... 3-4
Use of Optional Attachment ...............................4-19
Removing Machine from Storage ...................... 4-30
Utility Safety .........................................................2-4
Removing the Bucket ........................................ 6-54
Required Filters ................................................... 5-4 W
Required Fluids/Lubricants and Capacities ......... 5-3 Warm Engine Oil ..................................................6-4
Right Hand Operator Console and Monitor ......... 3-9 Warming of Hydraulic Oil ......................................4-8
Right, Left, Front, and Rear of the Machine ........ 1-2 Warming Up of Engine .........................................4-7
Roll-Over Protective Structure (If equipped) ........ 2-8 Wear Safety Equipment .......................................6-4
Weight of Materials Table ...................................8-14
9-2 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

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OPERATOR’S MANUAL

COMPACT CRAWLER EXCAVATOR

READ, UNDERSTAND, AND FOLLOW ALL SAFETY

Bur • Issued 01Jan 08

87722071 NA Issued 01-08 Bur I

II Issued 01-08 Bur 87722071 NA

87722071 NA Issued 01-08 Bur 1-1

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

1. FRONT 3. RIGHT HAND SIDE 5. TRAVEL REDUCTION GEARS (TRAVEL MOTORS)

1-2 Issued 01-08 Bur 87722071 NA

87722071 NA Issued 01-08 Bur 1-3

PRODUCT IDENTIFICATION PLATE COMPONENT SERIAL NUMBERS

1-4 Issued 01-08 Bur 87722071 NA

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Issued 01-08 Bur 87722071 NA 2-1

Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-2 Issued 01-08 Bur 87722071 NA

BS06H091 Figure 1 BC02N198 Figure 2

1. OPERATOR’S MANUAL STORAGE SPACE 1. WORKING AREA

87722071 NA Issued 01-08 Bur 2-3

2-4 Issued 01-08 Bur 87722071 NA

87722071 NA Issued 01-08 Bur 2-5

OPERATING PRECAUTIONS • On machines with independently operated wheel

2-6 Issued 01-08 Bur 87722071 NA

87722071 NA Issued 01-08 Bur 2-7

2-8 Issued 01-08 Bur 87722071 NA

SEAT BELT PRECAUTIONS SPECIFIC PRECAUTIONS TO THIS MACHINE

WARNING: Before starting the engine make

EMERGENCY EXIT HAMMER

87722071 NA Issued 01-08 Bur 2-9

2-10 Issued 01-08 Bur 87722071 NA

BOOM AND ARM MOVEMENT - CAUTION

HYDRAULIC OIL - WARNING

87722071 NA Issued 01-08 Bur 2-11

SAFETY CONTROLS - WARNING

HOT SURFACES - CAUTION

2-12 Issued 01-08 Bur 87722071 NA

PRESSURIZED FLUIDS AND LUBRICANTS - WARNING

ENGINE STOP - CAUTION

87722071 NA Issued 01-08 Bur 2-13

COUNTERWEIGHT SWING AREA - DANGER

ENGINE STOP - CAUTION

2-14 Issued 01-08 Bur 87722071 NA

BOOSTER CABLE - WARNING

TRACK TENSION ADJUSTER - WARNING

87722071 NA Issued 01-08 Bur 2-15

KEEP CLEAR OF WORKING AREA - DANGER

DOZER BLADE - CAUTION

2-16 Issued 01-08 Bur 87722071 NA

ELECTRICAL LINE SAFETY - DANGER

87722071 NA Issued 01-08 Bur 2-17

SELECTOR VALVE - CAUTION

SAFETY LOCK LEVER - WARNING

2-18 Issued 01-08 Bur 87722071 NA

FOOT PEDAL- CAUTION

SEAT BELT - WARNING

87722071 NA Issued 01-08 Bur 2-19

WINDOW LOCK - CAUTION

FALLING FRONT WINDOW - CAUTION

2-20 Issued 01-08 Bur 87722071 NA

CAB DOOR - WARNING

HYDRAULIC OIL CHECK POSITION - NOTICE

87722071 NA Issued 01-08 Bur 2-21