Gehl 283Z Compact Excavator Operator’s Manual

Model 283Z

Compact Excavator

Form No.

918254

Revision B

Jan. 2012

®

© 2012 All Rights Reserved. • Printed in USA

GEHL COMPANY

WARRANTY

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the

Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,

EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS

EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED

DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO

APPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE

WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE

LAW.

GEHL WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the option of the

Original Retail Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Gehl warranties, such as tires, batteries, trade accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein.

204937/AP0407

TABLE OF CONTENTS

Chapter 1 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine and Cab Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Ownership Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fluid Capacities/Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Undercarriage and Swing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Coolant Compound Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sound Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Fields of Applications/Approved Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Load Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Attachment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Exposure to Crystalline Silica. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Travel Controls May Produce Reversed Travel Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Additional Travel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Snow, Ice and Cold Temperature Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Fire Extinguisher Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Additional Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Hydraulic Cylinder Seal Periodic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

High Pressure Hydraulic Lines Store Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Operator’s Cab and Swing Frame Deck Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery Electrolyte and Explosive Gas Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery Disconnection Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Jump-starting or Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Lifting the Machine with a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Printed in U.S.A.

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Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Safety and Information Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

New Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

ISO-Style Safety Decal Locations (Later Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ISO-Style Information Decal Locations (Later Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

ISO-Style Information Decal Locations (Later Machines) (Continued) . . . . . . . . . . . . . . . . . 2-15

ANSI-Style Safety/Information Decal Locations (Early Machines) . . . . . . . . . . . . . . . . . . . . 2-16

Chapter 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Machine Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Guards and Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Engine Compartment Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Accessing the Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Boom Swivel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Dozer Blade Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Engine Speed Control/Throttle Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SAE/ISO Selector Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

SAE Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

ISO Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Operator’s Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Ventilation (Cab Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Engine Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Engine Shut-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

New Machine Break-in Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Bucket Mounting/Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Auxiliary Hydraulics Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Operating Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Chapter 4 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Maintenance Label Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Check, Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fluid and Filter Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Swing Gear Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7


ii 918254/BP0112

Cab Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Final Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swing Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Ranges of Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Hydraulic Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Checking & Adjusting V-belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Windshield Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Track System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Replacing the Cab Filter

(cab model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

After Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Final Shutdown / Decommisioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Before Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Machine Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Chapter 5 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Seals and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Traveling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Bucket, Boom and Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4


iii 918254/BP0112

NOTES


iv 918254/BP0112

CHAPTER 1 –

GENERAL INFORMATION

INTRODUCTION

This Operator’s Manual was written to assist the owner/operator in preparing, adjusting, maintaining and servicing the compact excavator. More important, this manual provides an operating plan for safe and proper use of the machine. Major points of safe opera-

tion are detailed in Chapter 2–Safety.

Read and understand the contents of this manual completely and become familiar with the machine before attempting to operate it. Contact your dealer to obtain additional manuals.

Throughout this manual, information is introduced by the word Note or IMPORTANT. Be sure to read the message carefully and comply with the message. Following this information will improve operating and maintenance efficiency, help to avoid breakdown and damage and extend the service life of the machine.

Do not use the machine for any application or purpose other than described in this manual. Consult your dealer before using special attachments or equipment not approved for use with the machine. Persons making unauthorized modifications are responsible for the consequences.

Use of the machine is subject to certain hazards which cannot be eliminated by mechanical means – only by exercising intelligence, care and common sense. Such hazards include, but are not limited to: hillside operation, overloading, load stability, poor maintenance and using the machine for purposes for which it was not designed or intended.

It is essential to have competent and careful operators, who are not physically or mentally impaired and are thoroughly trained in safe operation and proper load handling.

It is recommended that operators be capable of obtaining a valid motor vehicle operator’s license.

Some illustrations in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are secured in the proper operating positions BEFORE starting the engine to operate the machine.

Manitou Americas, Inc. reserves the right to make changes and improvements in the design and construction of any part or feature on the machine without incurring the obligation to install such changes on any machine previously delivered

The Manitou Americas dealer network stands ready to provide any assistance you may require, including genuine Manitou Americas service parts. All service parts should be obtained from your dealer. Give complete information about the part and include the model and serial number of the machine. Record the serial numbers in the following spaces, as a handy reference.

Purchased From: _____________________________

Date of Purchase: ____________________________

Model No.: _________________________________

Machine Serial No.: ___________________________

Cab Serial No.: ______________________________

Engine Type No.:_____________________________

Machine and Cab Serial Number

Locations

The machine serial number plate (1, Figure 1-1) is

located on the front of the swing frame, below the operator’s cab and above the horn. The cab/canopy serial number (2) is located inside on the frame pillar near the cab door/canopy access.

2

1

Figure 1-1 – Serial Number Locations


1-1 918254/BP0112

Engine Serial Number Location

The engine serial number (3, Figure 1-2) is on the

engine’s cylinder head cover.

3

Figure 1-2 – Engine Serial Number Location

Ownership Change

If the machine was purchased second-hand, or if the owner’s address has changed, please provide your dealer or the Manitou Americas Service Department with the owner’s name and current address, along with the machine model and serial numbers. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

918254/BP0112 1-2 Printed in U.S.A.

15

11

7

1

21

2

10

22

3

19

18

4

13

14

15

12

20

9

16

15

1 Cab/Canopy

2 Hand-Hold

3 Boom

4 Dipper Arm

5 Track

6 Track Tension Lubrication Point

7 Track Frame

8 Tie-Down Point

9 Dozer Blade

10 Work Light

11 Engine Cover

12 Operator’s Seat

13 Bucket Cylinder

14 Boom Cylinder

15 Bucket

16 Counterweight

17 Travel Drive Motor

18 Left Lock-Out Console

19 Dipper Arm Cylinder

20 Fuel Fill

21 Rotating Beacon

(option)

22 Cab Light (option)

5

6

8

Figure 1-3 – Component Identification


1-3

17

918254/BP0112

SPECIFICATIONS

Fluid Capacities/Lubricants

Component/

Application

Diesel Engine

Lubricant

Engine Oil

2

Specification

SAE 10W-40

HVLP46

PANOLIN HLP Synth 46

BP BIOHYD SE-46

KP2N-20 calcium sulfonate complex

KF2K-25 lithium

FINA Marson L2

2-D ASTM D975 – 94

1-D ASTM D975 – 94

Season/

Temperature

-4°F (-20°C)

+104°F (+40°C)

Year-round

Capacity

1

3.5 qts. (3.3 L)

Travel Drive

Hydraulic Oil Tank

Grease

Grease Zerks

Battery Terminals

Diesel Fuel Tank

Gearbox Oil

3

Hydraulic Oil

4

Biodegradable Oil

Roller and

Friction Bearings 6

Open Gear

(live ring gears)

5

Multipurpose Grease

Acid-proof Grease 8

Diesel Fuel

9

7

SAE 80W-90

KF2K-25 lithium

Year-round

Year-round

Year-round

Year-round

Depending on outside temperatures

Year-round

0.63 qts. (0.6

L) each

7 gal. (26.5 L)

(Complete system capacity:

14 gal. [53 L])

As Required

As Required

As Required

9.5 gal. (36 L)

Engine and Hydraulic

Oil Cooler

Coolant Soft water + antifreeze

ASTM D4985

Distilled water + antifreeze

ASTM D4985

Water + Antifreeze

1.2 gal. (4.5 L)

Windshield Washer Cleaning Agent Year-round 1.25 qts. (1.2

L)

1. Capacities shown are approximate; use only oil level check to determine correct oil level

2. BP Vanellus MG 15W40, BP Vanellus C-Extra 10W30, Chevron Delo 400 15W40 or equivalent

3. Hypoid gearbox oil based on basic mineral oil (API GL-4, GL-5)

4. Mobile DTE15M, Amoco Rykon 46, BP Energol HLP-HD 46 or equivalent

5. Hydraulic ester oils (HEES)

6. FINA Energrease 21M, Chevron RPM Heavy-Duty Grease No. 2, Mobilgrease Moly 52, or BP Energrease Moly

EP2

7. FINA Energrease 21M, Chevron RPM Heavy-Duty Grease No. 2, Mobilgrease Moly 52, or BP Energrease Moly

EP2

8. Standard acid-proof grease

9. Sulphur content below 0.05%; Cetane number over 45

918254/BP0112 1-4 Printed in U.S.A.

Engine

Make and Model

Type

Displacement

Bore and Stroke

Net Power

Max. Torque

Max. Engine Speed (with no load)

Idle Engine Speed

Fuel Injection System

Starting Aid

Max. Inclined Angle (engine still supplied with oil)

Exhaust Emission Compliance

Hydraulic System

Pump

Flow Rate (@2500 rpm)

Working Pressure

Swing System Pressure

Boom/Bucket/Dipper Arm Pressure

Dozer Blade Pressure

Hydraulic Oil Cooler

Filter

Dozer Blade

Width

Height

Maximum Lift Above Ground

Maximum Depth Below Ground

Yanmar 3TNV76-NNS

3-cylinder, water-cooled diesel

68 cid (1116 cc)

2.9 x 3.2 in. (76 x 82 mm)

20.4 hp (15.2 kW) @ 2500 rpm

48.75 lb.-ft. (66.1 Nm) @ 1800 rpm

2675 +/- 25 rpm

1300 +/- 25 rpm

Indirect Injection

Glow Plug (preheating time 4 seconds)

25° in all direction

97/68EC; U.S. EPA – Tier 4 compliant

Double variable-capacity + Two gear pumps

0.70 + 0.70 + 0.48 + 0.16 cu. in.

(11.5 + 11.5 + 8 + 2.7 cm

3

)

8.1 + 8.1 + 5.6 + 2.0 gpm

(30.8 + 30.8 + 21.4 + 7.2 L/min.)

3263 psi (225 bar)

2987 psi (206 bar)

3263 +/- 44 psi (225 +/-3 bar)

2988 +/- 44 psi (206 +/-3 bar)

Standard

Return

5' 2" (1570 mm)

11.4" (290 mm)

15" (380 mm)

16.5" (419 mm)


1-5 918254/BP0112

Undercarriage and Swing System

Travel Speed (Dual Speed)

Low Speed

High Speed

Ground Clearance

Swing (Slew) Speed

Gradability

Rubber Track Width

Top / Bottom Rollers (per side)

Sprocket Center

Average Ground Pressure

Maximum Drawbar Pull

Electrical System

Alternator

Starter

Battery

Socket

Fuses

9

1 2 3 4 5 6 7 8

10

1.3 mph (2.1 km/hr)

2.3 mph (3.8 km/hr)

10.9" (277 mm)

10.25 rpm

30° = 58%

11.8" (300 mm)

1 / 3

104" (2642 mm)

3.8 psi (26.2 kPa)

5732 lbf (25.5 kN)

12 V, 40 A

12 V, 1.1 kW

12 V, 44 Ah; 630 CCA

15 A max. - Accessory Socket

7

8

9

10

5

6

3

4

Fuse No.

1

2

Rated

Current Protected Circuit

15 A

10 A

Accessory socket, cigarette lighter

Rotating beacon, radio

5 A

15 A

10 A

15 A

Proportional controls (unused)

Windshield wiper, interior light

Cab roof lights

Valves, horn

15 A

10 A

40 A

50 A

Boom light, heating

Indicators, cutoff solenoid, relays

Start, preheat, cutoff solenoid

Ignition lock

918254/BP0112 1-6 Printed in U.S.A.

Relays

K9

V1

K8

K6

Relay No.

V1

K6

K7

K8

K9

Protected Circuit

Blocking diode

Preheating time lag relay

Starting relay

Cutoff solenoid time lag relay

Pickup contact cutoff solenoid relay

K7

Coolant Compound Table

Note: Do not mix coolant types. Machine filled at factory with Eurolub SF D12 (ethylene glycol basis)

Outside

Temperature

Up to °F (°C)

+39 (4)

+14 (-10)

-4 (-20)

-13 (-25)

-22 (-30)

-34.6 (-37)

Water

% by Volume

99

79

65

59

55

50

Coolant: Halvoline XLC (based on ethylene glycol)

Anti-corrosion Agent Antifreeze Agent in³/gal (cm³/L)

% by Volume

% by Volume

2.6 (10) 1

–

20

34

40

44

50

Sound Levels

Sound Power (L

WA

)

Sound Pressure (L

PA

)

97 dB(A)

68 dB(A)


1-7 918254/BP0112

General Specifications

9' 3.25" (2827 mm) 2' 6"

(759 mm)

7' 11"

(2413 mm)

7' 11"

(2413 mm)

11.75"

(299 mm)

1 ' 9"

(533 mm)

6' 10.5" (2242 mm)

75

º

2 ' 6"

(764 mm)

50°

5 ' 2" (1570 mm)

R = 2

(759 m

' 6" m)

1 ' 0"

(300 mm)

6' 7.5" (2021 mm)

3' 2"

(970 mm)

5' 2" (1575 mm) 13' 11" (4255 mm) 1' 0"

(300 mm)

1' 0"

(300 mm)

Weight (with cab)

Weight (with canopy)

Height

Width

Transport length

Dipper arm length

Max. digging depth

Max. vertical wall digging depth

Max. digging height

Max. dump height

Max. digging radius

Max. reach at ground level

Max. bucket dig force

Max. arm force

Min. tail swing radius

Max. tail end lateral projection over tracks

5886 lbs. (2670 kg)

5681 lbs. (2577 kg)

7' 11" (2413 mm)

5' 2" (1575 mm)

13' 11.5" (4254.5 mm)

4' 1" (1250 mm)

9' 0" (2743 mm)

7' 1" (2152 mm)

14' 1" (4299 mm)

9' 8.9" (2972 mm)

15' 4" (4681 mm)

15' 4" (4681 mm)

5057 lbf (22.5 kN)

4923 lbf (21.8 kN)

2' 6" (760 mm)

0' 0" (0 mm)

Max. boom distance to bucket center (right side) 1' 9" (533 mm)

Max. boom distance to bucket center (left side) 2' 6" (764 mm)

Max. swing (slew) angle (left side/right side) 75°/ 50°

918254/BP0112 1-8 Printed in U.S.A.

Fields of Applications/Approved Attachments

The machine is designed and intended to be used only with the approved attachments listed in the following table. To avoid possible personal injury, equipment damage or performance problems, use only attachments that are approved for use on and within the rated operating capacity of the machine. Contact your dealer or the Manitou Americas, Inc. service department for information about attachment approval. Manitou

Americas, Inc. cannot be responsible if the machine is used with non-approved attachments.

Attachment

Heavy-Duty Bucket

Ditching Bucket

Swivel Bucket

Size

12 in. (300 mm)

16 in. (400 mm)

20 in. (500 mm)

24 in. (600 mm)

30 in. (700 mm)

42 in. (1000 mm)

55 in. (1400 mm)

39 in. (1000 mm)

55 in. (1400 mm)

Capacity

1.8 ft

3

(0.051 M

3

)

2.4 ft 3 (0.068 M 3 )

3.1 ft 3 (0.088 M 3 )

3.8 ft 3 (0.108 M 3 )

4.8 ft 3 (0.136 M 3 )

4.1 ft

3

(0.116 M

3

)

5.9 ft

3

(0.167 M

3

)

3.9 ft

3

(0.110 M

3

)

5.6 ft

3

(0.159 M

3

)


1-9 918254/BP0112

Load Diagrams

Without Counterweight

+4.0m

+3.0m

+2.0m

A +1.0m

0.0m

-1.0m

-2.0m

+4.0m

+3.0m

+2.0m

+1.0m

0.0m

B

Maximum permissible loads

MAX

11' 6"

(3.5 m)

A

B

+9' 10"

(+3.0 m)

+6' 6"

(+2.0 m)

+3' 3"

(+1.0 m)

0' 0"

(0.0 m)

-3' 3"

(-1.0 m)

1009*

(458*)

985*

(447*)

1000*

(453*)

1026*

(465*)

1033*

(468*)

747

(339)

558

(253)

499

(226)

512

(232)

626

(284)

993*

(450*)

1161*

(526*)

1269*

(575*)

705

(320)

659

(299)

621

(282)

9' 10"

(3.0 m)

933*

(423*)

1044*

(473*)

1378*

(625*)

1588*

(720*)

1425*

(646*)

933*

(423*)

919*

(417*)

837

(380)

776

(352)

769

(349)

8' 2"

(2.5 m)

1788*

(811*)

2116*

(960*)

1879*

(852*)

1101

(499)

1009

(458)

1004

(455)

B

*

Maximum permissible load on extended dipper arm

A Overhang from the center of the turntable

Height of load fixing point

Lifting capacity hydraulically limited

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction.

If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator’s lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.

918254/BP0112 1-10 Printed in U.S.A.

With Counterweight

+4.0m

+3.0m

+2.0m

A

+1.0m

0.0m

-1.0m

-2.0m

+4.0m

+3.0m

+2.0m

+1.0m

0.0m

B

Maximum permissible loads

MAX

11' 6"

(3.5 m)

A

B

+9' 10"

(+3.0 m)

+6' 6"

(+2.0 m)

+3' 3"

(+1.0 m)

0' 0"

(0.0 m)

-3' 3"

(-1.0 m)

1121*

(508*)

1078*

(489*)

1088*

(494*)

1110*

(504*)

1098*

(498*)

941

(427)

706

(320)

640

(290)

670

(304)

391

(399)

1084*

(492*)

1222*

(554*)

1282*

(581*)

808

(366)

768

(348)

738

(335)

9' 10"

(3.0 m)

1085*

(492*)

1157*

(525*)

1463*

(663*)

1611*

(731*)

1335*

(605*)

1085*

(483*)

1041*

(472*)

965

(437)

914

(414)

919

(417)

8' 2"

(2.5 m)

1297*

(588*)

1923*

(872*)

2132*

(967*)

1774*

(805*)

1297

(588)

1253

(568)

1182

(536)

1191

(540)

B

*

Maximum permissible load on extended dipper arm

A Overhang from the center of the turntable

Height of load fixing point

Lifting capacity hydraulically limited

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction.

If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement weight.

Calculation basis: According to ISO 10567.

The excavator’s lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.


1-11 918254/BP0112

NOTES

918254/BP0112 1-12 Printed in U.S.A.

Pre-Delivery Checklist

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer.

Check off each item after the prescribed action is taken.

 CHECK THAT:

 Machine has not been damaged in shipment. Check for such things as dents and loose or missing parts. Correct or replace components as required.

 Battery is securely mounted and not cracked. Be sure cable connections are tight.

 Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

 Coolant/radiator hoses and fittings are not damaged, leaking or loosely connected. Coolant system is filled to the proper level and has proper antifreeze protection.

 Filters are not damaged, leaking or loosely secured.

 Machine is properly lubricated and no grease fittings are missing or damaged.

 Hydraulic system reservoir, engine crankcase and drive motors are filled to their proper levels.

 All adjustments are made to comply with settings provided in Chapter 4 – Maintenance of this manual.

 All guards, shields and decals are in place and secured.

 Model and serial numbers for the machine are recorded in the space provided on this page and on page 1-1

IMPORTANT

CHECKLISTS

Start the engine and test run the unit while checking that all controls operate properly.

 CHECK THAT:

 Drive controls and boom/arm/bucket/dozer blade/swing/ pivot controls operate properly and are not damaged or binding.

 Drive controls are properly adjusted for correct neutral position.

 The parking and travelling gear brake, along with the lock-out devices, are activated with the machine stationary (no pilot control pressure).

 All hydraulic functions are NOT operational with the left control console in the raised lock-out position.

 All instrument panel gauges, indicator lights, etc.

function properly and all installed lights, such as work lights, function properly.

I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

_______________________________________________

Dealership’s Name

_______________________________________________

Dealer Representative’s Name

_______________________________________________

Date Checklist Filled Out

_______________________________________________

Model & Serial Number

Delivery Checklist

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

 EXPLAIN:

 The Safety and Operation chapters of this manual, regarding the safe operation of the machine.

 The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of the machine. Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

 Give this Operator’s Manual and the AEM Compact

Excavator Safety Manual to the customer and instruct the customer to read and completely understand the contents before operating the machine.

 Complete the Owner’s Registration, including customer’s signature and return it to Manitou Americas,

Inc.

 Explain that a copy of the product warranty is included on the inside front cover of this Operator’s Manual.

_______________________________________________

Customer’s Signature

_______________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS


1-13 918254/BP0112

INTENTIONALLY BLANK

918254/BP0112 1-14 Printed in U.S.A.

Pre-Delivery Checklist

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer.

Check off each item after the prescribed action is taken.

 CHECK THAT:

 Machine has not been damaged in shipment. Check for such things as dents and loose or missing parts. Correct or replace components as required.

 Battery is securely mounted and not cracked. Be sure cable connections are tight.

 Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

 Coolant/radiator hoses and fittings are not damaged, leaking or loosely connected. Coolant system is filled to the proper level and has proper antifreeze protection.

 Filters are not damaged, leaking or loosely secured.

 Machine is properly lubricated and no grease fittings are missing or damaged.

 Hydraulic system reservoir, engine crankcase and drive motors are filled to their proper levels.

 All adjustments are made to comply with settings provided in Chapter 4 – Maintenance of this manual.

 All guards, shields and decals are in place and secured.

 Model and serial numbers for the machine are recorded in the space provided on this page and on page 1-1

IMPORTANT

CHECKLISTS

I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

Start the engine and test run the unit while checking that all controls operate properly.

 CHECK THAT:

 Drive controls and boom/arm/bucket/dozer blade/swing/ pivot controls operate properly and are not damaged or binding.

 Drive controls are properly adjusted for correct neutral position.

 The parking and travelling gear brake, along with the lock-out devices, are activated with the machine stationary (no pilot control pressure).

 All hydraulic functions are NOT operational with the left control console in the raised lock-out position.

 All instrument panel gauges, indicator lights, etc.

function properly and all installed lights, such as work lights, function properly.

________________________________________________

Dealership’s Name

________________________________________________

Dealer Representative’s Name

________________________________________________

Date Checklist Filled Out

________________________________________________

Model & Serial Number

Delivery Checklist

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

 EXPLAIN:

 The Safety and Operation chapters of this manual, regarding the safe operation of the machine.

 The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of the machine. Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

 Give this Operator’s Manual and the AEM Compact

Excavator Safety Manual to the customer and instruct the customer to read and completely understand the contents before operating the machine.

 Complete the Owner’s Registration, including customer’s signature and return it to Manitou Americas,

Inc.

 Explain that a copy of the product warranty is included on the inside front cover of this Operator’s Manual.

________________________________________________

Customer’s Signature

________________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS


1-15 918254/BP0112

INTENTIONALLY BLANK

918254/BP0112 1-16 Printed in U.S.A.

CHAPTER 2 – SAFETY

GENERAL SAFETY

INFORMATION

Manitou Americas, Inc, in cooperation with the Society of Automotive Engineers (SAE), has adopted this safety alert symbol: This warning symbol, used with a “signal word,” indicates situations or conditions that can cause injury or death if precautions are not followed. The signal words used with the safety alert symbol are:

“CAUTION,” “WARNING,” and “DANGER,” which indicate the level of risk and severity of hazards.

All three levels indicate that safety is involved.

Observe the precautions whenever you see the safety alert symbol, no matter which signal word is used.

The following signal words are used throughout this manual and on decals on the machine to warn of potential hazards:

DANGER

“DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING

“WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION

“CAUTION” indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. May also alert against unsafe practices.

IMPORTANT

“IMPORTANT” is used to draw attention to a procedure that must to be followed to prevent machine damage.

GENERAL SAFETY RULES

Before operating the machine, first read and study the safety information in this manual. Be sure that anyone who operates or works on the machine is familiar with the safety precautions. This includes providing translations of the warnings and instructions for operators who are not fluent in reading English.

It is essential that operators be thoroughly trained in the safe operation of the machine and handling loads.

Operators must not be physically or mentally impaired.

Do not allow minors or unqualified personnel to operate the machine, or to be near the machine unless they are properly supervised. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the excavator.

Read the operator’s manual provided with each attachment before using it.

Use of the machine is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense. Such hazards include: hillside operation, overloading, load instability, poor maintenance, and using the machine for a purpose for which it was not intended or designed.

Manitou Americas, Inc. always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards.

Operators must be alert, however, because some areas cannot be guarded or shielded without preventing or interfering with proper operation.


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Different applications may require optional safety equipment. Users must evaluate the work site hazards and equip the machine and the operator as necessary.

The information in this manual does not replace any applicable safety rules and laws. Before operating the machine, learn the rules and laws for the local area.

Make sure the machine is equipped as required according to these rules/laws.

Remember that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.

Some photographs in this manual may show doors, guards and shields open or removed for the purposes of illustration only. Be sure all doors, guards, shields and panels are in the proper operating positions before starting the engine to operate the machine.

Do not modify the Falling Object Protective Structure

(“FOPS”) unless instructed to do so in approved installation instructions. Modifications, such as welding, drilling or cutting, can weaken the structure and reduce the protection it provides. A damaged protective structure cannot be repaired – it must be replaced.

For safety reasons, use only genuine replacement service parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compromised.

The machine is designed and intended to be used only with approved attachments. To avoid possible personal injury, equipment damage or performance problems, use only attachments that are approved for use on and within the rated operating capacity of the machine.

Contact your dealer or the Manitou Americas, Inc. service department for information about attachment approval and compatibility with specific machine models. Manitou Americas, Inc. cannot be responsible if the machine is used with non-approved attachments.

Do not use the machine for any application or purpose other than described in this manual.

Unauthorized Modifications

Any machine modification made without authorization from Manitou Americas, Inc. could create a safety hazard, for which the machine owner would be responsible.

For safety reasons, use only genuine replacement service parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compromised.

Attachment Precautions

Optional kits are available through your dealer. Contact your dealer for more information about optional kits.

MANDATORY SAFETY SHUTDOWN

PROCEDURE

Before leaving the machine:

1. Bring the machine to a complete stop on a level surface. Avoid parking on an incline or a hillside, but if this is not possible, park across the slope; place chocks under the tracks to prevent the machine from moving.

2. Lower the working equipment to the ground and support it securely.

3. Run the engine at idle speed for a few minutes to allow systems to cool after operation at full speed.

4. Turn the ignition key fully counter-clockwise to shut off the engine. Wait for all movement to stop.

5. Turn the ignition key to the first position. Move the joysticks in all directions to verify the hydraulic system is de-pressurized. Shut off the engine.

6. Lock out controls by raising left control console.

7. Remove the ignition key and take it with you. Exit the machine using the hand-holds.

SAFETY DURING OPERATION

Before Operation

Contact the proper local authorities for utility line locations BEFORE starting to dig. In North America, contact the North American One-Call Referral System at

8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and

Canada.

Remove all trash and debris from the machine every day, especially in the engine compartment, to minimize the risk of fire.

The operator’s area, steps and hand holds must be kept free of oil, dirt, ice and unsecured objects.

918254/BP0112 2-2 Printed in U.S.A.

Never use ether starting aids. Glow plugs are used for cold weather starting. Glow plugs can cause ether or other starting fluid to detonate, causing injury or damage.

Walk around the machine and inspect it before using it.

Look for damage, loose or missing parts, leaks, etc.

Repair as required before using the machine.

Check the tracks for damage at regular intervals.

Repair or replace as necessary.

Warn all nearby personnel before starting the machine.

Below-ground hazards also include water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.

Before working near power lines (either above-ground or buried cable-type), always contact the power utility and establish a safety plan with them.

Be aware of height obstacles. Any object in the vicinity of the boom could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.

Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur if the boom or bucket is closer than 10 ft. (3 m) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

If a lighting system is installed, check its operation before working in darkness.

Use warning tag/control lockout procedures during service. Alert others that service or maintenance is being performed by tagging the operator’s controls — and other machine areas if required — with a warning notice. NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cab.

Replace damaged safety decals and a lost or damaged operator’s manual. Always store this operator’s manual in the storage compartment provided for it inside the cab.

Work crew members should observe and monitor all terrain and soil conditions at the work site, along with traffic, weather-related hazards and any above- or below-ground obstacles and hazards.

If the machine is equipped with a cab, keep the windshield, mirrors and windows clean. If equipped, adjust the rearview mirrors to provide the best view to the rear of the machine. Poor visibility can cause accidents.

Adjust the seat to allow complete and comfortable access to the controls. Never adjust the seat during machine operation.

Stop the engine and lock out the controls by raising left control console before mounting attachments. Check that attachments are securely fastened to the excavator before using them.

Before working on or with the machine, remove jewelry, tie back long hair, and do not wear loose fitting garments, such as, scarves, ties, unzipped jackets, etc., which could become caught in the moving parts of the machine and cause injury.

Do not use the machine when maintenance is scheduled to be performed. Postponing maintenance can result in a serious reduction of the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

During Operation

ALWAYS fasten the seat belt securely and properly.

Never operate the machine without the seat belt fastened around the operator.

Operate ONLY while seated in the operator’s seat.

Never reach in through a window to work a control. Do not try to operate the excavator unless you’re in the operator’s position, seated at the controls. Stay alert and focused on your work at all times.

Always keep hands and feet inside the operator’s compartment while operating the machine.

Control the machine cautiously and gradually until fully familiar with all the controls and handling. Avoid high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines.

The bucket or boom does not have to make physical contact with power lines for current to be transmitted.

Use care on loose ground. Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side-load conditions and possible tip over and injury. Traveling with a suspended load or an unbalanced load can also be hazardous.


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Stay away from ditches and weak support surfaces. Be sure the surrounding ground has adequate strength to support the weight of the machine and the load.

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground.

Stay away from ditches, overhangs and other weak support surfaces. Halt work and install support mats or blocking if work is required in an area of poor track support.

Overhangs are hazardous. Digging under an overhang is dangerous. Know the height and reach limits of the excavator and plan ahead while working. Avoid creating dangerous situations caused by moving around the work site while making excavations. Move to another digging area before large overhangs are formed. Working around deep pits or along high-walls or trenches may require support blocks, especially after heavy rainfalls or during spring thaws. Park the excavator away from overhangs.

Exposed hydraulic hoses could react with explosive force if struck by falling or overhead items. NEVER allow hoses to be hit, bent or interfered with during operation. Extra guards may be required. Replace any damaged hoses.

To avoid tipping, travel with the bucket or attachment as low as possible: 8-12 inches (200-300 mm) from the ground. In an emergency, lower the attachment immediately to the ground to aid stopping the machine.

Sloping terrain requires caution. Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If it is not possible to level the area or avoid working on a slope, reduce the size and cycling rate of the load.

On sloping surfaces, use caution when positioning the excavator prior to starting a work cycle. Stay alert for instability situations. For example, always avoid working the bucket over the downhill crawler tracks when parked perpendicular to the slope. Slow all downhill swing movements and avoid full extensions of the bucket in a downhill direction. Lifting the bucket too high, too close to the machine, while the excavator is turned uphill can also be hazardous.

If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which can only protect the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

Stay alert for people moving through the work area.

When loading a truck you should always know where the driver is.

Avoid loading over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside.

Slow down the work cycle and use slower travel speeds in congested or populated areas. Use commonly understood signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

Use a signal person if you can’t see the entire work area clearly.

Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

All personnel at the work site should be aware of assigned individual responsibilities. Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above-or below-ground obstacles or hazards should be observed and monitored by all work crew members.

Be aware that attachments affect the handling and balance of the machine. Adjust the operation of the machine as necessary when using attachments.

Before coupling or uncoupling the hydraulic lines for the attachment, stop the engine and release the pressure in the hydraulic system by moving the joysticks in all directions a couple of times.

DO NOT raise or lower a loaded bucket suddenly.

Abrupt movements under load can cause serious instability.

Make sure that no one comes inside the swing radius of the machine. Anyone standing near the track frames, swing frame or the attachment is at risk of being caught between moving parts of the machine.

918254/BP0112 2-4 Printed in U.S.A.

Do not use the machine to lift or transport people.

Never carry riders. Do not allow others to ride on the machine or attachments, because they could fall or cause an accident.

Unless necessary for servicing the engine, the engine hood must not be opened while the engine is running.

Engine exhaust gases can cause unconsciousness and fatalities. Ensure adequate ventilation before starting the engine in an enclosed area.

Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.

Do not overload the machine. See the Load Diagrams

starting on page 1-10, for load limits.

If the machine becomes damaged or malfunctions, stop the machine immediately and lock and tag it. Repair the damage or malfunction before using the machine.

Never jump off the machine. Always leave the machine using the steps and hand-holds. Never get on or off a moving machine.

After the machine has been parked properly, shut down the engine and cycle all controls to release any remaining hydraulic system pressure. Be sure all switches and operating controls are in the OFF position and the lefthand console is raised, locking out the hydraulic functions.

Exposure to Crystalline Silica

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub.

No. 2002-129) by the U.S. National Institute for Occupational Safety and Health (NIOSH) indicates that a significant risk (at least 1 in 100) of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr workday during a 40-hr workweek. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection, and regular medical examinations for exposed workers.

Parking the Machine

When shutting down the machine for the day, plan ahead so that the excavator will be on a firm, level surface away from traffic and away from high-walls, cliff edges and any area of potential water accumulation or runoff. If parking on an incline is unavoidable, block the crawler tracks to prevent movement. Lower the bucket and dozer blade to the ground. There should be no possibility of unintended or accidental machine movement.

After the machine has been parked properly, shut down

the machine according to the “Mandatory Safety Shutdown Procedure” on page 2-2.

Travel Controls May Produce Reversed

Travel Operations

Before starting the machine, always check to see which end of the track frame is under the operator’s cab. In the normal travel configuration, travel motors are at the rear of the machine, under the engine, and with the dozer blade to the front.

If the operator rotates the swing frame 180º, travel motors will be underneath the operator’s cab, and operating travel will be reversed.

Use caution in reverse travel and swing frame rotation.

Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

Additional Travel Precautions

Swing frame control levers should not be operated while traveling.

Do not change selected travel mode (FAST/SLOW) while traveling.

Fold in work equipment so that the outer end of the boom is as close to the machine as possible, and is as low as possible (8”-12” [200 mm-300 mm]) to the ground.

Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that would cause a tilt greater than 10º.


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Snow, Ice and Cold Temperature

Operation Precautions

In cold weather, avoid sudden travel movements and stay away from even very slight slopes. The machine can slide sideways on icy slopes.

Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

FIRE HAZARDS

The machine has several components that operate at high temperature under normal operation conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

The machine must be cleaned on a regular basis to avoid the buildup of flammable debris such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, poses a fire hazard.

Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches turned off. The engine must be turned off before refueling or service checks are performed.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the filler neck of the fuel tank, to provide a ground. Make sure that the static line is connected from the excavator to the service truck before fueling begins.

Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

Do not smoke while filling the fuel tank, while working on the fuel or hydraulic systems, or while working around the battery.

Take care to avoid spilling combustible fluids, such as oil or fuel, on a hot engine.

Fire Extinguisher Recommendation

It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in the cab. on the cab/canopy frame behind the operator’s seat. Check the fire extinguisher periodically and be sure that work crew members are trained in its use.

IMPORTANT: Installation of a fire extinguisher according to DIN-EN 3 must be performed by an authorized dealer.

NOTE: A fire extinguisher is neither included as standard equipment nor available as an option from Manitou Americas, Inc.

IMPORTANT: Inspect the fire extinguisher at regular intervals as recommended by the fire extinguisher equipment manufacturer(s).

ADDITIONAL SAFETY

EQUIPMENT

Severe operation may require use of additional safety equipment

Work in mines, tunnels, deep pits or on loose or wet surfaces could produce the hazard of falling rock, roll over or falling objects.

Any operator protective system installed on the machine must comply with applicable safety standards and carry appropriate labeling and rating information.

For example, the cab of an excavator used in applications with falling object hazards must meet Society of

Automotive Engineers Standard SAE J1356, “Performance Criteria for Falling Object Guards for Excavators.”

Never attempt to alter or modify the protective structure, by drilling holes, welding or re-locating fasteners.

Any serious impact or damage to the system requires a complete integrity re-evaluation, and the replacement of the system may be necessary.

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Install additional safety equipment if conditions require.

When working with a hydraulic breaker, a front guard over the windshield may be required.

Laminated glass or polycarbonate protection for the front, side or rear windows may also be recommended depending upon particular work conditions.

Contact your dealer for available safety guards and/or recommendations if there is any risk of being hit by objects that could strike the operator’s cab.

Eye Protection and Safety Clothing

Wear full eye protection, ear and head protection, safety shoes, gloves and any other protective clothing or equipment as needed while operating the machine.

Safety Equipment Maintenance

Machinery guards and body panel covers must be in place at all times. Keep clear of rotating parts, such as cooling fan and alternator belts, which could catch hair, jewelry or loose clothing.

All safety equipment must be maintained so it is always in good condition.

Safety-critical parts must be periodically replaced.

Replace the following potentially fire-sensitive components as soon as they begin to show signs of deterioration:

• Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.

• Hydraulic system hoses, especially the pump outlet lines.

Keep mounting brackets and hose and cable routing straps tight. Hose routing should have gradual bends.

Breathing Masks and Ear Protection

Remember that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.

MAINTENANCE SAFETY

Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine.

Use solid support blocking. Never rely on jacks or other inadequate supports when maintenance work is being done. Block tracks front and back to prevent any movement.

Keep fuel and other fluid reservoir caps tight. Do not start the engine until caps have been secured.

Never attempt to bypass the ignition switch to start the engine. Use only the proper jump-starting procedure

according to See “Using a Booster Battery (Jump-

Starting)” on page 4-20.

Never use hands to search for hydraulic fluid leaks.

Instead, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor or gangrene may result.

Always wear safety glasses with side shields when striking metal against metal. In addition, it is recommended that a softer (chip-resistant) material be used to cushion the blow, otherwise, serious injury to the eyes or other parts of the body could result.

Use care when seating retainer pins — retainer pins can fly out or splinter when struck and could cause injury.

Do not smoke or have any spark- or flame-producing equipment or materials in the area while filling the fuel tank or working on the fuel or hydraulic systems.

Do not attempt to loosen or disconnect any hydraulic lines, hoses, fittings, covers or caps without first relieving hydraulic circuit pressure. Relieve hydraulic pres-

sure by performing the “Mandatory Safety Shutdown

Procedure” on page 2-2. Be careful not to touch any

hydraulic components that have been in recent operation, because they can be hot and cause burns.

Refer to the parts manual for information about assembly of components. Always use the correct parts and the proper torques — incorrect fastener connections can dangerously weaken assemblies.


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Do not run the engine if repairs are being performed alone. There should always be at least two people working together if the engine must be run during service. Both persons must maintain visual contact with each other. Keep a safe distance away from all rotating and moving parts.

Always use the proper tools while working on the machine. Inappropriate tools could break or slip, causing injury, or they may not adequately perform intended functions.

Unless necessary for servicing the machine, do not open the engine cover while the engine is running.

Keep mounting brackets and hose and cable routing straps tight. Hose routing should have gradual bends.

After cleaning the machine, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage. Tighten any loose connections and repair or replace parts as necessary.

Use warning tag/control lockout procedures during service.

Alert others that service or maintenance is being performed and tag operator’s cab controls — and other machine areas if required — with a warning notice.

Don’t run the engine if repairs or work is being performed alone.

Do not run the engine if repairs or work is performed alone. There should always be at least two people working together if the engine must be run during service.

Always use adequate equipment supports and blocking.

Lower bucket to the ground before leaving the operator’s seat. Don’t work under any equipment supported solely by a lift jack.

Track tension adjustments require caution.

NEVER fully remove the track tension grease fitting.

To release pressure from the crawler frame track tension assembly, you should loosen the grease fitting slightly, no more than two turns.

Keep your face and body away from the fitting. Refer

to “Checking and Adjusting Track Tension” on page 4-

23.

Don’t work on hot engines, cooling or hydraulic systems.

Wait for the engine to cool after normal operation. Park the excavator on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

Temperatures below 120°F (49°C) will reduce the chances of scalding exposed skin while allowing the fluid to drain quickly and completely. However, do not let the fluid to fully cool, because drain time will be substantially increased.

Cool-down is required prior to radiator or hydraulic reservoir checks.

Stop the engine and allow it to cool before performing service on the engine radiator or hydraulic reservoir.

Both assemblies have pressure vents at the filler cap for venting pressure. LOOSEN CAPS SLOWLY. Vent the pressure before removing the filler caps.

Release hydraulic system pressure by cycling controls and releasing hydraulic reservoir pressure before removing hydraulic reservoir access cover.

The hydraulic reservoir is pressurized. Vent the system pressure by rotating the filler cap. LOOSEN CAP

SLOWLY prior to removal.

Make sure to release any hydraulic pressure stored in the lines by cycling the operator’s controls in each direction after the engine has been shut down.

Pressurized hydraulic oil leaks can be hazardous.

Fluid leaks from hydraulic hoses and pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands.

Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

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Use correct replacement fasteners tightened to proper torque.

Refer to the Parts Manual for information on torques and assembly of components.

IMPORTANT

Always use the correct, original-equipment parts. Incorrect fastener connections can dangerously weaken assemblies.

Dispose of all petroleum-based oils and fluids properly.

Dispose of all petroleum-based oils and fluids properly.

Used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities.

Never drain any petroleum-based product on the ground or dispose of used oil in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other requirements.

When handling oil, grease and other chemical substances, follow the product-related safety requirements

(Material Safety Data Sheet (MSDS) carefully to prevent burning or scalding yourself or other persons.

Safety Decals

Safety decals must be replaced if they become unreadable. Safety decal mounting locations are shown start-

ing on page 2-11.

Hydraulic Cylinder Seal Periodic

Replacement

Check cylinder drift rate at regular intervals. Maximum allowable rates are included at the end of the Hydraulic section in the Excavator Service Manual. Overhaul seal kits are available through Manitou Americas dealer.

High Pressure Hydraulic Lines Store

Energy

Exposed hydraulic hoses on the arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation.


2-9

Operator’s Cab and Swing Frame Deck

Maintenance

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

Battery Electrolyte and Explosive Gas

Hazard

Flush eyes with water for 10-15 minutes if battery acid is splashed in the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control center listing in the telephone directory.

Sparks can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

Battery Disconnection Precaution

Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

Jump-starting or Charging the Battery

Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.

When jump-starting from another machine or vehicle, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

Batteries contain acid and produce explosive gases.

Keep sparks, flames and lit cigarettes away from batteries at all times.

Connect positive cable first when installing jumper cables. The final cable connection, at the metal frame of the machine being charged or jump-started, should be as far away from the batteries as possible.

Disconnect the negative cable first when removing the jumper cables. For specific jump-starting instructions

refer to “Using a Booster Battery (Jump-Starting)” on page 4-20 in the Maintenance chapter of this manual.

918254/BP0112

LIFTING THE MACHINE WITH A

CRANE

Only lift the machine according to the following guidelines:

• The crane and rigging equipment must have suffi-

cient capacity. See “Lifting the Machine” on page

3-28.

•

Lift the machine according to “Lifting the

Machine” on page 3-28.

• Secure the machine against unintentional movement. Use taglines as needed.

• Do not lift the machine with persons on or in the machine.

• Any person guiding the crane operator must be within sight or sound of the crane operator.

• Lift the machine only with the standard bucket installed, the bucket empty and in the transport position.

• Persons must stay clear of and not under the machine when it is lifted.

• Fasten the rigging equipment so the machine is horizontal when it is lifted.

• Do not lift the machine by the eye hooks on the cab. Attach the rigging equipment only at the lift points identified by this symbol:

SAFETY AND INFORMATION

DECALS

The machine has decals shown on the following pages that provide safety information and precautions. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your dealer.

Refer to the Parts Manual for decal part numbers and ordering information.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying the decal. Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface. Refer to the following pages for proper decal locations.

If replacing a part that has a decal on it, ensure that the replacement part has the same decal.

TRANSPORTING

Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width and length of a load. The hauling vehicle, trailer and load must all be in compliance with local regulations. Refer to the Transporting section of this manual.

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ISO-Style Safety Decal Locations (Later Machines)

7

1

11

1

9

1

13

8

12

10

3

12

14

2

3

5

4

3

6

WARNING! Danger Zone Decal

AVOID INJURY OR DEATH!

Located on both sides of the boom.

Keep bystanders away from the machine when it is in use.

2

WARNING! Hydraulic Reservoir Under Pressure


Located on the fuse box cover under the hydraulic system vent valve inside the engine compartment.

Relieve hydraulic pressure before servicing machine. Removed hydraulic reservoir cap slowly.

Refer to the maintenance section in the operator’s manual before servicing the machine.

WARNING! Stay Clear Decal


Located next to the track tension grease fitting on both sides of the machine.

WARNING! Grease is under high pressure. Keep your face and body away from the fitting.

Do not loosen the fitting more than two turns. Do not loosen parts other than the fitting.

Refer to the operator’s manual for track adjustment procedure.

4 WARNING! Hot Surfaces Decal

AVOID SERIOUS INJURY!

Located inside the engine compartment.

Stop the engine and wait for all parts to cool before opening the engine compartment. Hot surfaces can cause severe burns.

Read the operator’s manual before performing any maintenance on the machine.


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ISO-Style Safety Decal Locations (Later Machines) (Continued)

5 8

WARNING! Rotating and Hot

Components Decal


Located on the fan shroud inside the engine compartment.

Stop the engine and wait for all parts to cool before opening the engine compartment. Rotating parts can cause severe injury. Hot surfaces and liquids can cause severe burns.


9

WARNING! Read Operator’s

Manual


Located on the door pillar inside the cab.

Read the operator’s manual before operating or performing any maintenance on the machine.

6

WARNING! Rotating Components! Danger of

Entanglement! Decal


Located below the engine cover latch.

Stop the engine before opening the engine compartment. Rotating parts can cause severe injury.

WARNING! Decal



No riders! Never use work tool as work platform.

Operate only from operator’s seat.

ALWAYS wear seatbelt.

WARNING: Avoid Overturn

Side stability is reduced when: 1) turning; 2) operating on rough terrain or side slopes; and 3) carrying load raised.

Carry load low. Do not exceed

Rated Operating Capacity.

Avoid steep slopes and high speed turns.

Travel up and down slopes with heavy end uphill.

Read the operator’s manual before operating the machine.

7

10

WARNING! Crushing Hazard Decal


Located on the inside of the front window on cabequipped machines.

Only open and close the front window using the handles.

Always lock the front window using both locks.

WARNING! Hot Components Decal


Located on the hydraulic valve compartment cover in the location of the hydraulic oil fill (hydraulic oil fill is located inside the hydraulic valve compartment).

Stop the engine and wait for all parts to stop and cool before. Hot surfaces and liquids can cause severe burns.


918254/BP0112 2-12 Printed in U.S.A.

ISO-Style Safety Decal Locations (Later Machines) (Continued)

11 13



Located on the back of the swing frame.

Keep bystanders away from the machine when it is in use.

12

WARNING! Mandatory Safety

Shutdown Decal



Before leaving the machine, or performing any service on the

machine, perform the “Mandatory

Safety Shutdown Procedure” on page 2-2.

1. Lower the working equipment to the ground and support it securely.

2. Run the engine at idle speed for a few minutes to allow systems to cool after operation at full speed.

3. Turn the key fully counterclockwise to shut off the engine.

4. Lock out controls by raising left control console.

5. Remove the ignition key and take it with you.



Located on both sides of the boom swivel bracket.

Swiveling boom can cause crushing. Keep bystanders away from the machine when it is in use.

14

WARNING! Hot Components Decal


Located near the hydraulic system vent valve inside the engine compartment.

Stop the engine and wait for all parts to stop and cool before. Hot surfaces and liquids can cause severe burns.



2-13 918254/BP0112

ISO-Style Information Decal Locations (Later Machines)

6 7

2

7 3

2

2

3

4

1

8

2

5

4

5

1

2

5

Track Front Decal

Located near the front of the track frame on both sides of the machine

Indicates the front of the track frame.

1

Lift Point Decal

Located on both sides of the boom on the dipper arm cylinder bracket and on both ends of the dozer blade.

Apply lift hooks only in these locations.

Hydraulic Fluid Decal

Located on the back of the cab/ canopy in the location of the hydraulic oil fill (hydraulic oil fill is located inside the hydraulic valve compartment).

USE HYDRAULIC FLUID ONLY!

Diesel Fuel Decal

USE DIESEL FUEL ONLY!

Located near the fuel filler.

5

6

5

Tie-Down Point Decal

Located on both ends of the dozer blade and near the rear end of the track frame on both sides of the machine.

Only use tie-down points to secure the machine during transport.

Operator Controls Decal

Located on the ceiling inside the cab/canopy.

Provides quick-reference for the SAE operator’s control option inside the cab.

Read the operator’s manual before operating the machine. Refer to the operator’s manual for details about the operator’s controls.

918254/BP0112 2-14 Printed in U.S.A.

ISO-Style Information Decal Locations (Later Machines) (Continued)

7 8

KF K -

KF K -

KP 0

KF K -

KF K -

KF K -

KF K -

Maintenance Decal

Located on the back window of the cab and the side of the canopy.

Provides maintenance intervals quick-reference.

Read the operator’s manual before maintenance on

the machine. Refer to “Maintenance Schedule” on page 4-5.

Lift Capacity Decal

Located on the back window of the cab.

Provides maintenance intervals quick-reference.

Read the operator’s manual before maintenance on the machine. Refer to “Maintenance Schedule” on page 4-5.


2-15 918254/BP0112

ANSI-Style Safety/Information Decal Locations (Early Machines)

Lift Capacity Label

(cab/canopy ceiling)

Swing Radius Warning Decal

(boom - both sides)

Read Operator’s Manual Decal

(right inside cab/canopy wall)

918254/BP0112 2-16 Printed in U.S.A.

ANSI-Style Safety/Information Decal Locations (Early Machines) (Continued)

Hydraulic Oil & Pressure Warning Decals

(cab frame above rear cover)

Track Tensioner Warning Decal

(track frame - both sides)

Avoiding Injury Decal


Rotating Fan, Entanglement, and Hot Surface

Warning Decals (inside engine compartment)

Shutdown Procedures Decal


Hot Surface Warning Decal

(inside engine compartment )


2-17 918254/BP0112

ANSI-Style Safety/Information Decal Locations (Early Machines) (Continued)

Front Window Warning Decal

(near cab roof—cab model only)

Avoid Injury Warning Decal

(inside engine compartment)

Rotating Fan Warning Decal

(engine cover hand recess)

918254/BP0112 2-18 Printed in U.S.A.

CHAPTER 3 – OPERATION

OPERATING CONTROLS

WARNING

• Read and understand this entire manual. Follow warnings and instructions for operation and maintenance.

Failure to follow instructions can result in injury or death.

• Read and understand all safety decals before operating the machine. DO NOT operate the machine unless all factoryinstalled guards and shields are in place.

• Be sure you are familiar with all safety devices and controls before operating the machine.

• Know how to stop the machine before starting.

• Use only with approved accessories or referral attachments. The manufacturer cannot be responsible for safety if the unit is used with non-approved attachments.

• Check for correct function after adjustments or maintenance.

Guards and Shields

Whenever possible, guards and shields are used to protect potentially hazardous areas on the machine. In many places, decals are also provided to warn of potential hazards and/or to display special operating

procedures; see “Safety and Information Decals” on page 2-10.

The left operator’s console (A, Figure 3-1) should be

raised to enter and exit the cab. In the raised position, the console locks out all hydraulic functions of the machine.

A

Machine Orientation

All references to “right” and “left” are determined from the operator's position facing forward.

Figure 3-1 – Operator’s Left Console in Lockout Position

The height of the left operator’s console can be

adjusted using stop bolt (B, Figure 3-2).


3-1

B

Figure 3-2 – Left Console Height Adjustment

918254/BP0112

7

6

5

4

3

2

1

8 9 10 11 12 13

26

Figure 3-3 – Equipment and Controls

918254/BP0112 3-2

28

14

22

23

24

25

27 26


18

19

20

21

15

16

17

Item Description

1

For more info, see page

SAE/ISO changeover valve (behind operator’s seat) ............................................................................................................................... 3-8

26

27

28

29

30

31

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

4

5

2

3

Seat Belt (latch)

Throttle Lever ........................................................................................................................................................................................... 3-7

Armrest (left) .......................................................................................................................................................................................... 3-11

Control Lever Base (left)

Seat Horizontal Adjustment Lever .......................................................................................................................................................... 3-11

Joystick (left) ............................................................................................................................................................................................ 3-9

Hammer Pedal for Boom Swivelling ....................................................................................................................................................... 3-28

Drive Lever (left) ....................................................................................................................................................................................... 3-8

Drive Pedal (left) ...................................................................................................................................................................................... 3-8

Drive Pedal (right) .................................................................................................................................................................................... 3-8

Drive Lever (right) .................................................................................................................................................................................... 3-8

Air Temperature Control Knob ............................................................................................................................................................... 3-13

Auxiliary Hydraulics Pedal....................................................................................................................................................................... 3-28

Instrument Cluster .................................................................................................................................................................................... 3-4

Engine Preheating/Ignition Switch ........................................................................................................................................................... 3-7

Joystick (right) ................................................................................................................................................................................. 3-9, 3-28

Control Lever Base (right)

Dozer Blade Lever ................................................................................................................................................................................... 3-7

Switch Panel ............................................................................................................................................................................................ 3-4

Seat Backrest Adjustment ...................................................................................................................................................................... 3-11

Switch Panel ............................................................................................................................................................................................. 3-4

Radio (option)

Cigarette Lighter

Seat Suspension Adjustment ................................................................................................................................................................. 3-11

Cab Hold-down Hardware

Storage Net

Cup Holders

Windshield Wiper Motor (cab model only; inside front windshield)

Armrest (right)

Cab Light and Radio Speakers (cab model only; above rear window)

29 30 31


3-3 918254/BP0112

Console Switches Panel

Switches/indicators on control console

34

33

35

36

37

32

38

39 Instrument

Cluster

40

41

42

43

44

Cab Switches Panel

Switches/indicators on cab wall

45 46 47 48 49

Figure 3-4 – Instrument Panel, Switches and Indicators

50 51 52 53

918254/BP0112 3-4 Printed in U.S.A.

47

48

49

50

51

42

43

44

45

46

Item Description

32 Fuel level gauge – The fuel gauge displays the amount of fuel in the tank.

33

34

35

36

37

38

39

40

41

52

53

Unassigned

Unassigned

Cold-start indicator (yellow) – Cold start indicator light comes on when the ignition key is in the glow plug activation position; see “Ignition

Key Switch” on page 3-7. Indicator will go out when the engine pre-heater has heated the engine sufficiently to start.

Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter requires servicing or while the hydraulic oil is cold.

Unassigned

Battery charge indicator (red) – Battery charge indicator light comes on when the ignition is turned on and goes off when the engine starts.

If the indicator light comes on while the engine is running, the battery is not charging, indicating a faulty charging circuit in the alternator or problems with the V-belt. NOTE: a faulty V-belt affects cooling pump operation, which can lead to overheating and more serious engine problems. Shut off the engine IMMEDIATELY and determine/fix the cause if this indicator comes on when the engine is running.

Unassigned

Engine oil pressure indicator (red) – Engine oil pressure light comes on when the ignition is turned on and goes off as soon as the engine is running. During normal operation, this indicator should remain off. The indicator will light if the engine oil pressure drops too low. If this occurs, shut off the engine IMMEDIATELY and determine the cause of the pressure drop.

Engine coolant temperature indicator (red) – Coolant temperature indicator light comes on if coolant temperature rises above specification. Shut off the engine and determine/fix the cause if this indicator comes on when the engine is running

Unassigned

Unassigned

Hourmeter – Indicates the total operating hours of the machine. Use the hourmeter to track maintenance in the maintenance log.

Auto2Speed switch (transport speed) – Pressing the switch will enable high travel speed.

Ventilation fan (two-speed) – Press the two-position switch to turn on the ventilation fan. Pressing switch to the first position is the low fan speed position, and the second position is the high fan speed position. If the heater control (cab model only) is in the heating position, this switch functions as the cab heater ON/OFF switch.

Unassigned

Unassigned

Unassigned

Boom light – Press switch ON to turn on the boom work light.

Windshield wiper switch (cab models only) – Pressing the two-position switch to the first position turns on the windshield wiper. Pressing and holding the switch indicator in the second position activates the washer fluid pump.

Roof work lights (option, cab only) – Press switch ON to turn on the cab roof work lights.

Rotating beacon (option, cab only) – Press switch ON to turn on the rotating beacon.


3-5 918254/BP0112

Engine Compartment Components

Note: See Figure 3-4 for the corresponding numbers.

1. Windshield washer reservoir (cab only)

2. Air cleaner

3. Engine hood support arm

4. Engine coolant radiator cap

5. Radiator overflow reservoir

6. Engine coolant radiator

7. Battery

8. Engine oil fill (2 places)

9. Engine oil dipstick

10. Engine oil filter

11. Fuel filter

12. Hydraulic transfer case

13. Fuel/water separator

14. Hydraulic fluid level sight gauge

15. Fuse/relay box

16. Hydraulic oil cooler

17. Hydraulic oil pressure breather

18. Engine hood support bracket

Accessing the Engine Compartment

The engine hood must be opened to access the engine compartment. To open the hood, press in the hood latch

button (19, Figure 3-6). The hood is secured open when

its support arm (3) slides up and drops into the support bracket (18). To release the hood:

1. Push the hood up slightly to take pressure off the support arm (3).

2. With your free hand, lift the support arm and slip it into the hole above the support bracket (18).

Important: Ensure support arm (3) passes through the opening in support bracket (18). Prevent support arm

(3) from touching air intake hose (19) when closing the hood, or damage to intake hose (19) may result.

3. Close the engine hood.

The hood is properly closed and secured when the lock button makes an audible click sound. To lock or unlock the hood:

1. Insert the ignition key into the latch button (19).

2. Turn the key counter-clockwise (left) to lock hood.

3. Turn the key clockwise (right) to unlock hood.

15

14

13

18

1

12 11

3 17

2 18

10 9 8

19

6 16

Figure 3-5 – Engine Compartment Components

Lock

Figure 3-6 – Engine Hood Lock

3

19

4 5

7

Unlock

918254/BP0112 3-6 Printed in U.S.A.

Ignition Key Switch

Note: The engine can only be started if the both control lever consoles are pivoted down into the operation position.

With the key in the fully counter-clockwise “P” position, all power is shut off. The key can be inserted or removed when the switch is in this position.

With the key in the “0” position, power to the accessory circuit is turned on. The key can be inserted or removed when the switch is in this position.

With the key in the “I” position, power is turned on to all controls and electrical circuits. The battery charge indicator light and the oil pressure indicator light will come on.

With the key in the “II” position, the engine pre-heater indicator will come on while the pre-heater warms intake air in cold weather.

With the key turned fully clockwise “III” and held in position, the engine will crank/start. The indicator lights should go out when the engine starts. Release the key after the engine starts (the key returns to the “I” position when it is released after starting the engine).

Note: The key must be in the “I” position between attempts to start the engine to activate the pre-heat system.

Boom Swivel Control

The boom can be swiveled without moving the swing

frame. See “Swiveling the Boom” on page 3-10.

Dozer Blade Control

The dozer blade is controlled by the dozer control lever

(1) located next to the right joystick. See Figure 3-8.

• Push lever forward to lower the blade.

• Pull lever rearward to raise the blade.

Figure 3-8 – Dozer Blade Lever

1

Engine Speed Control/Throttle Lever

The engine speed is controlled by the throttle lever (2)

located behind the left joystick. See Figure 3-9.

• Push lever forward to decrease engine speed.

• Pull lever rearward to increase engine speed.

2

Figure 3-7 – Ignition Key Switch


3-7

Figure 3-9 – Throttle Lever

918254/BP0112

Travel Controls

WARNING

• Levers and controls should return to neutral position when released.

• Be sure the levers and controls are in the neutral (middle) position before starting the engine.

• Operate controls gradually and smoothly. Excessive speed and quick control movements without regard for conditions and circumstances are hazardous and could cause an accident.

WARNING

Be sure that the dozer blade is “in front.”

When the operator’s cab is facing forward, the blade will be visible and travel controls will operate as expected. If the dozer blade is not visible, the operator’s cab is facing to the rear, and the travel controls will operate in reverse.

Forward Travel

Both travel control levers or pedals must be moved forward. The farther they are moved forward, the faster

the machine will travel. See Figure 3-10.

Reverse Travel

Both travel control levers or pedals must be moved rearward. The farther they are moved rearward, the

faster the machine will travel. See Figure 3-10.

Turning During Travel

Pivot (wide) turns are made by rotating only one track forward or rearward so the machine pivots on the stationary track. Spin turns are made by rotating one track forward and one track rearward. The machine

will spin around its mid-point. See Figure 3-10.

1F

1B

3F 4F

2F

2B

3B 4B

F=Forward; B=Rearward

Drive Levers

Move: For Excavator To:

1F and 2F Move Forward

1B and 2B Move Rearward

1F Wide Turn Right

1F and 2B Spin Turn Right

2F Wide Turn Left

1B and 2F Spin Turn Left

Drive Pedals

Move: For Excavator To:

3F and 4F Move Forward

3B and 4B Move Rearward

3F Wide Turn Right

3F and 4B Spin Turn Right

4F Wide Turn Left

3B and 4F Spin Turn Left

Figure 3-10 – Travel Controls

Spin Turn

Move the levers in opposite directions to spin the machine on its axis. To spin turn left, move the right control lever forward while pulling the left control lever to the rear; to spin turn right, move the left control lever forward while pulling the right control lever to

the rear. See Figure 3-10.

High-Speed Travel

Toggle switch (2, Figure 3-11) controls the two-speed travel drive. Press switch (2) to select high-speed travel. Press switch (2) again to select low-speed travel.

Press and hold switch (3) to change to high-speed travel momentarily.

3

2

Figure 3-11 – High-Speed Switches

918254/BP0112 3-8 Printed in U.S.A.

CAUTION

The high-speed travel setting can reduce traction and will effect control when cornering.

SAE/ISO Selector Valve

The SAE/ISO selector valve is behind the operator’s seat and accessible through an opening in the rear cab

wall. See Figure 3-12.

Note: The machine has been set at the factory for SAE stan- dard operation (2).

To change selector valve setting:

1. Using the horizontal seat adjustment lever (see

Figure 3-18 on page 3-11), move the operator seat

as far forward as possible.

2. Locate the valve access cover on the rear cab wall

(1, Figure 3-12). Open the door to access the valve.

3. Loosen wing nut (4) on top of the valve.

4. Rotate the valve handle 90° to the desired position.

SAE is position (2), and ISO is position (3), shown

in Figure 3-12.

5. Tighten wing nut (4).

6. Close the valve access cover and return the operator seat to the operating position.

SAE Operating Controls

SAE boom and bucket functions are controlled by the right and left joystick control levers located on the seat consoles.

SAE Left Joystick – See Figure 3-13.

1 – Arm extend

2 – Arm retract

3 – Swing left

4 – Swing right

Figure 3-13 – SAE Left Joystick

SAE Right Joystick – See Figure 3-14.

5 – Boom lower

6 – Boom raise

7 – Curl bucket in

8 – Curl bucket out

4

1 2

Figure 3-12 – SAE/ISO Selector Valve

3

Figure 3-14 – SAE Right Joystick

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.


3-9 918254/BP0112

ISO Operating Controls

ISO boom and bucket functions are controlled by the right and left joystick control levers located on the seat consoles.

ISO Left Joystick – See Figure 3-15.

1 – Boom lower

2 – Boom raise

3 – Swing left

4 – Swing right

Swiveling the Boom

WARNING

Working with the boom swiveled to the side reduces lifting capacity.

Overloading the bucket can cause an unstable condition and increase the possibility of tipping the machine.

The boom can be swiveled 55º to the right and 75º to the left for excavating trenches along walls, fences, etc.

See Figure 3-17.

1

Swivel Left Swivel Right

2

Figure 3-15 – ISO Left Joystick

ISO Right Joystick – See Figure 3-16.

5 – Arm extend

6 – Arm retract

7 – Curl bucket in

8 – Curl bucket out

Wall

Trench

Figure 3-17 – Boom Swivel Controls

Lift cover (1, Figure 3-17) over the hammer pedal and push down on the left or right side of the hammer pedal

(2, Figure 3-17) to swivel the boom to the left or right, respectively.

Note: Bucket controls are not affected when the boom is swiveled.

Figure 3-16 – ISO Right Joystick


CAUTION

Lower cover (1) over the hammer pedal when it is not in use to prevent the boom from swiveling unintentionally .

918254/BP0112 3-10 Printed in U.S.A.

Operator’s Seat Adjustments

3

2

1

1

3

2

3. Seat Suspension Adjustment

a. Pull the seat adjustment lever (1, Figure 3-18)

and slide the seat as far forward as possible.

Release the lever to lock the seat in place.

b. Locate the seat suspension handle (3, Figure 3-

18) on the left side of the seat. Rotate the han-

dle clockwise to stiffen suspension and counter-clockwise to loosen suspension. c. Use the seat adjustment lever (1) to return the seat to its previous location.

4. Armrest Adjustment

The armrest on either console is adjusted using

knurled-head screw (4, Figure 3-19). Loosen the

screw on the armrest you wish to adjust so the armrest bracket can move vertically. Once the desired position is reached, tighten the screw to secure the armrest.

Figure 3-18 – Seat Adjustment

1. Horizontal Seat Adjustment

The seat adjustment lever (1, Figure 3-18) moves

the seat forward and rearward. Pull up and hold the lever while moving the seat to the desired position.

Release the lever to lock the seat into place.

2. Backrest Adjustment

The backrest adjustment knob (2, Figure 3-18)

moves the seat backrest forward (incline) and rearward (recline). Rotate the knob counter-clockwise to recline the backrest and clockwise to incline the backrest.

Figure 3-19 – Armrest Adjustment

4


3-11 918254/BP0112

Seat Belt

4

WARNING

ALWAYS fasten the seat belt securely and properly. Never operate the machine without the seat belt fastened around the operator.

Keep the seat belt clean because dirt can impair seat belt operation. Check seat belt condition regularly and have damaged or worn belts immediately repaired by an authorized workshop.

After an accident the seat belt strap is stretched and must be replaced with a new strap installed by an authorized workshop.

Figure 3-20 Seat Belt

1

Make sure the seat belt is not twisted when it is fastened, and that it is fastened over the hips and not the stomach.

Fasten the seat belt tightly and securely. Remove hard, edged or fragile objects from your pockets or clothes that might lie between the seat belt and your body.

Fastening/Unfastening the Seat Belt

Fasten the seat belt around your hips and waist and insert tab (1, Figure 3-20) into buckle (2) until it clicks securely in place. Slack in the seat belt should automatically retract into seat belt spool (4).

Unfasten the seat belt by pressing button (3).

2

3

918254/BP0112 3-12 Printed in U.S.A.

Ventilation (Cab Only)

Windshield

WARNING

When opening the windshield, be sure to lock both latches. When closing the windshield, keep hands on handle and away from path of window. Head injury can result if the windshield falls unexpectedly.

Opening the Windshield

The windshield can be opened to provide cab ventilation.

1. Push latches (1, Figure 3-21) down on both handles

to unlock the windshield.

Opening/Closing the Lower Front Window

The lower front window (5, Figure 3-22) can be

removed.

• To remove the lower front window, open and lock the windshield and lift the lower front window out of the window frame.

Note: A storage location for the lower front window is provided between the operator’s seat backrest and the rear cab wall.

• To replace the lower front window, open and lock the windshield and slide the lower front window into the window frame.

5

1

2

4

3

Figure 3-21 – Windshield Handles

2. Pull the windshield inward and push upward to the roof with the handles (2). Align each handle with its corresponding ceiling catch (3). Push the window (1) firmly up and confirm it has locked into the ceiling catches (3).

Closing the Windshield

1. Keep a hand on each windshield handle (2, Figure

3-21) to avoid sudden windshield movement and

possible head injury when the windshield is released from the cab ceiling catches.

2. Squeeze each latch (1) until the windshield is released. Pull the windshield down by the handles

(2) and push it forward toward the frame. Be sure each latch rests against its cab frame catch (4).

Push the window forward (1) and confirm it has locked into the frame catches (4).

Figure 3-22 – Lower Front Window


3-13 918254/BP0112

Opening the Side Window

IMPORTANT

The side window must be locked into place, whether open or closed, to avoid breakage when driving and working the machine.

1. Press and hold button (5, Figure 3-23) up to release

the side window lock.

2. Slide the window to any of the six slots (6) on the track where the lock can be secured.

3. Once the lock is in one of the six slots (6), release the button (5) to secure the side window into place.

Opening, Securing and Releasing the Cab Door

The cab door can be secure in the open position for additional ventilation.

1. Press the lever next to the door lock (1, Figure 3-

24) down to open the cab door from inside the cab.

2. Open the door and swing it around until the door fastener (2) on the outer door frame engages the door latch (3) on the side of the cab frame. There will be a click sound when the door is securely latched.

3. To release the door fastener, pull knob (4) forward.

2

3

6

5

4

Figure 3-23 – Side Window Lock Release

Figure 3-24 – Cab Door

918254/BP0112 3-14 Printed in U.S.A.

Cab Air Circulation/Heat Control (cab only)

Air is circulated through the grille underneath the

operator’s seat (5, Figure 3-25). Air flow is controlled

with the fan speed switch (7) located on the switch panel.

During colder months, the cab can be heated using the heater control knob (6). The knob is on the cab rightside wall near the floor. Rotate the control knob clockwise to lower the circulated air temperature, and counter-clockwise to raise the circulated air temperature.

7

5

6

Figure 3-25 – Cab Heater Control


3-15 918254/BP0112

MACHINE OPERATION

WARNING

• Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Failure to follow instructions can result in injury or death.

• Read and understand all safety decals before operating the machine. DO NOT operate the machine unless all factory installed guards and shields are in place.

• Be sure you are familiar with all safety devices and controls before operating the machine.

• Know how to stop the machine before starting.

• Use only with Manitou Americasapproved accessories or referral attachments. The Manitou Americas cannot be responsible for safety if the unit is used with non-approved attachments.

• Check for correct function after adjustments or maintenance.

Pre-Operation Checklist

IMPORTANT

See the table of recommended lubricants in

“Fluid Capacities/Lubricants” on page 1-4

for the proper engine and hydraulic oil specifications. Only use lubricants specified in the table.

Check the following items at the beginning of each work day or every 12 working hours:

• Seat belt and mounting hardware

• Safety decals (replace as required)

• Air cleaner and intake hoses

• Engine coolant level and system for leaks

• Clean engine area of any flammable materials

(clean as required)

• Engine oil level (fill if required)

• Hydraulic system for leaks

• Hydraulic fluid level (fill if required)

• Pivot points for proper operation

• Track tension and condition

• Windshield washer reservoir level (cab machines only)

• Attachment safely locked onto machine and attachment condition

• V-belt condition and tension

• Lubrication points lubricated

• Broken and/or loose parts (repair as required)

• Engine cover securely latched

• Fuel level

IMPORTANT

Do not run the engine until the fuel tank is completely empty. If this happens, air will enter the fuel system, and the fuel system will have to be bled. Always fill the tank with fresh fuel at the end of the working day.

WARNING

Never use ether starting aids. A pre-heater is used for cold weather starting. The preheater can cause ether or other starting fluid to detonate, causing injury.

918254/BP0112 3-16 Printed in U.S.A.

Engine Start

Note: When all machine controls are stationary (no pilot control pressure), the swing motor and travel motor brakes are automatically applied. When any control is activated, the appropriate brake is automatically released.

Note: All hydraulic functions are locked out when the opera- tor’s seat left console is in the raised position.

Engine Start Procedure

DANGER

DO NOT run the engine in an enclosed area without proper ventilation. Be sure there is adequate fresh air if running the machine in an enclosed area.

1. Adjust the operator’s seat to desired settings.

2. Fasten the seat belt.

3. Pivot the left control console down.

4. Be sure all levers and controls are in the neutral positions.

5. Insert the ignition key into the switch and turn it

clockwise to the “I” position; see Figure 3-7 on page 3-7. Indicators for oil pressure and battery

voltage will light. In cold weather, the glow plug indicator will come on while the glow plugs warm the engine.

6. Turn the key fully clockwise and hold it until the engine starts, and then release the key.

Note: The key must be returned to the OFF position between attempts to start the engine in order to activate the pre-heating system.

IMPORTANT

Do not activate the starter motor for longer than 20 seconds during each starting attempt. If the engine does not start, turn the key to the OFF position, wait 30 seconds, and then attempt to start the engine again.

IMPORTANT

Indicator lights must go out when engine starts. If they do not, turn the engine off

IMMEDIATELY. Do not use the machine until the problem has been identified and repaired.

7. If necessary, clean the tracks. See “Track Cleaning” on page 4-22.

8. Allow engine to warm up at idle speed for approximately 10 - 15 minutes to fully warm up all systems before using the machine at maximum loads and speed. Use the warm-up time to check for unusual noise, exhaust color, leaks, malfunctions or damage. Additionally, check instruments and indicators and controls pedals/levers for any malfunctions. If anything is detected, shut down the machine, determine the cause, and have it repaired.

Cold-weather Engine Starting Procedure

Note: Install an in-block engine heater to keep engine block and oil warm for easier cold-weather starting.

Note: Be sure the engine oil is correct type and viscosity for

the ambient (air) temperature. Refer to “Fluid Capacities/

Lubricants” on page 1-4.

Note: Be sure the battery is fully charged.

1. Start the engine according to “Engine Start

Procedure” on page 3-17.

2. Advance the throttle to 1/4 engine speed for a faster warm up.

3. As the engine warms up, move the throttle lever to the idle position.

Engine Shut-down

Perform the “Mandatory Safety Shutdown Procedure” on page 2-2 before leaving the machine:

1. Lower the working equipment to the ground and support it securely.

2. Run the engine at idle speed for a few minutes to allow systems to cool after operation at full speed.

3. Turn the key fully counter-clockwise to shut off the engine.

4. Lock out controls by raising left control console.

5. Remove the ignition key and take it with you.


3-17 918254/BP0112

New Machine Break-in Procedure

A new machine requires reduced operational speed during the first 100 operating hours for proper break-in.

If the machine is subjected to hard use during the break-in period, damage to operating systems may occur.

Perform the following when operating a new machine:

• Check all fluid levels:

• Engine oil

• Engine coolant

• Hydraulic fluid

• Start engine and let it idle for 10 - 15 minutes so all components and systems can warm up.

• Operate machine at about 80% of maximum loads and speed.

• Do not abruptly change engine speed during operation.

• After the first 100 operational hours, drain and replace the engine oil and engine oil filter.

Travel

Travel Speed Selection

Two travel speed ranges can be selected by using the

Auto2Speed switch (1, Figure 3-26) located on the

control console. The machine’s transmission automatically switches from high to low speed when it senses a load during operations such as grading, changing direction, and travelling uphill. The transmission automatically returns to the higher speed once the resistance is gone.

Travel speeds are:

• Slow Speed (maximum): 1.3 mph (2.1 km/h)

• High Speed (maximum): 2.4 mph (3.8 km/h)

1

WARNING

• Before operating the travel levers, be sure you know which direction the machine is pointing. If the dozer blade is not visible from the operator’s cab, you are facing the rear of the machine and the travel controls will be the reverse of normal operation.

• Before moving, be sure no one is in the way of the machine. Sound the horn as an alert that you are about to move the machine.

• Be sure the path is clear during travel.

• Use extreme caution when reversing travel. Be sure there is a clear path behind the machine.

• Operate the travel control levers smoothly to avoid sudden starts and stops.

• Before leaving the operator’s seat, be sure to lock out all control systems and shut down the engine to avoid accidental activation.

Figure 3-26 – Travel Speed Selection

General Travel Instructions

1. Avoid sudden movements and sharp turns.

2. Travel slowly on rough, frozen, or uneven terrain.

3. Travel straight up and down slopes – never across.

See Figure 3-29. Extend the dipper arm and lower

the boom to keep the bucket about 12” (300 mm) off the ground. If the machine starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, make sure all controls are in the neutral position and restart the engine.

4. See “Travel Controls” on page 3-8 for moving the

machine forward, rearward, or turning it in either direction.

5. The excavator can travel in water as deep as the top of the upper track rollers. Be sure that the footing is solid so that the machine will not sink.

918254/BP0112 3-18 Printed in U.S.A.

Operating Instructions

Operating Precautions

Travel Motor(s)

DANGER

• DO NOT elevate the front end of the tracks using downward pressure on the dozer blade. This will cause the machine to become unstable.

• DO NOT excavate underneath the machine.

• Always be sure that there is adequate support when working near trenches.

Be aware of conditions that could cause the earth to collapse, resulting in risk of injury or death.

• Be sure there is the proper clearance from overhead electrical lines.

• Be sure that all underground electrical power and gas supply lines are clearly marked and avoided.

WARNING

• DO NOT rest your feet on the travel pedals during normal machine operation. Unexpected machine movement could occur.

• When working close to an excavated edge, be sure that the ground the machine is sitting on is solid and keep

the travel motors to the rear. See Figure

3-27.

Figure 3-27 – Machine Position for Edge Excavating

DO NOT use machine travel or swing to provide additional breakout force when the bucket is in the ground.

DO NOT jam the bucket into the ground and/or use the weight of the machine to provide additional breakout force.

DO NOT use the bucket as a hammer or ramming device.

When working on soft or muddy ground, be sure that the machine does not sink.

IMPORTANT

When digging at maximum excavation depth, BE SURE that the dozer blade does not contact the boom cylinder. Damage to the boom cylinder can occur if it contacts the dozer blade.

Joystick Controls

Extending and retracting the cylinders (boom, dipper arm and bucket) are controlled by the joysticks located on the consoles attached to the operator’s seat. See the

information starting on page 3-9 for control

configurations.



3-19 918254/BP0112

Hydraulic Swivel Unit Brake

The upper carriage’s rotation is sufficiently braked by moving the control lever back to the initial position.

Moving the control lever in the opposite direction brakes the upper carriage with full hydraulic pressure.

IMPORTANT

Hydraulic swivel unit brake function is not optimal if the hydraulic system has not reached operating temperature.

• Travel straight up and down slopes — never across.

See the bottom of Figure 3-29. Extend the dipper

arm and lower the boom to keep the bucket about

12” (300 mm) off the ground. If the machine starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, be sure that all controls are in the neutral position and restart the engine.

• When traveling down a slope, put the machine in the

position shown in the middle of Figure 3-29, control

the speed with the travel levers and the throttle controls, and reduce engine speed.

Mechanical Stop Brake

A multi-disc brake integrated into the rotation drive has an additional mechanical brake effect with a time delay. This brake is used to prevent unintentional swivel unit rotation.

Slope Operation

Uphill Travel with Attachment Tucked

WARNING

• Do not travel up or across a slope steeper than 15°. Do not travel down a slope steeper than 25°. Keep the boom centered while traveling.

• Keep attachments as low as possible when traveling on slopes or rough terrain.

15° Max. Uphill

12" (300 mm)

Maximum

Downhill Travel with Attachment Extended

12" (300 mm)

Maximum 25° Max. Downhill

Always drive straight ahead; driving diagonally or at an angle on slopes is very dangerous

Figure 3-28 – Working from a Level Area

Operating on a slope is hazardous. It is recommended

the work area be leveled as shown in Figure 3-28. If

this is not possible, use the following guidelines:

918254/BP0112 3-20

Figure 3-29 – Traveling Up or Down Slopes


• To achieve the best stability while excavating, lower the dozer blade to the ground.

• Operate as slowly as possible and avoid sudden changes in direction.

• Avoid traveling over objects such as rocks, trees, stumps, etc.

• Stop the machine travel before moving the bucket or dozer controls.

• Slow the work cycle. Take your time.

• Avoid working with the tracks positioned across the slope. Position the machine with the dozer blade downhill and lowered.

• Avoid swinging or extending the bucket farther than necessary in a downhill direction. If you must swing the bucket downhill, keep the boom low and skid the bucket along the ground.

• When working with the bucket on the uphill side, keep the bucket as close to the ground as possible.

Unload far enough away from the excavation to prevent the possibility of a cave-in.

Cold Weather Operation

In cold weather, mud should be removed from the machine before parking. If possible, park the machine on solid ground, or on wood planks, to prevent the track or undercarriage from freezing to the ground.

Operating in Water

1. In cold weather, remove mud and/or water from the machine before parking. If possible, park the machine on solid ground, or wood planks, to prevent the track or undercarriage from freezing to the ground.

2. Do not operate or immerse the machine in water higher than the tracks.

3. Thoroughly grease the machine if it has been operated in deep water.

Excavation

The following section applies to an excavator with a standard bucket, which is used mainly for digging into the ground to loosen, excavate and load loose or solid material.

IMPORTANT

The excavator attachments should never be used to perform actions other than digging, grading, loading or excavating. Equipment damage may result when:

• the machine’s swivel force is employed so the bucket serves as a hammer or

battering ram (1, Figure 3-30).

• the bucket is lowered into the ground while rotating the upper carriage or driving the excavator (2).

• the dipper arm’s falling force is employed so the bucket serves as a hammer, hoe or pile-driver (3).

• the machine’s falling force is employed for digging or excavating (4).

• Use caution when retracting the bucket to prepare for driving or transport. Hitting the bucket into the dozer blade might damage either attachment, especially the bucket teeth.

• The dozer blade is meant for grading only; using it as a battering ram risks serious damage to the blade, its cylinder or connections.

• When excavating, lower the dozer blade to the ground to aid machine stability. It is best to use the dozer blade on the same side as excavating but lower the blade on the opposite side of excavating if the situation prevents the former.


3-21 918254/BP0112

Proper Excavation Bucket Position

Move the flat side of the bucket cutting edge so it is

parallel to the ground. See 1, Figure 3-31.

IMPORTANT

Positions 2 and 3 in Figure 3-31 show

improper positions for using the bucket.

Position 2 forces the bucket downward into the ground, slowing work and subjecting the engine and hydraulic pump to overloading.

Position 3 forces the bucket upward toward the ground surface, slowing work because of smaller loads being dug.

1 2 3

Figure 3-31 – Proper Bucket Position

Figure 3-30 – Machine Operation Exclusions

918254/BP0112 3-22 Printed in U.S.A.

Proper Digging Technique

1. Lower the bucket into the ground (4, Figure 3-32).

2. Once the bucket penetrates the ground, adjust so the flat side of the cutting edge is parallel to the

ground (5, Figure 3-32).

3. Pull the bucket towards the excavator by: a. Moving the dipper arm towards the excavator and b. Lowering the boom.

4. Once the bucket is sufficiently filled: a. Continue moving the dipper arm towards the excavator.

b. Extend the dipper arm cylinder so the bucket is

tilted upward (6, Figure 3-32) and

c. Raise the boom.

Trench Excavation

Trench excavating is most efficient when the machine tracks are parallel to the limit line of the trench. See

Figure 3-33. For large trenches, excavate both ends of

the trench first and then the center.

Figure 3-33 – Efficient Trench Excavating

When trench excavating is needed in confined areas, the excavating can be done by rotating the upper

carriage and swiveling the boom. See Figure 3-34.

6

4 5 5

Figure 3-32 – Proper Digging Technique

Figure 3-34 – Excavating Trenches Sideways


3-23 918254/BP0112

• Working alongside trenches and deep excavation are two applications where the dozer blade might restrict bucket movement. When working alongside trenches, lower and place the dozer blade onto the ground for greatest stability. When deep excavating, position the machine so the lowered dozer blade is on the side opposite the excavation to avoid contacting the boom cylinder against the dozer blade. See

Figure 3-35.

1. Raise or lower the dozer blade using the control

lever (1, Figure 3-36) located next to the right

joystick. Move the lever forward to lower the dozer blade and rearward to raise it.

1

Figure 3-35 – Machine Position for Deep Excavating

WARNING

Placing the dozer blade on the opposite side of the excavating decreases machine stability. Always operate the machine with operator safety in mind, especially when less-than-ideal working conditions exist.

Figure 3-36 – Dozer Blade Lever

2. The boom must be fully raised and the bucket curled in (up) when grading.

3. When grading, the material may be pushed away to the front or the side.

4. Raise the dozer blade slightly if excessive resistance occurs.

Grading (Bulldozing)

WARNING

• Be sure there is proper clearance for attachments when bulldozing.

• Be sure that attachments do not contact overhead power lines or obstructions during bulldozing.

• DO NOT drive the machine into the excavation or onto loose soil, which can cause an unstable condition, and could possibly tip the machine.

Figure 3-37 – Grading

918254/BP0112 3-24 Printed in U.S.A.

Loading Vehicles

When loading vehicles, consider the following:

• Whenever loading in a confined area with a limited range of motion, position the truck so maximum visibility is ensured for the excavator operator.

• When work conditions permit, position the truck so the excavator can load material at the rear of the

truck instead of the sides (1, Figure 3-38). The

most effective way to load into the rear of the truck is when the truck and excavator form a 45° angle

(2, Figure 3-38).

• Raise the boom and dipper arm to dump height just before you rotate towards the truck.

• Whenever possible, dump upwind to keep dust and airborne debris away from your eyes, and the excavator air filters and fans.

1

Bucket Mounting/Removal

ALWAYS wear protective goggles, helmets, gloves, steel-toed shoes, etc.

DO NOT service the bucket while the engine is running.

DO NOT stand behind the bucket when removing the pins.

DO NOT use your hands or fingers to align the bucket and dipper arm holes.

ALWAYS verify the bucket is safely locked before starting the engine and resuming operation.

WARNING

• DO NOT use a hammer directly on a securing pin to loosen it. The pounding may cause splintering, which may lead to serious injury.

• The bucket can crush hands or feet. DO

NOT use your hands or feet as substitutes for the correct equipment.

2

Figure 3-38 – Loading Vehicles

Bucket Removal

1. Lower the bucket to the ground with the flat side

facing down (1, Figure 3-39).

IMPORTANT

Place the bucket against the ground with minimum pressure. More pressure increases resistance, which will make it more difficult to remove the pins.

2. Stop the engine.

3. Remove the two lynch pins (2A and 2B, Figure 3-

39).


3-25 918254/BP0112

1

Attaching A Bucket

1. Grease the dipper arm and bucket holes.

2. Since the bucket is on the ground and stationary, maneuver the machine until the dipper arm holes align flush with the bucket holes.

2A

2B

WARNING

DO NOT use your hands or fingers to align the bucket and dipper arm holes.

2

3

3. Stop the engine.

4. Insert the upper securing pin first (3A, Figure 3-

39). If needed, use a hammer and brass punch to

gently tap the pin through the hole. Insert a lynch

pin (2A, Figure 3-39) through the hole in the pin

and lock.

IMPORTANT

The flat side of each securing pin head must align with the flat guide on each side

of the hole; see (3A) and (3B) in Figure 3-39

for how the pins look when properly installed.

3B

3A

Figure 3-39 – Bucket Removal/Mounting

4. Remove the lower securing pin first (3B, Figure 3-

39) and then the remaining pin (3A). Carefully

remove the pins with a hammer and brass punch if they are stuck. Once pin (3B) is removed, pin (3A) might have more pressure applied against it, making it difficult to remove. If this happens: a. Start the engine.

b. Slightly raise and lower the boom to relieve pressure from the pin.

c. Turn off the engine.

d. Try removing the pin again, using a hammer and brass punch if needed.

5. Insert the lower securing pin (3B, Figure 3-39). If

needed, use a hammer and brass punch to gently tap the pin through the hole. Insert a lynch pin (2B,

Figure 3-39) through the hole in the pin. Lock the

lynch pin securely in place.

6. Verify the bucket is locked and secure before starting the engine and resuming operation.

918254/BP0112 3-26 Printed in U.S.A.

Auxiliary Hydraulics Connections

IMPORTANT

Follow the instructions in the operator’s manual from the attachment manufacturer for connecting the attachment to the machine’s auxiliary hydraulics.

Figure 3-40 shows the three quick connections on the

dipper arm meant for auxiliary hydraulics, which are for the following:

•

•

•

1:

2:

3:

Pressure line (male connector)

Large return line (female connector)

1

Pressure line (female connector)

2

3

Figure 3-40 – Auxiliary Hydraulics Connections

Connecting the Quick Couplings

1. Park the machine on firm and level ground.

2. Extend the dipper arm cylinder halfway (1, Figure

3-41).

3. Stop the engine.

4. Turn the ignition key to position I. See “– Ignition

Key Switch” on page 3-7 for more details.

5. Release pressure from the bucket cylinder by moving the left control lever to the left and right.

See left joystick control details on page 3-9 for

more information.

6. Lift the left control lever base as a safety

precaution. See “– Operator’s Left Console in

Lock-out Position” on page 3-1 for more details.

7. To connect couplers:

a. If necessary, rotate lock sleeve (2, Figure 3-41)

so notch (3) aligns with lock ball (4).

b. Pull lock sleeve (2) downward.

c. Insert the attachment coupling into the corresponding auxiliary hydraulics connection coupling.

d. Release lock sleeve (2) so it snaps into place and locks the couplings together. Verify the lock sleeve (2) is snapped closed and the coupling is securely locked together.

e. Twist lock sleeve (2) so notch (3) is NOT aligned with lock ball (4), to help prevent accidental de-coupling.

Disconnecting the Quick Couplings

1. Perform steps 1 through 6 in “Connecting the

Quick Couplings” on page 3-27 before proceeding

to the next step.

2. To disconnect each coupling: a. Pull down on the spring-loaded lock sleeve (2,

Figure 3-41).

b. Listen for the hissing sound to verify that any pressure has been released from the connection.

c. Turn the notch in the lock sleeve (3, Figure 3-

41) so it is aligned with the lock ball (4).

d. Push lock-sleeve (2) up in the direction of arrow (6) to disconnect the coupling.

2

1

4

3

Figure 3-41 – Quick Coupling Connections


3-27 918254/BP0112

Operating Auxiliary Hydraulics

Use the auxiliary hydraulics pedal (1, Figure 3-42) to

regulate oil flow through auxiliary attachments. Press the pedal forward (F) for oil to flow into the auxiliary attachments and rearward (R) for oil to flow out.

The excavator can be towed by using the towing

bracket (1, Figure 3-43). Secure a towing shackle,

shackle pin and lock (2) of adequate size to the towing bracket (1) as shown. Tow the machine slowly.

1

1

2

Figure 3-42 – Auxiliary Hydraulics Control

Transporting

Towing

Figure 3-43 – Towing

Lifting the Machine

WARNING

• When towing the machine, make sure no one is close to the towing apparatus, or in between the vehicles. The machine may only be towed using suitable towing equipment, in connection with suitable towing apparatus, such as a towing coupling, hooks and eyes.

• Do not use a towing apparatus that is kinked, twisted, or otherwise damaged.

• Do not apply high loads abruptly to the retrieval apparatus. The towing bracket has a maximum admissible load of 6992 lbf (3110 daN).

• The towing bracket is designed for retrieving the machine only. Do not use the excavator to tow other vehicles.

• Do not tow the machine if the travel drive is damaged. Damage to the machine cause by towing is not covered under warranty.

WARNING

• Use a lifting device with sufficient capacity for the weight of the machine plus any attachments.

• Maintain the center-of-gravity and balance points on the machine. See

Figure 3-44.

• Do not swing the boom.

• Never lift the machine with the operator aboard.

The lifting point decals on the boom and dozer blade

(see Figure 3-44) identify the lifting point locations.

Secure the lifting fixture sling to these lifting points (1,

Figure 3-44) on the machine as follows:

• Length L1 on the lifting sling for the boom must be

6' 6-3/4" (2 m) long.

• Length L2 on the lifting sling must be 11' 4-1/4"

(3.47 m) long.

Do not exceed rated load capacity of the lifting

machine. See “General Specifications” on page 1-8 for

excavator weight.

918254/BP0112 3-28 Printed in U.S.A.

(Both Sides)

1

1

doors, guards and shields open or removed for the purposes of illustration only. Be sure all doors, guards, shields and panels are in the proper operating positions before starting the engine to operate the machine.” on page 2-2.

6. Lock the cab.

7. Place chocks under the excavator tracks.

8. Secure the excavator to the transporter at the tie-

down points (2, Figure 3-45) to prevent the

excavator from slipping, overturning or moving during transport.

Note: The tie-down points on the excavator are identified by

decals (3, Figure 3-45).

(Both Sides)

Figure 3-44 – Machine Lifting Points

Loading and Transporting

Note: Refer to Figure 3-45.

Use only transporters that are in proper working order and are approved for use on public roads.

When using ramps to load the transporter:

• Do not exceed an incline of 17°.

• Clean dirt, mud, ice and snow from the ramps and tracks.

• Use metal loading ramps with a slip-resistant surface, and with beveled ends to prevent damage to rubber tracks.

Loading Procedure:

1. Attach ramps securely to the transporter to prevent them from slipping off during loading.

2. Load the transporter on solid, even ground.

3. Engage the transporter parking brake and chock the wheels.

4. Determine the direction of the track movement

(blade facing forward) before moving the excavator onto the ramps.

5. After the excavator is on the transporter, perform

the “Some photographs in this manual may show

2

Figure 3-45 – Loading and Transporting

3


3-29 918254/BP0112

Notes:

918254/BP0112 3-30 Printed in U.S.A.

CHAPTER 4 – MAINTENANCE

GENERAL INFORMATION

WARNING

Read and understand this entire manual before operating and/or servicing the machine. Follow warnings and instructions for operation and maintenance. Check for correct function after adjustments or maintenance. Failure to follow instructions can result in injury or death.

WARNING

Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting. The machine is designed for use only with approved accessories or referral attachments. The GEHL Company cannot be responsible for safety if the machine is used with non-approved attachments.

Care and Servicing

Care and servicing have a significant influence on the operational condition and the service life of the machine.

Use of lubricants not corresponding to the manufacturer’s recommendations may invalidate warranty claims.

More frequent servicing, other than the recommended intervals, may be required under extreme conditions

(extremely dusty or hot conditions).

Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

DO NOT power-wash the main hydraulic pumps and controls, throttle solenoids and sealed bearings. High pressure water can be forced through seals and trapped within these components, causing premature failure.

The operating pressure settings of the hydraulic system should only be adjusted by trained, qualified personnel.

If malfunctions are caused by unauthorized alteration of operating pressure settings, all warranty responsibilities of the manufacturer are invalidated.

WARNING

The hydraulic reservoir is under pressure.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin and eyes.


4-1 918254/BP0112

Maintenance Safety

• Never service the machine without reading the applicable instructions.

• Always lower bucket and dozer blade to the ground before performing any maintenance.

• Use correct procedures to lift and support the machine. Always lift the dozer blade fully before installing jackstands.

• Keep the engine hood and hydraulic valve covers closed except for service. Close and latch covers before operating the machine.

• Be sure to have the work area properly ventilated when grinding or welding parts. Wear a dust mask.

• Exhaust fumes can kill. Exhaust system must be tightly sealed. If working in an enclosed area, vent exhaust to outside if the engine must be run for service.

• Never perform unapproved modifications or add unapproved attachments.

• Stop the engine and let cool, then clean any flammable materials from the engine before checking fluid levels.

• Never service or adjust the machine with the engine running unless it is required by the service procedure.

• Avoid contact with leaking hydraulic fluid and diesel fuel under pressure. The pressurized fluids can penetrate the skin and eyes. NEVER use your hands to search for hydraulic fluid leaks — use a piece of paper or cardboard. Escaping fluid under pressure can be invisible, and if it penetrates the skin it can cause serious injury. If any fluid is injected into your skin, see a doctor at once.

Injected fluid MUST be surgically removed by a doctor familiar with this procedure or gangrene may result.

• Never fill the fuel tank with the engine running, while smoking or when near open flame.

• Wipe up fuel spills immediately.

• Keep your body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

• Wear eye protection when servicing the machine.

• Lead-acid batteries produce flammable and explosive gas. Keep arcs, sparks, flames and lighted tobacco away from batteries.

• Batteries contain acid, which burns eyes and skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact, flush well with water and get immediate medical attention.

918254/BP0112 4-2 Printed in U.S.A.

Maintenance Label Symbols

Symbol Assembly Explanation

General Visual check

Engine

Engine

Engine

Engine

General

Fuel system

Fuel system

Radiator

Radiator

Engine

Grease instructions

Drain condensation from fuel

Replace the fuel filter, clean the fuel prefilter

Check the coolant level

Drain and fill in new coolant

Check valve clearance (adjust if necessary)

Check the engine oil level

Change engine oil

Replace the oil filter

Check V-belt tension

Travel drive

Travel drive

Change oil

Check the oil

Undercarriage Check track tension

Hydraulic system Check oil level

Hydraulic system Change hydraulic oil

Hydraulic system Replace the hydraulic oil filter, replace the breather filter

Radiator fins Clean


4-3 918254/BP0112

Maintenance Label

1000h

500h

250h

50h

10h

3

KF2K - 25

Li - soap

3

KF2K - 20

Ca - sulfonat complex

1

50h

10h

1000h

500h

250h

ISO 6743/4

DIN 51524-3

HVLP46

1

D

API GL5

SAE 80W90 1

D

4

2

3

4 / 6

KF2K - 25

Li - soap

ASTM D4985

-34°C / -29°F

ASTM D6210

250h

500h

1000h

10h

50h

1 1

D

1

10h

50h

250h

500h

1000h

API CF

SAE 10W-40

D

Note: Maintenance label is located on cab rear window or inside right canopy wall.

918254/BP0112 4-4 Printed in U.S.A.

MAINTENANCE SCHEDULE

The following service schedule is a recommended. Maintenance work must be done at regular intervals. Failure to perform scheduled maintenance work will result in excessive wear and early machine failures. The following service schedule is a recommended.

Check, Clean and Inspect

Service Activity Daily Every 50

Hours

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

Engine oil level

Engine coolant level

Hydraulic oil level

Check engine/hydraulic oil radiator and air conditioning for debris; clean if necessary

Cab machines: windshield wipers condition; replace if necessary

Cab machines: windshield washer reservoir; fill if necessary

Check cooling system, heating and hoses for leaks and pressure (visual check)

Air filter for damage; squeeze dust valve

Inspect water separator pre-filter; drain water if necessary

Check V-belt condition and tension

Check exhaust system for damage

Check tracks for cracks, cut or other damage

Check track tension; adjust if necessary

Inspect cylinder piston rods for damage

Ensure bucket and attachment pins are secure and locked

Pin lock (dipper arm and attachment)

Inspect hydraulic line clamps for tightness/damage; hydraulic system for leaks

Clean hydraulic couplings/dirt build-up on the hydraulic system dust caps

Grease frame lubrication system

Check air filter restriction indicator

1

Check primary pressure relief valve pressure

1

Travel final drive gearbox oil level

Check fasteners for tightness 2

Check indicator lights for correct function

1 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

1. Use in acidic air environments, such as acid/chemical, steel/aluminum/non-ferrous metal production facilities.

2. Check after first 50 hrs; every 500 hrs thereafter.

x x x x


4-5 918254/BP0112

Check, Clean & Inspect (continued)

Service Activity Daily Every 50

Hours

Every 250

Hours

Every 500

Hours

Every

1000

Hours

Customer Dealer

Insulating mats in the engine compartment

Warning decals and Operator’s Manual in place/undamaged

Clean water separator

Clean battery

Replace cab air filter for heating and air conditioning

Empty diesel fuel tank

1

Check alternator, starter and electrical connections, starter bearing play and function

Preheating system and electrical connections

Check bearing play on tread rollers, track carrier rollers and front idlers

Fuel injection pump, injection and pressure, injection nozzles and valves

Check injection timing; adjust if necessary

Check engine valve clearance; adjust if necessary

Check pilot control valve filter/restrictor; clean/replace if necessary

Clean drain holes in cab/canopy x x x x x x x x x x x x x x x

1. After emptying the tank, water must be removed and air must be purged from the fuel system before use. See

“Water Separator” on page 4-13 and “Purging Air from the Fuel System” on page 4-14.

x x x x x x x x x x x x

Fluid and Filter Changes

Service Activity

Engine oil

Engine oil filter

Fuel filter

Hydraulic oil filter

Gearbox oil

Hydraulic oil

Breather-hydraulic oil tank

Air filter element when indicator light comes on

Engine coolant

Daily Every 50

Hours x

1 x

1 x 3 x

3 x

4

Every

250

Hours x

2

Every

500

Hours x x x x x

Every

1000

Hours x x x x

Customer x

1. Change after first 50 hrs; every 500 hrs thereafter.

2. Dusty work environment, high temperature, high rate of hammer use, and similar intensive use conditions.



Dealer x x x x x x x x

918254/BP0112 4-6 Printed in U.S.A.

Swing Gear Ring


Check gear ring

Check bearing system

Cab Heating System


Daily x x x

Weekly Every 50

Hours x

Every

125-250

Hours

Every 500

Hours x

Every

1000

Hours

Annually x

Check fan

Check system function

Check heating system for leaks

Check seals

Bucket, Boom and Dozer Blade

Service Activity Daily

Daily Weekly Every 50

Hours

Every

125-250

Hours

Every 500

Hours x x x x

Every

1000

Hours

Annually

Lubricate daily service points

Lubricate weekly service points

Check bucket teeth for wear

Check hydraulic fittings for leaks

Check hydraulic cylinder under load

Check bearing play

Weekly Every 50

Hours

Every

125-250

Hours

Every 500

Hours

Every

1000

Hours

Annually x x x


4-7 918254/BP0112

Daily Lubrication

(See Figure 4-1)


Dozer blade

Swiveling console

Boom

Dipper arm

Attachments

Chassis (front of undercarriage)

Lubricate daily at the points indicated x x x x

Daily Every

50

Hours x x

Every

250

Hours

Every

500

Hours

Every

1000

Hours

Customer Dealer x x x x x x

Boom Swivel (right side) Boom Boom Swivel (left side)

Dozer Blade Cylinder (top)

Dozer Blade Arms and Cylinder (bottom)

Dipper Arm (left side)

Figure 4-1 – Lubrication Points

918254/BP0112 4-8

Frame (left front near horn)


RECOMMENDED LUBRICANTS

Engine Oil

IMPORTANT

Be sure to read the engine manual supplied with the machine for detailed engine specifications.

ENGINE

Checking Engine Oil Level

IMPORTANT

See “Fluid Capacities/Lubricants” on page 1-4 for engine oil grade. To prevent

damage to the engine, only use the engine oils specified, or oils of equivalent quality and grade.

See “Fluid Capacities/Lubricants” on page 1-4 for proper

engine oil specifications.

Hydraulic Oil

See “Fluid Capacities/Lubricants” on page 1-4 for proper

hydraulic oil specifications.

Swing Ring

Lubricate with a heavy-duty lithium complex grease with 3% molybdenum disulfide, such as Chevron RPM

Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP

Energrease Moly EP2.

Final Drive Unit

An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W90 or BP Transgear

80W90.

Swing Gear Unit

An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W-90 or BP Transgear 80W-

90 is required.

Lubrication Points

See Figure 4-1 for lubrication points. Apply a heavy-

duty lithium complex grease with 3% molybdenum

disulfide. See “Fluid Capacities/Lubricants” on page 1-

4 for more detailed specifications.

Ranges of Applications

From -4° F to +104° F (-20° C to +40° C) for the outside temperature.

To check the engine oil, the machine must be on a level surface and the engine turned off. Check the oil level before starting the engine or at least 5 minutes after shutting off the engine.

1. Open the engine hood (see “Accessing the Engine

Compartment” on page 3-6).

2. Check the engine oil level using the dipstick (1,

Figure 4-2) located on the right side of the engine.

The acceptable oil level is between the maximum and minimum marks on the dipstick.

3. Add oil, if required, through the oil filler neck (2,

Figure 4-2).

4. Drain excess oil if required .

5. Close the engine hood and confirm it is latched securely.

Minimum

Maximum

1 2

Figure 4-2 – Oil Dipstick and Filler Neck

Locations


4-9 918254/BP0112

Changing Engine Oil and Filter

1. Position the machine on a level surface.

IMPORTANT

The machine must be positioned on a level surface for the oil to drain completely.

8. Remove the oil filter (1, Figure 4-4), using a filter

wrench as needed.

1

2. The engine oil drain plug is accessed from underneath the machine. If necessary, rotate and position the cab/canopy so the engine oil drain

access hole (9, Figure 4-3) is accessible.

3. Perform the “Mandatory Safety Shutdown

Procedure” on page 2-2, but do not allow the

engine to fully cool because warm oil will drain more completely.



5. Access the oil pan drain plug from underneath the

machine through hole (9, Figure 4-3) at the bottom

of the engine compartment.

9

Figure 4-3 – Engine Oil Drain Access

6. Position a waste oil collection container underneath the access hole and engine oil drain plug.

7. Remove the drain plug from the oil pan and allow the oil to drain into the collection container.

IMPORTANT

Dispose of waste engine oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste engine oil onto the ground or down a drain.

2

Figure 4-4 – Oil Filter Location

9. Clean the filter gasket surface on the engine block.

Put a film of clean oil on the filter gasket.

10. Install the new filter and gasket and hand-tighten.

Once hand-tightened, tighten the filter another 1/4 to 1/2 rotation.

11. Reinstall the drain plug.

12. Clean the area around the oil filler cap (2, Figure 4-

2).

13. Remove the oil filler cap and raise the oil dipstick

(2, Figure 4-4) slightly to allow any trapped air to

escape.

14. Add oil to the engine through the oil filler.

Crankcase capacity with filter is 3.5 qts. (3.3 L).

Do NOT fill crankcase above the MAX mark on the dipstick.

15. Reinstall the oil filler cap.

16. Wait about three minutes to allow the oil to settle

and check the oil level according to “Checking

Engine Oil Level” on page 4-9.

17. Start the engine and let it run for several minutes.

Watch the engine oil light on the control panel. The light should turn off after several seconds. If it does not, shut off the engine, determine the cause and fix the problem before restarting the engine.

18. Stop the engine and check for leaks at the oil filter and oil drain plug. If no leaks are found, close the engine hood and confirm it is latched securely.

918254/BP0112 4-10 Printed in U.S.A.

Engine Air Cleaner

Air Cleaner Dust Valve

Squeeze dust valve (6, Figure 4-5) daily to purge accumulated dust from the air cleaner housing.

Early Machines Later Machines

6. Press button (7, Figure 4-6) on air filter restriction

gauge to reset the gauge.


IMPORTANT

Do not knock air filter elements against a solid object to remove dust. The elements may become distorted and damaged.

6

IMPORTANT

Do not operate engine without the air cleaner components installed or damage to the engine could occur.

Figure 4-5 – Air Filter Dust Valve

Air Filter Element Replacement

To access the engine air cleaner, open the engine hood

(see “Accessing the Engine Compartment” on page 3-

6). The air filter restriction gauge (1, Figure 4-6) will

read “Service” when the elements require replacement.

2

3

4

7 4

1

Figure 4-6 – Air Filter Restriction Gauge

To service the elements:



2. Release the bow clips (2, Figure 4-7) to remove the

air cleaner cover and gasket (3).

3. Carefully remove the outer air cleaner element (4).

Carefully remove the inner air cleaner element (5).

4. Clean all contamination (dust) inside the air cleaner housing and cover.

5. Replace the filter elements as required and/or

according to “Maintenance Schedule” on page 4-5.

Install both elements (4 and 5), gasket and air cleaner cover (3). Fasten bow clips (2). Ensure dust valve (6, Figure 4-5) points down.


4-11

5

Figure 4-7 – Air Filter Service

918254/BP0112

Fuel System

Filling the Fuel Tank

WARNING

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

IMPORTANT

Unless draining fuel tank for servicing, never operate the machine until the fuel tank is completely empty. The fuel system has to be bled of air whenever the fuel tank is run empty. Always fill the fuel tank after use.

The fuel gauge on the cab console indicates the fuel level in the tank.

1. To fill the tank, swivel lock cover (7, Figure 4-8)

on fuel filler cap (5) and unlock cap (5) using key

(7). Remove cap.

2. Check fuel filler screen (8) for debris, and clean if necessary. Replace screen (8) back into the fuel filler neck.

3. Fill the fuel tank using only high-grade diesel fuel

(rated 1-D or 2-D ASTM D975-94).

4. After fueling, re-install and lock the fuel cap.

5

Figure 4-8 – Fuel Filler

8

7

7

IMPORTANT

When using the machine in cold weather, make sure to use the proper fuel blend to prevent the fuel filters from “jelling” up. If this happens, the fuel filter and water separator elements will have to be replaced, and the fuel will have to be replaced with the proper fuel.

DANGER

When handling fuel, there is a high risk of fire. Never work on the fuel system around open flames or sparks. DO NOT smoke when working on the fuel system or refueling. Before refueling, turn off the engine and remove the ignition key. Do not refuel in closed rooms. Wipe up fuel spills immediately. Keep the machine clean to reduce the risk of fire.

Fuel Filter

Note: For fuel filter location, see “Engine Compartment

Components” on page 3-6.


Procedure” on page 2-2. Wait for the engine to

cool.



3. Turn fuel shut-off valve lever (1, Figure 4-9) on the

fuel filter to the “OFF” position.

4. Loosen retaining ring (2, Figure 4-9) until the cup

(3, Figure 4-9) can be removed.

918254/BP0112 4-12 Printed in U.S.A.

5. Carefully remove cup (3). Discard any fuel in the cup according to environmental laws. DO NOT pour fuel onto the ground or down a drain.

6. Wash the inside of the cup. Inspect the O-ring (not shown) and replace it if required.

7. Remove and discard the old fuel filter properly.

8. Install a new fuel filter in the cup. Install the cup onto the mounting flange and tighten retaining ring

(2). Hand tighten only.

9. Turn the fuel shut-off valve on the fuel filter to the

“ON” position.


11. Purge air (bleed) from the fuel system according to

“Purging Air from the Fuel System” on page 4-14.

IMPORTANT

Do not turn the ignition key to the start position before bleeding/priming the fuel system. Damage to the starter motor, coils, pinion or ring gear could result.

Water Separator

Note: For water separator location, see “Engine Compart- ment Components” on page 3-6.

The water separator contains a red indicator ring that will float on top of any accumulated water. Under normal conditions, this ring sits at the bottom of the separator. If the red ring is somewhere between the

bottom and the white ring (5, Figure 4-10), then the

accumulated water must be drained.

4

5

6

ON

OFF

1

2

3

ON

OFF

Figure 4-9 – Fuel Filter

12. Start the engine and run for one minute. Check the fuel filter for leaks and repair/tighten as necessary.

Figure 4-10 – Water Separator



cool.



3. Turn the fuel shut-off valve lever (4, Figure 4-10)

on the water separator to the “OFF” position.

4. Drain plug (6, Figure 4-10) has a hose connected to

it. Place a container underneath this hose to collect the water. Loosen plug (6) until water begins draining out through the hose. Allow water to drain until the red indicator ring returns to the bottom of the water separator.

5. Tighten the drain plug and discard fuel/water according to environmental laws. DO NOT pour the fuel/water onto the ground or down a drain.

6. Turn the fuel shut-off valve lever (4) on the water separator to the “ON” position.



4-13 918254/BP0112

Purging Air from the Fuel System

IMPORTANT

DO NOT bleed/prime the fuel system if the engine is hot. Spilled fuel can cause a fire.

Trapped air must be removed (bled) from the fuel system if the following conditions exist:

• the fuel tank has run dry

• any component in the fuel system was replaced, including the fuel filter element

• the machine has not been operated in a long time

To bleed air from the fuel system:

1. Fill the fuel tank.

2. Verify the fuel shut-off valve levers (1, Figure 4-9 and 4, Figure 4-10) on the fuel filter and the water

separator are both in the “ON” position.

3. Turn the ignition key to the “I” (ON) position.

4. Wait five minutes.

5. Start the engine.

If the engine runs smoothly and then stops, or if it does not run smoothly, switch off the engine and repeat steps 1 through 6. If the engine still does not run smoothly, contact your dealer.

Cooling System

Checking Coolant Level



cool.

Note: The engine must be cold in order to accurately check the coolant level.



3. Check the coolant level in the expansion reservoir.

If the coolant level is at or below the low line (3,

Figure 4-11), remove the reservoir cap (1).

4. Carefully loosen the radiator cap to allow the coolant system to vent. Fill reservoir to FULL line

(2). Refer to “Fluid Capacities/Lubricants” on page 1-4 for the correct coolant type and to

“Coolant Compound Table” on page 1-7 for the

correct coolant mixture. Replace the reservoir cap.

Tighten the radiator cap


1

2

3

Figure 4-11 – Coolant Expansion Reservoir

918254/BP0112 4-14 Printed in U.S.A.

Hydraulic System

WARNING

The hydraulic reservoir is under pressure.

Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this procedure, or gangrene may result.

g. Cycle all hydraulic functions and check the oil level at the sight glass. Repeat steps “a” through “f” (excluding b) if oil must be added.

h. Once oil is at the correct level (3, Figure 4-12),

replace the hydraulic valve cover (5) and tighten the hardware securely.


Checking Hydraulic Oil Level


2. For an accurate reading, fully extend the bucket and boom. Retract the dipper arm and lower the bucket and dozer blade to the ground. Refer to

Figure 4-12.





Note: See “Engine Compartment Components” on page 3-6

to locate the sight gauge and breather cap described below.

3. Check the hydraulic oil level sight gauge (2, Figure

4-12). Oil level should be approximately at point

(3).

4. If the hydraulic oil level is low:

a. Slowly loosen the breather cap (4, Figure 4-12)

to relieve pressure in the hydraulic system. Retighten the breather cap after relieving pressure.

b. Remove the hydraulic valve cover on the rear

of the machine (5, Figure 4-12) to access the

hydraulic oil filler cap (6).

c. Slowly open and remove the hydraulic oil filler cap (6).

d. Add hydraulic oil until it is at the ideal level

registered at the sight glass (2, Figure 4-12).

e. Replace and tighten the oil filler cap (6).

f. Start the engine and let it idle for a few minutes.

MAX

3

MIN

4

5

2

6

Figure 4-12 – Hydraulic Reservoir


4-15 918254/BP0112

Changing Hydraulic Oil

1. Position the machine on a level surface. Fully extend the bucket and boom, retract the arm and

position as shown in Figure 4-12.

2. Lower the bucket and dozer blade to the ground.

Perform the “Mandatory Safety Shutdown




4. Slowly loosen the breather cap (3, Figure 4-12) to

relieve pressure in the hydraulic system. Re-tighten the breather cap after relieving pressure.

5. Remove the hydraulic valve cover on the rear of the machine to access the hydraulic oil filler cap.

6. Slowly open and remove the hydraulic oil filler cap

(4, Figure 4-13). Cover the hydraulic oil filler

opening with a clean cloth to prevent contamination.

IMPORTANT

Protect the area from spilled or dripping hydraulic fluid.

7. Open the hydraulic reservoir drain plug and drain the oil into a suitable container. Once drained, reinstall the drain plug and tighten securely.

IMPORTANT

Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO

NOT pour onto the ground or down a drain.

1

4

Figure 4-13 – Hydraulic System Filter

9. Remove the cloth from the hydraulic oil filler opening and add hydraulic oil until it is at the

correct level (3, Figure 4-12) indicated at the sight

glass.

10. Replace and tighten the hydraulic oil filler cap (4,

Figure 4-13).

11. Start the engine and let it idle for a few minutes.

12. Cycle all hydraulic functions and check the oil level at the sight glass. If oil must be added, repeat the preceding steps except for steps 5 and 7.

13. Replace the hydraulic valve cover. Tighten hardware securely.


Hydraulic Cooling System

See “Engine Compartment Components” on page 3-6

for the hydraulic cooler location. Inspect the cooler for leaks or damage.

8. Remove the hydraulic system filter cover (1, Figure 4-13). Remove and discard old filter. Put clean

hydraulic fluid onto the gasket on a new filter and install the new filter into the filter reservoir.

Replace and tighten filter cover (1).

918254/BP0112 4-16 Printed in U.S.A.

Pilot Valve

IMPORTANT

Hydraulic oil contamination can damage pilot valve control spools. Check the pilot control valve filter/restrictor every 1000 hours and clean if necessary. Replace the filter/restrictor if it is damaged in any way.

Checking Pilot Control Valve Filter:

1. Fully extend the bucket and boom, retract the arm

and position as shown in Figure 4-12.

2. Lower the bucket and dozer blade to the ground.

Perform the “Mandatory Safety Shutdown Procedure” on page 2-2.



4. Slowly loosen the breather cap (4, Figure 4-12) to

relieve pressure in the hydraulic system. Re-tighten the breather cap after relieving pressure.

5. Disconnect the hose connected to the pilot control filter/restrictor fitting (B, Figure 4-14) on the right joystick control valve.

IMPORTANT

Hydraulic oil will leak during this procedure. Place absorbent material under valve to catch leaking oil. Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal.

D

C

B D

Figure 4-14 Pilot Control Filter/Restrictor

7. Check the filter/restrictor fitting filter screen (C) for contamination/dirt and clean if necessary.

Replace the filter/restrictor if it is damaged.

8. Replace filter/restrictor fitting (B) back into the valve, and reconnect hose to the filter/restrictor

(C). Tighten securely.

9. Repeat steps 5-8 for the left joystick control valve,

checking the filter/restrictors (D).

6. Disconnect the pilot control filter/restrictor fitting

(B) from the valve.


4-17 918254/BP0112

Hydraulic Hose Maintenance

1 Q/10

WARNING

• Hydraulic hoses and connections must be inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage.

• Leakages and damaged pressure lines must be immediately repaired or replaced by an authorized service center.

• Never use your hands to check for suspected hydraulic leaks. Always use a piece of wood or cardboard.

• Leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

• Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

• Always relieve hydraulic system pressure before performing any maintenance on the machine. Do not tighten leaking connections when the hydraulic system is under pressure.

• Never weld or solder damaged or leaking pressure lines and/or screw connections. Always replace damaged hydraulic components.

• Hydraulic hoses must be replaced every six years from the date of manufacture, even if they do not appear damaged.

The date of manufacture (month or quarter and year) is indicated on hydraulic hoses. See Figure 4-15.

Figure 4-15 Hydraulic Hose Manufacture Date

918254/BP0112 4-18 Printed in U.S.A.

Electrical System

Fuses



2. See “Fuses” on page 1-6 to locate and identify the

fuses.

3. To replace a fuse:

a. Perform the “Mandatory Safety Shutdown Procedure” on page 2-2. Wait for the engine to

cool.

b. Remove the panel cover. c. Remove the old fuse from the socket. d. Install a new fuse of the same rating.

IMPORTANT

Determine what caused the fuse to blow and repair the problem before replacing the fuse.

WARNING

Never lay a metal object on top of a battery, because a short circuit can result. Battery acid is harmful to skin and fabrics. If acid spills, follow these first-aid tips:

Immediately remove any clothing on which acid spill.

• If acid contacts skin, rinse the affected area with running water for 10 to 15 minutes.

• If acid contacts eyes, flood eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

• To neutralize acid spilled on the floor, use one of the following mixtures:

• 0.5 kg (1 lbs.) of baking soda in 4 L (4 qts.) of water.

• 0.5 L (0.5 qts.) of household ammonia in

4 L (4 qts.) of water.

4. Replace the fuse panel cover.


Battery

WARNING

Before servicing the battery or electrical system, disconnect the negative cable from the negative battery terminal, or if the machine is equipped with a battery disconnect switch, turn the switch to the “OFF” position.

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. ALWAYS charge the battery in a well ventilated area.

Do not jump-start a frozen battery, or it may explode. A discharged battery can freeze at

14°F (10°C).

Note: See “Engine Compartment Components” on page 3-6

to locate the battery.

Battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery-saver grease.

Note: The battery is maintenance-free and requires no other service.

IMPORTANT

Damage to the alternator can occur if:

• the engine is operated with the battery cables disconnected,

• the battery cables are connected when using a fast charger or when welding on the machine (When welding on the machine, remove both cables from the battery and ground the welder to the machine frame near the repair area), or

• extra battery cables (booster cables) are connected incorrectly.


4-19 918254/BP0112

Using a Booster Battery (Jump-Starting)

WARNING

• Keep arcs, sparks, flames and lighted tobacco away from batteries. When jump-starting from a booster battery, make final connection (negative) at engine frame away from the battery.

Batteries can create flammable gases.

Sparks or open flames can cause this gas, and the battery, to explode.

• DO NOT jump-start or charge a frozen battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

7. Connect the other end of the same cable to the frame of the machine with the discharged battery.

8. Start the engine of the machine with the discharged battery.

9. Once the engine is running, remove the cable connected to the frame first.

10. Disconnect the other cable from the positive (+) terminal on the discharged battery.

11. Remove the cables from the booster battery.

IMPORTANT

DO NOT allow the booster cable ends to touch together when removing them from the batteries. Arcs and direct short circuits can cause severe damage to the electrical systems.


IMPORTANT

When jump-starting from another machine, be sure the second machine is not running if pre-heating the unstarted machine. High voltage spikes from a running machine can burn out the engine pre-heating system.

P

0

I

II

IMPORTANT

The booster battery must be 12 volt.

III

Discharged

Battery

12 V

1. Turn the ignition key on the machine with the discharged battery to the “P” position (see Figure

4-16).



3. Stop the engine of the machine with the booster battery.

4. Connect one end of a jumper cable to the positive

(+) terminal on the booster battery.

5. Connect the other end of the same cable to the positive (+) terminal on the discharged battery.

6. Connect one end of the second jumper cable to the negative (-) terminal on the booster battery.

Figure 4-16 – Jump-starting

12 V

Booster

Battery

918254/BP0112 4-20 Printed in U.S.A.

Checking & Adjusting V-belt Tension



cool.



3. Inspect the V-belt (1, Figure 4-17) for damage. If

the V-belt is damaged, have it replaced by your dealer.

4. Press on the V-belt to check deflection. The belt should deflect no more than 5/16" (8 mm).

5. If deflection is more than 5/16" (8 mm):

a. Loosen the adjustment bolt (2, Figure 4-17)

and rotate the alternator (3) as necessary until

V-belt tension is correct.

b. Tighten bolt (2) and re-check V-belt tension.

Windshield Washer Fluid





3. Open the windshield washer reservoir cover (1,

Figure 4-18) and fill the tank with windshield washer fluid.

4. Close the windshield washer tank cover securely.


1

1 approx. 5/16" (8 mm)

Figure 4-18 – Fluid Reservoir

2

Figure 4-17 – V-belt Tension

3


4-21 918254/BP0112

Track System

Track Cleaning

If dirt or mud builds up in the track frame, raise the track frame using the boom and dipper arm and then operate the elevated track to clean it. Be sure that the build-up has been cleared from the track. Repeat for the

other track. See Figure 4-19.

Position track so drain plugs align vertically

1

2

3

Figure 4-19 – Track Cleaning

Checking the Drive Oil

1. Position the machine on a level surface with drive

plugs positioned as shown in Figure 4-20.



3. Remove the top and center plugs (1 and 2, Figure

4-20).

4. If a slight amount of oil does not flow out of the opening for center plug (2), add oil (Chevron Delo

Gear 80W-90 or BP Transgear 80W-90) into the top opening (1) until oil flows out of center plug opening (2).

5. Re-install plugs (1) and (2).

6. Wipe off any oil that has flowed out and properly dispose of the soiled towel(s).

Figure 4-20 – Plugs for Drive Oil Check/

Change

Changing the Drive Oil

1. Position the machine on a level surface with final

drive plugs positioned as shown in Figure 4-20.



3. Place a container to catch draining oil underneath

the bottom drain plug (3, Figure 4-20).

4. Remove the center plug (2, Figure 4-20).

5. Remove the bottom plug (3) to drain oil into the container. Once all oil has drained, re-install the bottom plug (3).

6. Remove the top drain plug (1, Figure 4-20).

7. Add oil (Chevron Delo Gear 80W-90 or BP

Transgear 80W-90) into top plug (1) until oil begins to flow out of center plug hole(2).

8. Re-install plugs (1) and (2).

9. Wipe off any oil that has flowed out and properly dispose of the soiled towel(s) and drained oil in the container.

IMPORTANT

Always dispose of oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

918254/BP0112 4-22 Printed in U.S.A.

Checking and Adjusting Track Tension


2. Locate the mark (1, Figure 4-22) on the rubber

track. Move the machine until this mark is at top

center, midway between points A and B (2, Figure

4-22).

3. Use the bucket and dozer blade to lift the unit up until the track is just clear of the ground as shown

in Figure 4-21.



5. Measure the clearance of the raised track at the second track roller from the drive gear. Deflection should be between 3/4 - 1" (20 - 25 mm). See

Figure 4-22.

6. Using a wrench, loosen the grease fitting (3, Figure

4-22) one full turn only. Using a grease gun, pump

grease into the fitting until the track is properly tensioned.

Note: A grease gun is supplied in the machine tool kit.

IMPORTANT

Do not over-tension the track. If the track is too tight, loosen the grease fitting no more than one full turn to relieve the pressure.

Figure 4-21 – Track Adjustment Position

A

1

2 B

WARNING

Do not loosen the grease fitting more than two turns, or the fitting could be ejected under pressure and cause injury. Keep your face and body away from the fitting when loosening.

7. Start the engine. Lower the unit to the ground.

8. Repeat this procedure for the other track.

3/4 - 1"

(20-25 mm)

Figure 4-22 – Track Adjustment

3


4-23 918254/BP0112

Replacing the Cab Filter

(cab model only)

The heater unit is located underneath the operator’s seat. It has an intake filter that will affect heater performance if it becomes clogged or filled. To check the filter:

1. Use a socket wrench to remove the four bolts securing the heater intake plate (2, Figure 4-16).

2. Lift the floor insulating mat (3) and the floor access door (4).

3. Remove the heater intake plate to access the heater unit.

4. Remove and visually inspect the existing filter (5).

If it is clogged with dust and other particulates, replace with a new filter.

5. Replace the heater intake plate. Replace and hand tighten the top two bolts.

6. Close the floor access door and replace the floor insulating mat before replacing the bottom two bolts.

7. Once the four bolts have been replaced and hand tightened, finish tightening them with the socket wrench.

2

3

4

5

Figure 4-23 – Accessing the Heater Filter

918254/BP0112 4-24 Printed in U.S.A.

LONG-TERM STORAGE

If storing the machine for a long period (longer than two months), perform the procedures in this section.

Before Storage

1. Wash the entire machine.

2. Lubricate all grease fittings. See “Daily Lubrication” on page 4-8.

3. Change the engine oil and filter according to

“Changing Engine Oil and Filter” on page 4-10.

4. Add a fuel stabilizer to the fuel system according to the fuel supplier’s recommendations.

5. Remove and fully charge the battery. Store the battery in a cool, dry location.

6. If the machine will not be operated for a month or longer, apply grease to all exposed hydraulic cylinder rod areas or retract all cylinders so rod exposure is minimized. Apply grease to any remaining rod areas.

7. If the ambient temperature (at any time during the storage period) is expected to drop below freezing, make sure the engine coolant is either completely drained from the radiator and engine block or that the amount of anti-freeze is adequate to keep the coolant from freezing. Refer to the engine manual for anti-freeze recommendations and quantities.

8. Protect against extreme weather conditions such as moisture, sunlight and temperature.

During Storage

About once each month, connect the battery and check all fluid levels to make sure they are at the proper level before starting the engine.

Start the engine and allow it to run until it warms up and then move the machine a short distance to help lubricate internal parts. Run the engine until the battery has a chance to recharge and then shut off the engine.

IMPORTANT

If it is desired to operate the hydraulic cylinders at this time, BE SURE to wipe the protective grease (and any adhering dirt) from the cylinder rods prior to starting the engine. After operating, BE SURE to reapply grease to the cylinder rods if the machine will be returned to storage.

After Storage

After removing the machine from storage and before operating it, perform the following:

1. Replace and re-connect the battery.

2. Wipe off grease (and any adhering dirt) from cylinder rods.

3. Check V-belt tension.

4. Check all fluid levels and top-off as necessary.

5. Start the engine. Observe all indicators. If all indicators are functioning properly and reading normally, move the machine outside.

6. When outside, park the machine and let the engine idle for at least five minutes.

7. Shut off the engine and walk around machine.

Make a visual inspection looking for evidence of leaks.Review and re-familiarize yourself with all

safety precautions starting on page 2-1.

8. Follow the starting and warm-up procedures

according to starting on page 3-17.


4-25 918254/BP0112

FINAL SHUTDOWN /

DECOMMISIONING

IMPORTANT

Dispose of all materials properly. Used oils/ fluids are environmental contaminants and may only be disposed of at approved collection facilities. Never drain any oils/ fluids directly onto the ground, in municipal waste collection containers, or into metropolitan sewer systems or landfills.

Check state and local regulations for other material disposal requirements.

If the machine will no longer be used as intended, shutdown, decommision and dispose of it according to the valid regulations.

Before Disposal

1. Shutdown the machine according to valid regulations regarding proper shutdown.

2. Park the machine on level, dry ground. Ensure the surface can support the weight of the machine.

Ensure the location is protected against access by unauthorized persons.

3. Move the throttle to the low-idle position and allow the engine to cool for approximately 2 minutes.

4. Shut off the engine.

5. Move the hydraulic controls to verify that the controls do not cause movement.

6. Raise the left operator console to lock out the hydraulic controls.

7. Switch off all electrical switches.

8. Unfasten the seat belt, remove the ignition key and take it with you.

9. Ensure the machine cannot be operated after shutdown until further disposal.

10. Ensure no environmentally hazardous materials, fluids and/or fuel can escape the machine.

Specifically check for leaks form the engine, the hydraulic system and the coolant system.

11. Ensure the machine poses no dangers in the place where it is standing.

12. Remove any dirt and/or debris from the engine compartment, the chassis and the cylinder rod surfaces.

13. Remove the battery

14. Lock the cab door and the storage, hydraulic valve and engine compartments. Remove all keys and take them with you.

Machine Disposal

Make sure all materials are disposed of in an ecologically sound manner.

Recycling the machine in accordance with the current state of the art at the time of recycling. Observe all accident prevention regulations.

Dispose of all parts at the at the recycling sites specific to the material of the part. Take care to separate different materials for recycling.

918254/BP0112 4-26 Printed in U.S.A.

CHAPTER 5 – TROUBLESHOOTING

ENGINE

Problem

Engine hard staring or fails to start

Rough running engine

Insufficient engine power

No fuel

Possible Cause

Incorrect engine oil SAE grade

Incorrect fuel grade

Fuel filter contaminated

Malfunctioning fuel injector(s)

Corrective Action

Add fuel to tank; bleed air from fuel system

Replace engine oil with proper grade (“Fluid

Capacities/Lubricants” on page 1-4)

Replace fuel with proper grade (“Fluid


Loose, or corroded starter circuit connections Repair starter circuit. Contact authorized service center

Incorrect engine valve clearance Adjust valve clearance. Contact authorized service center

Battery power insufficient Charge battery or replace if necessary

(“Battery” on page 4-19)

Replace fuel filter (“Fuel Filter” on page 4-12)

Starter not working / pinion fails to engage

Repair fuel injector(s). Contact authorized service center

Repair starter/pinion. Contact authorized service center

Pre-heating system not working


Incorrect engine valve clearance

Fuel line leakage

Repair pre-heating system. Contact authorized service center



Adjust valve clearance. Contact authorized service center

Replace fuel line. Contact authorized service center


Fuel line leakage

Air filter contaminated

Engine not at operating temperature


Repair fuel injector(s). Contact authorized service center.

Replace fuel line. Contact authorized service center

Service air filter. (“Engine Air Cleaner” on page 4-11)

Warm up the engine



Incorrect engine valve clearance

Oil level too high


Engine overheated

Adjust valve clearance. Contact authorized service center

Adjust oil level (“Changing Engine Oil and

Filter” on page 4-10)


Check cooling system


5-1 918254/BP0112

Problem

Engine overheats

Possible Cause

Oil level too low

Fouled oil cooler fins

Damaged fan. Damaged or loose V-belt

Coolant level too low


Add engine oil (“Checking Engine Oil Level” on page 4-9)

Clean oil cooler. Contact authorized service center

Replace the fan / service V-belt (“Hydraulic

Hose Maintenance” on page 4-18). Contact

authorized service center

Add coolant (“Fluid Capacities/Lubricants” on page 1-4)

High engine oil consumption

Engine smoke

Oil level too high

Oil level too low


Oil level too high

Machine inclination too high


Blue

White

Black

Oil level too high



Add engine oil (“Checking Engine Oil Level” on page 4-9)




15° maximum inclination up and across slopes; 25° maximum inclination down slopes







Engine starting temperature too low

Wait for engine pre-heat cycle to complete before starting engine










Malfunctioning fuel injector(s) Repair fuel injector(s). Contact authorized service center


5-2 918254/BP0112

INDICATOR LAMPS

Problem

Engine oil pressure indicator light comes on during operation

Possible Cause

Engine oil pressure too low

Engine oil level too low

Oil pump not working



Coolant level too low Water temperature display light comes on during operation (Engine overheating)

Fuel light comes on

Air filter light comes on

Fan blades rotating too slowly


Coolant system malfunction

Battery voltage light comes on during operation

Alternator not charging properly / malfunctioning alternator

Loose, or corroded charging circuit connections

Low fuel


SEALS AND HOSES

Problem

Oil, coolant or fuel leakage under engine

Possible Cause

Loose hose connection(s)

Seals or hoses damaged

Hydraulic fluid losses from hydraulic system

Loose hose connection(s)

Seals, hoses or lines damaged


Stop engine immediately. Check oil level and

add oil if necessary (“Checking Engine Oil

Level” on page 4-9). If oil level is correct, oil

pump may have failed

Add oil (“Checking Engine Oil Level” on page 4-9)

Stop engine immediately. Replace oil pump.

Contact authorized service center




Add coolant (“Fluid Capacities/Lubricants” on page 1-4)

Adjust V-belt tension (“Hydraulic Hose

Maintenance” on page 4-18)


Service cooling system. Contact authorized service center

Adjust V-belt tension (“Hydraulic Hose

Maintenance” on page 4-18). Service

alternator. Contact authorized service center

Repair charging circuit. Contact authorized service center

Add fuel

Service air filter (“Engine Air Cleaner” on page 4-11)


Tighten hose connection(s)

Change seals or hoses and check engine oil, engine coolant or fuel levels. Add engine oil, coolant or fuel if necessary

Tighten hose connection(s)

Service seals, hoses and/or lines. Contact authorized service center


5-3 918254/BP0112

TRAVELING GEAR

Problem

Machine will not travel

Possible Cause

Obstruction jamming track mechanism

Gears inoperative

Machine will not travel straight forward or rearward

Obstruction jamming track mechanism

Unequal track tension

Travel valves damaged


Remove object

Repair gears. Contact authorized service center

Remove object

Adjust track tension (“Checking and Adjusting

Track Tension” on page 4-23)

Repair/replace valves. Contact authorized service center

BUCKET, BOOM AND DOZER BLADE

Problem

Swing frame rotation malfunctioning

Front end attachments do not work or work only at a low performance level

Possible Cause

Swing brake does not release

Insufficient lubrication

Low hydraulic fluid level

Low engine power


Contact authorized dealer

Lubricate swing gear using remote grease fitting

Add hydraulic fluid (“Checking Hydraulic Oil

Level” on page 4-15)

See Insufficient engine power on page 5-1.



Hydraulic cylinders lower too quickly

Hydraulic lines overheat

Engine to pump coupling or hydraulic pump damaged

Pressure limiting valves set too low

Hydraulic cylinder damaged

Control valves damaged

Seals contaminated or damaged

Heavy internal leakage at control spools

Secondary cartridge valves damaged

Hydraulic oil filter blocked

Low hydraulic fluid level

Secondary cartridges set too low

Hydraulic fluid cooling system not in working order







Replace filter

Add hydraulic fluid (“Checking Hydraulic Oil

Level” on page 4-15)


Service hydraulic fluid cooling system.



5-4 918254/BP0112

A

Air Conditioning ..............................................4-7

Air Filter Element Replacement ....................4-11

Approved Attachments ....................................1-9

Attachment Mounting/Removal ....................3-25

Auxiliary Hydraulics

Connections .............................................3-27

Operation .................................................3-28

Index

Components ...............................................3-6

Shut-down ................................................3-17

Specifications .............................................1-5

Speed Control/Throttle ..............................3-7

Start ..........................................................3-17

Excavation .....................................................3-21

Trench Excavation ...................................3-23

F

B

Battery ............................................................4-19

Boom Swivel Control ......................................3-7

Bucket Mounting/Removal ............................3-25

C

Cab Door ........................................................3-14

Cab Filter Replacement .................................4-24

Component Identification ................................1-3

Controls Identification .....................................3-2

Cooling System ..............................................4-14

Fields of Applications ......................................1-9

Fluid Capacities/Lubricants .............................1-4

Fuel System ....................................................4-12

Bleeding ...................................................4-14

Fuel Filler Cap .........................................4-12

Fuel Filter .................................................4-12

Fuel Tank, Filling ....................................4-12

Purging Air ..............................................4-14

Fuses ..............................................................4-19

G

D

General Information .........................................1-1

General Specifications .....................................1-8

Grading (Bulldozing) .....................................3-24

Guards and Shields ..........................................3-1

Decals

Safety and Information ............................2-10

ANSI-Style Safety/Information Decal 2-16

ISO-Style Information Decal .............2-14

ISO-Style Safety Decals ....................2-11

Decommisioning ............................................4-26

Delivery Checklists ........................................1-13

Dozer Blade .....................................................1-5

Control .......................................................3-7

Maintenance ...............................................4-7

E

I

H

Heater Filter Replacement .............................4-24

High-Speed Travel .........................................3-10

Hydraulic Cooling System .............................4-16

Hydraulic System ................................... 1-5, 4-15

Changing Oil ............................................4-16

Hose Maintenance ....................................4-18

Ignition Key Switch .........................................3-7

Instruments and Indicators ...............................3-4

ISO-Pattern Operating Controls .....................3-10

Electrical System .......................... 1-6, 4-15, 4-19

Battery ......................................................4-19

Fuses ..........................................................1-6

Relays .........................................................1-7

Engine ...................................................... 1-5, 4-9

Air Cleaner ...............................................4-11

Air Cleaner, Dust Valve ...........................4-11

Changing Oil and Filter ...........................4-10

Checking Oil Level ....................................4-9

Compartment Access .................................3-6

J

Jump-Starting .................................................4-20


A-1 918254/BP0112

Index

L

Load Diagrams ...............................................1-10

Loading Trucks ..............................................3-25

Long-Term Storage ........................................4-25

Lubrication .......................................................4-7

Daily ...........................................................4-8

S

M

Machine Orientation ........................................3-1

Maintenance .....................................................4-1

Label ..........................................................4-4

Symbols ...............................................4-3

Safety .........................................................4-2

Schedule .....................................................4-5

Maintenance Safety ..........................................2-7

Maintenance Schedule

Bucket, Boom and Dozer Blade ................4-7

Check, Clean and Inspect ...........................4-5

Fluid and Filter Changes ............................4-6

Swing Gear Ring ........................................4-7

Mandatory Safety Shutdown Procedure ..........2-2

Mechanical Stop Brake ..................................3-20

N

New Machine Break-in ..................................3-18

O

Operation .........................................................3-1

Pre-Operation Checklist .....................3-16

Cold Weather Operation ..........................3-21

Controls ......................................................3-1

Operating Instructions ..............................3-19

Operational Safety .....................................2-2

Water Operation .......................................3-21

Operator’s Seat Adjustments .........................3-11

Ownership Change ...........................................1-2

R

Recommended Lubricants ...............................4-9

Relays ...............................................................1-7

SAE/ISO Selector Valve .......................... 3-8, 3-9

SAE-Pattern Operating Controls .....................3-9

Safety

Additional Safety Equipment .....................2-6

Attachment Precautions .............................2-2

Crane Lifting ............................................2-10

Crystalline Silica Exposure ........................2-5

Danger, Warning, Caution Signal Word ....2-1

Fire Hazards ...............................................2-6

Mandatory Safety Shutdown Procedure ....2-2

Safety During Maintenance .......................2-7

Safety During Operation ............................2-2

Travel Control Reversal .............................2-5

Safety Decal Locations ..................................2-11

Serial Number Location ........................... 1-1, 1-2

Specifications ...................................................1-4

Coolant Compound Table ..........................1-7

Dimensions ................................................1-8

Dozer Blade ...............................................1-5

Electrical System .......................................1-6

Engine ........................................................1-5

Fluid Capacities/Lubricants .......................1-4

Fuses ..........................................................1-6

General .......................................................1-8

Hydraulic System .......................................1-5

Load Diagrams

With Counterweight ...........................1-11

Without Counterweight ......................1-10

Relays .........................................................1-7

Sound Levels ..............................................1-7

Undercarriage and Swing System ..............1-6

Storage, Long-Term .......................................4-25

Swivel Unit Brake ..........................................3-20

T

Track Cleaning ...............................................4-22

Track System .................................................4-22

Changing the Drive Oil ............................4-22

Checking the Drive Oil ............................4-22

Track Tension Adjustment .......................4-23

Transporting ...................................................3-28

Travel .............................................................3-18

Travel Controls ................................................3-8

Travel Control Reversal .............................2-5


A-2 918254/BP0112

Index

Travel Speed Selection ...................................3-18

U

Undercarriage and Swing System ....................1-6

V

V-Belt

Adjustment ...............................................4-21

Ventilation – Cab Only ..................................3-13

W

Water Separator ..............................................4-13

Windshield .....................................................3-13

Windshield Washer Fluid ..................... 4-21, 4-24


A-3 918254/BP0112

Index


A-4 918254/BP0112

TORQUE SPECIFICATIONS

Note: Use these torque values when tightening Gehl hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Straight pipe fitting with thread and screwed plug (GE)

Sealing washer Elastic seal O-ring

Non-return with elastic seal

Identification aid outside Ø

M10X1.0

M12X1.5

M14X1.5

M16X1.5

7 (9)

15 (20)

26 (35)

33 (45)

13 (18)

18 (25)

33 (45)

41 (55)

11 (15)

18 (25)

26 (35)

30 (40)

13 (18)

18 (25)

26 (35)

37 (50)

0.4 in. (10 mm)

0.5 in. (12 mm)

0.6 in. (14 mm)

0.6 in. (16 mm)

M18X1.5

M22X1.5

M27X2.0

M33X2.0

M42X2.0

M48X2.0

G1/8A

G1/4A

41 (55)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

7 (9)

26 (35)

52 (70)

92 (125)

133 (180)

229 (310)

332 (450)

398 (540)

13 (18)

26 (35)

33 (45)

44 (60)

74 (100)

118 (160)

155 (210)

192 (260)

11 (15)

22 (30)

52 (70)

92 (125)

107 (145)

155 (210)

266 (360)

398 (540)

13 (18)

26 (35)

0.7 in. (18 mm)

0.9 in. (22 mm)

1.0 in. (27 mm)

1.3 in. (33 mm)

1.7 in. (42 mm)

1.9 in. (48 mm)

0.4 in. (9.73 mm)

0.5 in. (13.16 mm)

G3/8A

G1/2A

G3/4A

G1A

G1 1/4A

G1 1/2A

33 (45)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

52 (70)

66 (90)

133 (180)

229 (310)

332 (450)

398 (540)

33 (45)

41 (55)

74 (100)

118 (160)

155 (210)

192 (260)

37 (50)

48 (65)

103 (140)

140 (190)

266 (360)

398 (540)

0.7 in. (16.66 mm)

0.8 in. (20.96 mm)

1.0 in. (26.44 mm)

1.3 in. (33.25 mm)

1.7 in. (41.91 mm)

1.9 in. (47.80 mm)

M22X1.5

M27X2.0

M33X2.0

M42X2.0

M48X2.0

G1/8A

G1/4A

G3/8A

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE)

Thread

Sealing washer Elastic seal O-ring

Non-return with elastic seal

Identification aid outside Ø

M12X1.5

15 (20) 26 (35) 26 (35) 26 (35) 0.5 in. (12 mm)

M14X1.5

M16X1.5

M18X1.5

M20X1.5

26 (35)

33 (45)

41 (55)

41 (55)

41 (55)

52 (70)

66 (90)

92 (125)

33 (45)

41 (55)

52 (70)

59 (80)

33 (45)

41 (55)

52 (70)

74 (100)

0.6 in. (14 mm)

0.6 in. (16 mm)

0.7 in. (18 mm)

0.8 in. (20 mm)

G1/2A

G3/4A

G1A

G1 1/4A

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

26 (35)

33 (45)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

100 (135)

133 (180)

229 (310)

332 (450)

398 (540)

41 (55)

59 (80)

85 (115)

133 (180)

229 (310)

332 (450)

398 (540)

74 (100)

125 (170)

229 (310)

243 (330)

310 (420)

33 (45)

44 (60)

55 (75)

125 (170)

229 (310)

243 (330)

310 (420)

92 (125)

100 (135)

155 (210)

266 (360)

398 (540)

33 (45)

44 (60)

74 (100)

107 (145)

192 (260)

266 (360)

398 (540)

0.9 in. (22 mm)

1.0 in. (27 mm)

1.3 in. (33 mm)

1.7 in. (42 mm)

1.9 in. (48 mm)

0.5 in. (13.16 mm)

0.7 in. (16.66 mm)

0.8 in. (20.96 mm)

1.0 in. (26.44 mm)

1.3 in. (33.25 mm)

1.7 in. (41.91 mm)

1.9 in. (47.80 mm)

Thread

M12

M14

M16

M18

M5

M6

M8

M10

M20

M22

M24

M27

M30

Thread

M8X1.0

M10X1.0

M10X1.25

M12X1.25

M12X1.5

M14X1.5

M16X1.5

M18X1.5

M20X1.5

M22X1.5

M24X2.0

M27X2.0

M30X2.0

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

12.9

Threads according to DIN 7984

8.8

10.9

4.1 (5.5)

7 (10)

18 (25)

33 (45)

6 (8)

10 (14)

26 (35)

48 (65)

7 (10)

13 (17)

31 (42)

59 (80)

4 (5)

6.3 (8.5)

15 (20)

30 (40)

5 (7)

9 (12)

22 (30)

44 (59)

64 (87)

100 (135)

155 (210)

207 (280)

302 (410)

406 (550)

524 (710)

767 (1040)

1047 (1420)

81 (110)

133 (180)

203 (275)

302 (410)

420 (570)

575 (780)

738 (1000)

1092 (1480)

1482 (2010)

108 (147)

170 (230)

258 (350)

354 (480)

509 (690)

686 (930)

878 (1190)

1305 (1770)

1770 (2400)

51 (69)

81 (110)

125 (170)

181 (245)

251 (340)

339 (460)

435 (590)

642 (870)

885 (1200)

74 (100)

118 (160)

184 (250)

254 (345)

361 (490)

487 (660)

620 (840)

922 (1250)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

12.9

Threads according to DIN 7984

8.8

10.9

18 (25)

37 (50)

36 (49)

64 (87)

27 (37)

55 (75)

52 (71)

96 (130)

32 (43)

65 (88)

61 (83)

111 (150)

16 (22)

32 (43)

31 (42)

55 (75)

24 (32)

48 (65)

46 (62)

81 (110)

61 (83)

100 (135)

155 (210)

232 (315)

325 (440)

435 (590)

546 (740)

811 (1100)

1106 (1500)

92 (125)

148 (200)

229 (310)

332 (450)

465 (630)

620 (840)

789 (1070)

1143 (1550)

1586 (2150)

107 (145)

173 (235)

266 (360)

391 (530)

538 (730)

723 (980)

922 (1250)

1328 (1800)

1844 (2500)

53 (72)

89 (120)

133 (180)

199 (270)

277 (375)

369 (500)

465 (630)

679 (920)

959 (1300)

77 (105)

129 (175)

195 (265)

284 (385)

391 (530)

524 (710)

664 (900)

959 (1300)

1364 (1850)

WARNING

THIS OPERATOR'S MANUAL IS

PROVIDED FOR OPERATOR USE

DO NOT REMOVE

FROM THIS MACHINE

Do not start, operate or work on the machine until you carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of the machine, contact your dealer or the Gehl Company

Service Department before starting or continuing operation.

California Proposition 65 Warnings:

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer and birth defects and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery.

®

918254/BP0112

Manitou Americas, Inc.

One Gehl Way, P.O. Box 179

West Bend, WI 53095-0179 U.S.A.

www.gehl.com

© 2012 All rights reserved.


Gehl 283Z Compact Excavator Operator’s Manual

Assistant Bot

Model 283Z

Compact Excavator

®

GEHL COMPANY

WARRANTY

GEHL WARRANTY SERVICE INCLUDES:

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,

EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS

EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY DOES NOT INCLUDE:

TABLE OF CONTENTS

Chapter 1 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chapter 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Chapter 5 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHAPTER 1 –

GENERAL INFORMATION

INTRODUCTION

Machine and Cab Serial Number

Locations

Engine Serial Number Location

Ownership Change

15

11

7

1

21

2

10

22

3

19

18

4

13

14

15

12

20

9

16

15

5

6

8

17

SPECIFICATIONS

Fluid Capacities/Lubricants

Engine

Hydraulic System

Dozer Blade

Undercarriage and Swing System

Electrical System

Fuses

Relays

Coolant Compound Table

Sound Levels

General Specifications

Fields of Applications/Approved Attachments

Load Diagrams

Maximum permissible loads

Maximum permissible loads

CHECKLISTS

RETAIN FOR CUSTOMER’S RECORDS

INTENTIONALLY BLANK

CHECKLISTS

RETAIN FOR CUSTOMER’S RECORDS

INTENTIONALLY BLANK

CHAPTER 2 – SAFETY

GENERAL SAFETY

INFORMATION

GENERAL SAFETY RULES

Unauthorized Modifications

Attachment Precautions

MANDATORY SAFETY SHUTDOWN

PROCEDURE