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.
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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.
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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.
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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.
Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.
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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:
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Figure 3-29 – Traveling Up or Down Slopes
Printed in U.S.A.
• 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.
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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
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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
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• 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
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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).
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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.
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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
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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.
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(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
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Notes:
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