CX14 Op's Manual

CX14
MINI-EXCAVATOR
Operator’s Manual
Bur 6-37900NA
CX14
MINI-EXCAVATOR
OPERATOR’S MANUAL
Part Number: 6-37900NA
CASE TECHNICAL MANUALS

Manuals are available from your Dealer for the operation, service, and repair of your machine. For
prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your
machine.
Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and
Maintenance records.
Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial
Number) of your machine so your Dealer can provide the correct manuals for your machine.
NOTE: Case, LLC reserves the right to make improvements in design or changes in specifications at
any time without incurring any obligation to install them on units previously sold.
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE
ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY
M171D
Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:
DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or
serious injury. The color associated with Danger is RED.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury. The color associated with Warning is ORANGE.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices. The color associated with
Caution is YELLOW.
If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:
The first panel indicates the nature of the hazard.
The second panel indicates the appropriate avoidance of the hazard.
Background color is YELLOW
Prohibition symbols such as and STOP if used, are RED.
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE
USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:
Is instructed in safe and proper use of the machine.
Reads and understands the Manual(s) pertaining to the machine.
Reads and understands ALL Safety Decals on the machine.
Clears the area of other persons.
Learns and practices safe use of machine controls in a safe, clear area before operating this
machine on a job site.
It is your responsibility to observe pertinent laws and regulations and follow CASE instructions on
machine operation and maintenance.
WARNING_01_NA
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
Battery post, terminals and related accessories contain lead and lead compounds.
Wash hands after handling.
Copyright © 2003 Case LLC. Bur 6-37900NA

All Rights Reserved Issued January, 2003
CASE is a registered trademark of Case, LLC.
TABLE OF CONTENTS
Safety Precautions ................................................................................................................. Section 1
Machine Familiarization ......................................................................................................... Section 2
Basic Machine Operation ....................................................................................................... Section 3
Maintenance ........................................................................................................................... Section 4
Transportation ......................................................................................................................... Section 5
Specifications ......................................................................................................................... Section 6
Troubleshooting ...................................................................................................................... Section 7
Optional Equipment................................................................................................................ Section 8
Specifications (EPA Engine) .................................................................................................. Section 9
I
GENERAL INFORMATION
Your machine has been designed and built to the highest standards of quality. It conforms to all current safety
regulations. See Official documents. However, the risk of accidents can never be completely excluded. That is
why it is essential to observe elementary safety rules and precautions.
Read this manual carefully, paying particular attention to the instructions concerning safety, operation, and
maintenance so as to avoid the risk of injury while operating or servicing the machine.
The standard attachments and tools of this machine are designed to carry out all kinds of earthmoving and
rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make
sure that it is designed to carry out this kind of work. For this type of application, the machine must be equipped
with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its
attachment and a load fixing point. All legal requirements must also be strictly observed.
Do not use this machine for any application or purpose other than those described in this manual. If the machine
is to be used for work involving the use of special attachments, accessories, or equipment, consult your CASE
Dealer in order to make sure that any adaptations or modifications made are in keeping with the machines
technical specifications and with prevailing safety requirements.
Any modification or adaptation which is not approved by the manufacturer may invalidate the machines initial
conformity with safety requirements.
The machine must undergo regular inspections, the frequency of which varies according to the type of use.
Consult your CASE Dealer.
Before permitting a new operator on this machine, make sure:
1. That the operator has received the necessary training on how to operate the machine correctly and
safely in one of our training centres or from an approved organization.
2. That the operator has read and understood the instructions given in this manual.
Always keep this manual in the operators compartment. Make sure it is always complete and in good condition.
If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your CASE
Dealer.
Your CASE Dealer is at your disposal for any further information. He will also provide any after-sales service you
may require, and genuine CASE spare parts, your guarantee of quality and match.
Materials and specifications are subject to change without notice.
II
FOR ORDERING
For ordering parts and service, inform an authorized dealer of your machines Serial Number and Engine Serial
Number stamped in the locations, and Hourmeter read, shown on the illustrations below. For future reference,
record these Serial Numbers in the spaces provided below:
MACHINE No.
ENGINE No.
MACHINE NO.
NOTE
The numbers in the illustrations
are for explanation only and differ
from actual numbers.
III
NOTES
IV
SECTION 1
SAFETY PRECAUTIONS
TABLE OF CONTENTS
1.1 GENERAL SAFETY INFORMATION .................................................................................................... 1-2

1.2 SAFETY PRECAUTIONS ..................................................................................................................... 1-3
1.3 PRE-START SAFETY ........................................................................................................................... 1-5
1.4 SAFETY DURING OPERATION ......................................................................................................... 1-11
1.5 INSPECTION & MAINTENANCE SAFETY ......................................................................................... 1-19
1.6 BATTERY SAFETY ............................................................................................................................. 1-26
1.7 WARNING LABELS & DECALS .......................................................................................................... 1-27
1.8 PROHIBITED MACHINE OPERATION ............................................................................................... 1-31
1.9 END OF WORK SHIFT SAFETY ........................................................................................................ 1-33
1.10 PRECAUTIONS FOR TRANSPORTATION ......................................................................................... 1-34
1.11 TOWING THE MACHINE .................................................................................................................... 1-35
Read, understand and follow all safety precautions and procedures found in this manual before
attempting any operation, inspection or maintenance of this machine, attachment or systems. CASE
cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by CASE is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance and/or repair procedures you
choose.
1-1
SECTION 1 - SAFETY PRECAUTIONS
1.1 GENERAL SAFETY INFORMATION 3. Messages of safety appear in this manual and on
the machine. All messages of safety are identified
by the words DANGER, WARNING and CAU-
TION.
Do not operate or perform any maintenance on a. DANGER - Indicates an imminently hazardous
this machine until all instructions found in this situation which, if not avoided, will result in death
manual have been thoroughly read and understood. or serious injury and is represented as follows:
Improper operation or maintenance of this ma-
chine may cause accidents and could result in
serious injury or death.
Always keep this manual in the operators seat
pocket. b. WARNING - Indicates a potentially hazardous
If it is missing or damaged, place an order with situation which, if not avoided, could result in death
an authorized dealer for a replacement. or serious injury and is represented as follows:
If you have any questions, please consult an
authorized dealer.
1. Most accidents, which occur during operation, are c. CAUTION - Indicates a potentially hazardous
due to neglect of precautionary measures and situation which, if not avoided, may result in mi-
safety rules. Sufficient care should be taken to nor or moderate injury. It may also be used to
avoid these accidents. Erroneous operation, lubri- alert against possible damage to the machine
cation or maintenance services are very danger- and its components and is represented as fol-
ous and may cause injury or death of personnel. lows:
Therefore all precautionary measures, NOTES,
DANGERS, WARNINGS and CAUTIONS con-
tained in this manual and on the machine should
be read and understood by all personnel before 4. It is very difficult to forecast every danger that may
starting any work with or on the machine. occur during operation. However, safety can be en-
2. Operation, inspection, and maintenance should sured by fully understanding proper operating pro-
be carefully carried out, and safety must be given cedures for this machine according to methods rec-
the first priority. Messages of safety are indicated ommended by CASE.
with marks. The safety information contained in 5. While operating the machine, be sure to perform
this manual is intended only to supplement safety work with great care, so as not to damage the ma-
codes, insurance requirements, local laws, rules chine, or allow accidents to occur.
and regulations.
6. Continue studying this manual until all Safety, Op-
eration and Maintenance procedures are com-
pletely understood by all persons working with the
machine.
1-2
1.2 SAFETY PRECAUTIONS The following is a list of basic precautions that must
always be observed.
1. Read and understand all Warning plates and de-

cal on the machine before Operating, Maintaining
The proper and safe lubrication and maintenance or Repairing this machine.
for this machine, recommended by CASE, is out-
lined in this OPERATORS MANUAL for this machine. 2. Always wear protective glasses and protective
Improper performance of lubrication or mainte- shoes when working around machines. In particu-
nance procedures are dangerous and could result lar, wear protective glasses when using hammers,
in injury or death. Read and understand this OP- punches or drifts on any part of the machine or
ERATORS MANUAL before performing any lubri- attachments. Use welders gloves, hood/goggles,
cation or maintenance. apron and the protective clothing appropriate to the
welding job being performed. Do not wear loose
fitting or torn clothing. Remove all rings from fin-
The serviceman or mechanic may be unfamiliar
gers, loose jewelry, confine long hair and loose
with many of the systems on this machine. This
clothing before working on this machinery.
makes it important to use caution when perform-
ing service work. A knowledge of the system and 3. Disconnect the battery and hang a Do Not Oper-
or components is important before the removal or ate tag in the Operators Compartment. Remove
disassembly of any component. ignition keys.
Because of the size of some of the machine com- 4. If possible, make all repairs with the machine
ponents, the serviceman or mechanic should parked on a level, hard surface. Block the machine
check the weights noted in this manual. Use proper so it does not roll while working on or under the
lifting procedures when removing any components. machine. Hang a Do Not Operate tag in the Op-
Weight of components table is shown in Section erators Compartment.
6, SPECIFICATIONS.
5. Do not work on any machine that is supported only
by lift, jacks or a hoist. Always use blocks or jack
stands, capable of supporting the machine, before
performing any disassembly.
Do not operate this machine unless you have read

and understand the instructions in this OPERA-
TORS MANUAL. Improper machine operation is
dangerous and could result in injury or death.
6. Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are dis-
connected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting any
device from a system that utilizes pressure.
7. Lower the bucket, blade, or other attachments to

the ground before performing any work on the ma-
chine. If this cannot be done, make sure the bucket,
blade or other attachment is blocked correctly to
prevent it from dropping unexpectedly.
1-3
8. Use steps and grab handles when mounting or 16. Do not damage wiring during removal opera-
dismounting a machine. Clean any mud, grease, tions. Reinstall the wiring so it is not damaged
oil or debris from steps, walkways or work plat- nor will be damaged in operation of the machine
forms before using. Always face the machine by contacting sharp corners, or by rubbing
when using steps, ladders and walkways. When against some object or hot surface. Do not con-
it is not possible to use the designed access sys- nect wiring to a line containing fluid.
tem, provide ladders, scaffolds, or work platforms
17. Be sure all protective devices including guards
to perform safe repair operations.
and shields are properly installed and function-
Refer to item L on page 1-7 . ing correctly before starting a repair. If a guard
or shield must be removed to perform the repair
9. To avoid back injury, use a hoist when lifting com-
work, use extra caution and replace the guard or
ponents which weigh 20 kg (45 lb) or more. Make
shield after repair is complete.
sure all chains, hooks, slings, etc., are in good
condition and are the correct capacity. Be sure 18. The maintenance and repair work while holding
hooks are positioned correctly. Lifting eyes are the bucket raised is dangerous due to the possi-
not to be side loaded during a lifting operation. bility of a falling attachment. Do not fail to lower
the attachment and place the bucket to the
10. To avoid burns, be alert for hot parts on ma-
ground before starting the work.
chines which have just been stopped and hot
fluids in lines, tubes and compartments. 19. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
11. Be careful when removing cover plates. Gradu-
bend or strike high pressure lines or install ones
ally back off the last two capscrews or nuts lo-
which have been bent or damaged. Inspect lines,
cated at opposite ends of the cover or device and
tubes and hoses carefully. Do not check for leaks
carefully pry cover loose to relieve any spring or
with your hands. Very small (pinhole) leaks can
other pressure, before removing the last two
result in a high velocity oil stream that will be
capscrews or nuts completely.
invisible close to the hose. This oil can penetrate
12. Be careful when removing filler caps, breathers the skin and cause personal injury. Use card-
and plugs on the machine. Hold a rag over the board or paper to locate pinhole leaks.
cap or plug to prevent being sprayed or splashed
20. Tighten connections to the correct torque. Make
by liquids under pressure. The danger is even
sure that all heat shields, clamps and guards are
greater if the machine has just been stopped be-
installed correctly to avoid excessive heat, vibra-
cause fluids can be hot.
tion or rubbing against other parts during opera-
13. Always use the proper tools that are in good con- tion. Shields that protect against oil spray onto
dition and that are suited for the job at hand. Be hot exhaust components in event of a line, tube
sure you understand how to use them before per- or seal failure must be installed correctly.
forming any service work.
21. Do not operate a machine if any rotating part is
14. Reinstall all fasteners with the same part num- damaged or contacts any other part during op-
ber. Do not use a lesser quality fastener if re- eration. Any high speed rotating component that
placements are necessary. has been damaged or altered should be checked
for balance before reusing.
15. Repairs which require welding should be per-
formed only with the benefit of the appropriate 22. Be careful when servicing or separating the
reference information and by personnel ad- tracks (crawlers). Chips can fly when removing
equately trained and knowledgeable in welding or installing a track (crawlers) pin. Wear safety
procedures. Determine type of metal being glasses and long sleeve protective clothing.
welded and select correct welding procedure and Tracks (crawlers) can unroll very quickly when
electrodes, rods or wire to provide a weld metal separated. Keep away from front and rear of
strength equivalent at least to that of the parent machine. The machine can move unexpectedly
metal. Make sure to disconnect battery before when both tracks (crawlers) are disengaged from
any welding procedures are attempted. the sprockets. Block the machine to prevent it
from moving.
1-4
1.3 PRE-START SAFETY
Many failures that occur during machine operation or servicing result from neglecting fundamental safety
precautions. The following safety precautions are given to prevent such failures, but they are only a part of
what you must follow. Read, understand and follow all safety precautions found in this manual and on the
machine thoroughly before operating the machine.
A. OBSERVE SAFETY PRECAUTIONS

Follow all safety rules, precautions, and
operating procedures. If there are other
personnel and flagmen working in the area,
have them observe the specified signs.
B. WEAR PROTECTIVE CLOTHING

Wear well fitting safety shoes, hard hat, and
working clothes, and put on protective glasses,
face shield, ear protection and gloves. When
necessary, wear reflective vest.
Do not wear the working clothes with adhered

oil, since it is easy to catch fire.
PV1-02
WEAR PROTECTIVE CLOTHING
C. READ and UNDERSTAND THE OPERATION &

MAINTENANCE MANUAL
Before operating the machine, read and
understand this OPERATION & MAINTENANCE
MANUAL thoroughly in order to use the machine
effectively and safely.
D. KEEP OPERATION & MAINTENANCE MANUAL

IN STORAGE
Keep this MANUAL in the specified storage
located behind the operators seat for quick
reference. Should the OPERATION & ZL11V04204
PM1-03
MAINTENANCE MANUAL become lost or READ MANUAL / KEEP IN STORAGE

damaged, contact an authorized dealer to order
the OPERATION & MAINTENANCE MANUAL.
In the case of ROPS canopy, keep this manual
in the storage box of the roof.
1-5
E. DO NOT OPERATE MACHINE EXCESSIVELY
TIRED OR UNDER THE INFLUENCE OF DRUGS
Your poor physical condition causes improper
reactions. Voluntarily refrain from operating the
machine when feeling excessively tired, and
never operate the machine under the influence
of drugs.
PV1-04
REFRAIN POOR PHYSICAL CONDITION
F. PREPARE FOR EMERGENCIES
Have a fire extinguisher and first aid kit ready
for emergencies. Know how to operate the fire
extinguisher and know where the first aid kit is
located for easy access in case of emergency.
Prepare beforehand the communication means

in case of any emergency, and take note of
telephone numbers for emergency contact.
PV1-05
PREPARE FOR EMERGENCIES
G. ENSURE SAFETY AT THE WORK SITE
Know the work area! Before operating the
machine, carefully survey and record the land
and work site features to prevent the machine
from falling or the soil from caving in.
PV1-06
WORK SITE SAFETY-KNOW THE AREA
H. ENGAGE SAFETY LOCK LEVER BEFORE
LEAVING MACHINE
Before leaving the operator’s seat, move the LOCKED (UP) POSITION
safety lock lever to the “LOCKED” (Up) position.
This will not allow operation of any hydraulic
controls should they be accidentally moved. If
the lever is not set to the "LOCKED" position
and hydraulic controls are touched accidentally,
the machine may move suddenly resulting in
serious injury.
Also before leaving the machine, lower the
bucket to the ground, place the safety lock lever
PV1-07
in the “LOCKED” (Up) position, stop the engine
and remove the starter switch key. SAFETY LOCK LEVER
1-6
I . SIGNS, SIGNALS & FLAGMEN
Install signs on soft shoulders and ground
areas, have a flagman direct the operation if
necessary. The operator should note marks and
follow signals from the flagman. All personnel
should know the meaning of the signs, marks,
and signals. Only one flagman should give the
signs and signals.
PV1-08
SIGNS, SIGNALS & FLAGMEN
PV1-09
J. KEEP FIRE AWAY FROM FUEL AND OIL
Oil, antifreeze, and especially fuel are highly
flammable. Never use fire near the machine.
Securely tighten all fuel and oil caps. Keep fuel
and oil in the designated storage areas.
Promptly clean up any all spills and dispose of
waste properly.
KEEP FIRE AWAY FROM FUEL AND OIL
K. SURELY INSTALL SAFEGUARD

Confirm that all guards and covers are securely
and properly installed. If damaged, immediately
restore them to proper condition.
Do not operate the machine without guards or
covers. Make sure to maintain them in normal
condition.
PV1-10
SURELY INSTALL SAFEGUARD
L. MOUNTING & DISMOUNTING MACHINE

When getting on and off the machine, always
maintain three point contact by using the
handrails and step. Inspect and clean
handrails, step, and mounting parts. Remove
slippery materials, such as lubricants, and mud.
Always place the cab entrance parallel to the
tracks (crawlers) before stopping the engine
for dismounting.
PVK1-11
MOUNTING & DISMOUNTING MACHINE

1-7
M. PAY ATTENTION TO WORKING MACHINE
Do not approach a working machine. Make
sure to make visual contact with the operator
before approaching a working machine.
PV1-12
PAY ATTENTION TO WORKING MACHINE
N. USE THE PROPER OPTIONAL ATTACHMENT
Use only optional attachments designed for and
approved by CASE. Read, understand and
follow all instructions in the manual
accompanying the optional attachment. Use of
any optional attachment not approved by CASE
in writing, can cause serious injury to
personnel, damage to the machine and its
components and shorten the life of the
machine. Contact an authorized dealer for
optional attachments available for the machine.
PV1-13
USE PROPER ATTACHMENT
O. PREVENT FIRES
Leaking or spilled fuel, lubricants and hydraulic
oil are fire hazards. Clean and properly dispose
of spills as they occur. Repair or replace all
leaking components to prevent fire. Also, clean
the machine regularly removing all debris to
help prevent fires, pay particular attention to
removal of leaves, sticks, paper etc. Keep fire
extinguisher in an accessible area and know
how to use the fire extinguisher should a fire
occur.
PV1-14
PREVENT FIRES-CLEAN UP SPILLS
P. CONFIRM OPERATING LEVER PATTERNS

Slowly operate the control levers to confirm the
operating patterns in advance.
The figure shows the standard operating
system, specified in ISO.
Refer to page 2-9 for more details regarding
the different operating control functions.
YN20T01089P1
PV1-15
CONFIRM OPERATING PATTERNS
1-8
Q. KEEP CLEAN CAB FLOOR AND DRIVER'S
SEAT
Do not place any parts and tools in the driver's
cabin to prevent injury due to slippage and
stumbling. Remove any debris from the cab
floor, control levers, handrails, etc. Make sure
to keep all operating controls clean at all times
PV1-16
KEEP CLEAN AROUND DRIVERS SEAT
R. HOW TO HANDLE LIFE HAMMER-CAB only

A life hammer is provided on the right side of
cab. In case of emergency, take the life
hammer, break the cab glass, and escape from
the cab. In addition, the life hammer is equipped
with a cutter on the lever side to cut the seat
belt, etc. CUTTER
LIFE HAMMER
PV1-17
HOW TO HANDLE LIFE HAMMER-CAB ONLY
S. PERFORM PRE-START INSPECTION

Walk around the machine before starting the
machine, perform a PRESTART inspection of
the machine and make note of any abnormality.
If any problems are found, repair or replace
defective components immediately. DO NOT
OPERATE THE MACHINE until all problem
areas are properly repaired. Always keep the
windshield, working lamps, and mirrors clean
for good visibility.
PV1-18
PERFORM PRE-START INSPECTION
T. TAG OUT MACHINE DURING MAINTENANCE

Before performing any inspection or
maintenance procedures to the machine, fill
out and post to the operators controls a DO
NOT OPERATE tag to warn persons not to start
the machine. Order tag Part No.
DO NOT
OPERATE
LC20T01001P1. Make sure to inform the

supervisor and all operators that the machine
is under inspection or maintenance and they
will be informed when the machine is ready for
normal operation.
PV1-19
TAG-OUT MACHINE
1-9
U. USE CAUTION NEAR NOISE
If noise is high during operation, hearing loss
may result. Approved hearing protection should
be used if personnel will be exposed to high
noise levels for a long period of time.
PV1-20
USE CAUTION NEAR NOISE
V. AVOID HOT SURFACES & AREAS

Immediately after the machine is operated, the
temperature and pressure of the engine
coolant, engine oil, and hydraulic oil are very
high. Burns may result if caps are removed, or
oil, water, or filters are changed under these
conditions. Wait until the temperature goes
down, before attempting to check fluids or
change filters.
PV1-21
AVOID HOT SURFACES & AREAS
1-10
1.4 SAFETY DURING OPERATION
A. PASSENGERS
This equipment is not intended or designed for
the transportation of persons. Never allow
persons to ride on the machine. Serious injury
or death can result from allowing passengers
on or in the machine.
PV1-22
NO PASSENGERS
B. STARTING ENGINE
Start engine from the operator’s seat. Do not
short circuit the starter circuit or battery to start
the engine. This may cause serious injury or
cause damage to the electrical system.
PV1-23
DO NOT SHORT CIRCUIT
C. HORN BEFORE STARTING ENGINE

Sound the horn before starting the engine to
alert people that the machine is being started.
Make sure no one is near the machine.
HORN SWITCH
Do not start the engine if the machine has been

tagged out.
PV1-24
SOUND HORN BEFORE STARTING
D. CHECK AFTER STARTING ENGINE

Make sure to check machine for proper
functioning after starting the engine. Slowly
cycle attachments, swing, and travel functions
in an area with sufficient space, without
obstacles, and personnel. Failure to do so could
result in injury or machine damage. Make note
of any abnormalities and repair as needed.
PV1-25
CHECK AFTER STARTING ENGINE
1-11
E. WARM UP MACHINE BEFORE OPERATION
Take a sufficient time to warm up the machine,
especially at cold season, otherwise the
response of machine against the operation of
operating lever is delayed which may cause
injury and / or machine damage.
PAE-1-10
WARMING UP OPERATION
F. CONFIRM OPERATING CONTROL PATTERN

Slowly operate the control levers to confirm the
operating patterns in advance. Make sure the
operation control pattern is according to the
indication plate.
PV1-27
CONFIRM OPERATING PATTERN
G. CONFIRM TRAVEL DIRECTION CONDITION WHERE THE TRAVEL

Make certain of the location of the travel motors DIRECTION IS REVERSED
before operating travel.
Pay attention that in the case where the travel
motors are in the front side, the travel function TRAVEL
is reversed. DIRECTION
Sound horn before moving the machine to
inform any personnel around the machine that TRAVEL
the machine is now in operation. MOTOR
PV1-28
KNOW TRAVEL MOTOR POSITION
H. DO NOT HIT THE CAB WITH ATTACHMENT

Check clearance between bucket and cab
before operation. Slowly cycle bucket, check for
interference with arm and cab, particularly if a
lifting eye is welded on bucket bottom. Exercise CAUTION FOR
INTERFERENCE
care when operating the bucket near the cab.
PV1-29
DO NOT HIT CAB
1-12
I . SWINGING FUNCTION
Make certain the swing area of machine is clear
of all persons and obstacles before operating
swing controls. Sound horn before swinging
machine. If necessary, have a flagman signal
operator during operation to help prevent injury
to persons or damage to obstacles and
equipment.
PV1-30
SLEW / SWING / TRAVEL SAFETY
J. TRAVELING ON SLOPE
Use extreme caution when traveling on slopes,
machine could turnover or slide causing injury
or machine damage.
Keep the bucket at the height 30 ~ 40 cm (12 ~
16 inch) above the ground level, and wear the
safety belt at all times.
Never make a change of direction on the slope
or cross over the slope.
PV1-31
PAY ATTENTION ON SLOPE
K. FROZEN & SNOW COVERED WORK SITES

Use extreme caution when operating the
machine on frozen or snow covered work sites.
Operate all controls slowly and cautiously to
prevent sudden movements such as start/stop/
turn, that may cause the machine to
unexpectedly shift, slide or move. Even on the
slightest slope, when snow is present or work
area is frozen, it can allow a machine to
unexpectedly move. Snow on shoulders or snow
drifts can be much deeper than expected. The
PV1-32
machine can easily become buried under such
conditions. Use extreme caution while operating USE EXTREME CAUTION ON FROZEN
the machine around or in snow. SURFACES OR SNOW
Be careful for frozen ground that becomes soft
along with the increase of ambient temperature.
L. TRAVEL 90˚~110˚
Position the attachment as shown in illustration
before beginning travel. On rough terrain move
the machine at slow speeds, and do not turn 30cm~40cm
suddenly. Avoid travelling over obstacles. (12~16in)
Should it become necessary to travel over an
obstacle, keep the attachment low to the ground
PV1-33
and travel at extremely slow speed.
TRAVEL POSTURE
1-13
M. GROUND STABILITY
Be certain the condition of the work site is stable
and capable of supporting the machine weight
during operation. Do not operate attachment too
close to the machine. Operation of the machine
on shoulders or filled areas could cause the
machine to become unstable presenting a work
hazard. Position the crawler at right angle to
shoulder and the travel motors to the rear of
the machine, allowing for quick reversal, should
the work area become unstable.
PV1-34
WORK ON STABLE GROUND
N. LIFTING
This machine is an excavator. Use extreme
caution when lifting or moving heavy loads. Use
proper lifting equipment rated at a capacity to
handle the load. NEVER USE BUCKET TEETH
TO LIFT OR MOVE HEAVY LOADS.
PV1-35
O. OPERATING ON INCLINES OR SLOPES USE PROPER LIFTING DEVICES
Operation of this machine on an incline or slope
may cause the machine to become unstable or
unbalanced. Work up and down inclines or
slopes, never across. Never slew/swing or turn
machine around on slopes. Build a level area
for the machine to operate. Operate controls
carefully to prevent sudden movements which
may cause the machine to slide or tip over.
P. WORKING AROUND ELECTRIC POWER LINE

If it is suspected that utility lines such as phone
or electrical power are in the work area, contact
the local utility authority for line location PV1-36
BEFORE beginning work in the area. Use BUILD BANKING FOR SLOPE OPERATION
extreme caution around electrical power lines.
Keep a sufficient distance away from electrical
lines during operation. See chart below for
minimum distances.
PV1-37
PV1-42 KEEP A SAFE DISTANCE FROM UTILITIES
1-14
Q. WORKING AROUND UTILITY LINES
UNDERGROUND
At the work around presumable place of laying
power, water or gas line under the ground, ask
the actual location of them to the organization
concerned, give a trial digging, and proceed the
work with care after confirmation for
nonexistence of them or location of them.
PV1-38
CHECK LOCATION OF UTILITIES
R. PARKING THE MACHINE

Always park the machine on a firm, level
surface.
If no firm level surface is available, block the
crawler and lower bucket and dozer blade to BUCKET
the ground to help prevent machine movement. DOZER
BLADE
Should the machine be parked on a roadway,
move the machine to the shoulder to allow
BLOCK
passing of traffic. Also post reflective warning
signs and markers at a distance from the
machine to safely warn motorists. Refer to local
code and regulations regarding the posting of PV1-39
work area warnings and markers. PARKING SAFETY
S. RESTRICTED WORK AREAS

In work sites with limited height and slew/swing
areas such as tunnels, bridges, around electrical
power lines, other utilities, or inside structures,
use extreme caution in keeping the machine
and its attachment at a safe distance to prevent
personal injury and / or equipment or structure
damage.
Use a flagman to guide the operator.
PV1-40
USE EXTREME CAUTION AT RESTRICTED AREA
T. DO NOT WORK UNDER PRECIPICES

Don't dig under the precipice. It causes for
falling rocks or loosening of the precipice
resulting in injury and / or machine damage.
PV1-41
DO NOT DIG UNDER PRECIPICE
1-15
U. WORK WITH SUFFICIENT LIGHTING
When working in dark places, turn on the
working light. And if required, provide additional
lighting facilities to ensure the visual field.
Stop working when it is impossible to ensure
the visual field due to fog, snow or rain.
PV1-43
WORK WITH SUFFICIENT LIGHTING
V. SET LIMITS TO WORKING AREA

Set limits around the working area to avoid
collision or personal injury. Make sure to check
for obstacles and personnel while swinging. Use
a flagman to guide the operator whenever
necessary.
PV1-44
SET LIMITS TO WORKING AREA
W. CAUTION FOR WORK IN URBAN AREAS

It is dangerous to allow other personnel to enter
into the working area.
Make the working area off-limits to other people
providing caution plates.
Make sure to provide a flagman in working
areas with heavy traffic to avoid accidents.
PV1-45
USE A FLAGMAN WHEN NECESSARY
X. PROHIBITION TO USE NON-SERVICED

MACHINE
The use of non-serviced machine may cause
for an unexpected accident or breakdown.
Stop operation of a faulty machine. Make sure
to repair any abnormalities before resuming
operation.
PV1-46
DO NOT USE NON-SERVICED MACHINE
1-16
Y. SLIPPERY GROUND SURFACE
Use caution when operating machine on boards
or steel plates. Boards and steel plates become
very slippery when wet.
Pay special attention when working on inclined
areas.
Provide a device to prevent skidding and
proceed to work with extra care. Piled up tree
leaves or branches also may cause skidding.
PV1-47
PAY ATTENTION AT SLIPPERY SLOPE
Z. STRENGTHEN SOFT GROUND

When working on a soft ground or marshy area,
the machine may sink.
Provide logs or lumber to pave horizontally to
prevent the machine from sinking.
Frozen ground becomes soft along with the
increase of ambient temperature.
PV1-48
STRENGTHEN SOFT GROUND
AA. LOOSENED GROUND AFTER RAIN

After raining, there is a possibility of getting into
danger of tumbling down or falling down of the
machine with vibration and weight of the
machine due to loosened shoulder of road.
Pay attention to loosened precipice or shoulder
of road, and do not access to such place without
care.
PV1-49
PAY ATTENTION TO LOOSENED GROUND
BB.LOOSENED GROUND AFTER EARTHQUAKE

OR DYNAMITING
Pay attention to the loosened precipice or
shoulder of road, and falling rocks. Also pay
attention to the unexploded dynamite.
PV1-50
PAY ATTENTION TO LOOSENED GROUND

1-17
CC. BOOM, ARM & ATTACHMENTS
Give the work you are doing your undivided
attention. Make certain the attachment being
used is suited for the job at hand. Make certain
of obstacles in the work area and operate the
machine within those limits. If necessary have
a flagman signal the operator to prevent injury
to persons or damage to the machine or
obstacles in the work area.
ALWAYS PLACE ATTACHMENTS ON THE
GROUND AND RAISE THE SAFETY LOCK
LEVER BEFORE LEAVING THE CAB. PV1-30
SLEW / SWING SAFETY
DD. STABILIZE ATTACHMENTS

Stabilize all attachments removed from the
machine to prevent the attachment falling over.
PV1-51
STABILIZE ATTACHMENTS
1-18
1.5 INSPECTION & MAINTENANCE SAFETY
A. UNDERSTAND INSPECTION/MAINTENANCE
PROCEDURES
Incorrect maintenance may cause not only
damages on the machine, but also injury.
Make sure to read and fully understand the
maintenance procedures and safety
precautions described in the operation and
maintenance manual before performing any
maintenance in this machine.
PV1-52
UNDERSTAND PROCEDURES
B. MEETING PRIOR TO WORK

To prevent any accidents or injury due to errors,
have a meeting before start working. When a
flagman is provided, make sure that all signals
are understood accordingly.
PV1-53
MEETING PRIOR TO WORK
C. ORGANIZE AND CLEAN UP WORKING AREA

Organize and clean up the working area.
Remove any obstacles and also remove any
grease, oil, paint, broken pieces, etc., from the
working area to avoid injury.
PV1-54
CLEANING UP WORKING AREA
1-19
D. “TAG-OUT” MACHINE
maintenance procedures to the machine, fill out
and post to the operator’s controls a "DO NOT
OPERATE" tag to warn persons not to start the
machine. Order tag part No. LC20T01001P1.
DO NOT
OPERATE
Also inform the supervisor and all operators that
the machine is under inspection or maintenance
and they will be informed when the machine is
ready for normal operation.
PV1-19
TAG-OUT MACHINE
E. TOOLS & EQUIPMENT

Use the proper tools and equipment for the task
at hand. Know the proper use of the tools and
equipment before starting any inspection or
maintenance procedures.
PV1-55
USE PROPER TOOLS
F. SET THE ATTACHMENT HYDRAULIC OIL LEVEL CHECK POSITION

Always set the machine in the hydraulic oil check
position on firm level ground before attempting
any inspection or maintenance procedures to
the machine. If it is not possible to put the DOZER
BUCKET
machine in this position, secure the boom, arm BLADE
and attachment to help prevent sudden
movement. ALWAYS PLACE ATTACHMENTS
ON THE GROUND AND RAISE THE SAFETY
LOCK LEVER BEFORE LEAVING THE CAB.
PV1-56
HYDRAULIC OIL LEVEL CHECK POSITION
G. CLEAN THE MACHINE

Keep the machine clean and free of debris,
excess or spilled lubricants, fuel and fluids. Use
approved solvents, detergents and water to
clean the machine and its components on a
regular basis. Be careful not to allow water to
reach electrical components. Serious damage
can occur to the electrical system by allowing
water to reach the electrical components. Never
clean inside of cab, or electrical components
with pressurized water or steam.
PV1-57
KEEP MACHINE CLEAN
1-20
H. STOP THE ENGINE
BE CERTAIN TO TURN ENGINE OFF AND
PLACE THE SAFETY LOCK LEVER IN THE
“LOCKED” (UP) POSITION before attempting
any inspection or maintenance procedures to
the machine. Failure to stop engine could result
in serious bodily injury or death.
PV1-58
STOP ENGINE / ENGAGE SAFETY LOCK LEVER
PV1-09
I . REFUELING
Move the machine to a well ventilated area for
refueling. Use only specified fuel as described
in the MAINTENANCE section of this MANUAL.
Immediately clean up all spilled fuel and dispose
of properly. After refueling is complete, securely
tighten fuel cap.
Never use the fuel for cleaning.
REFUELING
J. SUPPORT THE MACHINE

If it becomes necessary to raise the machine
for inspection or maintenance, always support
the machine by positioning the machine as
shown in the illustration and use safety supports 90˚~110˚
or blocks, with a sufficient capacity rating to
SUPPORT
support the machine, under the crawler/frame.
NEVER INSPECT OR PERFORM
MAINTENANCE PROCEDURES UNDER A
RAISED MACHINE THAT IS NOT
SUFFICIENTLY SUPPORTED.
PV1-59
SUPPORT THE MACHINE
K. HYDRAULIC PRESSURE
Under normal conditions, all circuits of the
hydraulic system are under extreme pressure.
When inspecting for leaks, use a small piece of
cardboard, wood or metal to locate leaks.
SMALL (PINHOLE) LEAKS CAN BE
DANGEROUS IF CONTACT WITH SKIN OR
EYES IS MADE. Wear approved safety glasses
or face shield, gloves, hard hat, safety shoes
and work clothes during all inspection and
maintenance procedures. Seek for immediate
PV1-60
medical assistance if injury occurs.
CHECKING FOR HIGH PRESSURE LEAKS
1-21
L. PRESSURIZED FLUIDS & LUBRICANTS
Always release pressure from hydraulic
reservoir, engine coolant, fuel system and all
systems containing pressure before removing
any caps or components. BE CAUTIOUS OF
HOT FLUIDS AND GASSES FROM SYSTEMS
ON MACHINES THAT HAVE JUST BEEN
STOPPED. ALLOW SUFFICIENT TIME FOR
SYSTEMS TO COOL BEFORE PERFORMING
ANY INSPECTION OR MAINTENANCE
PROCEDURES.
PV1-61
RELEASE HYDRAULIC TANK PRESSURE
M. CARE ABOUT VENTILATION
Maintenance for the machine indoor or in the
place with poor ventilation may cause poisoning
by gas.
Pay special attention to ventilate any exhaust
gas, fuel, cleaning oil, paint or similar articles.
Ensure proper ventilation to the working area
when the machine is operated indoor. Provide
a ventilating fan, if required.
PV1-62
CARE ABOUT VENTILATION
N. PREVENTIVE AGAINST FIRE
It is unavoidable to handle flammable materials
such as battery, fuel, lubricating oil, etc. in a
maintenance area; therefore, follow the general
guidelines to prevent fire:
• Use a nonflammable cleaning oil to clean the
parts, etc.
• Extinguish any bare fire possible to inflame.
• Provide an appropriate fire fighting
equipement such as fire extinguisher.
• Refrain from smoking during maintenance
PV1-63
work.
PREVENTIVE MEASURE AGAINST FIRE
• Put away any flammable materials when
grinding work or welding work.
O. USE APPROVED WORK LIGHTS

Use only approved work lights when performing
inspection and maintenance procedures to
prevent possible fire or explosion. Certain types
of work lights should not be used due to the
possibility of ignition of certain flammable
gasses and fluids from the machine.
PV1-64
USE APPROVED WORK LIGHTS

1-22
P. DO NOT HEAT HYDRAULIC EQUIPMENT OR
PIPING
Never apply heat to hydraulic equipment or
piping, such as welding, soldering, heating with
torch, etc.
Heating of hydraulic components or piping will
cause gas expansion, which can easily catch
fire and / or explode.
Q. WORKING ABOVE GROUND

There exists danger of falling when working on PV1-65
areas above ground. Be careful not to approach DO NOT HEAT HYDRAULIC PIPING
edges.
• Make sure to use the appropriate equipment,
such as ladders or a manlift when working
above ground. In addition, strap yourself to
the proper equipment accordingly.
• Avoid spillage of any oil or grease.
• Do not leave any tools around the working
area.
• Use extreme caution to avoid slipping while
walking.
• Never jump into or from climbing equipment. PV1-66
Use a step-ladder or handrail and securely TAKE CARE AT ELEVATED SPOT
maintain a three point contact while mounting
or dismounting at all times.
• Make sure to read the manlift equipment
operator’s manual before using.
• Comply with climbing equipment weight
ratings.
R. DO NOT DROP TOOLS AND PARTS

Dropping of any tools and parts in the working
area may cause injury or faulty machine
operation.
Do not leave any tools or articles in the working PV1-67
area or component compartment. Make sure DO NOT DROP OFF TOOLS AND PARTS
to store all tools properly when the work is
completed. WHEN REMOVING, REMOVE THE
NEGATIVE TERMINAL FIRST
S. ELECTRICAL SYSTEM
maintenance to the electrical system, or
performing any welding procedures, disconnect
the negative(–) cables from the battery
terminals. Not disconnecting the negative(–)
cable could cause extensive damage to the
electrical system.
PV1-68
ELECTRICAL SYSTEM PRECAUTION

1-23
T. CAUTION TO MODIFICATION
CASE will not be liable for any injury or damages
due to equipment modification without approval.
When any modification is intended, consult with
an authorized dealer in advance.
PV1-69
CAUTION TO MODIFICATION
U. AFTER COMPLETION OF MAINTENANCE

WORK
Always, make sure to check machine for proper
functioning when any maintenance is
completed:
• After any maintenance work is completed,
operate the engine at low idle, and check for
leakages and abnormalities.
• Slowly operate each machine function to
confirm proper operation.
• Increase the engine speed gradually, and
PV1-25
again check for leakages and abnormalities.
CONFIRM SMOOTH OPERATION
• Operate each operating lever normally to
confirm smooth operation.
V. DISPOSE OF WASTE PROPERLY

Dispose of oils, fuel, coolant, solvents, filters,
batteries etc. according to federal, state and
local codes and regulations regarding
hazardous waste disposal. Contact local
authorities for proper disposal methods of such
materials.
PV1-70
DISPOSE OF WASTE PROPERLY
1-24
W. GENERAL GUIDELINES FOR WELDING X. CRAWLER SHOE TENSION
Welding work must be performed by a certified The grease used to adjust the crawler shoe
welder with sufficient experience. In addition, tension is under extreme pressure in the
safety practices must be followed by any cylinder. Use extreme caution when adjusting
personnel involved in such work. Identify all crawler shoe tension. KEEP FACE, HANDS
cracks to be repaired or areas to be welded by AND LEGS AWAY FROM THE GREASE
thoroughly cleaning the suspected surface, NIPPLE AREA.
remove paint, and check with dye penetrant Carefully and slowly loosen the grease nipple
or magnetic particle testing. The life expectancy when lessening crawler shoe tension. Never
of the welded area depends on the work quality loosen grease nipple more than one complete
and the attention given to details during turn.
welding.
Refer to page 4-16 for the procedures to
• Avoid welding structures with surface
adjust the tension on the crawler shoe.
temperature below 16°C (60°F). If needed,
preheat surface to hand-touch. In cases
where the machine components are
extremely cold, it is recommended that the
components be brought inside and allow
them to warm to 16°C ~ 20°C (60°F ~ 70°F)
for at least 12 hours prior to welding.
• Remove paint from any surface to be heated
or welded. Painted surfaces give off
unhealthy gasses when heated or welded.
Use mask and proper skin protection when
removing paint from any surface. When
removing paint sanding, do not breath the
PV1-72
generated dust. Make sure to use plenty
soap and water to rinse the surface to be USE CAUTION WHEN ADJUSTING CRAWLER
welded, since chemicals will generate
unhealthy gasses when heated and / or
welded.
Y. PAYING ATTENTION TO BROKEN PIECES
• Provide a fire extenguisher reachable at all times WHEN HAMMERING
while performing grinding, heating, or welding. Flying particles may cause injury when
• Make sure to clean oil and / or flammable materials hammering tempered parts, such as pin,
from any surface to be cut. edge, tooth, bearing, etc.
• Protect all flammable parts and surfaces from sparks Wear protective clothes such as protective
and / or flames.
glasses, safety hat, etc. during maintenance.
• Make sure to perform work in a well ventilated area.
• Keep sparks and flames away from paint and / or
solvent.
• Keep sparks and flames from cylinder rods, seals,
electrical wires, and / or hydraulic hoses.
PV1-73
USE CAUTION WHEN HAMMERING
PV1-71
PAY ATTENTION TO WELDING WORK
1-25
1.6 BATTERY SAFETY
A. WEAR PROPER PROTECTIVE CLOTHES
Wear long sleeve shirt, gloves and approved
safety glasses or face shield when working with
or around batteries. Battery electrolyte (acid)
will cause severe burns if allowed to make
contact with clothing, skin or eyes. Should
electrolyte (acid) come in contact with clothes,
skin or eyes, immediately remove effected
clothing, flush area with clean water for 15 PV1-74
minutes and get prompt medical attention. WEAR PROPER PROTECTIVE CLOTHES
B. KEEP AWAY FROM FIRE OR FLAMES

Never allow batteries in the vicinity of fire or
flames and do not smoke when working with
batteries. Explosive hydrogen gas is produced
by the electrolyte (acid) in the batteries. Always
work with batteries in a well ventilated area.
C. CHARGING BATTERY
Charge battery off of and away from machine
in a well ventilated area. When charging battery, PV1-75
remove cell caps to allow gasses to escape.
Avoid breathing gasses from battery. KEEP AWAY FROM FIRE OR FLAMES
CABLE CONNECTING ORDER
D. USING BOOSTER CABLES CABLE DISCONNECTING ORDER
• If using another machine or vehicle to boost
batteries, make certain the machine or vehicle
DOES NOT touch the disabled machine. (RED)
• Make certain of the positive (+) and negative

(–) terminals on the booster battery and the
disabled machine before connecting booster
cables. NORMAL DISCHARGED
BATTERY BATTERY
• Connect the positive (+) cable first, then
connect negative (–).
• When disconnecting, disconnect the negative (BLACK)
(-) cable first, then disconnect the positive (+) TO THE ENGINE OF THE TROUBLED
MACHINE PV1-76
cable.
• Refer to BASIC MACHINE OPERATION
section of this manual for proper procedures
for use of booster cables. IMPROPER BOOSTER CABLE CONNECTIONS CAN
CAUSE AN EXPLOSION RESULTING IN PERSONAL
E. OTHER PRECAUTIONS INJURY.
• Pay attention to danger of sparks triggered CONNECT BOOSTER CABLES USING FOLLOWING
off by erroneous connection between the PROCEDURE.
positive (+) terminal of battery and the 1. Connect booster cable to positive (+) battery terminal
of discharged battery. Connect other end of booster
machine body with a tool, etc.
cable to positive battery terminal of normal battery.
• Make certain of tightening the battery caps. 2. Connect other booster cable to negative (-) battery
• Securely tighten up the battery terminals. terminal of normal battery. Connect other end of
booster cable to engine of troubled machine.
• Leave the waste battery to a specialist for
3. Start engine and remove booster cables in reverse
disposal. order.
1-26
1.7 WARNING LABELS & DECALS
Warning labels and decals are affixed to the machine to remind operators and personnel specific safety
precautions in certain areas of the machine. The following are illustrated examples of all warning labels
and decals along with their locations.
NOTICE FOR WARNING LABELS & DECALS

• Do not take away the attached warning labels • Use a cloth, water, and detergent to clean the
and decals. labels. Never use organic solvents or gasoline.
• Confirm whether labels can be easily read. • If labels are damaged, missing or illegible,
If words or illustrations are illegible, clean off or replace them with new ones.
replace the labels. Contact your authorized dealer for new labels.
LOCATION OF WARNING LABELS & DECALS
15
B
C
2
2 12 12
13
4
11
1
6
19 14 A
7 16
3
5
17
8 10 9 18
VIEW A VIEW B VIEW C
1-27
1-28
1-29
1-30
1.8 PROHIBITED MACHINE OPERATION
The following examples of machine abuse and
misuse should never be attempted by even the
most experienced operator. Such abuse and mis-
use of this machine and its attachments can re-
sult in serious bodily injury, death, severe equip-
ment damage and shortened service life of the
machine. Under no circumstance should any of
these operations be attempted. Use common
sense and follow proper operation procedures
found in this OPERATOR’S MANUAL while op-
PV1-77
erating this equipment.
DO NOT USE TRACTIVE FORCE
A. DO NOT USE TRACTIVE FORCE OF THE

MACHINE FOR LOADING THE BUCKET
ATTACHMENT.
Doing so will exert excessive force on the
machine structure, front end attachments and
could cause severe equipment damage. Use
crawlers for normal travel operations only.
B. DO NOT USE THE MACHINE’S SLEWING /

SWINGING FORCE FOR OPERATIONS.
PV1-78
Doing so will exert excessive force to the
DO NOT USE SLEWING / SWINGING FORCE
machine structure, front end attachments and
shorten life of the slewing/swinging system of
the machine. Also, serious injury or death could
result from such operations.
C. DO NOT PERFORM “HAMMERING”

OPERATIONS WITH THE BUCKET.
Performing operations such as hammering and
piling will cause extensive damage to the
machine and its components. These types of
operations can also result in serious injury or
death. PV1-79
DO NOT HAMMER WITH ATTACHMENT
D. DO NOT USE THIS MACHINE FOR ANYTHING

OTHER THAN ITS INTENDED PURPOSE.
This machine is designed and manufactured for
digging, loading and ground leveling operations
only. Any other use can exert excessive force
to the machine, its components, its systems and
result in serious bodily injury or death to the
operators and other personnel working in the
vicinity of or with the machine.
PV1-35
USE ONLY FOR INTENDED PURPOSE
1-31
E. DO NOT OPERATE BUCKET AND ARM
CYLINDERS TO STROKE END REPEATEDLY.
Extending the bucket and arm cylinders to stroke
end to clean debris from the bucket, will cause ALLOWANCES
impact to the bucket cylinder causing cylinder
damage. Use high pressure water or manually
remove stubborn material from the bucket.
PV1-80
DO NOT OPERATE CYLINDER TO STROKE END
F. DO NOT OVER EXERT THE MACHINE’S

CAPACITIES.
Know the limitations of the machine and its
attachments and operate the machine within
those specifications. Do not exceed lift charts.
Never tip or raise the machine to obtain power
to move material. This could cause extensive
damage to the machine and its components as
well as result in serious bodily injury or death.
PV1-81
DO NOT OVER EXERT THE MACHINE
G. CAUTION FOR DOZER BLADE NOT TO HIT

OBSTACLES.
Pay attention to the dozer blade not to hit any
obstacles such as rock lump.
It may cause damages to the dozer blade and
cylinder.
PV1-82
DO NOT HIT ROCK, ETC. BY DOZER
H. CAUTION FOR FOLDING UP ATTACHMENT.

When the attachment is folded up to travel or
transport, pay attention to the bucket not to hit
the dozer blade.
PV1-83
DO NOT HIT DOZER BY BUCKET

1-32
I . DO NOT SUPPORT MACHINE WITH DOZER
BLADE AT ONE END.
When the dozer blade is used as an outrigger,
do not support the machine at one end of the
dozer blade, but surely at both ends.
PV1-84
DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END
J. CAUTION FOR DEEP EXCAVATION.

Pay attention during deep excavation with the
dozer blade in front. The boom cylinder could
come in contact with the dozer blade.
Place the dozer blade in the back of the machine
for deep excavations, unless the working area
does not permit it.
PV1-85
1.9 END OF WORK SHIFT SAFETY
TAKE CARE FOR DEEP EXCAVATION
Perform all of the following procedures after each
shift is complete to insure the machine it in optimal
operating condition for the next shift or job site.
A. Move the machine to a firm, level surface.
B. Lower attachment to the ground.
C. Refill fuel tank to full mark to reduce air volume
and condensation (moisture). This will decrease
the possibility of freezing in the fuel tank, rusting
due to moisture and other problems associated
with start up and operation.
D. Close and secure all windows in place to prevent
water or moisture reaching the electrical
components of the machine (CAB only). PV1-86
E. Thoroughly clean and inspect the machine. END OF WORK SHIFT SAFETY
Perform lubrication maintenance and repair or
replace any problem areas found before
restarting the machine.
F. If performing the machine in cold climates, it may
be necessary to remove the batteries from the
machine and store in a warm well ventilated
area. Install the batteries in the machine before
next start up. This will help prevent premature
battery deterioration.
G. Remove key from key switch and lock all doors
and access panels.
1-33
1.10 PRECAUTIONS FOR TRANSPORTATION
Use the following general guidelines for loading
or unloading the machine to the transportation
vehicle:
• Loading and unloading of the machine must
be carried out on firm leveled areas away
from the road shoulder. Do not use the
attachments to load or unload the machine
from the trailer.
• When needed, use a ramp capable of
withstanding the machine weight. Check the PV1-87
ramp’s width, length and thickness to secure TAKE CARE FOR LOADING / UNLOADING
the loading / unloading work. And when much
warp appears on the ramp structure, support
them with safety blocks or alike.
• Remove any mud, oils and grease from the
ramp surface as well as from crawler shoes
on the machine, to prevent the machine from
side skidding.
• Do not change the traveling direction on the
ramp. When required, back down the machine
to the ground, reposition and try it again.
• Always use low travel speed for loading or
15˚ PV1-88
unloading from the trailer.
USE RAMP FOR LOADING AND UNLOADING
• After loading the machine, shut off the engine
and set the safety lock lever to “LOCKED” up
LOCKED (UP)
position. POSITION
• Use cable or wire rope with sufficient capacity
to secure front and rear of the machine to
trailer. Provide chock blocks to the machine
crawlers, to avoid any movement of the PAD FOR PAD FOR
machine. EDGE EDGE
• Protect wire rope against edges providing

pad.
WIRE ROPE
• While transporting, observe legal regulations
concerned, keeping the safety in mind. PV1-89
SECURE FROM MOVEMENT
• Select the routing taking overall height and
length of the truck into consideration.
• Refer to Section 5 “TRANSPORTATION” for OVERALL LENGTH
the details of loading, unloading and fixing
OVERALL HEIGHT
procedures of the machine.
PV1-90
OBSERVE LEGAL REGULATION

1-34
1.11 TOWING THE MACHINE
1. If the machine should become stuck in soft
soil areas it may be necessary to tow the ma-
chine. Attach a wire rope or chain, with the
capacity to pull the machine out, to the lower
frame axles.
2. Attach other end to the vehicle used to pull
the machine. Operate the machines travel
lever in the proper direction while pulling with
the other vehicle.
• While towing, do not enter between the

machine and towing vehicle.
• Do not apply a shock load onto the towing
rope.
• Do not use eyes on machine lower frame to
tow machine.
• Keep the wire rope horizontally, and
perpendicularly to the crawler frame.
• Tow the machine slowly at low speed mode.
PVK1-91
• For the towing of the machine body, provide
pads to be applied to the corner of crawler TOW MACHINE PROPERLY
frame to prevent the wire rope and crawler
NOTE : Do not pull machine utilizing the brackets

welded on the lower plates of the carbody.
These brackets are provided for pulling light-
weight objects. See figure for better reference.
1-35
NOTES
1-36
SECTION 2
MACHINE FAMILIARIZATION
TABLE OF CONTENTS
2.1 FAMILIARIZATION ................................................................................................................................... 2-2

2.2 GENERAL MACHINE NOMENCLATURE ................................................................................................ 2-2
2.3 OPERATOR CAB NOMENCLATURE ....................................................................................................... 2-3
2.4 COMPONENT & CONTROLS NOMENCLATURE ................................................................................... 2-4
A. Monitor Panel (Gauge Cluster) ...................................................................................................... 2-4
A.1 Meters .................................................................................................................................... 2-4
A.1.a Coolant Temperature Meter ........................................................................................... 2-4
A.1.b Fuel Meter ..................................................................................................................... 2-4
A.1.c Hourmeter ..................................................................................................................... 2-4
A.2 WARNING LAMPS ................................................................................................................. 2-5
A.2.a Battery Charge Lamp (Red) .......................................................................................... 2-5
A.2.b Engine Oil Pressure Lamp (Red) .................................................................................. 2-5
A.2.c Coolant Temperature Lamp (Red) ................................................................................. 2-5
A.2.d Low Fuel Warning Lamp (Red) ...................................................................................... 2-5
A.3 Indicator Lamps .................................................................................................................... 2-5
A.3.a High (2nd) Travel Speed Lamp (Yellow). ....................................................................... 2-5
B. Switches ......................................................................................................................................... 2-6
B.1 Starter Switch ....................................................................................................................... 2-6
B.2 Travel Speed Select Switch ................................................................................................... 2-6
B.3 Horn Switch ........................................................................................................................... 2-6
C. Levers and Pedals ......................................................................................................................... 2-8
C.1 Safety Lock Lever ................................................................................................................. 2-8
C.2 Operating Levers (ISO Operating Pattern) ........................................................................... 2-9
C.3 Travel Control Levers ............................................................................................................ 2-9
C.4 Throttle Lever ....................................................................................................................... 2-9
C.5 Adjustable Crawler Frame Width/Dozer Operating Lever ..................................................... 2-9
C.6 Swing Lock Lever ............................................................................................................... 2-10
C.7 Boom Swing Operating Pedal ............................................................................................. 2-10
C.8 Nibbler & Breaker Operating Pedal .................................................................................... 2-10
D. Guard with Locking Device & Covers ........................................................................................... 2-11
E. Seat Front to Back Adjustment .................................................................................................... 2-11
F. Electrical Equipment ..................................................................................................................... 2-12
F.1 Working Light Switch ........................................................................................................... 2-12
F.2 Fuse Box (Main) .................................................................................................................. 2-12
2.5 STORAGE & OTHERS ........................................................................................................................... 2-13
A. Storing Place for Manual ........................................................................................................ 2-13
B. Tools ....................................................................................................................................... 2-13
C. Grease Gun ........................................................................................................................... 2-13
2.6 SEAT BELT ............................................................................................................................................ 2-14
2-1
SECTION 2 - MACHINE FAMILIARIZATION
2.1 FAMILIARIZATION 2.2 GENERAL MACHINE NOMENCLATURE
All operators, service mechanics and personnel The Nomenclature drawing below points out locations
responsible for operation, inspection and maintenance of major components of the CASE Hydraulic
of the machine should become thoroughly familiar with Excavator (TYPICAL).
the controls and components and their functions Study these areas and locate these components on
before working with or on this equipment. the machine. Specific information regarding these
Study the information in this section to become components are explained on the following pages of
familiar with the controls and components of this this section.
machine.
ARM CYLINDER LEFT OPERATING LEVER

BOOM
TRAVEL LEVER
BOOM CYLINDER
BUCKET CYLINDER SAFETY LOCK LEVER
CANOPY
RIGHT OPERATING LEVER
ARM
ADJ. CRAWLER FRAME WIDTH /
DOZER OPERATING LEVER
LINK
MONITOR PANEL
BUCKET THROTTLE LEVER
AIR CLEANER
RADIATOR
PILOT VALVE CONTROL VALVE

SAFETY LOCK LEVER RESERVE TANK
HYDRAULIC TANK
BATTERY
FUEL TANK
DOZER BLADE
ENGINE
DOZER BLADE CYLINDER
s
MUFFLER
SOLENOID VALVE
SWING CYLINDER
SLEWING BEARING
IDLER
SWIVEL JOINT
IDLER ADJUSTER
LOWER ROLLER SLEWING MOTOR
ADJ. CRAWLER FRAME HYDRAULIC PUMP
WIDTH- CYLINDER
RUBBER / STEEL CRAWLER SHOE
SHOE SLIDE TRAVEL MOTOR
PEE-2-101
2-2
2.3 OPERATOR CAB NOMENCLATURE
The operator cab nomenclature, see Figure below, points out locations of operator controls of the CASE
Hydraulic Excavator operator cab (Typical). Study these areas and locate these components on the machine.
Specific information regarding these components are explained on the following pages of this section.
TRAVEL SPEED SELECT SWITCH

RIGHT OPERATING LEVER
HORN SWITCH
LEFT TRAVEL LEVER RIGHT TRAVEL LEVER
LEFT OPERATING LEVER SAFETY LOCK LEVER (RIGHT)
LEFT TRAVEL BOOM SWING OPERATING

PEDAL RIGHT TRAVEL
PEDAL
PEDAL
SAFETY LOCK LEVER (LEFT)
ADJ. CRAWLER FRAME

WIDTH / DOZER
OPTION PEDAL OPERATING LEVER
(NIBBLER & BREAKER)
J/D MULTI
CONTROL LEVER
MONITOR PANEL
(GAUGE CLUSTER)
THROTTLE LEVER
OPERATOR SEAT
ADJ. CRAWLER FRAME WIDTH /

DOZER SELECT LEVER BOOM SWING STARTER SWITCH
LOCK LEVER
PAE-2-102
Front, rear, right and left direction

In this manual, the front, rear, right and left directions are based on the conditions where the travel motors are
positioned at the rear and the operator is facing the direction in which the machine advances (forward).
PAM-2-2
2-3
2.4 COMPONENT & CONTROLS NOMENCLATURE
The following information provides a brief description and function of the components and controls of the CASE
Hydraulic Excavator.
All personnel associated with this machine should read and understand this information BEFORE beginning any
work with or on this equipment.
(1)
(4)
(5) ( A.2 )
WARNING
LAMPS
( A.1 ) (2) (6)
METERS
(7) ( A.3 )
INDICATORS
(3)
PAE-2-4-1
A. MONITOR PANEL (GAUGE CLUSTER) A.1.b FUEL METER

The monitor consists of the following: This indicates the amount of fuel.
A.1 METERS F : Full tank is about 15 liters (4.0
A.2 WARNING LAMPS GREEN gal)
A.3 INDICATORS. The gauge indicates the residual
volume of fuel in the fuel tank.
PAE-2-6 Make sure to refuel when the indi-
A.1 METERS cator is approaching to the "E"
A.1.a COOLANT TEMPERATURE METER point. Refill the fuel tank with diesel fuel only. Normally
This indicates the temperature of the gauge takes time to move up to the apropiate leve
RED the engine coolant water, and op- after turning the key switch to the ON position.
GREEN
erates when the starter switch is
turned to the "ON" position. A.1.c HOURMETER
The temperature is normal in the The hourmeter indicates the total
PAE-2-5 green range. If the indicator enters time the engine has run.
the red range, let the engine run in low idle until the Even if the machine is not moving,
temperature cools down and the indicator moves back the hourmeter continues to count
into the green range. as long as the engine is running,
PAJ-2-7 regardless of the engine speed.
While the engine is running, the indicator flashes to
show that the hourmeter is active.
Use the hourmeter as reference for maintenance.
2-4
A.2 WARNING LAMPS
When any of the warning lamps are illuminated, immediately stop the work. Then investigate the cause for it, and
carry out appropriate inspection and maintenance referring to the Section "INSPECTION AND MAINTENANCE."
A.2.a BATTERY CHARGE LAMP

(Red)
This is to warn an abnormality in Do not perform any kind of maintenance on an
the battery charging system during engine that has just stopped working. Fluids and
engine running. This indicator will surfaces will be extremely hot. Allow the engine to
illuminate when the starter switch cool before proceeding to inspection and/or
PR-2-9 is turned to the "ON" position, and maintenance.
should turn off after the engine is
started.
Check the charging system if this
indicator does not turn off after the A.2.d LOW FUEL WARNING LAMP
engine is started. See Section 4 (Red)
(Maintenance) for details. If the fuel is low, a warning lamp
lights. Stop the engine immediately
A.2.b ENGINE OIL PRESSURE and add fuel.
LAMP (Red) PM2-14
This warning lamp will illuminate if

the engine oil pressure drops A.3 INDICATOR LAMPS
abnormally while the engine is These lamps indicate the working conditions.
PR-2-8 running. A.3.a HIGH (2ND) TRAVEL SPEED
Stop the engine and check the LAMP (Yellow).
quantity of engine oil. This indicator will be illuminated
(Refer to page 3-4 .) when the travel speed is switched
to high (2nd) speed.
A.2.c COOLANT TEMPERATURE
Y2-281 The travel speed selector switch is
LAMP (Red)
located on the grip of the right travel
If the coolant temperature rises
lever.
abnormally, this warning lamp lights.
The speed automatically returns to
The coolant temperature may rise
low (1st) speed when the starter
SF2-103 abnormally if the engine is run with
switch is set to "OFF".
an excessive load.
The engine may suffer sever damage if the ma-

chine is operated with the engine oil pressure lamp
illuminated.
NOTE: If the engine is overheating, stop operation

immediately and let the engine run at idling to
lower the engine temperature.
2. Once the coolant has cooled down, stop
the engine.
3. Once the engine temperature lowers,
inspect the coolant level, fan belt, clogging
of radiator core, etc. Refer to Section 4
(Maintenance) for details.
2-5
B. SWITCHES B.2 TRAVEL SPEED SELECT SWITCH
Use this switch to select travel
(3) speed, HIGH (2nd speed) or
(2) LOW (1st speed). When the
starter switch is turned to the
"OFF" position, the travel
PR-2-29 speed is automatically set to
LOW. Select the desired
(4) speed before starting to
travel.
...................Select this speed when traveling
(1)
on rough or soft terrains,
LOW (1st) speed
slopes, in narrow places,
when powerful tractive force
PA-2-8 is required, or loading or
unloading from a truck/trailer.
NO. SWITCH See Section 6 for speed.
1 STARTER SWITCH
2 TRAVEL SPEED SELECT SWITCH
3 HORN SWITCH ........................Set to HIGH when traveling
on flat, hard ground.
HIGH (2nd) speed See Section 6 for speed.
B.1 STARTER SWITCH

This is used to start or stop the Travel the machine in LOW speed on slopes and
engine. at loading/unloading the machine on a truck/trailer.
Sudden change of the machine travel speed may
cause the machine to roll over.
PR-2-28
HEAT..........When engine start up is difficult due to cold B.3 HORN SWITCH

climate, turn the key to this position to activate Depress this switch, provided
the pre-heating and the glow lamp indicator will on the top of left operating lever,
illuminate. Hold the key in this position for around to sound the horn.
15 seconds and then turn the key to the START
position to start the engine. Release key after
engine starts. PV-6
OFF...........In this position, the electrical system is
turned off and the engine is stopped.
ON.............In this position, the machines electrical cir-
Sound horn before starting the engine, travelling,
cuit is energized. Maintain the key in this position
swinging or operating the attachments.
while the machine is in operation.
START......Turn the key to this position to start the en-
gine and release it after the engine starts, the
key will automatically return to the "ON" position.
2-6
C. LEVERS AND PEDALS
1 9 3 3 8 1 No. Operating Levers and Pedals

2
2 1 Safety lock levers
2 Right/ Left operating levers
6 3 Travel levers with pedals
4 Throttle lever
5 Crawler width/ Dozer selector lever
6 Crawler width/ Dozer operating lever
4 7 Slewing (swing) lock lever
8 Boom swing operating pedal
10 5 7 9 Option pedal (Nibbler & Breaker)
PAE-2-103
10 J/D Multi control lever
Always place the Safety Lock Lever in the locked (UP) position before leaving the operator cab. never leave
the machine unattended with engine running or lever in the down position.
Note that even when the Safety Lock Lever is set in the locked (UP) position, the functions for dozer and
boom swing are still activated.
C.1 SAFETY LOCK LEVER

The safety lock lever is provided to prevent
any unexpected operation due to involuntary
movement of the operators control levers.
* LOCKING HYDRAULIC SYSTEM

When the safety lock lever is set in the
"LOCKED (UP) Position" the hydraulic
system is shut down, except the dozer
blade and the boom swing functions.
PWE-2-7
* UNLOCKING HYDRAULIC SYSTEM

When the safety lever is set to the
"UNLOCKED (DOWN) Position" all
hydraulic functions are active.
ED
NOTE: When the safety lock lever is set to the
"LOCKED" (UP) position, each attachment and
swing motor are locked simultaneusly even
though each lever can be moved, because PWE-2-8
they are of a hydraulic lock system. However,
the travel levers are separately locked with
their mechanical locking mechanism to lock
the movement itself of the levers.
2-7
C.2 OPERATING LEVERS (ISO OPERATING
PATTERN)
C.2.a STANDARD OPERATION
These two levers activate each operation
as illustrated in the right.
Confirm for safety around the working area. Also

ensure that each lever operation is in accordance
with the operating pattern indicated on the labels.
If labels do not match the operators control pat-
tern, replace them immediately to avoid accidents
and/or injury.
NOTES
The operators control levers return to the original
neutral position when released, and the operation of
attachment is stopped.
All functions can be activated simultaneously. PME-2-11
C.2.b J/D MULTI CONTROL SHIFTING ISO OPERATING PATTERN

In the J/D multi control shifting the Boom LH OPERATING LEVER RH OPERATING LEVER
and Arm functions are opposite to the 5 ARM OUT 1 BOOM DOWN
ISO system. 6 ARM IN 2 BOOM UP
7 SLEWING LEFT 3 BUCKET IN
8 SLEWING RIGHT 4 BUCKET OUT
C.3 TRAVEL CONTROL LEVERS
The travel levers are located in front of opera-
tor seat. They are used to move the left or
right track of the machine either forward or
backward. These controls have 2 basic op-
erational functions:
Use caution to avoid coming in contact with other

machine functions while travelling.
Make sure to know the location of the travel motors
before operating the travel function
The travel functions described below are with the travel

motors located behind the Operators cab.
(A): Push both levers forward to travel
Forward.
(B): Pull both levers back to travel in Reverse.
(C): Neutral (Release levers in the center
position to stop the travel function)
Refer to Section 3 for changing travel direction.
PME-2-14
2-8
C.4 THROTTLE LEVER (A) (B)
The throttle control lever is located to the right THROTTLE LEVER
side of the operators seat and it is used to
control the engine speed.
(A) : LO (Low Idling).....
Push the lever fully forward to set the
engine in low idle.
(B) : HI (High Idling).......
Pull the lever fully reverse to set the engine
in high idle.
PAE-2-10
C.5 ADJUSTABLE CRAWLER FRAME WIDTH/
DOZER SELECTOR LEVER ADJUSTING CRAWLER (D)
FRAME WIDTH
This lever is located on the front lower side
of the operators seat and it is used to select
the dozer operation or adjust the crawler
frame width. Usually, this lever is to be set to
(C) position (dozer side). Only when chang-
ing the machine width (crawler frame width), (C) DOZER
this lever is set to (D) position (crawler frame
side) to allow the adjusting crawler frame
width with the adjustable crawler frame width/ PAE-2-11
dozer operating lever, by actuating cylinder.
DOZER OPERATION
(F)
(E)
The frame width/dozer function is active at all times,
even whith the safety lever in the lock (up) position.
DO NOT TOUCH THE FRAME WIDTH/DOZER
CONTROL LEVER UNLESS ONE OF THESE
FUNCTIONS NEED TO BE ACTIVATED, SEVERE
INJURY COULD OCCUR.
C.5.a DOZER OPERATION DOZER
This lever is to control the dozer up or (F)
down function.
(E) : Dozer down (Push the lever for-
ward.)
(F) : Dozer up (Pull the lever back.)
(E)
C.5.b ADJUSTING CRAWLER FRAME PAE-2-12
WIDTH
This lever is to change the machine ADJUSTABLE CRAWLER FRAME WIDTH
width (crawler frame width). (H)
(G)
(G) : Push the lever forward to widen
the width of crawler frame: 1200
mm (3 11.2).
(H) : Pull the lever back to narrow the
width of the crawler frame: 890
mm (2 11.0).
NOTE: It is recommended to operate the machine

with wider width to make the machine more
stable during operation. Use the narrower
width only when the job site space is limited.
Refer to Section 3 for the procedures to
H
change the machine width (crawler frame
G
width).
PAE-2-13
2-9
C.6 SWING LOCK LEVER
This lever is located on the front lower side
of the operators seat, and it is used to lock UNLOCK
the machines upper frame for transporta-
tion. Refer to Fig. PAE-2-14 for better refer-
ence. The upper frame can be locked in two
different positions, forward or backward. LOCK
Do not operate the swing function when the upper

frame is locked, damage to the machine could occur. PAE-2-14
C.7 BOOM SWING OPERATING PEDAL

The boom swing control pedal is located to
the right of the travel levers, see Fig. PA-2-
(A)
15, and it is used to operate the boom swing (B) (A)
function. (B)
Lock the boom swing control pedal when this

function is not operated, failure to do so may
cause serious accidents.
PAE-2-15
(A) : Depress the pedal to the right to acti-
vate the boom Right-Swing function.
(B) : Depress the pedal to the right to acti-
vate the boom Right-Swing function.
C.8 OPTION PEDAL (NIBBLER & BREAKER)

This pedal, located to the left side of the OPTION PEDAL
travel control levers, is used to operate the
optional attachment such as the Nibbler &
Breaker.
Lock the optional pedal while this function is not

operated, failure to do so may cause serious PAE-2-16
accidents.
LOCK
Refer to Section 8 OPTIONAL EQUIPMENT for the
Operation of Hydraulic Nibbler & Breaker.
The pedal lock becomes effective by means of push-

ing the pedal down forward as illustrated in Fig. PAE-
2-17.
UNLOCK
PAE-2-17
2-10
D. GUARD WITH LOCKING DEVICE & COVERS
A locking mechanism is provided for the engine
guards. Use the key to open and close engine
guards. See Fig. PM2-55 for better reference.
Make sure to stop the engine when the engine

guard or radiator cover is opened.
D.1 Opening PRE-2-54

[1] Insert the key.
[2] After releasing the lock, remove the key
and open the cover. ENGINE GUARD
[3] Fit the cover in the open position with the
rod.
GUARD(L/H)
D.2 Locking
[1] Return the rod to the original position,
and fix it into the holder.
[2] Close the cover.
[3] Insert the key, and turn it in a
ROD
counterclockwise direction to lock the
cover. Then remove the key. GUARD(R/H) PEE-2-3
NOTE: Make sure to insert the key completely for

proper operation; otherwise damage may
occur to the key or locking mechanism.
Always, make sure to use the open door lock rod to

secure the engine covers whenever they are in the
open position.
E. SEAT FRONT TO BACK ADJUSTMENT

a. Pull the seat adjustment lever to right side.
b. Move the seat forward or backward to desired
position.
c. Release the lever to lock the seat in position.
PAE-2-31
2-11
F. ELECTRICAL EQUIPMENT
F.1 WORKING LIGHT SWITCH
A working light is provided on the right side of SWITCH
the boom to improve the visual field during
poor lighting conditions.
To turn ON or OFF the working light, use the
switch provided on the back of the working
light lamp.
Refer to Section 4 for the replacement of the
light bulb.
PAE-2-21
F.2 FUSE BOX (Main)
Be sure the starter switch is in the "OFF" position

when replacing fuses.
The fuses protect the electrical system from

excess current. If operation is not normal, a
fuse may be blown. Replace blown or faulty
fuses with the spare fuses as follows.
Replace any fuse generating white powder on

it or in case that some looseness exists between MAIN FUSE BOX
the fuse and fuse holder. PAE-2-23
Fuse Circuits Wire

No. capacity Color
FUSE BOX COVER
1 10A Horn Red
2 30A Timer, Relay Red

Blue
3 10A Monitor Panel (Gauge Cluster) White
Green
4 20A Working Light Red
White
5 20A Lever Lock Switch Yellow
PAE-2-24
NOTE : (a) When replacing a fuse, replace it with one

of the same capacity. Fusible Link
(b) The spare fuses are stored in the back side (For Starter)
of fuse box cover.
FUSIBLE LINK
(RED)
NOTE : Refer to Section 4 MAINTENANCE for more

details on replacing fuses.
PAE-2-25
2-12
2.5 STORAGE & OTHERS
A. STORING PLACE FOR MANUAL
Store the Operators Manual in the storage box
provided on the back of seat.
PAE-2-30
B. TOOLS
Use the standard tools supplied with the machine
for the maintenance work.
Refer to Section 4 for the details of the tools.
PA-2-26
C. GREASE GUN (OCEANIA Spec.)

Use the grease gun supplied with the machine for
lubrication. After use, fold the grease gun handle,
wipe off the grease adhered to the nozzle with cloth
and store it in place.
PA-2-27
NOTE : Handling and Precaution for Grease Gun.
Always, facilitate air bleeding from the grease
gun by fully opening the lever and fill grease
to the section line portion, see Fig, PAE-2-
28.
Always, operate the lever at full open or full
close condition, otherwise the grease in the
cartridge is not sucked up.
Some air may mix into the cartridge from the
fixing thread up to the next use of the grease
gun, causing difficulty to extrude grease.
When this happens, remove the cartridge,
bleed the air mixed in, and reset it. PAE-2-28
2-13
2.6 SEAT BELT
Fastening / Unfastening ATTACH BELT ENDS
AROUND WAIST
1. Confirming no twisting on the seat belt, fully in-
sert the other side into the buckle until engaging
is heard.
2. Adjust the belt length so that there is no slack-
ness.
3. Push down the red button on the buckle to un-
fasten the seat belt. TIGHTEN BY PULLING
LOOSE END PV2-29
Inspect seat belts daily. Replace seat belt if it shows

deformation or damage. Always, make sure the seat
belt support capscrews are properly tighten. RELEASE BY DEPRESSING
RED BUTTON
PV2-30
2-14
SECTION 3
BASIC MACHINE OPERATION
TABLE OF CONTENTS
3.1 PRE-START CHECK .................................................................................................................................................... 3-2
A. Daily Inspection of Machine ...................................................................................................................... 3-2
B. Inspection Before Operation ...................................................................................................................... 3-3
C. Confirmation Before Starting Machine Engine ........................................................................................... 3-8
3.2 STARTING AND STOPPING MACHINE ENGINE. ..................................................................................................... 3-9
A. Start-up Under Normal Conditions ............................................................................................................. 3-9
B. Start-up Under Cold Conditions ............................................................................................................... 3-10
C. Start-up with Booster Cables .................................................................................................................. 3-11
D. Connecting/Disconnecting Booster Cables .............................................................................................. 3-12
3.3 STOPPING MACHINE ENGINE ................................................................................................................................ 3-13
3.4 INSPECTION AFTER STARTING MACHINE ENGINE ............................................................................................ 3-14
A. Exhaust Gas Color, Abnormal Sound & Smell ......................................................................................... 3-14
B. Check Each Switch & Lever .................................................................................................................... 3-15
C. Check Monitor Panel (gauge Cluster) ...................................................................................................... 3-15
3.5 WARMING UP ENGINE ............................................................................................................................................. 3-16
A. Engine Warm Up ..................................................................................................................................... 3-16
B. Warming Up Hydraulic Oil ........................................................................................................................ 3-16
3.6 MACHINE OPERATION ............................................................................................................................................. 3-17
A. Machine Travel ........................................................................................................................................ 3-17
B. Stop Traveling ......................................................................................................................................... 3-18
C. Travel Precautions ................................................................................................................................... 3-18
D. Care On Up/Down Slope .......................................................................................................................... 3-20
E. Machine Operation In Water/On Soft Ground ........................................................................................... 3-21
F. Getting Out of Soft Ground ...................................................................................................................... 3-22
G. Slewing Operation ................................................................................................................................... 3-23
G. Changing Machine Width (Crawler Frame Width) ..................................................................................... 3-24
3.7 PRACTICES TO IMPROVE EFFICIENCY ................................................................................................................ 3-25
A. Digging .................................................................................................................................................. 3-25
B. Loading .................................................................................................................................................. 3-27
C. Works In Narrow Space .......................................................................................................................... 3-27
D. Minimum Slewing Position ...................................................................................................................... 3-27
3.8 MACHINE PARKING .................................................................................................................................................. 3-28
3.9 CHECK & CONFIRMATION AFTER WORK ............................................................................................................. 3-28
3.10 PRECAUTIONS AFTER OPERATION .................................................................................................................... 3-29
3.11 MEASURES AFTER EMERGENCY STOP ............................................................................................................ 3-29
3.12 LOCKING UP WITH KEY ........................................................................................................................................ 3-30
3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE .......................................................... 3-31
A. Releasing Lock for Travel Motor .............................................................................................................. 3-31
B. Lowering Bucket ..................................................................................................................................... 3-35
C. Lowering Arm & Boom ............................................................................................................................ 3-36
D. Slewing Upper Slewing Structure ............................................................................................................. 3-36
3.14 CAUTION ON USING RUBBER CRAWLER SHOES ............................................................................................. 3-37
A. Proper Usage .......................................................................................................................................... 3-37
B. Prohibited Work ....................................................................................................................................... 3-37
C. Caution On Usage ................................................................................................................................... 3-38
3.15 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS ......................................................................... 3-40
A. Operation In Extreme Cold ...................................................................................................................... 3-40
B. Operation At Seashore or Salty Climate .................................................................................................. 3-41
C. Care for Electrical Equipment .................................................................................................................. 3-41
D. Operation In Dusty Areas ........................................................................................................................ 3-41
3.16 PERCAUTIONS WHEN STORING THE MACHINE FOR A LONG TIME .............................................................. 3-42
3-1
SECTION 3 - BASIC MACHINE OPERATION
3.1 PRE-START INSPECTION
A. DAILY INSPECTION OF MACHINE NOTE
Before starting the engine, walk around the machine The daily inspection must be carried out in accordance
to check for any loose nuts and capscrews, any oil, with the instructions provided in this MANUAL.
fuel or coolant leakage, and the condition of attach-
ment and hydraulic system. Check for any loose-
ness in the electrical wiring and for any accumulated
material ( leaves, dirt, etc).
2,3
6
1
PA-3-1
1. Check the engine for any oil, fuel or coolant leakage. 5. Check the attachments, cylinders, linkages and
Repair as required. hoses for any cracks, wear or looseness and repair
2. Check the area around the engine and radiator for as required.
any accumulated material and remove as required. 6. Check the guards, steps and handrails for damage,
3. Check the hydraulic equipment, hydraulic oil tank, and the capscrews for looseness.
hoses, and joints for oil leakage, and repair as re- Repair and tighten capscrews as required.
quired. 7. Verify that the gauges and the monitor panel (gauge
4. Check the travel system, such as the crawler, idlers, cluster) function properly.
and sprockets, for any damage or wear, and the cap
screws for looseness.
3-2
B. INSPECTION BEFORE OPERATION
The following items should be inspected before start-
ing machine operation: BE CAUTIOUS OF HOT FLUIDS AND SUR-
FACES. WEAR GOGGLES, SAFETY SHOES,
1. CHECK COOLANT LEVEL HARD HAT, WORK CLOTHES, AND WORK
GLOVES TO PERFORM INSPECTION AND
MAINTENANCE ON THIS MACHINE.
NEVER REMOVE RADIATOR CAP WHEN ENGINE

IS HOT. ALLOW ENGINE TO COOL DOWN BE-
FORE REMOVING RADIATOR CAP.
The radiator reserve tank is provided on the right side of

the engine compartment, see Fig. PAE-3-2.
[1] Check the coolant level with cold engine.
[2] Open engine cover to check the coolant level in
the radiator reserve tank. The coolant level should
be between the lines of FULL and LOW.
PAE-3-2-2
NOTE : Engine coolant level is higher than normal when
the engine is warm. The coolant level will lower with
engine temperature.
(B) RADIATOR
(A)
Maintain coolant level at the full mark with engine cold.

Refer to page 4-7 for engine coolant specifications. FULL
[3] Open radiator expansion tank cap (A) to refill with LOW RESERVE
proper coolant mixture. TANK
Check the radiator coolant level when the coolant level PAE-3-2
in the reserve tank drops below the LOW level mark.

Make sure to check the engine cooling system for
leakages and repair as needed, before resuming op-
eration.
[4] See Fig. PAE-3-2 and Z2-303P for reference. Re-
move the radiator cap (B), and check for proper
coolant level.
[5] Refill radiator with proper coolant mixture.
[6] Install radiator cap (B) and tighten securely.
Z2-303P
3-3
2. CHECK COOLANT LEAKAGE
If the coolant level in the radiator reserve tank does
not lower, but the coolant inside the radiator does,
there is a possibility of air leakage in the cooling sys-
tem. Make sure coolant level is to specifications and
pressurize system to check for leakages. Consult
with an authorized dealer for advise and/or repairs.
Make sure to repair leakages before resuming op-
eration.
3. CHECK ENGINE OIL LEVEL

NOTE :
Make sure the machine is on firm level when check-
ing engine oil level.
Always make sure to check engine oil level before
starting the engine.
Keep the engine to a standstill for at least 30 min-
utes, when checking engine oil level after working,
PMJ-3-11
[1] Use the ignition key to unlock and open engine

covers.
[2] Pull out engine oil dipstick (G), clean it and insert
it fully into its sleeve. Remove dipstick to check
oil level. Oil level should be between the marks
"H" and "L".
If the oil is heavily contaminated or deteriorated,
change it regardless of periodical schedule.
Refer to page 4-7 for oil specifications.
[3] If needed, remove the filler cap (F) to refill.
Make sure to check the oil level again after refill-
ing.
[4] Clean engine oil filler cap (F), before installing. PAE-3-3
[5] Close the engine cover and secure it with key.
3-4
4. CHECK HYDRAULIC OIL LEVEL
BE CAUTIOUS OF HOT FLUIDS AND

NEVER PERFORM MAINTENANCE OR INSPECTION SURFACES. WEAR GOGGLES,
ON A MACHINE THAT HAS JUST FINISHED WORK- SAFETY SHOES, HARD HAT, WORK
ING. ALLOW SUFFICIENT TIME TO THE MACHINE CLOTHES, AND WORK GLOVES TO
TO COOL OFF. RELEASE HYDRAULIC TANK PERFORM INSPECTION AND MAIN-
PRESSURE BEFORE WORKING WITH ANY HY- TENANCE ON THIS MACHINE.
DRAULIC COMPONENT.
4-1 Check
[1] Move the machine to firm level ground and set it
in the hydraulic oil level check position, as shown
in Fig. PAE-1-22.
[2] Check the oil level through sight level gauge pro-
vided on the side of the hydraulic tank. Hydrau-
lic oil level should be between H and L.
Oil level varies depending on oil temperature.
Check the oil level referring to the followings.
Before starting : "L" level
[oil temp.10-30°C (50-86°F)] PAE-1-22
Normal operation : "H" level

AIR PLUG
[oil temp.50-80°C (122-176°F)] OIL FILLING PORT
HYDRAULIC
OIL TANK
NOTE : Avoid overfilling. It causes damages on hy-

draulic equipment or oil spouting.
LEVEL GAUGE
4-2 Refill with oil when the level is below "L."
Refer to page 4-7 for the recommended oil to be PFE-3-3
used.
[1] Refer to page 2-11 to open the cover.
[2] Make sure the temperature of hydraulic oil is
(A)
around 40½C (104½F), before refilling.
[3] Release hydraulic tank pressure as instructed
(K)
on page 4-13.
[4] Remove plug (A) completely.
[5] Check the O-ring (K), and replace it if needed.
[6] Refer to page 4-7 for hydraulic oil specifica-
tions.
[7] Install the plug (A) and tighten securely.
[8] Start the engine and operate each cylinder PA-3-6
PA-3-6
evenly 5 to 10 times with no load. Reset the
machine to the hydraulic oil level check posi-
LEVEL GAUGE
tion and stop the engine.
[9] Check the oil level again, and correct as needed.
H
[10] Pressurize the hydraulic oil tank, referring to
page 4-14 for the procedures.
L
PFE-3-4
3-5
5.CHECK FUEL LEVEL
MAKE SURE TO USE DIESEL FUEL ONLY, AND

STOP ENGINE BEFORE REFILLING.
BE CAREFUL NOT TO OVERFLOW FUEL AT RE-
FILLING. CLEAN UP ALL SPILLED FUEL TO PRE-
VENT FIRE.
DISPOSE OF HAZARDOUS WASTE ACCORDING
TO ENVIRONMENTAL LAWS AND REGULATIONS.
[1] Turn ignition key (1) to "ON" position to illuminate

the monitor panel.
[2] Check the fuel gauge (2), and remove filler cap (3)
to refuel if needed.
[3] Refer to page 4-7 for fuel specifications.
Fuel tank capacity: 15 liter (4.0 gal)
[4] Do not remove fuel tank strainer (4) for refilling to
avoid contamination.
[5] After refueling, install fuel cap (3) and tighten se-
curely. PWJ-3-4
Close the engine cover and use key to lock it prop-
erly.
We recommend to refuel at the end of the workshift.

Refueling should be done to full mark to reduce air
volume (condensation). Failure to do so could create !
problems such as rusting and fuel freezing, as well

"
as other associated problems.
NOTE : If the machine runs out of fuel during opera-

tion, air may get mixed in the fuel lines. Pro-
ceed to bleed the air out of the fuel system as
indicated in page 4-15.
PFE-3-5
6. CHECK FOR FUEL LEAKAGE

Check and repair any fuel leakage. Do not operate a
machine leaking fuel. Fuel leakage may be caused WATER SEPARATOR
by faulty drain plug (A), crack on hose in fuel line,
loosened hose clip, etc. Make sure to stop the en-
gine immediately if any fuel leakage is found. Repair
fuel leakage before resuming operation.
FUEL HOSE
(A) PAE-3-9
3-6
7. CHECKING BELT
ROTATING PARTS CAN CAUSE PERSONAL IN-

JURY. KEEP AWAY FROM FAN AND BELT WHEN
ENGINE IS RUNNING. MAKE SURE TO STOP
ENGINE BEFORE SERVICING.
Check the fan belt for insufficient tension, wear, and STOP
damage. Insufficient belt tension may cause battery
charge failure, engine overheating, or abnormal belt wear.
Likewise, If too much tension is applied to the belt, the 10kg (22lb) GENERATOR
bearings or belt may be damaged prematurely.
Apply a force of 10 Kg (22 lb) to the center of belt be-
tween pullies, and measure the belt deflection. The
table below shows normal condition.
Fan Belt defelection 8-10 mm (0.31-0.39 in)
See the section, MAINTENANCE (EVERY 250 HOURS),

for details on the inspection and adjustment procedure
for the belt.
PULLEY
PAE-3-10
3-7
C. CONFIRMATION BEFORE STARTING MACHINE
ENGINE
1. CHECK WARNING LAMPS
CARELESS MOVEMENT OF ANY OPERATING

LEVERS MAY CAUSE SUDDEN MOVEMENT OF
THE MACHINE. MAKE SURE TO SET THE
SAFETY LOCK LEVER TO THE "LOCKED" (UP)
POSITION BEFORE LEAVING THE CAB. REMEM-
BER THAT THE FUNCTIONS FOR DOZER AND
BOOM SWING ARE STILL ACTIVE, EVEN WITH
THE SAFETY LEVER ON THE LOCKED (UP)
POSITION.
Before starting the engine, check the warning lamps

and indicator lamps according with the following proce-
dures:
[1] Make sure the safety lever is in the "LOCKED"
(up) position.
[2] Make sure all control levers are in the "NEUTRAL"
position.
[3] Use the ignition key and the table below (as refer-
ence) to check all warning lamps and indicators
for proper functioning.
[4] Do not operate the machine under faulty condi- PAE-3-11
tions. Consult with an authorized dealer if nec-

essary. Refer to page 2-5 and make sure all warn- Key Operation OFF HEAT OFF ON START ON
ing lights and indicators function properly. Re- Lamp Pre-Heating Before Start Just After Start
pair any mal functioning before resuming opera- 1 Battery Charge Light OFF Light ON Light OFF
tion. Lamp
2 Engine Oil Light OFF Light ON Light OFF
Pressure Lamp
3 Engine Coolant Light OFF Light OFF Light OFF
Temperature Lamp
NOTE : Make sure all warning lamps and indicators func- 4
2nd Speed Travel Light OFF Light OFF Light OFF
tion properly before operating the machine. Lamp
5 Air Cleaner Light OFF Light OFF Light OFF
Clogging Lamp
P3-8OUT
2. CHECK WORKING LIGHT

While the key position in the starter switch is being WORKING LIGHT
"ON" position, turn on the working light switch to
check the lightening of working light.
If it does not lighten, presumably the light bulb is
burned out or electrical wire is broken. Repair it refer-
ring to page 4-25 .
PAE-3-12
3-8
3.2 STARTING AND STOPPING MACHINE ENGINE
A. START-UP UNDER NORMAL CONDITIONS
[1] Make sure that safety lock lever (1) is set to the
"LOCKED" (up) position.
[2] Make sure all control levers are set to the "NEU-
TRAL" position.
[3] Slightly move the throttle control lever (2) from the
low idling position.
[4] Turn the ignition key (3) to the START position to
start the engine and release after starting the en-
gine.
Release the ignition key immediately after the en-
gine starts.
The key will return to the "ON" position by itself. PWE-2-7
(2)
MAKE CERTAIN THE SWING AREA OF MACHINE

IS CLEAR OF PEOPLE AND OBSTACLES BEFORE
OPERATING. KNOW THE POSITION OF THE
TRAVEL MOTORS BEFORE STARTING TRAVEL-
LING AND MAKE SURE TO SOUND HORN BEFORE
STARTING THE ENGINE.
NOTE :
PAE-3-13
(a) Do not increase the engine speed (high idling) with
cold engine.
(b) Do not hold the ignition key in the START position for
more than 15 seconds. If the engine does not start,
return the key switch to the OFF position, wait 30
seconds, and then try again.
PAE-3-14
3-9
B. START-UP UNDER COLD CONDITIONS
In cold weather, due to the increase in oil viscosity
and decrease in battery performance, starting the THROTTLE LEVER
engine may be difficult. Use the preheater to start
the engine easily under these conditions.
[1] Perform steps [1] - [3] mentioned in START-UP

UNDER NORMAL CONDITIONS shown on the pre-
vious page.
PAE-3-15
[2] Turn the key (3) to the HEAT position and hold
position or 15 seconds to preheat before starting.
[3] Turn switch key to the START position to start the
engine.
Do not hold the key switch in the START position for

more than 15 seconds. If the engine does not start,
return the starter switch to the OFF position, wait 30
seconds, and then try it again.
PAE-3-16
[4] Release the key switch immediately after starting
the engine. The key will return to the ON position
by itself.
3-10
C. START-UP WITH BOOSTER CABLES
Observe the following precautions when using booster
cables to jump-start the battery.
FLAMMABLE GAS (HYDROGEN GAS) IS GEN-

ERATED IN THE BATTERY. DO NOT ALLOW
SPARKS OR FLAMES TO COME IN CONTACT
WITH BATTERIES TO AVOID TRIGGERING AN EX-
PLOSION.
DO NOT ALLOW THE VEHICLE OR MACHINE
USED FOR BOOSTING TO TOUCH METAL TO
METAL WITH THE DISABLED MACHINE.
WEAR HARD HAT, APPROVED SAFETY
GLASSES OR FACE SHIELD, GLOVES AND
OTHER SAFETY EQUIPMENT WHEN WORKING
WITH BATTERIES.
NEVER ALLOW THE BOOSTER CABLE CLIPS
TO COME IN CONTACT WITH EACH OTHER ONCE
CONNECTED TO A BATTERY.
THE NEGATIVE CABLE, WHEN CONNECTED TO
THE UPPER FRAME OF DISABLED MACHINE,
MAY ARC CAUSING SPARKS. MAKE SURE TO
CONNECT THE BOOSTER CABLE TO A GROUND
SURFACE IN THE ENGINE COMPARTMENT AS
FAR AS POSSIBLE FROM THE BATTERY.
WHEN THE BATTERY FLUID IS FROZEN, DO NOT
START UP THE ENGINE WITH ANOTHER POWER
SOURCE.
PAE-3-17
FOLLOW THE ORDER INDICATED IN THE NEXT
PAGE FOR CONNECTING OR DISCONNECTING
THE BOOSTER CABLES.
NOTE : Select suitable size for the booster cables

and clips according to battery size.
Use the booster cables and clips without any dam-
ages or corrosion.
PAE-3-18
3-11
D. CONNECTING/DISCONNECTING BOOSTER
CABLES
Make sure the key switch is in the OFF position
before connecting the booster cables. Proceed as
follows to connect and disconnect the boosting
cables:
ERRONEOUS CONNECTION OF BOOSTER

CABLES MAY CAUSE EXPLOSION OF THE BAT-
TERIES. PAY SPECIAL ATTENTION TO CONNECT
AND DISCONNECT THE BOOSTER CABLES.
THE ELECTRICAL SYSTEM OF THIS MACHINE
WORKS WITH 12 V DC.
[1] Set the key switch to "OFF" for both normal

vehicle and troubled machine.
[2] Refer to page 2-11 and remove the left side cover.
BATTERY
Then open the cover under the operators seat. PAE-3-19
[3] Remove the cover from the battery terminals.

[4] Connect the booster cable (red) clip to the posi-
tive (+) terminal on the battery of troubled ma-
chine.
[5] Connect the clip from the other end of the posi-
tive (+) booster cable (red) to the positive (+) ter-
minal on the battery of normal vehicle.
[6] Connect the booster cable (black) clip to the
negative (-) terminal on the battery of normal ve-
hicle.
[7] Finally, connect the clip from the other end of the PA3-20
negative (-) booster cable (black) to the engine
body (hook, etc.) of troubled machine, away from
the battery.
DO NOT CONNECT THE NEGATIVE (-) BOOSTER

CABLE TO THE MACHINE CARBODY (LOWER
STRUCTURE)
[8] Start the engine of normal vehicle, and operate it

for around 10 minutes at high idling.
[9] Start the engine of troubled machine.
[10] After starting the engine of troubled machine, re-
move the booster cables in the reverse order of
PRE-3-11
the above connection.
[11] Make sure to check and repair the cause of the
problem of the charging system on the troubled
machine.
3-12
3.3 STOPPING MACHINE ENGINE
Make sure to idle the engine for at least 5 minutes
THROTTLE LEVER
before machine shut down.
When the machine is suddenly stopped while high

speed operation of the engine, temperature of the
engine is rapidly increased causing deterioration
of engine oil and seizure of seals.
[1] Normally, place the attachment on the ground be- PAE-3-15-1

fore stopping the engine (except for special situa-
tions).
[2] Make sure to place the safety lock lever in the
LOCK (up) position before leaving the cab. OFF ON
[3] Push the throttle lever all the way forward to low
HEAT START
idle position for about 5 minutes.
Operate the engine at idling for a while to lower
the coolant temperature.
[4] Turn the starter key to OFF to stop the engine.
[5] Remove the ignition key.
STARTER KEY
PA3-22
3-13
3.4 INSPECTION AFTER STARTING MACHINE
ENGINE
Check and ensure the following items after starting CARELESS CONTACT WITH ANY OPERATING
the engine: LEVER WILL CAUSE UNEXPECTED SUDDEN
MACHINE MOVEMENT. STANDING OR SHIFT
A. EXHAUST GAS COLOR, ABNORMAL SOUND & BODY POSITION OF THE OPERATOR AFTER SE-
SMELL CURELY SETTING THE SAFETY LOCK LEVER AT
While operating the engine, check the following items. "LOCK" (UP) POSITION.
[1] Check for abnormal exhaust color during the en- MAKE CERTAIN THE SWING AREA OF MA-
gine operation. CHINE IS CLEAR OF PEOPLE AND OBSTACLES
Avoid continuous operation if the engine exhaust BEFORE OPERATING. KNOW THE POSITION OF
is black. Black exhaust is an indication of an ex- THE TRAVEL MOTORS BEFORE STARTING TO
cessive rich fuel/air mixture. Check and service TRAVEL AND MAKE SURE TO SOUND HORN
the engine accordingly if this condition is present. BEFORE STARTING OPERATION.
[2] Stop operation immediately when any abnormal
sound exists during the machine operation. Check
the cause of the abnormal sound, and repair as
needed.
[3] Avoid the operation at the speed range with reso-
nance. There may be a certain rotating speed range
at which the vibration suddenly becomes large due
to resonance. Avoid the operation at such speed
range because some parts may be damaged due
to vibration.
[4] If burning smell or smoke is generated, immedi-
ately stop the engine. Check for any abnormali-
ties and repair as needed before resuming opera-
tion.
NOTE : When ever necessary, consult with an autho-

rized dealer for appropriate repairs.
PAE-3-23
NOTE :
Do not apply any heavy load on to the new engine for
the first 50 hours operation.
Confirm the LIGHT-OFF for each warning lamp.
Carefully listen to any abnormal sound.
Check leakages for oil and water around the engine.
At the first engine start-up of the day, operate the
engine for around 5 minutes with no load to warm up
the engine and reach oil to every part of the engine.
3-14
B. CHECK EACH SWITCH & LEVER
After warming up the engine, check the following
items:
NOTE : Appropriate operation temperature range for

hydraulic oil is 50 to 80°C (122 to 176°F). Avoid ma-
chine operation when the hydraulic oil temperature is
below 20°C (68°F). Failure to do so will reduce the
life of the hydraulic components.
* SAFETY LOCK LEVER

[1] With the engine running, set the safety control PAE-3-24
lever to the "LOCKED" (up) position.
[2] Move all control levers, except the dozer/width and
boom swing control lever.
[3] Make sure that all functions, except the dozer/
width and boom swing functions, are not active
when the safety control lever is in the LOCKED
(up) position.
[4] Ensure that the travel levers are mechanically
locked and do not move at all.
NOTE : When any abnormalities are found, immedi-

ately stop the engine, proceed with the appropiate

repairs, and request assistance from an authorized

dealer if necessary.

C. CHECK MONITOR PANEL (GAUGE CLUSTER)
Check all gauges and indicators on the gauge clus-
ter, after starting the engine. Confirm that engine
temperature gauge and fuel level gauge work prop-

erly.
PA-3-25
3-15
3.5 WARMING UP ENGINE
A. ENGINE WARM-UP
Avoid rapid speed increase of engine speed with

a cold engine.
Do not idle the engine for more than 20 minutes.
Extended periods of idling reduce the life of the
engine.
PAE-3-26
Set the throttle lever in the middle position, between
the low idling and high idling (see Fig. PAE-3-26),
and operate the engine for around 5 minutes with no
load. RIGHT OPERATING LEVER
BUCKET OUT
BUCKET IN
B. WARMING UP HYDRAULIC OIL
Appropriate operation temperature range for hydrau-
lic oil is 50 to 80°C (122 to 176°F). Avoid machine
operation when the hydraulic oil temperature is be-
low 20°C (68°F). Failure to do so will reduce the life
of the hydraulic components.
[1] Set the throttle lever in the "MIDDLE SPEED" UNLOCKED

PAE-3-27
position.
[2] Set the safety control lever in the "UNLOCK"
(down) position, see Fig. PAE-3-27.
[3] Operate the boom control lever to raise it all the
way up.
[4] Operate the bucket control lever to retract it or
extend it completely against relief, see Fig. PAE-
3-27. Hold this position for one minute, then re-
lease lever and wait for another minute before re-
peating process. Repeat this procedure at least
10 times or until the temperature of the pilot hy-
draulic oil is safe for smooth attachment opera-
tion.
[5] After warming up hydraulic oil, slowly extend and
retract each cylinder several times, and actuate
traveling and slewing motors to complete the warm-
In extremely cold climate it may be necessary to

increase the warm-up time to ensure proper and safe
operation. When operating the machine with cold
hydraulic oil, the operator may experience slow or
unexpected movement of functions. Likewise, cold
hydraulic oil will not provide adequate lubrication
to hydraulic components; thus, reducing the life ex-
pectancy of the machine.
3-16
3.6 MACHINE OPERATION
The following instructions are aimed at providing an
operator with the basic function of each hydraulic con-
trol. Use of these instructions, and practice with a
machine, will allow a given operator to become more
efficient in the operation of this equipment. Each op-
erator must read thoroughly, understand, and follow
these basic instructions along with all safety precau-
tions found in this manual and on the machine be-
fore operating this equipment.
A. MACHINE TRAVEL PAE-3-28
Make certain the swing area of machine is clear

of people and obstacles before operating. Know
the position of the travel motors before starting
the travel function and make sure to sound horn
before starting the engine.
If any abnormality is found during the machine
operation, immediately stop working. Make sure
to repair any faulty conditions before resuming
operation.
NORMAL POSITIONING OF THE MACHINE FOR
THE PURPOSE OF DETERMINING FRONT, PAE-3-29
REAR, FORWARD AND REVERSE ARE WITH
THE TRAVEL MOTORS LOCATED BEHIND THE
OPERATORS CAB.
1. Forward/Reverse Travel
[1] Make sure the safety control lever is in the "UN-
LOCK" down position. Operate the boom, arm, and
bucket control levers to raise the attachments from
the ground.
[2] Pull the dozer operating lever to raise the dozer.
[3] To move the machine forward, push both (right
and left) travel levers toward the front of machine.
To move the machine in reverse, pull back both
travel levers.
Travel speed changes depending on how far you
PAE-3-30
push or pull the levers.
2. Pivot turn
· Push the left travel lever toward front of machine to
turn machine RIGHT (PAE-3-30).
· Push the right travel lever toward front of machine to
turn machine LEFT.
· Pull the left travel lever back to turn machine RIGHT
in reverse.
· Pull the right travel lever back to turn machine LEFT
in reverse.
3. Counter Rotating Machine (PAE-3-31)

To counter rotate machine to the left, pull left travel
lever back and push right travel lever forward.
PAE-3-31
To counter rotate machine to the right, pull right travel
lever back and push left travel lever forward.
3-17
4. Travel Speed Shifting (1st/2nd)
[1] For fast travel speed, depress and release the travel
speed selector switch once before operating the
travel controls. The fast lamp indicator (A) will illu-
minate in the cluster gauge.
[2] Start the machine travel by operating the travel
levers.
[3] To return to SLOW travel speed, stop travel and
depress and release the travel speed selector
switch once.
NOTE: The travel speed is always reset to SLOW
PR-2-29
speed every time the key switch is turned to the
OFF position.
B. STOP TRAVELING (PAE-3-21)
When the operation for the attachment or slewing is

inevitable during traveling, pay attention not to oper-
ate it rapidly.
[1] Put the travel levers of left and right at neutral po-
sition to stop the machine travel.
Avoid to stop the machine travel suddenly. Stop
the machine travel as slowly as possible.
PAE-3-21
3-18
USE A FLAG-MAN WHEN TRAVELING ON THE

SHOULDER OF A ROAD OR IN CONFINED AREAS.
NEVER ALLOW PERSONS TO RIDE ON THE
MACHINE.
C. TRAVEL PRECAUTIONS
[1] Make certain the travel motor location is known

before performing any travel operation. Travel
with travel motors in the back of the machine for
long distance travel.
[2] Travel on flat and firm ground and in straight lines
(or large angles) as much as possible. When
turning the machine, move forward and backward
alternately as much as possible instead of mak-
ing one sharp (pivot) turn. PAE-1-12
[3] Check the strength of bridges and road shoul-
ders, and reinforce them if necessary.
[4] Be careful not to come into contact with bridges
or electrical power lines.
[5] When traveling on rough ground, use low (1st)
speed to reduce the shock to the machine.
[6] Do not allow large or heavy objects to strike travel
motors. Likewise, do not travel over large objects
such as boulders, rocks, etc.
PMJ-1-9
[7] On a snowy or icy road, travel with slower speed

avoiding any sudden start, sudden stop and sud-
den slewing.
[8] For loading/unloading at the transport, remove

any mud clogged in the crawler shoes to prevent
the machine from side skidding on the ramps.
Refer to page 5-2 for the usage of ramps, etc.
PAE-3-33
3-19
D. CARE ON UP/DOWN SLOPE
Never take such traveling manner as changing

direction on a slope or crossing a slope. Once get
down to a flat ground and take a detour, keeping
in mind the safety traveling.
Raise the bucket 30 to 40 cm (12~16 in) above
the ground level, while traveling. And do not get
down the slope with reverse traveling.
When the machine is skidded, immediately get
PMJ-3-34
down the bucket and take braking.
The slewing on a slope may cause the machine
turning over due to losing balance on the machine.
It is quite dangerous to slew to down side of the
slope with a full load in the bucket. When such
work is inevitable, make the ground level on the
slope to secure the flat working area.
Never travel on the slope more than 30°
gradient.
When parking on the slope is inevitable, make
sure to apply skids to the crawlers and get down
the bucket to the ground.
PMJ-1-15
[1] The max gradeability of the machine is 58% (30°).

[2] While getting down slope, slowly operate the
travel levers.
[3] Travel slope with low speed (1st speed).
[4] While traveling slope, keep the bucket at 30~40
cm (12~16 in) of height above the ground level,
and travel with low speed.
[5] When the engine is stalled on a slope, place the
attachment on the ground, and make sure each
operating lever is in the neutral position. Then
start the engine again.
PAE-3-34
[6] If it is difficult to climb a slope with the travel mo-
tor due to skidding crawlers, etc., the power of
the arm can be utilized to pull up the machine
with the bucket engaged on the ground.
[7] When parking the machine on a slope, even if it
is a short time of period, place all attachments
on the ground, place each operating lever in the
neutral position, set the safety control lever to
the "LOCK" (up) position and block the crawlers.
NOTE : When the hydraulic oil is not warmed up suf-

ficiently, the machine may not be able to display its PAE-1-17
full performance. Make sure the machine is suffi-
ciently warmed up before climbing a slope.
3-20
E. MACHINE OPERATION IN WATER/ON SOFT

GROUND
NOTE : Pay attention not to immerse the slewing bear-

ing, slewing pinion and swivel joint into the water or SURFACE SLEWING
mud. RIVERBED BEARING
If the machine is operated in water or mud, the
slewing bearing and others may be worn ab- (A)
normally. Immediate replacement of grease
or overhaul of the slewing bearing, etc. is re- UPPER ROLLER
quired.
PWJ-3-28
[1] Where a river bed is flat and water flow is slow, the
machine may be operated in a water-depth to the
upper rollers (A).
[2] Operate the machine in the water with care check-
ing river bed conditions with bucket, etc. And never
enter into the water of the depth beyond (A)(PWJ-
3-28).
[3] On a soft ground, the machine body sinks little by
little in some cases. Therefore, pay full attention
to the machine at all times during operation.
[4] After traveling in seawater, thoroughly wash up
the machine to remove salt.
PAE-3-36
[5] Make sure to lubricate bucket pins and bushing
every 4 hours if working with materials in wet con-
ditions, supply grease with a grease gun until
grease purges.
3-21
F. GETTING OUT OF SOFT GROUND
If possible, avoid traveling on soft ground.
Avoid getting caught in the mud. In the event that the
machine gets caught in the mud, get out of it as fol-
lows:
(a) ONE CRAWLER SHOE GETS CAUGHT IN MUD

When either side of crawler shoes gets caught in the
mud, lay logs or boards on the mud to form a base.
Operate the boom and arm to form an angle between
boom and arm of about 90 ~ 110° and push on the
PMJ-3-39
ground with the bottom of the bucket to lift the ma-
chine body up to climb on the logs or boards (PMJ-3-
39).
(b) BOTH CRAWLER SHOES GET CAUGHT IN MUD

When both sides of crawler shoes get caught in mud
and the machine does not move due to skidding, pro-
vide logs and boards, as described in the above sec-
tion. And firmly catch the hard ground on which the
machine should get out of mud with the bucket, and
pull up the machine toward the hard ground with the
same operation of digging (PMJ-3-40).
PMJ-3-40
In case the machine is not able to travel because its

crawler is stuck in mud, sand or gravel on the soft
ground, take each crawler off the ground by pushing
the boom and arm against the ground, scrape off mud,
sand and gravel and then get the machine out of the
trouble. Gravel and mud may be cleared if you rotate
the raised crawler back and forth.
Operate the machine at the operator's seat. Do not

allow any person to come near the machine. PMJ-3-41
3-22
G. SLEWING OPERATION
SLEWING PATTERN (ISO)

OPERATION OF THIS MACHINE ON AN INCLINE LEFT OPERATING LEVER
OR SLOPE MAY CAUSE THE MACHINE TO BE-
COME UNSTABLE OR UNBALANCED. SLEWING RIGHT
MAKE CERTAIN THE SLEWING AREA OF THE SLEWING
LEFT
MACHINE IS CLEAR OF PEOPLE AND OB-
STACLES BEFORE SLEWING.
WORK UP AND DOWN INCLINES OR SLOPES,
NEVER ACROSS.
NEVER SLEWING OR TURN MACHINE AROUND
ON SLOPES.
OPERATE CONTROL LEVERS CAREFULLY TO PWA-3-37
PREVENT SUDDEN MOVEMENTS WHICH MAY
CAUSE THE MACHINE TO SLIDE OR TIP OVER.
BUILD A LEVEL AREA FOR THE MACHINE TO
OPERATE.
USE A FLAGMAN TO GUIDE THE OPERATOR.
PMJ-1-15
3-23
H. CHANGING MACHINE WIDTH (CRAWLER FRAME

WIDTH)
Change the machine width on a flat and hard

ground without any obstacles.
Make sure to lift the machine body up to change
the crawler width. Otherwise, the crawler frame PA-3-38
and width adjusting cylinder may be damaged.
(A)
[1] Lift up the machine body as shown in the sketch
(PA-3-38).
[2] Set the crawler/dozer shifting lever to (A) posi-
tion (crawler frame width side).
PA-3-39
[3] Expanding (PAE-3-40)

Move the adjustable crawler frame width/dozer
lever to (B) position (crawler frame width expan-
sion) to expand the machine width (crawler frame
width).
PAE-3-40
[4] Retracting (PAE-3-41)

Move the adjustable crawler frame width/dozer
lever to (C) position (crawler frame width retract-
ing) to contract the machine width (crawler frame
width).
PAE-3-41
I. CHANGING DOZER WIDTH PIN

If required, the width of dozer blade can be extended
by setting the additional plate as follows (PAE-3-42).
[1] Pull the pin off, and remove the plate.

[2] Set the plate outside, and align the pin bores.
PAE-3-42
3-24
3.7 PRACTICES TO IMPROVE EFFICIENCY
SWINGING ON A SLOPE MAY CAUSE THE MA-

CHINE TO BECOME UNSTABLE OR UNBAL-
ANCED. DO NOT SWING DOWN SIDE OF THE
SLOPE WITH A FULL BUCKET. WHEN WORK- NOTE : Other than showing in the below sketches,
ING IN SLOPES, BUILD A LEVEL AREA FOR THE wider range of the machine application is obtain-
MACHINE TO OPERATE SAFELY. able by means of utilizing the optional attachments.
MAKE CERTAIN THE SWING AREA OF THE MA- Refer to Section 4 for changing the bucket.
CHINE IS CLEAR OF PEOPLE AND OBSTACLES
BEFORE SWINGING.
A. DIGGING
[1] Use Arm In Action
Operate the bucket at shallow depth, use the arm
mainly, and use the bucket as required, in action
to fill the bucket. Setting the bucket too deep will
decrease the machine's efficiency.
[2] Maximum Digging Force Position
The attachment will provide maximum digging force
when the arm and boom are at 90° -110° of each
other. Operate slowly to get maximum digging
force.
[3] Bucket Teeth Direction
Always point bucket teeth in the direction the ma-
chine will be digging, and operate the bucket at
shallow depth, to reduce digging resistance and
the possibility of bucket teeth damage.
[4] Operate Boom Smoothly
Always begin and end boom operation slowly with
smooth, careful movement of the control lever. Do
not perform sudden starts and stops, especially
sudden stops during dropping, of the boom as this
creates unnecessary stress on the machine and
its components.
PMJ-3-43
[5] Cleaning Sand & Soil from Bucket

Operate arm to a near level position and bring the
bucket to a dumping position. If sand and soil do
not fall out, move the bucket lever right and left a
few times.
PAE-3-43
3-25
1. DITCH DIGGING
The working efficiency is much improved by means of
setting the bucket suitable for trench digging and set-
ting the machine in parallel to the trench to be digged
(PMJ-3-44).
For wide ditch digging, dig both sides portions at first,
then dig the center portion.
2. USING THE DOZER

PMJ-3-44
[1] The dozer is used to push the soil back to digged
ditch, or for ground leveling.
[2] Scrape the soil laid on the ground at its upper or
side face with the dozer. Adjust the height of dozer
with the dozer control lever to avoid overloading
the engine.
Carefully operate the attachment paying attention PMJ-3-45

to the surrounding conditions, since the boom
swing operating range is wide.
3. SIDE DIGGING
The boom swings to the left and to the right enabling
side digging in narrow spaces, by depressing the
left and right sides of the swing pedal.
By depressing the left side of boom swing pedal,

the boom swings leftward, and by pressing the right
side the boom swings rightward.
The advantage of this function is that it enables side
digging work as shown in limited spaces as shown
in (PWJ-3-29).
PWJ-3-29
3-26
B. LOADING
[1] The working efficiency is improved, if the dump
truck is set at the position so that the slewing
angle becomes minimum keeping a good visual
field of the operator.
[2] It is recommended that loading be started from
the front side of the dump truck body. This will
make loading easier and more soil can be loaded
than loading from the side (PMJ-3-47). PMJ-3-47
C. WORKING IN NARROW SPACE

The position shown (PR-1-44) is available for slewing
in narrow spaces.
D. MINIMUM SLEWING POSITION

[1] Extend arm cylinder and bucket cylinder to maxi-
mum length, and fold bucket.
[2] Extend boom cylinder to maximum length.
[3] Keep the switch on the left control lever depress-
ing and operate the left control lever left.
[4] Handle operating lever to swing boom.
NOTE : Use care to protect attachment from interfer-

PR-1-44
ence.
* MINIMUM SLEWING RADIUS

Model CX14
Boom
At Swing
(Left 80°) 1,080mm (3 6.5)
Without Swing 1,420mm (4 7.9)
3-27
3.8 MACHINE PARKING
ALWAYS PARK THE MACHINE ON A FIRM, LEVEL

SURFACE.
AVOID PARKING ON A SLOPE. WHEN PARKING
ON A SLOPE IS INEVITABLE, MAKE SURE BUCKET
TEETH ARE DUG IN THE GROUND, REST THE
DOZER BLADE ON THE GROUND, AND BLOCK
THE CRAWLERS. PAE-1-17
MAKE SURE TO SET THE SAFETY LOCK LEVER
TO THE "LOCKED" (UP) POSITION TO AVOID ANY
UNEXPECTED MACHINE MOVEMENT AND STOP
THE ENGINE BEFORE LEAVING THE CAB.
[1] Place both travel levers (1) in the "NEUTRAL"

position.
[2] Set the throttle lever (2) to "LOW IDLING" posi-
tion.
[3] Place the bucket on the ground.
[4] Place the dozer blade on the ground.
[5] Block the crawlers.
[6] Set the safety lock lever (3) to the "LOCKED" (up)
position. PA-3-44
PME-3-23
3.9 CHECK & CONFIRMATION AFTER WORK

Regularly check the monitor panel (gauge cluster) for
warning lamps and indicators.
[1] If the fuel is insufficient, fully refill the tank with
fuel, after stopping the engine.
[2] If any trouble is indicated with the warning lamps
for the coolant temperature and/or engine oil, move
the machine to a safe place, immediately stop
the engine, and repair as necessary before resum-
ing operation. Refer to Section 4 for the "INSPEC-
TION & MAINTENANCE CHART" for details on
preventive maintenance.
PA-3-45
3-28
3.10 PRECAUTIONS AFTER OPERATION
[1] Check for any oil or coolant leakage. Check the
attachment, exterior, and travel system compo-
nents. Repair as needed before resuming opera-
tion.
[2] Fully refIll with fuel. However, do not overfill (to the
top of the tank) to avoid overflowing due to fluid
expansion under normal temperature.
[3] Remove mud, etc., adhered to the traveling com-
ponents.
YN-3-52
3.11 MEASURES AFTER EMERGENCY STOP

Avoid emergency stops of the engine as much as
possible.
It should be kept in mind that the engine is to be
operated for around 5 minutes with no load (to disipate
heat), before stopping the engine.
The most important matter is to always pay attention
to safety so that the emergency stop of the engine
will not be required.
When the emergency stop of the engine is inevitable
due to dangerous condition or trouble on the machine,
take the the following preventive measures to avoid
any injury or damages to the machine.
Do not restart the engine until its temperature is com-
pletely lowered.
SUDDEN STOP OF THE ENGINE JUST AFTER OP-

ERATION IN HIGH SPEED CAUSES A SUDDEN
RISE OF ENGINE TEMPERATURE RESULTING IN
DETERIORATION OF OIL, SEIZURE OF SEALING
COMPONENTS, ETC.
3-29
[1] Even if the engine ceases its operation, keep the
safety lock lever in the "LOCKED" (up) position.
[2] When the emergency stop is done without plac-
ing the bucket on the ground, support it with safety
blocks under the attachment or the bucket, and
block the crawlers.
[3] When the emergency stop is activated on a slope,
block both crawlers at their lower sides.
[4] Make sure to set limits around the machine while
it is down for repairs and tag it properly. Use DO
PAE-1-17
NOT OPERATE tag P/N: YN20T01320P1.
[5] Consult with an authorized dealer for repairs if
needed.
[6] After an emergency stop, do not restart the en-
gine until the temperature of the engine is com-
pletely lowered.
PAE-3-46
3.12 LOCKING UP WITH KEY

Make sure to use the ignition key to lock the follow- KEY
ing items: CYLINDER
(a) Engine guard
(b) Filler cap for fuel
PEE-3-47
(c) Storage box KEY CYLINDER
PAE-3-48
3-30
3.13 EMERGENCY MEASURES AGAINST SUDDEN
FAILURE OF MACHINE
A. RELEASING LOCK FOR TRAVEL MOTOR

While travel motors are at a standstill, they are hy-
draulically locked by the counter balance valve, and
also mechanically locked by the brake system. When
the machine becomes unable to travel due to failure PEE-4-103
on the travel motors, etc., it is possible to tempo-
rarily move the machine by means of releasing lock
for the travel motor with either of the following meth-
ods:
AVOID CONTAMINATION OF REDUCTION UNITS

WHILE THEIR COVERS ARE REMOVED.
A-1) REMOVING GEARS
*This is the preferred method.
MAKE SURE TO APPLY SAFETY BLOCKS TO PEE-4-102

FRONT AND BACK SIDES OF CRAWLER SHOES
BEFORE REMOVING THE GEARS FROM THE
TRAVEL REDUCTION UNITS.
PROVIDE A SUPPORT FOR THE ATTACHMENT IF
NECESSARY.
1. Provide a container under the travel motor to col-

lect drained oil, see (PEE-4-101). 4
Slowly remove to plug (4), then remove lower plug
to drain reduction unit oil.
Plug (4): 8 mm hex. bore
CONTAINER
Clean up all spilled oil. Dispose of all hazardous PEE-4-101
waste in accordance with local government
environmental regulations.
3-31
2. Insert a (flat) screwdriver into gap between the body
(1) and the snap ring (3), to remove the snap
ring(3).
3. Remove the cover (2) together with the snap ring

(3).
PEE-4-107
4. Remove the carrier assy (6) from the reduction

unit and protect it from contamination and/or dam-
age.
NOTE: the sprocket for this crawler becomes free

from the travel motor.
5. Temporarily install the cover (2).
6. Repeat steps 1 through 5 on the opposite travel

reduction unit to remove the carrier assy (6).
Toe the machine to a safe place to proceed with PEE-4-106

the appropriate repairs.
Clean up all spilled oil. Dispose of all hazardous

NOTE : After all repairs are made, reinstall the carrier

assy (6) on both travel reduction units in reverse order
and make sure to use fresh gear oil. Refer to Mainte-
nance Section (4) for proper oil and capacities.
3-32
A-2) REMOVING SPOOL AND BRAKE
1. Remove the track links according to the instruc-

tions "REMOVAL OF RUBBER CRAWLER
SHOE" in Section 4.
2. Make sure to use safety blocks under the crawler

frames (travel motor side)
3. Remove the travel motor covers (1) from both sides

of lower frame loosening three capscrews (2).
PAE-3-49
4. Provide an empty container to catch drain oil, then

disconnect the hoses, see (PAE-3-50). Make sure
to release hydraulic system and tank pressure,
see page 4-13. Make sure to mark all hydraulic
lines connecting on travel motors and remove them.
Never allow a hydraulic line or component to become

contaminated. This could cause severe system
damage. Contact an authorized dealer to obtain the
proper caps and plugs to be used on this machine.
PAE-3-50
5. Remove the socket capscrews (3) to remove the

travel motor from the lower (crawler) frame. Gradu-
ally loosen the capscrews paying attention not to
drop off the travel motor.
8-Socket capscrew (3): M10x20
6. Remove the plug (4).

Plug (4): 27 mm of hex. size
PAE-3-51
3-33
7. Remove the spool (5). Be careful not to damage
the spool during removal. Place spool (5) and loose
parts (6) and (7) in a clean container with clean oil
to protect them from rust and contamination.
8. Install plugs (4) to prevent contamination.
PAE-3-52
9. Remove 7-socket capscrew (12), and separate the

bodies (10) and (11) from assembly, see (PEE-2-
104).
Make sure to contain oil spillage and dispose of

all hazardous waste in accordance with local gov-
ernment regulations.
10. Remove 10-spring (13) for parking brake.
11. Temporarily reassemble bodies (10) and (11) in

without springs (13).
12. Install the travel motor to the lower (crawler) frame

and reinstall hydraulic lines.
PEE-3-104
13. Repeat steps 3 through 12 on the opposite track

side to remove the other travel motor.
14. Install track chains in accordance with "INSTALLA-

TION OF RUBBER CRAWLER SHOE" in page 4-17, and
move the machine to a safe place to proceed with
repairs.
By removing the spools and springs, the travel mo- contaminated. This could cause severe system
tors are released from locked condition. damage. Contact an authorized dealer to obtain
the proper caps and plugs to be used on this
Move the machine to a safe place and call a ser-
machine.
vice-man as mentioned in Item A-1).
NOTE : After all repairs are made, reinstall the counter

balance spools and brake springs on both travel mo-
tors. Make sure hydraulic oil level is to specifications.
Refer to Maintenance Section (4) for proper oil and
capacities.
3-34
B. LOWERING BUCKET
This procedure is to be used only as an emergency

to lower the position of the bucket. Extreme caution
should be exercized since the weight of the bucket
will tend to move the bucket abruptly when the lines
are disconnected.
Make sure to block the attachments to avoid sudden
changes in their position. Slowly remove hydraulic
lines until oil pressure is completely released. Then PAE-3-53
control the bucket movement by slowly removing the
block.
To lower the bucket position, proceed as follows:

When the bucket is in digging position (A) (bucket
cylinder completely extended, see PAE-3-53), dis-
contaminated. This could cause severe system
connect hose (H) side, see PAE-3-54. Conversely,
damage. Contact an authorized dealer to obtain
when the bucket is in dump position (B) (bucket cyl- the proper caps and plugs to be used on this
inder completely retracted, see PAE-3-53), discon- machine.
nect the hose (R) side, see PAE-3-54.
Clean up all spilled oil. Dispose of all hazardous waste

in accordance with local government environmental
regulations.
PAE-3-54
3-35
C. LOWERING ARM & BOOM
This procedure is to be used only as an emer-

gency to lower the position of attachment. Ex-
treme caution should be exercized since the
weight of the attachments will tend to drop them
abruptly when the lines are disconnected.
Make sure to block the attachments to avoid
sudden changes in their position. Slowly remove
hydraulic lines until oil pressure is completely re- PAE-3-55
leased. Then control the attachment movement
by slowly removing the blockage.
DO NOT ENTER INTO THE AREA UNDER AT-
TACHMENTS, WHILE LOWERING THEM.
1. Lowering Arm (Step 1)

Gradually loosen the hose of rod side connected
to the arm cylinder.
2. Lowering Boom (Step 2)

Gradually loosen the hose of head side connected
to the boom cylinder. PAE-3-56
Clean up all spilled oil. Dispose of all hazardous

3. Keep the attachment at 30-40 cm (12-16 in) above NOTE : If necessary, contact an authorized dealer
ground level, taking the occasion of moving the for advise and/or repairs.
machine into consideration.
4. Securely retighten the hoses not to lower the at-

tachment anymore.
5. After moving the machine to a safe place, touch

the attachment with the ground.
6. Call up a serviceman to have the machine investi-

gated.
D. SLEWING UPPER SLEWING STRUCTURE

The upper slewing structure has no braking system.
Therefore, it is possible to slew the upper slewing struc-
ture by means of pushing the attachment with a few
persons.
3-36
3.14 CAUTION ON USING RUBBER CRAWLER
SHOES * Although the rubber crawler shoe displays many ad-
vantages because of its material properties, it has
A. PROPER USAGE disadvantages in terms of strength. It is therefore
The rubber crawler shoe offers excellent features which necessary to get fully familiar with the characteris-
a steel crawler shoe does not possess. tics of the rubber crawler shoe and observe what are
However, if it is used in the same way as the steel prohibited and cautioned against, in order to extend
crawler shoe, then its advantages can not be fully the service life of the rubber crawler shoe and have it
taken. Operation of the machine varies upon site and fulfill its advantages to a maximum possible extent.
working conditions. Read thoroughly "CAUTIONS ON USING RUBBER
SHOES" before use.
Comparison between rubber and steel crawler shoes:
Rubber shoe Steel shoe *GUARANTEE OF RUBBER CRAWLER SHOE

Guarantee does not cover such damages done to the
Less vibration
rubber crawler shoe that result from improper working
Smooth run
and/or operation as: execution of site work in such
Low noise
places where there are steel plates, U-drains, block
Harmless for paved road
corners, sharp slashed gravel and stones, ferrocon-
Easy handling
crete debris, metal scraps and others which may tear
Not damageable off the rubber crawler shoe, and neglect to observe
Large traction force prohibited operations.
; Excellent ; Good ; Ordinary
B. PROHIBITED WORK
Do not carry out the following operations:
[1] Do not operate and/nor travel in gravel-mixed land,
rugged and solid rock bed, ferroconcrete, iron
scraps, edges of iron plates.
PMJ-3-66
[2] Do not operate and/nor travel in such places as

river beds where there are lots of stones of differ-
ent sizes. The rubber crawler shoe tends to be
damaged or come off from the rollers as the result
of being caught in the grooves on the rubber crawler
shoes. The service life of the rubber crawler shoe
will be reduced if soil is pushed by force when the
rubber crawler shoe is slipping.
PR-3-70
[3] Do not let oil, fuel, solvents, etc., come in contact

with rubber shoes. If it does, wipe it off with a cloth
immediately.
Do not travel on a puddle of oil, etc. on the road
surface.
PR-3-71
3-37
[4] Do not enter such hot places as an open-air fire,
and steel plate left in the open sun.
Do not work in asphalt leveling.
[5 When storing the machine for long periods (more

than three months) , keep it indoors which will not
be exposed to direct sunshine and rain.
Refer to page 3-40 for the storing procedures.
PMJ-3-67
[6] If the machine travels using one side crawler, with

the crawler of another side floating, the rubber
crawler shoe may come off from the rollers or be
damaged.
PMJ-3-68
C. CAUTIONS ON USAGE
Use care of the following when working:
[1] Rubber shoes slip easily on icy surfaces
Take the necessary safety precautions, such as
not driving on snowy/icy slopes.
[2] Avoid making a spin turn on a concrete road.
[3] Avoid abrupt change of directions because it will

cause early wear or chipping of the rubber crawler
shoe.
PMJ-3-69
[4] Exercise care so that the rubber crawler shoe is
not damaged by the bucket while working.
[5] Do not operate the machine by pressing the bucket

against concretes and walls.
[6] When the machine is lifted up by the attachment,

lower it slowly.
PR-3-75
3-38
[7] If the machine is operated in salty or corrosive
places, the adhesion of the core metal of the shoe
will get loose. Refrain from using the shoe, or
wash it with water after use.
[8] The rubber shoe should be used within -25° C to
+55° C (-13° F to 13° F) , considering the physi-
cal properties of rubber.
PR-3-76
NOTE : Use the rubber shoe under proper tension to

prevent it from coming off from the rollers. Operate
the rubber shoe carefully even when tensioning is
proper.
[9] Avoid changing direction of the machine on ground

with difference in level (about 20 cm/8 in). When
crossing over a place where there is a difference
in level, do it at right angles to the difference in PMJ-3-70
level, see (PMJ-3-70).
[10] When climbing back on a slope, avoid changing

direction of the machine while climbing on a point
between a level ground and the slope, see (PMJ-
3-71).
PMJ-3-71
[11] If you travel on a slope or a concave with one side

of the machine lifting, it will damage the rubber
crawler shoe. Always travel with both sides of
the machine level.
PMJ-3-72
[12] Do not change direction of the machine with the

rubber crawler shoe on ground with high spots,
see (PMJ-3-80) as it will cause the rubber crawler
shoe to come off or be damaged.
PMJ-3-80
3-39
3.15 MACHINE OPERATION IN ADVERSE WEATHER [3] BATTERY
CONDITION When the ambient temperature lowers, the charg-
A. OPERATION IN EXTREME COLD ing performance goes down or the battery may
freeze. Keep the charging rate as close as pos-
sible to 100%. Cover the battery with insulation
When the temperature is extremely low, oil flow is material.
reduced due to increased viscosity, making start- Perform test on the battery. We recommend the
up difficult. Coolant may freeze damaging radiator test be performed at room temperature for best
and/or engine. results. Use a hydrometer to check the specific
gravity of each cell and compare the readings with
[1] FUEL AND OIL
Use fuel and oil of high quality and low viscosity
for each system. See MAINTENANCE section, Temp.of battery
-10° C 0° C 20° C
"LUBRICANT, FUEL & COOLANT SPECIFICA- fluid
Charging rate (14° F) (32° F) (68° F)
TIONS" page 4-7 for details.
100% 1.28 1.27 1.26
[2] COOLANT
When operating or storing the machine in cold 90% 1.26 1.25 1.24
regions, the ratio of mixing antifreeze into the cool-
ing system should conform with the lowest pre- 80% 1.24 1.23 1.22
dicted ambient temperature. If coolant freezes,
75% 1.23 1.22
the radiator, crankcase and cylinder head may be
damaged. Do not measure the specific gravity of battery fluid just
When shipped from the factory, the machine con- after operation.
tains coolant mixed with all-season-type LONG
LIFE COOLANT.
NOTE : Keep battery terminals free of ice and snow to
When operating or storing the machine in extreme
avoid short circuits. Check the battery electrolyte (acid)
cold, inspect the coolant to maintain proper con-
level frequently and fill as needed with distilled water.
centration.
In extremely cold climates, remove the battery and
store it overnight at room temperature.
NOTE : In extremely frigid climates, covering the ra-
diator is a method to aid the machine warm up. If
necessary to maintain temperatures, cover the outer
edges of the radiator, leaving an opening in the cen- [4] AFTER OPERATION
ter part of the cover; thus, avoiding fan overload. Mud and water adhering to the machine may freeze
Keep a close watch on the cluster gauge for warn- interfering with proper machine operation. Use the
ing icons during operation. It may be necessary to following general guidelines as reference to pre-
use coolant heater, fuel heater, engine heater jacket, vent malfunctions:
and/or additional battery power to aid engine start- Remove mud and water adhering to the machine.
ing. Likewise, mix coolant to a protection tempera- Remove water adhering to the travel system thor-
ture of 5 °C (9°F) lower than the machine will expe- oughly and park on dry ground to prevent the travel
rience during operation, storage or transport. system from freezing.
Retract the cylinder rods to minimum length to
reduce exposed area of the rods. This will prevent
mud or water on the rod faces from damaging the
seal.
3-40
B. OPERATION AT SEASHORE OR SALTY CLIMATE D. OPERATION IN DUSTY AREAS
[1] BEFORE OPERATION [1] AIR CLEANER
Check all mounting hardware for proper tightness. Clean or replace the element at adequate interval.
Torque to proper value to aid in preventing salt from See Maintenance Section for details.
entering the machine systems. [2] RADIATOR
Apply grease to the electrical equipment as re- Clean the radiator regularly to prevent the radiator
quired to prevent corrosion. core from becoming clogged with dust.
[3] FUEL
[2] AFTER OPERATION Be careful not to let contamination in the fuel when
Wash the machine thoroughly to remove salt. refueling. Inspect the elements and filters at ad-
Apply oil or grease as necessary to prevent corro- equate interval.
sion. [4] ELECTRICAL EQUIPMENT
Clean the starter and generator especially, at ad-
equate interval, to prevent dust from accumulat-
C. CARE FOR ELECTRICAL EQUIPMENT ing. See Maintenance Section for details.
The electrical equipment is especially sensitive to
water. Be careful not to expose the electrical equip-
ment to water when washing the machine or during
rain. The electrical components (relays, fuses, etc.)
are installed at the operator's seat of the machine.
Never expose the operator's seat to water.
3-41
3.16 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD
When storing the machine for more than one month, observe the following points to prevent the machine
function from deteriorating.
Item Action
Wash the machine thoroughly.

Washing machine Check the travel system for any malfunctions and service as required. Lubricate every
required part.
Check the lubrication oil to make sure it is at the proper level and for contamination. Replen-
ish if necessary, and change if contaminated.
Lubricating oil deteriorates even when the machine is not used.
Lubrication
Be sure to check the oil before operating the machine again.
Apply sufficient rust inhibiters to portions where rust is likely to occur, especially the ex-
posed rod of the cylinders.
Remove the negative terminal from battery and cover the battery, or remove the battery from
Battery the machine and store it at room temperature placing it over a wood deck.
Charge the battery once a month to replenish spontaneous discharging.
If there is a possibility that the coolant may freeze, add antifreeze in the coolant. Normally,
Coolant
long life coolant is mixed in, so it is not necessary to change the coolant.
Dust and humidity

prevention
PMJ-3-76
Keep the machine in a dry place indoors. If the machine must be kept outdoors, lay wood
block on the flat ground and protect the machine with cover.
Park the machine with the exposed piston rod of the cylinder retracted as much as
possible.
Get down the bucket to the ground and set the skids to the crawler.
If the oil film on the parts is insufficient and rust occurs, abnormal wear may occur when the
machine is operated.
Start the engine and operate the machine and attachment, etc. once a month to lubricate
all of the parts.
Periodical operation Before starting the engine, check the engine oil and coolant level, and replenish if insuf-
for lubrication ficient.
(during storage) Wipe off the rust inhibiter from the cylinders and piston rod thoroughly.
Apply rust inhibiters to the cylinder rods after the above operation.
After starting the engine, warm up the machine completely. Repeat traveling, slewing,
and digging several times to lubricate each part of the machine.
Ensure proper ventilation during warming-up operation.
Before placing the machine back into operation, proceed as follows before starting up.
Operation after long Fully wipe off the rust inhibiters from the cylinders and piston rods.
term storage Refill fluids to proper levels and lubricate as required.
3-42
SECTION 4
MAINTENANCE
TABLE OF CONTENTS
4.1 GENERAL INFORMATION ....................................................................................................................... 4-3

4.2 GENERAL SAFETY & PRECAUTIONS .................................................................................................... 4-4
4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS .............................................................................. 4-7
4.4 FILTERS & ELEMENTS, AND BUCKET .................................................................................................. 4-8
4.5 ACCESSORY TOOLS .............................................................................................................................. 4-9
4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS .................................................................... 4-10
4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES ...................................................... 4-11
4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINT .............................................................................. 4-12
4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC OIL SYSTEM ................................................... 4-13
4.10 PRESSURIZING HYDRAULIC OIL TANK ............................................................................................ 4-14
4.11 BLEEDING AIR IN FUEL SYSTEM ...................................................................................................... 4-15
4.12 REPLACEMENT OF RUBBER CRAWLER SHOE ............................................................................... 4-16
A. Removing Rubber Crawler Shoe .................................................................................................. 4-16
B. Installing Rubber Crawler Shoe .................................................................................................... 4-17
C. Check and Adjustment of Tension On Crawler Shoe .................................................................... 4-18
4.13 INSPECTION AND MAINTENANCE CHART ....................................................................................... 4-21
4.14 WHEN REQUIRED .............................................................................................................................. 4-24
A. Cleaning Radiator Cores ............................................................................................................... 4-24
B. Cleaning or Replacement of Radiator Cap ................................................................................... 4-24
C. Replacement of Working Light ...................................................................................................... 4-25
D. Reconditioning Bucket .................................................................................................................. 4-26
1. Check for Abrasion/Damages On Tooth Point & Side Cutter ................................................... 4-26
2. Replacing Tooth Points ............................................................................................................ 4-27
3. Replacing Side Cutter ............................................................................................................. 4-28
E. Replacement of Bucket ................................................................................................................. 4-29
1. Removal of Bucket .................................................................................................................. 4-29
2. Installing Bucket ...................................................................................................................... 4-30
3. Adjusting Bucket Mount Gap ................................................................................................... 4-30
F. Inspecting Rubber Crawler Shoe ................................................................................................. 4-32
G. Lubrication For Operating Levers ................................................................................................ 4-34
H. Checking Electrical Wiring and Fuses .......................................................................................... 4-35
4-15 8-HOUR (DAILY) INSPECTION AND MAINTENANCE ........................................................................ 4-37
A. Check External Conditions of Machine ......................................................................................... 4-37
B. Check Capscrews and Nuts For Looseness and/or Missing ........................................................ 4-37
C. Check Each Cylinder, Piping and Hose For Leakage and Damages ........................................... 4-38
D. Check Travel System For Leakage and Abrasion ......................................................................... 4-38
4.16 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE .................................................................. 4-39
A. Adjusting Crawler Tension ............................................................................................................. 4-39
B. Greasing Pins Around Bucket ....................................................................................................... 4-39
C. Draining Water from Water Separator and Cleaning ..................................................................... 4-40
D. Draining Water and Deposits from Fuel Tank ................................................................................ 4-41
E. Check Battery Fluid Level and Specific Gravity ............................................................................ 4-42
4-1
4.17 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE ............................................................. 4-43
A. Greasing Attachment and Dozer Pins ........................................................................................... 4-43
B. Oil Change for Engine ................................................................................................................... 4-44
C. Greasing To Slewing Bearing ........................................................................................................ 4-44
D. Adjustment for Belt Tension .......................................................................................................... 4-45
E. Adjustment for Fan Belt ................................................................................................................. 4-45
F. Replacement of Engine Oil Filter ................................................................................................... 4-46
G. Cleaning Engine Fuel Filter .......................................................................................................... 4-47
H. Checking Radiator Hose ............................................................................................................... 4-48
I. Replacing Radiator Hose .............................................................................................................. 4-48
J. Checking/Cleaning/Replacing Air Cleaner Element ...................................................................... 4-49
1. Check Element ........................................................................................................................ 4-49
2. Cleaning Element .................................................................................................................... 4-49
4-18 500-HOUR (6-MONTH) INSPECTION AND MAINTENANCE ............................................................. 4-51
A. Replacement of Element ............................................................................................................... 4-51
B. Replacement of Hydraulic Return Filter ........................................................................................ 4-52
C. Replacement of Fuel Filter ........................................................................................................... 4-53
4.19 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE ......................................................... 4-54
A. Replacement of Coolant ............................................................................................................... 4-54
B. Check and Adjustment for Valve Clearance .................................................................................. 4-55
C. Check and Adjustment for Starter And Generator ....................................................................... 4-55
4.20 2000-HOUR INSPECTION AND MAINTENANCE ............................................................................... 4-56
A. Oil Change In Hydraulic Oil Tank and Cleaning of Suction Strainer .............................................. 4-56
B. Cleaning Line Filter of Pilot Valve and In-line Filter of Solenoid Valve .......................................... 4-58
C. Oil Change for Travel Speed Reduction Unit ............................................................................... 4-60
D. Gear Oil Change for Lower Roller and Idler ................................................................................ 4-61
1. Lower Roller ............................................................................................................................ 4-61
2. Idler ......................................................................................................................................... 4-63
E. Replacement of Grease in Slewing Grease Bath ......................................................................... 4-64
F. Check and Adjustment for Fuel Injection Timing ........................................................................... 4-64
G. Check and Adjustment for Contact Surface of Intake and Exhaust Valve .................................... 4-64
INSPECTION MAINTENANCE CHECK LIST ................................................................................................ 4-65
4-2
SECTION 4 - MAINTENANCE
4.1 GENERAL INFORMATION
NOTE: Make sure to consult with an authorized dealer
for the adjustment, disassembling and repair of the
engine, reduction gear and electronic equipment
READ, UNDERSTAND AND FOLLOW ALL SAFETY
(controller, etc.).
PRECAUTIONS CONTAINED IN THIS MANUAL
BEFORE PERFORMING ANY INSPECTION OR
MAINTENANCE PROCEDURES ON THIS MA-
CHINE , ITS SYSTEMS OR COMPONENTS.
A. It is recommended by CASE, that an inspection and

maintenance schedule be developed and main-
tained on a regular basis for this machine. Devel-
oping and maintaining such a schedule, helps to
keep the machine in optimum operating condition.
B. The information contained in this section gives the
proper procedures for performing inspection and
maintenance functions for this machine. Use these
procedures when performing inspection and main-
tenance as they will guide the technician step by
step for each procedure. Also, refer to the Inspec-
SK32004001
tion and Maintenance Charts for general service
interval recommendations.
C. Basically, lubrication and maintenance intervals are
determined by the hourmeter. If performing lubri-
cation and maintenance according to calendar time
is preferred, the hourmeter reading corresponds
to the lubrication and maintenance period (daily,
weekly, monthly, etc.) in calendar time; thus calen-
dar time can be used. Items for which service time
cannot be specified are explained in the section
WHEN REQUIRED.
NOTE : The inspection and maintenance charts pro-

vided in this section give only general time intervals.
It may be necessary to develop a custom schedule
to perform machine maintenance at more frequent
intervals based on the work conditions such as se-
vere applications, work in dusty or humid circum-
stances, etc.
D. Use only specified oils, fluids, lubricants, filters and

replacement parts to keep machine in optimum op-
erating condition.
Furthermore, use the oils and greases with the
specified viscosity depending on the ambient tem-
perature.
Store the vessels and containers indoor for the oils,
fluids and greases, taking suitable measures to pre-
vent them from invading dust, water, etc. SK32004003
4-3
4.2 GENERAL SAFETY & PRECAUTIONS
Do not carry out any other inspection and maintenance
procedures than specified in the manual. Carry them
out by parking the machine at a flat and conveniently
situated place.
A. KEEP MACHINE CLEAN

Thoroughly clean machine before performing in-
spection and maintenance procedures. It is easier
and safer to locate problems, perform maintenance
SK32004004
and also reduce the risk of hydraulic system con-
tamination when machine is clean.
B. CONFIRMATION FOR HOUR-METER

Read the hourmeter daily, and check with the sched-
uled maintenance book. See pages 4-21~4-23 for
better reference. Proceed with any maintenance
as required.
PM2-10
C. STOP ENGINE
Never attempt any MAINTENANCE with engine run-
ning. Always stop the engine and allow machine to
cool. Otherwise, there is a possibility of danger that
your hand may be caught in the cooling fan or fan
belt resulting injury. If it is inevitable to operate the
engine for the inspection or maintenance, carry out PMJ-4-2
the work with a pair of two persons. And either per-
son makes the engine ready to stop at any time at
the signal of the partner.
D. "TAG-OUT" MACHINE
Before beginning any inspection or maintenance pro-
cedures, secure a " DO NOT OPERATE" tag to the
operators console to inform the operator that the
machine will be inoperable for inspection and main-
tenance. This tag will help prevent accidental start-
ing of the machine.
PMJ-1-9
E. OBSERVE PRECAUTIONS
Start the inspection and maintenance work fully un-
derstanding the contents of safety precautions indi-
cated on the machine decals.
PAE-4-1
4-4
F. HOT SURFACES & FLUIDS
Use cautions and wear the proper safety equipment
when working around hot areas. Never change oils,
engine coolant or filters immediately after machine
has been stopped. Allow machine to cool down be-
fore performing maintenance procedures.
PR-1-38
WARM ENGINE OIL
Engine oil should have a temperature of between
20~40° C (68~104° F) before the oil is changed. If
necessary run engine until the oil is warm within the
recommended oil change temperature.
G. USE CAUTION IN REGARD TO THE INTERNAL

PRESSURE
Release the internal pressure before removing the
YRM-4-41
hydraulic system, air system, or fuel system; piping
or coupling of the cooling system; other related parts
to which internal pressure is applied. See page 4-
13 TO RELEASE INTERNAL PRESSURE.
H. PREVENT CONTAMINATION
Always cap or plug lines when hydraulic components
are removed to prevent hydraulic system contami-
nation that can be caused by dirt, dust and debris
entering a line or port. YRM-4-42
I. INSPECT WASTE OILS AND FILTERS

Before disposal, inspect all waste oils, fluids and fil-
ters for debris and foreign material. It is recom-
mended to cut open the oil filters to determine any
abnormal wear.
PMJ-4-4
J. CAUTION FOR OIL FILLING

When a strainer is provided on the filling port, do not
remove it at refilling fuel, oil or fluid.
PWJ-4-1
4-5
K. DISPOSAL OF HAZARDOUS WASTE
Dispose of waste oils, fluids, lubricants, filters and
other hazardous waste properly.
Dispose of all hazardous waste in accordance with

government environmental regulations, laws and
codes. PA-4-2
L. KEEP THE MOUNTING FACE CLEAN

After removing the O-ring or gasket, clean the install-
ing face, and replace with a new one. When install-
ing the O-ring or gasket, apply a thin layer of oil to the
seal, and install securely.
PR-4-5
M. PROVIDING LOCKING DEVICE

When the inspection or maintenance is carried out
under the attachment, provide proper support or
blocks to secure the attachment.
PW-1-1
N. CAUTION AT CHANGING BUCKET

Never insert your finger into the pin bore.
When aligning the pin bores, never insert your finger,
hand or arm into the pin bore. The alignment must be
carried out visually.
PW-1-2
O. DUSTY CIRCUMSTANCES
When the machine is operated in dusty circum-
stances, take the precaution of doing as follows.
Frequently check the alarm lamp for the air cleaner
clogging. Clean up the air cleaner element more fre-
quently than the specified interval.
Clean up the radiator core more frequently than the
specified interval to prevent it from clogging.
Clean up and replace the fuel filter element more
frequently than the specified interval. PMJ-4-95
Clean up the electric equipment, especially for starter
and generator, not to allow deposit of dust on them.
4-6
4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS
The following information is designed to allow usage of the proper oils, grease, fuels and coolants in various
climates and certain working conditions.
* Indicates type of oil shipped with the machine from factory.
4-7
4.4 FILTERS & ELEMENTS, AND BUCKET
Replace consumable parts, such as filters and elements, during the periodical maintenance or before the
service life. The machine can be used economically if the consumable parts are changed properly and timely.
A. FILTER AND ELEMENT LIST Items enclosed in parenthesis { } are the parts to be changed at the same time.
No. Device Parts No. Parts Name Qty Replacement Interval
PA33H01040P1 Return filter After 50 hours (first change)

(1) Hydraulic oil tank 1
(ZD11G10000) {O-ring} Every 500 hours (from 2nd. change)
PA33H01015P1 Suction strainer

(2) Hydraulic oil tank 1 Every 2000 hours
(ZD11G08000) {O-ring}
(3) Air cleaner PA11P00002S002 Element 1 Every 500 hours
After 50 hours (first change)

(4) Engine oil filter 119305-35150 Cartridge 1
Every 250 hours (from 2nd.change)
124550-55700 Element
(5) Fuel filter 1 Every 500 hours
(102103-55520) {O-ring}
171081-55910 Element
(6) Water separator 1 When required
(102103-55520) {O-ring}
B. BUCKET (Japanese standard bucket)
PU69B00002P1
(7) BUCKET Side Cutter 2 When required
PU69B00001P1
PW69B01001P1 Tooth
(8) BUCKET 3 When required
(PW69B01002P1) (Pin)
(3)
(7)
(8)
(1)
(2)
(5)
(4)
(6)
PW-5-3
4-8
4.5 ACCESSORY TOOLS
FOR GREASE
1 PIPE-WRENCH PM01T01002P1 NIPPLE OF IDLER
ADJUSTER
DISCHARGE
PRESSURE
2 GREASE GUN PV01T00003F1 250kg.cm2(3560psi)
CARTRIDGE
400cc(24cu-in)
3 TOOL CASE PW01T01005P1
4 WRENCH PU01T01003P1 FOR ENGINE OIL

FILTER
operate
LABEL
do not
5 LC20T01001P1
(WARNING TAG)
If tools become lost or damaged, contact an authorized dealer to order the tools.
4-9
4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS
The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the
periodical maintenance. Retighten the loose bolt and install new ones when ever lost. For the new machine,
checking and retightening of bolts and nuts must be carried out at the first 50 hours operation. When replace-
ment is needed, make sure to use the same size of authorized genuine parts.
Refer to the table below for proper tightening of Numerical indication on the capscrew head shows
capscrews. the classification for strength (e.g., 7 = 7 T). No in-
The table below is not applicable for the capscrews dication is provided for smaller size of capscrews,
holding plastic covers, etc. For proper tightening M 5 or less.
of such capscrews, consult with an authorized
dealer. Over-tightening may cause damages on
the parts to be fixed.
In case that the tightening torque is specified in
the manual, use such torque values regardless to
the table below.
PAE-4-4
4-10
4.7 TORQUE SPECIFICATIONS FOR JOINTS & HYDRAULIC HOSES

A. SLEEVE TYPE TUBE FITTINGS
Tube size Tightening torque
ODX Thickness (mm) Spanner size (mm) kgfm (lbfft)
10 X 1.5 19 4.5 +
- 0.5 (33 +
- 4)
15 X 2.0 27 15 +
- 2.0 (110 +
- 14)
18 X 2.5 32 18 +
- 2.0 (130 +
- 14)
22 X 3.0 36 22 +
- 2.0 (160 +
- 14)
28 X 4.0 41 28 +
- 3.0 (200 +
- 22)
35 X 5.0 55 45 +
- 4.5 (330 +
- 33) Z2-0061
B. JOINTS FOR PIPING (O-RING SEALING TYPE)

Nominal screw Tightening torque
size (PF) Spanner size (mm) kgfm (lbfft)
1/8 14 1.7 +
- 0.2 (12 +
- 1)
1/4 19 3.7 +
- 0.2 (27 +
- 1)
3/8 22 7.5 +
- 0.5 (54 +
- 4)
1/2 27 11.0 +
- 1.0 (80 +
- 7)
3/4 36 + 1.0 (119 -
16.5 - + 7)
1 41 Z2-0081
C. HYDRAULIC HOSES
Nominal screw Tightening torque
size (PF) Spanner size (mm) kgfm (lbfft)
1/8 14 + 0.2 (11 +
1.5 - - 1)
1/4 19 + 0.5 (22 +
3.0 - - 4)
3/8 22 + 0.5 (36 +
5.0 - - 4)
1/2 27 + 0.5 (58 +
8.0 - - 4)
3/4 36 12.0 +
- 1.0 (87 +
- 7)
1 41 14.0 +
- 1.5 (101 +
- 11) Z2-0051
NOTE : All torque values are subject to a dry condition.

4-11
4.8 INSTALLING HYDRAULIC HOSE AND PIPE
JOINT
The following two types of joint are used on the joint
part of hose piping.
A. METAL JOINT (30° Flare type)

Sealing is performed with metal compression of the
opening of connector (tee, elbow) and hose. Use
cautions to disassemble and assemble it to protect
the damage on the seat surface.
B. O-RING SEAL JOINT

Hose fitting is equipped with O-ring which seals the
oil pressure on the joint and protects it from oil leak-
age. PME-4-13
The tightening torque of the joint of each hydraulic

hose is determined by the diameter of the hose fitting
screws. In case of any abnormality detected, the hose
piping joint should be repaired or replaced according
to the following procedure even before the periodic
inspection of the hydraulic unit.
* O-RING
[1] At reassembling, be sure to replace the O-ring
with a new one.
[2] Where the union is loosened and oil is leaked,
never tighten it as it is. Install a new O-ring and
check that the O-ring is securely fitted, and then
tighten it.
[3] Never install a damaged and deteriorated O-ring
even if it is new one. The use of an O-ring other
than specified, causes oil leakage and short life
of hydraulic equipment, because the material and
hardness differ even if they are the same size.
* JOINT
[1] Care must be exercised not to damage hose,
PME-4-14
pipe and O-ring groove face and seal face (dent,

etc.) of hydraulic equipment. The use of a dam-
aged parts causes oil leakage.
[2] Use care to prevent contamination.
Fitting with foreign materials inside causes oil
leakage.
* HOSE
[1] The hose should not be twisted and sharply bent
for installation.
If the hose is twisted or sharply bent, the life of
the hose is decreased.
[2] Clean the joints and surrounding of joints, and
remove and dry the cleaning solvent completely
prior to installing the joints.
4-12
4.9 RELEASING INTERNAL PRESSURE OF
HYDRAULIC SYSTEM
Release the internal pressure of hydraulic system be-
fore carrying out maintenance work such as hydraulic
oil change, return filter change, suction strainer clean-
ing, cylinder repair.
Pressurize the hydraulic oil tank after maintenance and
releasing air in the system.
A. RELEASING HYDRAULIC SYSTEM AND TANK

PAE-1-22
PRESSURE
NEVER CHANGE OILS OR FILTERS ON A MACHINE

AIR PLUG OIL FILLING PORT
HYDRAULIC
THAT HAS JUST FINISHED WORKING. ALLOW OIL TANK
MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS
ARE WARM, NOT HOT.
RELEASE HYDRAULIC TANK PRESSURE BEFORE

WORKING WITH ANY HYDRAULIC COMPONENT,
ACCORDING TO THE PROCEDURES PROVIDED LEVEL GAUGE
BELOW.
WHEN REPLACING ANY HOSE OR SEALS, MAKE PFE-3-3
SURE THE ATTACHMENTS ARE WELL SECURED TO

AVOID SUDDEN MOVEMENT OF ATTACHMENT.
SLOWLY REMOVE BOLTS TO RELEASE ANY
HYDRAULIC PRESSURE DURING DISASSEMBLY. AIR PLUG
[1] Place the machine in the "Hydraulic Oil Inspection

Position" as shown in (PAE-1-22). Fully retract the
arm and bucket cylinders, then lower the boom to place
the bucket on the ground, and lower the dozer to the
ground.
[2] In case of Pilot operating lines (Boom, Arm, Bucket,
Swing), stop the engine, then operate the control PFE-4-2
levers to release pressure of each line.
[3] Set the safety conrol lever to "LOCK" position.
[4] Make sure the hydraulic oil temperature is below
40°C (104°F).
Open the engine guard referring to page 2-11 .
[5] Slowly loosen the air plug on the upper side of the
hydraulic oil tank to release internal pressure.
[6] Remove the air plug, and check the packing. If the
packing is damaged, replace it with a new one.
[7] Temporarily install plug until completion of the
inspection and maintenance procedures.
[8] In case of Manual operating lines (Travel, Swing,
Dozer, Service), operate each control levers to release
pressure of each line after stoping engine.
Now inside pressure in the hydraulic oil tank is fully
released. Proceed the inspection and maintenance
procedures for the hydraulic system.
4-13
B. BLEEDING AIR IN HYDRAULIC SYSTEM
Bleed the air contained in the hydraulic circuit after
performing maintenance to the hydraulic system.
[1] Referring to page 3-9 , start the engine, and op-
erate the engine at low idle for around 5 min-
utes. Then proceed as follows:
[2] With the engine running in low idle, extend and
retract each cylinder 4 - 5 times. However, do
not extend and/or retract each cylinder to the end
of its stroke yet.
[3] Repeat extending and retracting each cylinder 2
PME-4-21
- 3 times but now to the end of its stroke.
[4] Air bleeding for the hydraulic circuit has been
completed. Stop the engine and let it set for more
than 5 minutes to dissipate the air bubbles in the
hydraulic oil tank.
NOTE : If engine speed is at high idle during the bleed-

ing, the piston and packings may be damaged due
to the air contained in the cylinder.
4.10 PRESSURIZING HYDRAULIC OIL TANK

After having performed maintenance to the hydrau-
lic system, make sure to pressurize the hydraulic
tank as follows;
[1] Start the engine and keep low idling under the
condition where the air plug on the hydraulic oil
tank is open.
[2] Slowly and gradually extend each cylinder to its
stroke end to obtain the "Hydraulic Oil Tank Pres-
surization Position". (PME-4-22) PME-4-22
[3] Tighten plug

Tightening torque : 3.0 -+ 0.3 kgfm (22 -+ 2 lbfft)
[4] Ensure that the tank is free from oil leakage, and AIR PLUG
close the tank cover. Operate the attachments
and retract the cylinder rods to pressurize the
hydraulic tank.
NOTE : If the hydraulic oil tank is not pressurized, the

hydraulic pump could be damaged. Make sure to
pressurize it.
PFE-4-2
4-14
4.11 BLEEDING AIR IN FUEL SYSTEM
If air enters the fuel system, the engine may become
FUEL FILTER
hard to start or it will malfunction. Bleed the air when-
ever the fuel tank is empty, the water separator is
drained, or the fuel filter element is replaced.
[1] Set the safety lock lever at "LOCKED" position,
and stop the engine.
[2] Make sure to fill the fuel tank.
[3] Ensure that the handle of fuel filter and water
separator are set in "OPEN" position.
[4] Unscrew the air bleeding plug on the top of the HANDLE
water separator by a few turns with a Phillips
screwdriver. CLOSE
[5] Turn the starter switch to the "START" position
to start the engine. The engine will rotate without OPEN
load to feed fuel.
[6] When fuel without bubbles is found to come out PFE-4-3
from the air bleeding plug hole, close the air

bleeding plug.
NOTE : Dont operate the starter continuously for 15

seconds or more.
If it is necessary to crank for 15 seconds or more,
stop cranking once, and start cranking again by set-
ting it at "START" position after approx. 30 seconds.
PME-4-25
By moving the priming lever at the side of fuel injec-

tion pump up and down, the fuel is fed while the en-
gine is stopped.
Therefore, release the air beforehand, and the
worktime is shortened.
Additional Information :
In case of the machine with an automatic air bleeder
(optional specification), turn the stator switch key to
the "ON" position to actuate the fuel feed pump to
enable air bleeding. PME-4-26
4-15
4.12 REPLACEMENT OF RUBBER CRAWLER
SHOE
This work must be carried out by two people. The

operator operates the machine in accordance with
the signal of the partner. The rubber crawler shoe
replacement is carried out lifting the machine body.
Erroneous falling of the machine body during the
work on the crawler shoe is quite dangerous. Do
not operate any other attachments than the crawler.
Grease in track tensioning mechanism is under
extreme high pressure and can penetrate skin
causing severe injury. Keep face and body away
from grease fitting area. Never loosen grease fit-
ting more than one turn. If grease does not re-
lease after one turn of the fitting, call an authorized
CASE service dealer for assistance.
Before removing the rubber crawler shoe, ensure
that the pressure inside grease has been com-
pletely released. Then turn the sprocket.
It is quite dangerous to allow the spouting out of
grease with any procedures other than the one de-
scribed in the "REMOVING OF RUBBER CRAWLER
SHOE" below. If the tension on the crawler shoe is
PMJ-1-31
not released, consult with an authorized dealer for
its repair.
A. REMOVING RUBBER CRAWLER SHOE

[1] Operate boom, arm, and bucket to set the at-
tachment on the ground as shown in (PMJ-1-31).
Slowly and gradually lower the boom to lift one
side of the machine.
[2] Support the lower travel structure of the machine
with safety supports.
[3] Slowly loosen the grease nipple(1) on the grease PME-3-79
cylinder to allow to discharge the grease and re-
lease tension.
[4] Slowly loosen the grease nipple less than one
turn.
[5] Engage some steel pipes into the rubber crawler
shoe, then slowly rotate the sprocket backward.
When the rubber crawler shoe floats from the
steel pipes, slide the shoe to the side to remove
it.
PRE-3-83
4-16
B. INSTALLING RUBBER CRAWLER SHOE
[1] Operate boom, arm, and bucket to set the at-
tachment on the ground as shown (PMJ-1-31).
Slowly and gradually lower the boom to lift one
side of the machine.
[2] Support the lower travel structure of the machine
with a safety support, etc.
[3] Engage the rubber crawler shoe with the sprocket
and hang it on the idler.
[4] Slowly rotate the sprocket backward and push
PMJ-1-31
the rubber crawler shoe into its position, then stop
the rotation.
[5] Engage a steel pipe into the rubber crawler shoe,
and rotate the sprocket backward again to se-
curely engage the rubber crawler shoe with the
idler.
[6] Stop the rotation of sprocket to ensure that the
rubber crawler shoe is securely engaged to the
sprocket, idler and lower rollers.
[7] Referring to the next Item "C", carry out the check
and adjustment of tension on rubber crawler shoe.
[8] After confirming the engagement of rubber crawler PRE-3-84
shoe to the sprocket, idler and lower roller, and
also the proper tension on the rubber crawler
shoe, place the machine on the ground. LOWER
ROLLER
RUBBER SHOE METAL CORE
STEEL CORD
IDLER
TRAVEL
MOTOR
SPROCKET
PMJ-3-74
4-17
C. CHECK AND ADJUSTMENT OF TENSION ON
CRAWLER SHOE
An appropriate adjustment of tension on the rubber
crawler shoe is important not only for prolonging the
service life of the rubber crawler shoe and machine
but also preventing the rubber crawler shoe from
coming out of place.
Since checking and adjustment for the tension on PME-4-56

the rubber crawler shoe is carried out with the ma-
chine lifted, it is quite dangerous if the machine is
erroneously dropped to the ground. Never move
the machine while checking and adjusting it. Work
has to be performed be two people, and the op-
erator must operate the machine in accordance with
the signal of the partner.
RUBBER CRAWLER SHOE

Since the abrasion of the rubber crawler shoe var-
ies depending on the working conditions and the
nature of the soil, a frequent check is required for PNE-4-57
wear and the tension condition. Especially, on the
new rubber crawler shoe, there is an initial stretch.
Therefore, frequently check crawler tension during
the first 30 hours on a new machine or new tracks.
1. CHECK
[1] Move the rubber crawler shoe so that the joint-
ing part (M mark) comes to the upper center po-
sition.
See Fig.PNE-4-57.
[2] Slewing the upper structure to place it at 90° (right
angle) to the crawler frame. Operate boom, arm,
and bucket to set the attachment on the ground
PMJ-1-31
as shown (PMJ-1-31). Slowly and gradually lower
the boom to lift one side of the machine.
[3] Measure the clearance (A) between the lower
face of crawler frame and the upper face of
crawler shoe at the center position of crawler
frame.
Proper value (tension) (A) mm : LOWER
CRAWLER
Rubber shoe ; 60~70mm (2.4~2.8 in) ROLLER
FRAME
Steel shoe ; 110~120mm (4.3~4.7 in)
[4] If the tension is not proper, adjust it referring to
the next item 2. ADJUSTMENT. A
A
NOTE : The machine operation with loosened rubber

RUBBER CRAWLER SHOE STEEL CRAWLER SHOE
crawler shoe causes the rubber crawler shoe to come PM5-43
out of place and wear prematurely.
4-18
2. ADJUSTMENT
It is required to adjust the tension on the crawler shoe
depending on the working place of the machine. When
working at the place with a lot of gravel or round
stones, looser tension (upper limit range of tension)
is preferable. And at hard ground, stronger tension
(lower limit range of tension) is preferable.
Grease in track tensioning mechanism is under ex-

treme pressure and can penetrate skin causing se-
vere injury. Keep face and body away from grease
fitting area. Never loosen grease fitting more than
one turn. If grease does not release after one turn
of the fitting, call an authorized service dealer for
assistance.
2-1) MAKING TENSION STRONGER

Provide a grease gun.
[1] Feed grease to the grease nipple (1) with the
grease gun so that proper tension on the crawler
shoe is obtainable. PRE-3-82
[2] Move the machine forward and backward to

equalize the tension on both crawler shoes of
left and right.
[3] Again check the tension on the crawler shoes,

and repeat the adjustment to obtain the proper
tension on both crawler shoes.
NOTE: When the tension on the crawler shoe is still

loose even grease is supplied to the grease
PME-4-9
nipple, it is presumable that some faulty con-
ditions may exist on the seal in the cylinder
or machine body. Request the repair to an
authorized dealer.
PRE-4-74
4-19
2-2) MAKING TENSION LOOSER
Grease in track tensioning mechanism is under ex-

treme high pressure and can penetrate skin caus-
ing severe injury. Keep face and body away from
grease fitting area. Never loosen grease fitting
more than one turn. If grease does not release
after one turn of the fitting, call an authorized ser-
vice dealer for assistance.
[1] Gradually loosen the grease nipple (1) to dis-

charge grease.
Do not loosen the grease nipple (1) more than
one turn.
[2] Move the machine (crawler shoe) forward and

backward, when grease does not discharge ad-
e q u a t e l y.
[3] Tighten up the grease nipple. PRE-4-75

- 1kgfm (43 +
Tightening torque : 6 + - 7 lbfft)
Move the machine forward and backward to en-
sure the correct tension on the crawler shoes.
Again check the tension, and if it is not correct,
adust it again.
PME-4-61
4-20
4.13 INSPECTION & MAINTENANCE CHART
Follow the chart below for recommended intervals
of regular inspection and maintenance procedures. READ, UNDERSTAND AND FOLLOW ALL
Perform inspection and maintenance according to SAFETY PRECAUTIONS FOUND IN THIS
the calendar time or operation time shown by the MANUAL BEFORE PERFORMING INSPECTION
& MAINTENANCE.
hourmeter, whichever comes first.
See the inspection and maintenance procedure men- Symbols and their meanings ;
tioned below for details. ....................Necessary regular inspection item to
hour meter.
*...................Only first replacing performed.
..................Inspection and / or maintenance is
needed.
When Pre- Every Every Every Every Lubricant

Interval re- opera- week 3 6 12 ,etc. Reference
Components quired tion months months months (Replacing part) page
Item 8h 50h 250h 500h 1000h 2000h
Check Engine oil 4-37
level
Engine oil
Change *
(First) 4-44
Engine oil filter Change *

(First) Cartridge 4-46
Water separator Drain / Element 4-40

Clean
Clean 4-47
Fuel filter
ENGINE
Change Element 4-53
Check / 4-49
Air cleaner Clean
element
Change Element 4-51
Check
level 4-37
Tap water
Radiator coolant Change 4-54
(LLC)
Check 4-37
leakage
Check 4-37
Fan belt
Adjust 4-45
4-21
Item 8h 50h 250h 500h 1000h 2000h
Radiator core Clean 4-24
Radiator cap Clean 4-24
Hoses in cooling Check / 4-48

system Change
ENGINE
Check color, sound,

smell of exhaust gas 4-37
Valve clearance Check / 4-55

Adjust
Compression Check /
pressure 4-64
Adjust
Injection timing Check / 4-64

Adjust
Starter and Check /
generator 4-55
Adjust
FUEL SYSTEM
Fuel Check 4-37

level
Fuel Drain water 4-41
tank and deposits
Check leakage 4-37
Check 4-37
level
Hydra- Hydraulic
ulic oil
oil Change 4-56
HYDRAULIC SYSTEM
Hydra-
ulic Suction Clean /
tank Strainer 4-56
strainer Change
Return Change *
(First) Element 4-52
filter
Check oil leakage and 4-38
damage of pipings and hoses
Check oil leakage and 4-38
damage of cylinders, etc.
Line filter
Inline filter Clean 4-58
Slewing bearing Grease Grease 4-44

FRAME
UPPER
Grease in N.L.G.I No.2

slewing grease Change Lithium base 4-64
bath MoS2 grease
4-22
Item 8h 50h 250h 500h 1000h 2000h
Travel reduction Oil *
(First)
Gear oil 4-60
motor Change
Check/Adjust 4-18
LOWER FRAME
tension of rubber/steel shoe

Check crawlers and links of 4-32
rubber/steel shoe
Check 4-38
Roller
Idler Change Gear oil 4-61
Check oil leakage and wear of 4-38

sprocket/travel reduction motor
Bucket 4-39
Grease for pins Grease
Boom&Arm 4-43
ATTACHMENT
cylinder
Change 4-29
Bucket
Adjust 4-30
mount gap
Check wear and damage of 4-26
tooth and side cutters
Check damage of electrical 4-35
wirings
ELECTRICAL EQUIPMENT
Check electrolyte 4-42

level
Battery Distilled
Measure specific water 4-42
gravity
Check function of warning 4-37

lamps
Check switches / levers 4-37
Change working light(Lamp) 4-25
Check abnormal
deformation and damage of 4-37
machine exterior
Check looseness and
OTHERS
missing of capscrews and 4-37

nuts
Check 4-37
Operating lever
Lubricate Grease 4-34
4-23
4.14 WHEN REQUIRED
Thoroughly read and understand the section
SAFETY PRECAUTIONS of this MANUAL before op- BE CAUTIOUS OF HOT FLUIDS
erating or servicing the machine. AND SURFACES.
WEAR GOGGLES, SAFETY
A. CLEANING RADIATOR CORES SHOES, HARD HAT, WORK
CLOTHES, AND WORK GLOVES
TO PERFORM INSPECTION AND
MAINTENANCE ON THIS MA-
Direct contact of yourself with compressed air, steam
CHINE.
and high pressure water causes injury. Make sure to
wear the protective glasses, mask, safety cap, safety
shoes, etc.
[1] Open the left side cover and the cover under the
seat, referring to page 2-12 "Open/Close Guard
Cover."
[2] Check the radiator fins for clogging with dust and
mud.
[3] Remove the dust and mud on the radiator cores
and fins with compressed air.
PFE-4-4
NOTE : To avoid damages on the fins, take some

distance between the spray nozzle of compressed
air and the fins. If the fins gets some damages, it
causes water leakage resulting in overheating.
B. CLEANING OR REPLACEMENT OF RADIATOR CAP
USE EXTREME CARE WHEN REMOVING THE

PA-1-21
RADIATOR CAP. THE COOLANT IS UNDER HIGH
PRESSURE WHEN HOT. NEVER REMOVE THE
RADIATOR CAP WHEN THE SYSTEM IS HOT. AL-
LOW SUFFICIENT TIME FOR THE MACHINE TO
COOL DOWN BEFORE REMOVING THE RADIA-
TOR CAP.
[1] Remove the radiator cap after the engine has

cooled down to touchable with a bare hand.Slowly
loosen the cap to release the inside pressure. Z2-303P
Remove the radiator cap after all pressure is re-

leased.
[2] Check the cap for damages or adhesion of dust.
Clean it and/or replace it if needed. If the tightness of cap is insufficient, it may cause
[3] Securely tighten the cap. danger of getting burned due to spouting out of
hot water or steam during operation.
4-24
C. REPLACEMENT OF WORKING LIGHT
A light bulb of 23 W is used for the working light.
Since the light bulb develops high temperature while

working, the service life of the light bulb becomes
shorter if oil or grease is adhered on it.
When replacing the light bulb, hold it at the flange
portion not touching with its glass portion.
When the working light is not lightened even though

the switch for working light is turned on, the light
bulb or fuse may be burned out.
If there is no trouble on the light bulb, check the
fuse referring to page 2-12 . BOLT
The following is the description for the changing pro-
cedures of light bulb. OFF
ON
[1] Place the attachment on the ground, and set the (150mm)
safety control lever to "LOCK" position, then stop
the engine.
[2] Disconnect the connector, then remove the work-
ing light with spanner from the boom. WASHER NUT
[3] Remove the screw (1) (3 pieces), then remove PAE-4-18
the rim (2) and lens (3) from the housing (4) .
[4] Remove the light bulb (6) from the reflector (5),
and install a new light bulb.
[5] Assemble the working light in reverse order of
the above. (1)
NOTE : Pay attention not to break the light bulb at

the replacement. Hold the lens at removing the screw
(1), otherwise, the lens falls off. (2)
(3)
(6)
(5) OF
F
ON
(4)
PA-4-19
4-25
D. RECONDITIONING BUCKET
1. CHECK FOR ABRASION/DAMAGES ON TOOTH

POINT & SIDE CUTTER
When replacing the tooth point and side cutter, apply

a safety block to the bottom face of the bucket.
Check the tooth point and side cutter for their worn-
out condition. The tooth point holed or cracked must
be replaced before the abrasion on the adapter. And
the worn-out side cutter is also to be replaced ear-
lier.
If the replacement is too late, the bucket body will
be damaged.
PWE-4-13
REPLACEMENT OF TOOTH POINT & SIDE CUTTER
Consult with an authorized dealer for the replace-
ment of tooth point and side cutter.
WEAR GOGGLES, SAFETY SHOES, HARD HAT,

WORK CLOTHES AND WORK GLOVES TO
PERFORM INSPECTION AND MAINTENANCE ON
THIS MACHINE.
PWE-4-14
4-26
2. REPLACING THE TOOTH POINTS
Replace the bucket tooth in the following cases.
HAMMER
When little holes appear on the tooth point.
When the edge lines of the tooth point are worn.
PUNCHING TOOL
SUPPORT
Wear, goggles, safety shoes, hard hat, work (SAFETY BLOCK) TOOTH POINT PV4-49
clothes and work gloves to perform inspec-
tion and maintenance on this machine.
[1] Move the machine to a firm level surface and

place the bucket on a wood block (lumber) as
indicated in (PME-4-23).
[2] After the bucket is in a stable condition, set the PWE-4-17
safety control lever to lock position, then stop
the engine.
[3] Remove the sandwich pin (3) with a hammer us-
ing the punching tool.
[4] Check the sandwich pin (3). The faulty sand-
wich pin (3) such as crush and damage on in-
side rubber must be replaced with a new one.
[5] Make the surface of adapter nose (2) clean with
a putty knife, removing any dirt such as mud.
[6] After cleaning inside the tooth point (1), fit it to
the adapter nose (2). If some dirt remains inside
the tooth point (1) or any protrusion exists on it, PWE-4-15
it causes improper fitting of the tooth point (1)
with the adapter nose (2). 1 TOOTH POINT 3 SANDWICH PIN
[7] Drive the sandwich pin (3) into the bore up to the 2 ADAPTER NOSE
same level with the surface of tooth point (1).
NOTE: An arrow is stamped on the sandwich pin (3)

to show the inserting direction into the tooth
point (1).
Pay attention not to insert it at different direc-
tion.
PWE-4-17-1
4-27
[8] Make sure to check the following after the instal-
lation.
Slightly drive back the sandwich pin (3) reversely
after its insertion (from downward of the bucket)
that has been driven from the upward.
Confirm again if the sandwich pin (3) is being at
the same level to the surface of tooth point (1).
Slightly tap the tooth point (1) for up and down,
and left and right direction.
Ensure again the fitting condition of the tooth
point (1) and sandwich pin (3) through visually.
PWE-4-18
NOTE:
The sandwich pin (3) must be replaced with a new
one at every replacement of the tooth point (1).
This is quite effective to prevent the tooth point (1)
from dropping off.
PWE-4-19
Wear, goggles, safety shoes, hard hat, work

clothes and work gloves to perform inspec-
tion and maintenance on this machine.
3. REPLACING THE SIDE CUTTERS

[1] Remove the adhesion around the side cutter such
as sand, soil, etc. Use a torch to cut off the cap
screws, then remove the side cutters capscrews.
[2] Clean the mounting surface and install a new
side cutter with new capscrews and nuts.
[3] Firmly tighten nuts and spot weld them.
PWE-4-24
NOTE:
It is recommendable to replace the side cutter at
early stage. Delayed replacement would cause
damages on the bucket body.
PWE-4-25
4-28
E. REPLACEMENT OF BUCKET
Replace the bucket on firm flat ground. Pay close

attention to safety.
When aligning the pin bores, do not insert your
finger into the bores. It may cause severe injury.
Never insert your finger into the pin bores. Make sure
to align them visually.
7
A
8
1. REMOVAL OF BUCKET A
[1] Slightly operate the boom and the arm to re-
move load from the pins.
[2] Roll O-rings (1) onto the bucket boss. 6
After installing the pins, get them back to the
2 9 5
original position.
[3] Remove the spring lock ring (2) and lock pin
(3), then remove the pins (4) and (5) to remove 3
the bucket (6).
NOTE :
Pay attention not to adhere any sand or dust to the
1
pins removed.
Pay attention not to damage the dust seals (9) which
are installed in both ends of the arm (7) and bucket
link (8).
2 9 4
SECTION A-A PW-4-26
4-29
2. INSTALLING BUCKET
[1] Clean each pin and pin hole and grease suffi-
ciently.
[2] Move the bucket cylinder to match the pin bores
of the bucket (6) and bucket link (8) with each
other; then insert the pin (4) installing the shims
(10).
[3] Raise the boom up to lift the bucket slightly from
the ground.
[4] Move the arm (7) to match the pin bores of the
PMJ-4-34
bucket (6) and arm (7) with each other; then in-
sert the pin (5) installing the shims (10).
[5] Insert the lock pin (3) into pin (4) and (5), and
attach the spring lock rings (2).
[6] Fit the O-ring (1) into the normal position as
shown in the right Figure (PME-4-36).
Apply grease to the bucket link from the grease
nipples sufficiently.
NOTE : Replace the O-ring (1) showing cracks or los-

ing elasticity with a new one.
PWJ-4-27
PME-4-36
3. ADJUSTING BUCKET MOUNT GAP
Unexpected movement of attachment, while adjust-

ing the bucket mounting gap is quite dangerous.
Place the bucket on the ground in a stable condi-
tion, and set the safety lock lever to "LOCKED" posi- If the clearance of the bucket is not properly ad-
tion, then stop the engine. justed, galling may occur on the contact faces of
the bucket and arm, resulting in abnormal noise
and damage of the shaft and O-ring.
An adjusting device is provided to adjust the clear-
ance between the bucket and the arm. When the
clearance becomes large, adjust the clearance as
follows.
Standard clearance of the bucket in total of both
clearances:
Normal = 0.5 mm (0.02 in)
[1] Lower the bucket to the ground to stabilize, as

shown in the Figure (PME-4-37).
PME-4-37
Slightly lift boom to remove load from bucket pin con-
nections to properly adjust bucket clearance.
4-30
[2] Roll the O-ring (1) from its normal position to the
bucket boss to avoid damage.
2
[3] Slightly swing to the left direction to slightly push 4
the arm end to the bucket left side (where no 3
adjusting mechanism of clearance is equipped).
By contacting the arm and bucket, total clear- 5
ance is obtained on one place.
1
[4] Set the safety lock lever to the "LOCKED" posi- BUCKT
BOSS
tion; then stop the engine.
[5] Measure the total clearance "X" between the arm

and bucket boss. The clearance is the existing
total clearance. Exact clearance is gotten easily
by using a thickness gauge. SECTION C-C ARM BOSS
PMJ-4-38
[6] If the measurement value is 1.0 mm (0.04 in) or BUCKET CLEARANCE

more, decrease the clearance. ADJUSTING MECHANISM
Remove shims (3) to recondition the clearance
"X" after loosening 3-capscrew (2) with washer
(4).
The clearance decreases by extruding the bush-

ing (5), depending on the thickness of removed
shims.
X PMJ-4-39
NOTE : Thickness of shim is 0.6 mm (0.02 in). 8-

shims on the average are provided on one capscrew
(2).
PWE-2-7
[7] Tighten the 3-capscrew (2) with washer (4)

equally to the specified tightening torque.
[8] Return the O-ring (1) to the normal position.

(Groove between the arm and bucket bosses.)
PME-4-40
4-31
F. INSPECTING RUBBER CRAWLER SHOE
Repair or replace rubber crawler shoe if it falls into
the following condition. LOWER
ROLLER
(Contact an authorized dealer for repair or replace-
ment of rubber crawler shoes)
METAL CORE
RUBBER CRAWLER
SHOE
1. Height of lug
[1] If the lug of height (A) wears off, traction force
decreases. Replace the shoe with a new one if
LUG STEEL CORD
(A) decreases below 5 mm (0.2 in).
PM5-76
[2] If the lug wears out at an extent that the steel

cord in the shoe is exposed over two links, re-
place the shoe with a new one.
PME-4-42
2. Breakage of steel cord

If the steel cords of the rubber crawler shoe are bro-
ken by more than one half of one side row, replace
the shoe with a new one.
PME-4-43
3. Crack of rubber crawler shoe

If a crack which has developed to about 60 mm (2.4
in) length is seen between the lug of rubber shoe,
repair the shoe.
However, repair the shoe immediately if the steel cord
inside is exposed even though a crack is small and
short.
NOTE : For repairs or replacement of rubber crawler

shoes, contact an authorized dealer.
PRE-4-54
4-32
4. PEELING OFF OF METAL CORE ON RUBBER
CRAWLER SHOE
Depending on the usage of rubber crawler shoes,
there may occasionally happen a peeling off of metal
core on the rubber shoes (inner side) due to con-
tact with the rollers and idler/sprocket or abrasion,
even though there are no external damages or abra-
sion on the lug side (outer side) of it.
PME-4-44
NOTE :
1. THE METAL CORE STARTS PEELING WITH THE
PROHIBITED USAGE OF THE RUBBER CRAWLER
SHOE.
2. FULLY UNDERSTAND THE PROHIBITED USAGE
OF THE RUBBER CRAWLER SHOE REFERRING
TO PAGE3-36 "USING RUBBER CRAWLER
SHOES."
3. NOTE THAT THE WARRANTY IS NOT APPLI-
CABLE FOR ANY DAMAGES DUE TO THE PRO-
HIBITED USAGE OF THE RUBBER CRAWLER
SHOE OR THE USE OF IT WITH IMPROPER TEN- PME-4-45
SION ON IT.
[1] The rubber crawler shoe on which the peeling

off of metal core shows even at one place, must
be replaced with a new one.
[2] The cracked rubber crawler shoe by which the

metal core comes to the surface must be replaced
with a new one.
PME-4-46
[3] The cracked rubber crawler shoe on the con-

tacting portion of the metal core with the roller is
not required to repair.
PME-4-47
4-33
G. LUBRICATION FOR OPERATING LEVERS
When any operating levers become heavy to oper-
ate or do not move smoothly, apply grease to the
sliding and rotating portion (A) and the top portion
(B) of the universal joint.
[1] Move the machine to firm and level ground. Set

the attachment on the ground. Place the safety
control lever to LOCKED positon, then stop the
engine.
PRE-4-81
[2] Carefully raise up the rubber boot on the troubled
operating lever with hand paying attention not to
give any damages to it.
[3] Apply grease to the sliding and 4 places of rotat-

ing portion (A) and the top portion (B) of the uni-
versal joint.
[4] Set back the rubber boot to the original position.
[5] Check the pilot valve for any looseness, and if

loosened, retighten the socket bolt.
PRE-4-82
4-34
H. CHECKING ELECTRICAL WIRING AND FUSES
When a frequent replacement is required for the

fuses or there are any traces of short circuiting on
the electrical wiring, consult with an authorized
dealer.
Before checking the electrical system, make sure
to disconnect the battery cable of negative (-) side.
Erroneous short circuiting may cause fire.
UZ2-070
*Fusible Link (For starter)

In case power does not come when the starter switch
is turned ON, a disconnection of the fusible link is
suspected.
Inspect wires and fuse link. Replace the fusible link
FUSIBLE LINK
if needed. (RED)
NOTE : The fusible link is of a fuse wiring of big size

provided in the electric wiring for large cur-
rent. It protects the electrical equipment and
wiring from abnormal current just like an or-
dinary fuse.
PAE-2-25
4-35
*REPLACING PROCEDURES
When a new fuse is blown within a short time of ser-

vice or frequent replacement for fuses are required,
it may be caused by troubles in electric sequence.
Consult with an authorized dealer for repairs.
The main fuse box covered by the fuse box cover is

provided under the seat.
MAIN FUSE BOX
[1] Place the bucket to the ground. PAE-2-23
[2] Set the safety control lever to the lock position.

[3] Turn the starter switch to OFF to stop the en-
gine.
[4] Open the cover under the seat.
[5] The fuse box cover is locked on one side. Re- FUSE BOX COVER
lease the lock and remove the cover.
[6] When any fuse is blown as shown in the right,
replace it with the spare fuse stored in the fuse
box.
[7] After replacing the fuse, make sure to set the cover
with a click.
PAE-2-24
NEVER REPLACE A FAULTY FUSE WITH HIGHER
AMPERAGE FUSE. NEVER USE A JUMPER IN
PLACE OF A FUSE. NEVER SPLICE ACCESSO-
RIES DIRECTLY INTO FUSE TERMINALS.
Fuse Circuits Wire

No. capacity Color
1 10A Horn Red
2 30A Timer, Relay Red

Blue
3 10A Monitor panel (Gauge cluster) Withe
Green
4 20A Working light Red
Withe PRE-2-53
5 20A Lever lock switch Yellow
4-36
SECTION 4 - MAINTENANCE — 8Hr
4.15 8-HOUR (DAILY) INSPECTION AND
MAINTENANCE
Thoroughly read and understand the section, SAFETY
PRECAUTIONS of this MANUAL before operating or
servicing the machine.
The following inspection and maintenance shall be
carried out before starting / after starting and after
work.
REFER TO SECTION 3 "BASIC MACHINE OPERATION"

IN THE FOLLOWING ITEMS FOR INSPECTION AND
MAINTENANCE
Page 3-3 for checking and refilling of coolant.
Page 3-4 for checking of coolant leakage.
Page 3-6 for checking of fuel level and refilling.
Page 3-6 for checking of fuel leakage.
Page 3-7 for checking of fan belt. PMJ-1-6
Page 3-5 for checking of hydraulic oil level and

refilling.
Page 3-4 for checking of engine oil level and refill-
ing.
Page 3-8 for checking of warning lamps lighten-
ing.
Page 3-8 for checking of working light lightening.
Page 3-14 for checking of exhaust gas color, ab-
normal sound and smell.
Page 3-15 for checking of operating conditions of
each switch and lever,
A. CHECK EXTERNAL CONDITIONS OF MACHINE

A dent or distortion which apparently seems not to
be severe damage, may be abnormal contact on in-
ternal parts or hoses.
Consult with an authorized dealer for advise and/or
for repairs.
B. CHECK CAPSCREWS AND NUTS FOR LOOSE-

NESS AND/OR MISSING
Check for missing capscrews and nuts and replace
as needed. Check and make sure all capscrews and
nuts are properly tighten. Likewise, check and make
sure all hose clamps are properly tighten.
The abnormal sound during operation may cause leak-
age or fire. Use torque values from pages 4-10 and 4-
11.
NOTE : Use the tools suitable for the work referring to

page 4-9 , ACCESSORY TOOLS.
4-37
C. CHECK EACH CYLINDER, PIPING AND HOSE FOR
LEAKAGES AND DAMAGES
BE CAUTIOUS OF HOT
FLUIDS AND SURFACES,
HYDRAULIC LINE IS ALWAYS HIGHLY PRESSUR- WEAR GOGGLES,
IZED. MAKE SURE TO RELEASE THE PRESSURE SAFETY SHOES, HARD
IN THE LINE BEFORE STARTING SERVICE AND/ HAT, WORK CLOTHES,
OR MAINTENANCE, OR REFILLING. AND WORK GLOVES TO
NEVER USE HANDS TO CHECK FOR LEAKS. HIGH PERFORM INSPECTION
PRESSURE FLUID LEAKS WILL PENETRATE THE AND MAINTENANCE ON
SKIN AND CAUSE SEVERE INJURY. THIS MACHINE.
Hydraulic oil leakage will slow down a machine. Move

the machine to firm level ground and place the at- AIR PLUG
tachment in the oil check position and stop the en-
gine. HYDRAULIC
[1] Set the safety lock lever to "LOCKED" position,
OIL TANK
then stop the engine.
[2] To check the location of leakage, take a time to
allow getting the temperature on each portion of
the machine down to around 40° C (104° F). Make FUEL TANK
sure to wear the protective glasses and gloves for
the check.
[3] Press the rubber cap of the air breather on the top PFE-4-6
of the hydraulic oil tank several (five to seven) times
to release the internal pressure of the tank.
Consult with an authorized dealer for advise and re- NOTE : When any abnormalities happen on the ma-
pairs. chine, immediately stop operation, and ask for re-
pairs as needed.
When the volume becomes insufficient for the en-
gine coolant or oil due to leakage, a warning lamp
is illuminated.
D. CHECK TRAVEL SYSTEM FOR LEAKAGE AND

ABRASION
[1] Check the lower roller, idler and travel motor for
any leakages.
[2] Check the lower roller, idler, and sprocket for ab-
normal wear and loosened fixing bolts.
[3] Slowly travel the machine and check for any ab-
normal sound.
NOTE : Consult with an authorized dealer for advise

and/or repairs as needed.
PME-4-54
A TRAVEL MOTOR D CRAWLER SHOE

B SPROCKET E SHOE SLIDE
C LOWER ROLLER F IDLER
4-38
4.16 50-HOUR (WEEKLY) INSPECTION AND
MAINTENANCE
Perform together with 8-hour (daily) inspection and
maintenance.
A. ADJUSTING CRAWLER TENSION

Proper adjustment of the rubber crawler tension is
essential for extending service life of the crawler and
the travel system, and prevention of coming off of
crawler due to insufficient tension.
THE INSPECTION OF THE CRAWLER SHOE TEN-

SION IS CARRIED OUT WITH ONE SIDE OF MA-
CHINE LIFTED. IT IS QUITE DANGEROUS IF THE
MACHINE IS ERRONEOUSLY DROPPED. NEVER
OPERATE THE MACHINE DURING THE INSPEC-
TION. MAKE SURE TO CARRY OUT THE WORK
WITH THE HELP OF ANOTHER PERSON. THE OP-
ERATOR OPERATES THE MACHINE IN ACCOR-
DANCE WITH THE SIGNAL OF THE PARTNER.
Refer to page 4-18 for the check and adjustment of

PME-4-56
rubber crawler shoe tension.
B. GREASING PINS AROUND BUCKET

Request for Greasing
Generally the greasing is required at every 50 hours
operation or weekly. Refer to page 4-42 for greasing
under special conditions.
[1] Move the machine to firm level ground and place
the attachment on the ground in the oil check po-
sition, as indicated in (PAE-4-25). PAE-4-25
[2] Clean the grease fittings before greasing. Replace
the grease nipple with a new one, if damaged.
[3] Lubricate with a grease gun through the grease
fittings shown (PMJ-4-17) with arrows and the table
below.
NO. GREASING POINTS QTY

1 BUCKET CYLINDER ROD PIN 1
2 IDLER LINK/ARM CONNECTING PIN 1
3 BUCKET LINK PIN 1 PMJ-4-17
4 ARM/BUCKET CONNECTING PIN 1
[4] Properly wipe off any grease squirted out around DISPOSE OF ALL HAZARDOUS WASTE IN AC-
the pin connection CORDANCE WITH GOVERNMENT ENVIRONMEN-
TAL REGULATIONS.
4-39
C. DRAINING WATER FROM WATER SEPARATOR
AND CLEANING
If the red ring (D) in the water separator sinks down to
bottom of the case (F), no water is mixed in. When
the ring (D) is floating, water is mixed in up to the
level of the ring. Drain the mixed water in accordance
with the following procedures.
FUEL OIL ADHERED PERIPHERY MAY CAUSE

FIRE. WIPE IT OFF THOROUGHLY.

[1] Set the safety lock lever to "LOCKED" position,
[2] Open the engine guard. After cooling down each
portion, push the handle (A) of the water separa- PFE-4-7
tor upward to the "CLOSE" position.

[3] Loosen the ring (H) to remove the case (F), and
drain the water out.
NOTE : Pay attention not to lose the red float (D) and
spring (C).
DISPOSE OF ALL HAZARDOUS WASTE IN AC-
CORDANCE WITH GOVERNMENT ENVIRON-
Check the water drained for its contamination and MENTAL REGULATIONS.
when it is dirty, clean up the element (B) and inside of
the case (F).
[4] Remove the element (B), and clean it with diesel
fuel.
[5] Replace the O-ring (E) with a new one.
[6] Install the element (B) to the water separator body.
[7] Set the O-ring (E) to the case (F), then tighten it
up with ring (H).
[8] Push the handle downward to set at "OPEN" po-
sition.
[9] After draining water, make sure to bleed out the
air releasing for the fuel system referring to page
4-15 .
PMJ-4-49
NOTE : Do not clean up the element with gasoline.
PV-4-71
4-40
D. DRAINING WATER AND DEPOSITS FROM FUEL
TANK
MAKE SURE TO STOP THE ENGINE WHEN DIS-

CHARGING FUEL FROM THE FUEL TANK.
THOROUGHLY WIPE UP THE SPILLED FUEL.
FUEL TANK
Loosen the drain plug to drain the water and de-
posits in an empty container.
Since the water is deposited during the night, it is
effective to drain before starting up the engine in
the morning.
[1] Swing the upper structure of the machine so that
the drain plug (A) under the fuel tank comes to (A)
midway between the crawler shoes of left and

right. PFE-4-8
[2] Place an empty container under the drain plug
to catch the fuel discharged.
[3] Slowly loosen the drain plug to drain water mixed
in and deposits together with the fuel.
[4] When pure fuel begins to discharge, tighten up
the drain plug (A).
Tightening torque for drain plug :
NOTE : Check for fuel leakage after tightening up the

drain plug.
Consult it with an authorized dealer for advise and
repairs if needed.
Make sure to contain any fuel spillage. (A)
PA-4-23
If the leakage appears on the drain plug (A), check

the flange portion.
[5] Remove the drain plug (A) to fully discharge fuel
inside the fuel tank. FUEL
Tank volume ; 15 liters (4.0 gal)
[6] Check the packing (B) for any damages. If dam- WATER
aged replace it with a new one. DEPOSIT

Remove the flange (E). Check the O-ring (F) for
any damages. If damaged, replace it with a new (F)
one. (E)
[7] After the replacement, install the flange and drain
(B)
plug to the tank in reverse order of the above.
Tightening torque for Bolt (C) :
+ 0.1 kgfm (7.1 -
0.98 - + 0.7 ftlbs) (C)
(A)
[8] Refill the tank with fuel referring to page 3-6 .
PAE-4-24
4-41
E. CHECK BATTERY FLUID LEVEL AND SPECIFIC
GRAVITY
The battery fluid easily decreases with high ambient
temperature in summer season. Check the battery
fluid level in the morning before starting operation.
Continuous use of the battery with low fluid lowers
battery performance.
Check the battery fluid level periodically, and if insuf-
ficient, refill the battery with distilled water before start-
ing the engine (before charging battery).
FLAMMABLE GAS (HYDROGEN GAS) IS GEN-

ERATED IN THE BATTERY. DO NOT ALLOW
SPARKS OR FLAMES TO COME IN CONTACT
WITH BATTERIES TO AVOID TRIGGERING AN
EXPLOSION.
BATTERY FLUID HAS STRONG ACIDITY. IT
CORRODES METAL VERY RAPIDLY. IF IT AD-
HERES ON SKIN OR ENTERS INTO EYES, IT
CAUSES A BURN OR BLINDNESS.
AT SUCH CASES, IMMEDIATELY WASH SKIN OR
EYES WITH LOTS OF WATER, AND ASK A DOC-
TOR TO TREAT IT AS SOON AS POSSIBLE. PME-4-66
Check the indicator (A) on the battery, and always

keep it at green color. Red color means insufficient
battery fluid or battery charging.
[1] Set the safety control lever to "LOCK" position,

[2] Referring to page 2-11 "OPEN/CLOSE GUARD
AND COVER," remove the left guard and open
the cover under the seat. The battery is located
under the left operating contol panel. PVE-4-40
[3] Remove the caps (1) of each cell to check the

When it is difficult to obtain enough cranking speed at
fluid level.
the engine start-up, check the battery fluid for its spe-
[4] If battery fluid level is low, refill the cell with dis-
cific gravity. If it is insufficient, re-charging is required
tilled water up to the specified level (10-15 mm
for the battery.Standard Specific Gravity for Battery
(0.4-0.6in) above the plate).
Fluid : 1.28 (20°C or 68°F)
[5] Make sure the air vent holes on the caps (1) are
For the specific gravity of battery fluid at cold climate
clean and securely tighten caps (1).
or other specific conditions, refer to page 3-39 ,and
[6] If the terminal (2) are dirty, wash it with warm
make the charging rate around 100%.
water, then install it to the position applying
If it is difficult even after re-charging is carried out,
grease or spraying rust preventive solution. If
replacement of the battery with a new one is required.
the terminal is oxidized, polish it with a wire brush
or sand paper.
NOTE : Measure the specific gravity of battery fluid
with a gravimeter. The measured value varies depend-
ing on the ambient temperature. Consult with an au-
thorized dealer for advise and/or repairs as needed.
4-42
4.17 250-HOUR (3-MONTH) INSPECTION AND
MAINTENANCE
Perform together with 8-hour and 50-hour inspection
and maintenance.
A. GREASING ATTACHMENT AND DOZER PINS
NOTE :
In ordinary operation, apply grease every 250 hours of
operation or every six months, but under special con-
ditions, observe the following lubrication intervals
1) When operating the machine with a special attach- PAE-4-25
ment, apply grease every day before starting work.
2) For underwater digging operation, apply grease to
the areas to be immersed in water every day before
and after work.
3) Where the machine is stored for more than one
month, apply grease before working.
[1] Move the machine to a firm level area and place

the attachment in the oil check position.
[2] Make sure to clean the grease fittings before the
greasing. Replace the grease fittings with a new
one, if damaged.
[3] Use table below to lubricate all connections through PME-4-68
grease fittings as shown in (PME-4-68) and (PME-
4-69) unil grease purges out.
[4] Properly wipe off any grease oozed out around the
pin connection.
NOTE : Since the dozer foot pin (3) is supported by an
iron bushing, frequent greasing is required for it when
the dozer is frequently used at the work.
And when greasing the attachment, make sure to
grease to dozer foot pin (3), too.
NO. GREASING POINTS QTY

1 Dozer cylinder rod pin 1
2 Dozer cylinder foot pin 1 PME-4-69
3 Dozer foot pins 2

4 Boom foot pin 1
5 Boom cylinder foot pin 1
6 Boom cylinder rod pin 1
7 Arm cylinder foot pin 1
8 Arm cylinder rod pin 1
9 Boom/Arm connecting pin 1
10 Bucket cylinder foot pin 1
11 Bucket cylinder rod pin 1 14
12 Swing cylinder foot pin 1
13 Swing cylinder rod pin 1
14 Swing bracket/frame connecting pin 2 12 13 PW-5-9
4-43
B. OIL CHANGE FOR ENGINE
BE CAUTIOUS OF HOT FLUIDS

DO NOT CARRY OUT THE OIL CHANGE JUST
AND SURFACES.
AFTER STOPPING THE ENGINE WHICH IS KEPT
AT HIGH TEMPERATURE AT EVERY PORTION.
SHOES, HARD HAT, WORK
ALLOW SUFFICIENT TIME FOR THE ENGINE TO
COOL DOWN BEFORE MAINTENANCE.
THE FIRST OIL CHANGE MUST BE CARRIED
OUT AT 50 HOURS OPERATION FOR A NEW
CHINE.
MACHINE ENGINE.
Container to receive drained oil :

4 liter (1.1 gal) or more capacity
Oil volume to be refilled : 3.9 liter (1.06 gal)
(Upper limit of standard volume.)
[1] Place an empty container to receive the drain oil
under the drain plug (1) located at the bottom of
engine.
[2] Remove the bottom cover (4) under the drain plug.
[3] Slowly loosen the drain plug (1) so that the oil
does not splash over yourself.
Make sure to contain any oil spillage.
[4] Check drained oil. In case that lots of metal par- PME-4-71
ticles and/or foreign materials are contained in it,
consult with an authorized dealer for advise and/
or repairs.
[5] Securely tighten the drain plug (1).
[6] Open the engine guard, and remove the filler port
cap (Yellow) (2) . Refill the engine with the speci-
fied oil.
Refer to page 4-7 for the recommended oil.
[7] Start the engine, operate it for several minutes
at idling, and shut it down.
Check the oil level and make sure it is between
the "H" and "L" marks on the dipstick (3) referring
to page 3-4, the section for "CHECK & REFILL-UP
OF ENGINE OIL". PME-4-72
C. GREASING TO SLEWING BEARING
NEVER SLEWING THE MACHINE, WHILE FEEDING

GREASE TO THE SLEWING BEARING.
Feed grease to the swing bearing, slewing the ma-

chine and place it in 4 different positions (90° apart),
until grease oozes out. Only one grease nipple is
provided for the slewing bearing. Properly wipe off
any grease oozed out around the swing bearing seal. PWJ-4-37
4-44
D. ADJUSTMENT FOR BELT TENSION
MAKE SURE TO STOP THE ENGINE WHILE IN-

SPECTION AND MAINTENANCE. OTHERWISE,
YOUR FINGER OR HAND MAY BE CAUGHT BY
THE FAN OR FAN BELT RESULTING IN INJURY.
Check the fan belt for proper tension, wear conditions

and damages. Make sure to adjust tension properly.
STOP
Provide a lever (such as bar, wrench or handle) and a
wooden piece.
NOTE :
There may be big differences among individuals on
the adjustment for the belt tension with a lever caus-
ing too much or too little belt tension. Make sure to
check for deflection and tensile force after the adjust-
ment.
Use the lever with the length of 300-400 mm (12-16
in) suitable for the adjustment work.
E. ADJUSTMENT FOR FAN BELT

[1] Apply the lever between the generator (4) and
the cylinder block, and fix it on the generator. At
that time, insert a wooden piece between the
generator and the lever to avoid damaging he
generator.
Select the wooden piece of suitable thickness
for the clearance between the generator (4) and
the lever.
[2] Loosen the adjusting capscrew (5) and the fix-
ing capscrew (6).
PME-4-98
[3] Apply the lever to the wooden piece, and pulling
it with hands to give tension on the belt, tighten
the fixing capscrew (6).
[4] Tighten the adjusting capscrew (5).
[5] After adjustment, start the engine and operate it
at low idling for around 5 minutes, then stop the
engine to confirm the belt tension (deflection and
tensile force). Refer to page 3-7.
4-45
F. REPLACEMENT OF ENGINE OIL FILTER

AND SURFACES.
EVERY PORTION OF THE ENGINE IS KEPT AT
HIGH TEMPERATURE JUST AFTER STOPPING
THE ENGINE. TAKE TIME TO ALLOW COOLING
DOWN THE ENGINE FOR INSPECTION AND
MAINTENANCE.
CHINE.
NOTE :
The oil filter is of a cartridge type which can not be
reused nor cleaned with the filter disassembling. Re-
place it as a unit.
Replace it at 50 hours operation for the first use of
new machine.
The filter wrench provided on the machine is used for
removing.
The filter cartridge must be replaced with a new one

at 50 hours operation for the first use of new machine.
[1] Stop the engine, open the engine guard, and re- PAE-4-27
move the under cover.
[2] Apply the filter wrench (B) to the filter cartridge

(A), and turn the wrench with spanner to counter-
clockwise to remove it.
[3] Wipe off any dust on the seal face of filter base,
and avoid contamination.
[4] Thinly apply clean engine oil to the packing of new

filter cartridge, and install and tighten it up with
hand. Then retighten it by about 2/3 turns. PME-4-74
[5] Start the engine, and operate it at idling for several

minutes to check for any leakage at the installing
face.
[6] Close the engine guard and install the under cover.
NOTE :
When the machine is operated in dusty circum-
PVE-4-47
stances, a shorter interval is required for the replace-
ment.
When some metal particles are adhered on the ele-
DISPOSE OF ALL HAZARDOUS WASTE IN AC-
ment removed, consult it with an authorized dealer.
CORDANCE WITH GOVERNMENT ENVIRONMEN-
TAL REGULATIONS.
4-46
G. CLEANING ENGINE FUEL FILTER

AND SURFACES.
EACH UNIT IS HOT IMMEDIATELY AFTER THE
MACHINE HAS BEEN OPERATED.
CHANGE THE FILTER AFTER THE TEMPERA-
TURE HAS COOLED DOWN.
CLEAN UP ALL SPILLED FUEL TO AVOID A FIRE.
CHINE.
Prepare empty container.
[1] Stop the engine, and open the engine guard.
[2] Set the handle (A) of fuel filter at "CLOSE" posi- FUEL FILTER
tion. And remove the retaining ring (B), and take
out the cup case (D) and element (C).
[3] Drain dust and water accumulated on the bottom

of cup case (D) of fuel filter in the empty con-
tainer, and clean the fuel filter.
[4] Wash and clean the element (C) with diesel fuel,
(A)
and use compressed air, 2~3 kgf/cm2 (28~43 psi) HANDLE
from the inside to remove dust.
CLOSE
(B)
NOTE : It is strictly prohibited to wash and clean ele-
ment with gasoline. OPEN
(D)
PFE-4-9
[5] Replace O-rings (E) and install the fuel filter in

reverse order shown in the item [2].
[6] Bleed air referring to the item "BLEEDING AIR IN

FUEL SYSTEM" in page 4-15 .
[7] Ensure that the filter installing face is free from

possible fuel leakage, after running engine at idling
for several minutes.
Dispose of all hazardous waste in accordance with gov-

ernment environmental regulations.
PV-4-71
4-47
H. CHECKING RADIATOR HOSE
Replacing the hoses before any problems occur is both
economical and good maintenance practice. RADIATOR
This will reduce costs and minimize unexpected inter-
ruption of working. RESERVE TANK
Immediately replace the hose if it is cracked, worn, or
if water is leaking from it. This will prevent serious
problems, such as the engine overheating.
[1] Check the hoses for water leakage due to loose
clamps or cracked and worn hoses.
FULL
[2] Tighten any loose clamps and replace any cracked
LOW
or worn hoses following the procedures below.
PAE-4-29
I. REPLACING RADIATOR HOSE
DANGER OF HIGHLY PRESSURIZED STEAM IS

GENERATED IN THE RADIATOR. WHILE THE
COOLANT IS KEPT AT HIGH TEMPERATURE AND
PRESSURE, DO NOT LOOSEN NOR OPEN THE
RADIATOR CAP.
WHEN OPENING THE RADIATOR CAP, STOP
THE ENGINE.
TAKE A GOOD ENOUGH TIME TO ALLOW
COOLING DOWN THE COOLANT TEMPERA-
TURE.
[1] Loosen the radiator cap slowly. Ensure that pres- RADIATOR CAP CAP
sure has been released. Push the cap down and
hold it down while turning to remove.
[2] Drain the coolant from the drain hose until the
coolant level becomes below the hose to be re-
placed.
[3] Loosen the hose clamp and disconnect the dam-

aged hose; then replace it with a new one.
DRAIN HOSE
PAE-4-30
[4] Install the drain hose.
[5] Fill the radiator with coolant, then fill the reserve
tank with coolant, too. Refer to page 3-3 .
[6] After the fill-in, tighten securely the radiator cap.
4-48
J. CHECKING/CLEANING/REPLACING AIR CLEANER
ELEMENT
WEAR PROTECTIVE GLASSES OR GOGGLES

WHEN USING COMPRESSED AIR.
NOTE : Stop the engine before inspecting or clean-

STOP
ing the air cleaner element. This will prevent
the engine from getting damaged due to dust.
1. CHECK ELEMENT
When black smoke is discharged from the exhaust
outlet, check the air cleaner element, and clean or
replace if needed.
(1)
2. CLEANING ELEMENT
[1] Open the engine guard and the cover under the
seat referring to page 2-11 , "OPENING/CLOS-
ING OF GUARD AND COVER".
[2] Remove the wing nut (1) which holds the air PA-4-31
cleaner housing.
WING NUT(2) ELEMENT(3)

[3] Pull out the left side of element only, toward this
side, holding the hose side of exhaust port by
right hand. See the right Figure.
[4] Loosen the wing nut (2) on the housing by hand,

then take out the element (3).
WASHER
[5] Use a clean cloth or adhesive tape to cover the

engine air intake port on the housing in order to
avoid contamination. Then clean the inside of
the air cleaner housing.
[6] Use compressed air to clean the element from

inside along the folds. Use compressed dry air
lower than 3kgf/cm2 (43psi). And blow it off from AIR CLEANER HOUSING
outside. Then again blow it off from inside. PAE-4-32
[7] After cleaning element, put a light bulb inside the

element, and visually inspect for small cracks on
the element meshes. A faulty element on the
screen and/or packing must be replaced with a
new one.
PAE-4-33
4-49
[8] Remove the cloth or tape covering the engine

air intake port.
[9] Install the cleaned element into the air cleaner

housing, and securely tighten it with the wing nut
AIR CLEANER
(2) by hand. AIR INLET HOUSING
[10] Fix the air cleaner housing to the frame with the
wing nut (1).
NOTE : The element is reusable up to 6 times of clean-

ing or for one year, after that it must be replaced AIR OUTLET
with a new one. ADHESIVE TAPE
PAE-4-34
4-50
4.18 500 HOUR (6-MONTH) INSPECTION AND
MAINTENANCE
Thoroughly read and understand the section,
SAFETY PRECAUTIONS of this MANUAL before
operating or servicing the machine.
Perform together with 8 to 250-hour inspection and
maintenance.
A. REPLACEMENT OF ELEMENT
[1] Open the engine guard and the cover under the
seat referring to page 2-11, "OPENING/CLOSING
PA-4-35
OF GUARD AND COVER."
[2] Remove the wing nut (1) which is fixing the air
cleaner housing.
[3] Loosen the wing nut (2) on the housing with

fingers, then take out the element (3).
[4] Use a clean cloth or adhesive tape to cover the

engine air intake port on the housing in order to
avoid contamination. Take clean the inside of the
air cleaner housing.
PA-4-36
[5] Install a new element and secure it with the wing
nut (2) by hand.
Do not use any tools to tighten the wing nut (2).
[6] Fix the air cleaner housing to the frame with the
wing nut (1).
PAE-4-37
4-51
B. REPLACEMENT OF HYDRAULIC RETURN FILTER
The return filter keeps the hydraulic oil clean by re-
moving any foreign matter that may be in the oil. This BE CAUTIOUS OF HOT FLUIDS
will prevent the hydraulic equipment from becoming AND SURFACES.
damaged and prolong the equipment's life. Thus, since WEAR GOGGLES, SAFETY
the return filter is a very important part, treat it with SHOES, HARD HAT, WORK
care. CLOTHES, AND WORK GLOVES
CHINE.
• NEVER CHANGE OILS OR FILTERS ON A MACHINE
THAT HAS JUST FINISHED WORKING. ALLOW MA-
CHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE
WARM, NOT HOT.
• RELEASE HYDRAULIC TANK PRESSURE, BEFORE
WORKING WITH ANY HYDRAULIC COMPONENT,
ACCORDING TO THE PROCEDURES PROVIDED
BELOW.
• WHEN REPLACING ANY HOSE OR SEALS, MAKE
SURE THE ATTACHMENTS ARE WELL SECURED TO
AVOID SUDDEN MOVEMENT OF ATTACHMENT.
PAE-1-22
SLOWLY REMOVE BOLTS TO RELEASE ANY HY-
DRAULIC PRESSURE DURING DISASSEMBLY. AIR PLUG
[1] Move the machine to firm level ground, place the

attachment in the oil check position, and stop
the engine.
See Fig. PAE-1-22.
PFE-4-2
[2] Open the engine guard and the left side cover.
Then remove the left operating box upward.
Refer to page 2-11.
[3] Make sure to clean the hydraulic oil tank surface

to avoid contamination.
[4] Slowly loosen the air plug (2) to release inside pres-
sure in the hydraulic oil tank, referring page 4-13 for
the procedures.
[5] Loosen 4 capscrews (3) with 4 lock washers (4) PKE-4-3
to remove the cover (5). At that time, the cover

(5) may jump out due to spring force on the spring
(6). Remove the capscrews (3) holding the cover
(5) downward.
[6] Remove the spring (6) and valve (7), then re-
move the element (8) out of the tank.
[7] Make sure to clean all parts properly.
[8] Install the new element into the tank.

PEK-4-4
4-52
[9] Set the valve (7) and spring (6) on the return
filter. NOTE : For the machine with the breaker, the deterio-
[10] Replace the O-ring (9) on the fixing face of cover ration of hydraulic oil is increased by the breaker work
with a new one together with the return filter (8). compared with the standard digging with bucket.
[11] Set the cover (5), and holding it against spring Earlier replacement for the line filter and hydraulic oil
force, install it with the capscrew (3) and the lock is required. Follow the replacement intervals for them
washer (4). to page 8-8.
Tightening torque for capscrew (3) :
+ 0.2 kgfm(17 -
2.4 - + 1 ftlbs)
[12] Extend each cylinder up to their stroke ends,
and pressurize the hydraulic oil tank.
See page 4-14 .
[13] Install the cover. BE CAUTIOUS OF HOT FLUIDS
AND SURFACES.
C. REPLACEMENT OF FUEL FILTER SHOES, HARD HAT, WORK
• Each portion of the engine is kept at high temperature MAINTENANCE ON THIS MA-
just after the operation. Start the servicing after cooling
CHINE.
down each portion.
• Thoroughly wipe up the fuel spilled over, otherwise it
may cause fire.
Provide an empty container to receive the fuel.

[1] Stop the engine and open the engine guard. FUEL FILTER
[2] Put fuel container under the fuel filter.
[3] Set the handle (A) of fuel filter at "CLOSE" posi-

tion. And remove the retaining ring (B), and take
the element (C) out of the cup case (D). At this
time, care must be exercised not to miss the spring
which is placed in the cup case.
(A)
For the sake of safety and in order not to make HANDLE
the ground dirty, make sure to discharge the fuel
into the container and make the around clean. CLOSE
(B)
[4] Replace element (C) and O-ring (E) with new ones.
OPEN
(D)
PFE-4-9
[5] Install them in reverse order shown in the item [3].
[6] Bleed air referring to item "BLEEDING AIR IN FUEL

SYSTEM" in page 4-15 .
[7] Run the engine in low idle for several minutes to

ensure that the filter fitting section is free from
possible fuel leakage.
Dispose of all hazardous waste in accordance with

government environmental regulations.
PAE-4-41
4-53
4.19 1000-HOUR (12-MONTH) INSPECTION AND
MAINTENANCE
Thoroughly read and understand the section, SAFETY DANGER OF HIGHLY PRESSURIZED STEAM IS
PRECAUTIONS of this MANUAL before operating or GENERATED IN THE RADIATOR. WHILE THE
servicing the machine. COOLANT IS KEPT AT HIGH TEMPERATURE, DO
Perform together with 8 to 500-hour inspection and NOT LOOSEN NOR OPEN THE RADIATOR CAP.
maintenance. WHEN OPENING THE RADIATOR CAP, STOP THE
ENGINE.
ALLOW SUFFICIENT TIME TO COOL DOWN THE
A. REPLACEMENT OF COOLANT ENGINE BEFORE SERVICING.
Use of soft water with less impurities as base cool-
ant. Use the "Long Life Coolant" mixing it in the cool-
ant more than 30% of density to prevent the cooling
THE ANTI-FREEZE AGENT IS INFLAMMABLE AND
line from corroding and freezing. The density of "Long
DETRIMENTAL TO HUMAN BODY. KEEP AWAY
Life Coolant" must correspond to the expected low-
FROM FLAMES AND SPARKS.
est ambient temperature.
PAY ATTENTION NOT TO ADHERE THE ANTI-
Refer to page 4-7 for the required density of "Long
FREEZE AGENT ON SKIN OR ENTER INTO EYE.
Life Coolant."
IF IT ADHERES ON SKIN OR ENTERS INTO EYE,
Provide an empty container to receive the coolant
IMMEDIATELY WASH SKIN OR EYE WITH LOTS
drained.
OF CLEAN WATER, AND ASK A DOCTOR TO
TREAT IT.
[1] Stop the engine. Open the engine guard. Start the
servicing with the coolant cooled down enough.
[2] Loosen the radiator cap slowly. After ensuring

that the pressure has been released, push the cap
down and hold it down while turning to remove.
RADIATOR CAP CAP
[3] Discharge the coolant through the drain hose into
the empty container.
[4] After discharging, close the drain cock. Then fill

the cooling line with the mixture of water and clean-
ing solvent (radiator cleaner).
[5] Operate the engine at a speed slightly faster than

idling to raise the coolant temperature to 80° C
DRAIN HOSE
(176° F) or more within white range on the ther-
PAE-4-30
mometer for coolant temperature. Then, operate
the engine for approximately 10 minutes.
ACCELERATION LEVER
[6] Stop the engine and open the radiator drain cock.
Flush the radiator with tap water until the water
draining becomes clean.
PM5-124
4-54
[7] Close the radiator drain cock. Fill the radiator
with tap water in which LONG LIFE COOLANT
has been mixed (30% or more) up to the radiator DISPOSE OF ALL HAZARDOUS WASTE IN AC-
cap. Rotate the engine for a while to fully release CORDANCE WITH GOVERNMENT ENVIRON-
air from the cooling system. MENTAL REGULATIONS.
[8] Stop the engine. Check the coolant level (the

reserve tank water level should be between FULL
and LOW). Refer to page 3-3 . Make sure level is
to specifications.
[9] After checking for leakage, close the engine guard.
RADIATOR
NOTE : When the Long Life Coolant is not used,
replace the coolant two times a year in spring and RESERVE TANK
autumn.
NOTE : The following works require a professional skill

because they are the inspection and maintenance
inside the engine. Since the adjustment also re-
quires special knowledge and skill, consult them with FULL
an authorized dealer. LOW
PAE-4-29
B. CHECK AND ADJUSTMENT FOR VALVE CLEAR-

ANCE
This is to correct the time lag on the operating timing
of exhaust and intake valves. Negligence for this
service causes faults such as output shortage, im-
proper exhaust gas color, noise and so on.
C. CHECK AND ADJUSTMENT FOR STARTER AND

GENERATOR
There is a possibility of warn-out brush and/or lack of
grease lubrication on bearing.
This is of the adjustment to get good start ability and
power generation.
PA-4-44
4-55
4.20 2000-HOUR INSPECTION AND
MAINTENANCE
Thoroughly read and understand the section, SAFETY BE CAUTIOUS OF HOT FLUIDS
PRECAUTIONS of this MANUAL before operating or AND SURFACES.
servicing the machine. WEAR GOGGLES, SAFETY
Perform together with 8 to 1000-hour inspection and SHOES, HARD HAT, WORK
maintenance. CLOTHES, AND WORK GLOVES
A. OIL CHANGE IN HYDRAULIC OIL TANK AND MAINTENANCE ON THIS MA-
CLEANING OF SUCTION STRAINER CHINE.
DANGER OF HIGHLY PRESSURIZED FLUID WITH

HIGH TEMPERATURE EXISTS IN THE HYDRAU-
LIC OIL TANK JUST AFTER THE MACHINE OP-
ERATION. DO NOT START THE FLUID CHANGE
IMMEDIATELY.
START IT AFTER THE FLUID COOLED DOWN.
PME-4-58
WHEN LOOSENING THE AIR PLUG, LOOSEN IT
SLOWLY TO RELEASE INSIDE PRESSURE.
AIR PLUG OIL FILLING PORT
Container to receive discharged fluid : HYDRAULIC
17 liter (4.5 gal) or more capacity OIL TANK
Volume to be filled in : 11.3 liter (3.0 gal)
[1] Slew the machine so that the drain plug on the

hydraulic oil tank comes to midway between the
LEVEL GAUGE
both crawlers.
[2] Referring to page 4-49 Items [2] through [4], pro- PFE-3-3
ceed the work in accordance with the same pro-
cedures.
(4)
[3] After releasing inside pressure from hydraulic oil
tank, remove the plug (4) of oil filling port with a (13)
(
wrench.
(F)
[4] Using an oil suction pump, discharge the oil from

the oil filling port (F) into a container to receive
the drained oil.
[5] The remaining oil in the tank is drained from the PA-4-46
drain plug (1). Set up a container to receive the
drained oil under the drain plug on the bottom of

hydraulic oil tank. Then remove the drain plug

with a spanner (27mm) to drain up the remaining
oil.
[6] Check the O-ring (5) for any scores or other dam-
ages and replace it with a new one, if necessary.
NOTE : When loosening the drain plug (1), pay atten-
tion not to pour the fluid over yourself.
PFE-4-12
4-56
[7] After draining up the remaining oil, install the
drain plug (1) and O-ring (5) to the tank, and
tighten it up.
Then inspect the suction filter after removing it
from the hydraulic oil tank.
[8] Loosen the clip (6) for hydraulic piping, and dis-
connect the hose (7) from the flange (12) on hy-
draulic oil tank. Loosen the capscrews (8) with
lock washers (9) (4pcs.each), and take out the
suction strainer (10).
[9] Remove dust and other contamination on the

strainer (10), then clean it with diesel fuel or clean-
ing oil. Replace the strainer (10) with a new one
if it is damaged. PA-4-48
[10] Replace the O-ring (11) with a new one.
[11] Install the suction strainer (10) in reverse order

of the above [8].
Suction strainer (10) tightening torque :
+1 kgfm(13-
1.8- +7 lbfft)
capscrew (8) tightening torque :
+0.2 kgfm(17-
2.4- +1 lbfft)
PR-4-113
[12] Fill the hydraulic oil tank with the specified hy-
draulic oil of the specified volume. Check if the
oil level on the level gauge being between H and LEVEL GAUGE
L. Dot not fill the oil beyond the H level. For
the specified oil, refer to page 4-7 .
[13] Check the O-ring (13) for any damages, and re-
place it with a new one if necessary. Tighten up
the plug (4) securely with a wrench.
[14] After the completion of hydraulic oil change and

cleaning of suction strainer, carry out the air re-
leasing in the hydraulic line referring to page 4-
14 .
PAE-3-7
[15] After the air bleeding, return the machine attach-

ment to the hydraulic oil check position.
[16] Stop the engine, and again check the oil volume,
and if insufficient, refill with the oil again.
[17] Pressurize the hydraulic oil tank referring to page

4-14 . See Fig. PME-4-22.
[18] Check for any leakages. Thoroughly wipe off the

fluid spilled over. PME-4-22
NOTE : If the air bleeding is insufficient or the engine

is started up with insufficient oil in the hydraulic line,
it leads to short service life of the hydraulic equip-
ment, and may cause severe damage to it as well.
4-57
B. CLEANING LINE FILTER OF PILOT VALVE AND IN-
LINE FILTER OF SOLENOID VALVE
THE HYDRAULIC LINE IS ALWAYS PRESSURIZED.

DO NOT CARRY OUT ANY CHECK AND SERVIC-
ING BEFORE RELEASING THE INSIDE PRES-
SURE.
TO RELEASE INSIDE PRESSURE IN THE HY-
DRAULIC OIL TANK, LOOSEN THE AIR PLUG
SLOWLY WITH CARE.
MAKE SURE TO CLEAN ANY SPILLAGE TO AVOID
FIRE.
The (P) ports of right and left pilot valves and solenoid
valve are equipped with connector with filter. Dust,
etc. that adheres on the filter will decrease oil flow. If PILOT VALVE (P) port
dust, etc enter in the valve it may cause trouble. O - RING
Take out and clean filter, periodically. (A)
(B)
[1] Move the machine to firm level ground, place the

attachment in the oil check position, and stop the
engine.
[2] Carry out the air releasing for the hydraulic line
referring to page 4-13 .
(C)
[3] Loosen 2 bolts (C) on the operating box to remove
the cover. (C)
PAE-4-49
[4] Disconnect the hose (A) connected to "P port" on
the pilot valve at first, then remove the elbow (B).
After the removal, put a blinding plug to the bore
to prevent it from invasion of foreign matter. O - RING
FILTER
(B)
[5] Dust tends to accumulate on the inside elbow (B)
(dented portion). Make sure to properly clean parts
to avoid contamination (projected portion).
[6] Check the O-ring for damages, and replace it with PAE-4-50
a new one, if damaged.
[7] After cleaning, install it to the original position in

reverse order of the above [3] and [4]. Refer to
page 4-11 for the tightening torque for the adapter
hose.
Then the in-line filter of solenoid valve is removed
for cleaning.
[8] Remove the floor mat and floor plate. PAE-4-51
4-58
[9] Prior to removing the in-line filter assmbly, re-
(E)
move the hose (D).
Use caps and plugs on the hose to avoid con- ADAPTER
ASSEMBLY
tamination.
[10] Remove the adapter on the elbow (E) which is (D)

connected to the solenoid valve. Use a plastic
cover on the elbow oil port.
SOLENOID VALVE
PAE-4-52
[11] Remove the adapters (2) and (4), then remove
the filter (3).
[12] Dust and rubbish are accumulated outside the

filter (3). Make sure to clean properly to avoid
contamination.
1 2 3 4 6 5
[13] Check the O-rings (1) and (6) for damages, and
replace them with new ones, if damaged.
[14] After cleaning, assemble the filter (3) with the

adapter (4), then install the assembly to adapter
(2). PAE-4-53
[15] Removing plug from elbow (E) of the solenoid

valve, install the adapter assmbly.
[16] Removing plastic plug from the hose (D), install

it to the elbow (5). Attach the floor plate and floor
mat, then pressurize the hydraulic line. Refer to
page 4-13.
NOTE : Consult with an authorized Case Dealer, when

the boom, arm, bucket, boom, swing, and dozer are
PA-4-54
not activated against the operation of each operat-
ing lever, or the locking function does not work
against setting the safety control lever to the "LOCK"
position.
4-59
C. OIL CHANGE FOR TRAVEL SPEED REDUCTION
UNIT
The oil is very hot just after the machine operation.

Start the servicing after getting down the oil tempera-
ture.
Remaining some residual pressure in the travel mo-
tor may cause flying out of plug or spouting out of oil
at loosening the plug.
Slowly loosen the plug with care.
Container to receive discharged oil :

1000 cc (61 cuin) or more capacity
Oil volume to fill in : 750 cc (46 cuin) ---LH/RH each
2
Change the oil at 500 hours operation for the first use
of new machine.
[1] Set the machine on a level ground so that the

DRAIN (discharge) port (1) comes just to the bot- GL
tom. 3 90
1
[2] Provide a container under the DRAIN port (1) to PW-5-10
receive the discharged oil.
[3] Slowly remove the plug of the SUPPLY port (2)

and the LEVEL port (3) with an allen wrench.
Then remove the plug of the DRAIN port (1) to dis-
charge oil into the container.
[4] Apply sealing tape on the thread of plug of the

DRAIN port (1), and securely tighten it.
[5] Slowly fill in oil through the SUPPLY port (2), up to

overflowing of oil from the LEVEL port (3).
See page 4-7 LUBRICANT, FUEL & COOLANT PW-5-11
SPECIFICATIONS for the applied gear oil.
[6] Apply sealing tape on the thread of plug of the

LEVEL port (3), and securely tighten it.
Thoroughly wipe off oil spilled over.
[7] Ensure no oil leakages traveling the machine slowly.
NOTE : Check the waste oil. If any metal particles are

mixed in it, consult it with an authorized dealer.
PW-5-12
4-60
D. GEAR OIL CHANGE FOR LOWER ROLLER AND
IDLER
Highly pressurized grease is contained in the grease

cylinder of truck spring. When loosening the grease
nipple for the tension adjustment of crawler shoes or
disassembling, gradually loosen the grease nipple
within one turn to slowly release the pressurized
grease.
PA-4-57
The lower roller and idler have to be removed from the A Idler D Rubber Crawler Shoe
crawler frame to change the gear oil for each of them. B Idler Adjuster E Lower Roller
The following is to describe the procedures to remove/ C Shoe Slide F Crawler Frame
reinstall, and the gear oil change for each of them.
Refer to page 4-7 for the oil and grease to be used
and required volume.
1. LOWER ROLLER
[1] Loosen the rubber crawler shoe of the side to
change the gear oil referring to page 4-20 .
[2] The fixing capscrews (1) of lower roller is a bit

loosened in advance. (around one turn)
[3] Start up the engine, and lift up the oil filling side of
the machine, with boom and arm getting down the
back side of bucket to the ground.
[4] Support the machine with a safety support, etc.,

PMJ-1-31
[5] Remove the capscrews (1) with washers (2) which
are provided to install the lower roller to the crawler
frame at two positions of inside and outside. Then
remove the lower roller (3) .
[6] Remove the feeding port plug (4) with an allen

wrench, and discharge the old gear oil.
[7] Fill in the prescribed volume (60cc or 3.7cuin) of

gear oil through the feeding port.
[8] Apply sealing tape to thread on the plug (4), and

securely tighten it. Throughly wipe off oil adhered
PMJ-4-90
to periphery.
4-61
[9] Apply Locktight # 262 to thread on the capscrews
(1), and temporarily install the lower roller (3) to
the crawler frame.
[10] Remove the safety support which supports the

machine to get down the machine to the ground,
(5)
then tighten up the capscrew (1).
(R) (S)
+ 0.2kgfm(85 -
Tightening torque : 11.7 - + 1lbfft)
[11] Again lift up the machine to adjust the crawler

18mm 21.4mm
shoe tension referring to page 4-18 .
(0.71in) (0.84in)
PME-4-103
NOTE : The collars (5) are available for the rubber
and steel crawler shoes by changing the installing
direction.
(R) ; Rubber crawler shoe
Fit the collar (5) to the frame directing
the groove to lower side.
(S) ; Steel crawler shoe
Fit the collar (5) to the frame directing
the groove to upper side.
4-62
2. IDLER
For the gear oil change of idler, the rubber crawler
shoe of the changing side has to be removed.
The removal and installation of the rubber crawler shoe

require to lift up one side of the machine. It is quite
dangerous if the machine is erroneously fallen down.
Never operate the machine except the work for rubber
crawler shoe.
[1] Remove the rubber crawler shoe referring to page

4-16 . Make sure to apply the safety support,
etc. Stop the engine.
[2] Pull off the idler (1) and idler adjuster (2) from the
crawler frame.
Weight of Idler + Idler Adjuster =
approx. 22 kg (49 lb)
[3] Remove the feeding port plug (3) with an allen

wrench to discharge the old gear oil.
PAE-4-59
[4] Fill in prescribed volume (30 cc or 1.8 cuin) of

gear oil through feeding port.
[5] Apply sealing tape to thread on the plug (3), and

securely tighten it. Throughly wipe off oil adhered
to periphery.
[6] Apply grease to the sliding face on the piston (4)

and cylinder (5) of the idler adjuster (2).
[7] Install the idler so that the feeding port plug (3) of
idler and the grease nipple (6) of idler adjuster are
facing to outside.
[8] Install the rubber crawler shoe referring to page

4-17 .
PAE-4-60
[9] Adjust the tension on the rubber crawler shoe re-

ferring to page 4-18 .
After confirming the engagement of rubber crawler
shoe with the idler and the conditions for tension,
get down the machine to the ground removing the
safety support, etc.
4-63
E. REPLACEMENT OF GREASE IN SLEWING
GREASE BATH
If a bit water is mixed in grease, it may become muddy
into white color. When such machine work as im-
mersing in water closely to the slewing bearing is
repeated, grease in the slewing bearing as well as in
the grease bath may be deteriorated.
The deteriorated grease may cause damages on the
pinion gear of slewing motor and internal gears of
PAE-4-61
slewing bearing. Consult with an authorized dealer
for the judgement for the replacement of grease.
If the slewing ring ever becomes submerged in

water, it is mandatory that the sump bath grease
be changed.
Grease Type - N.L.G.I. Lithium Base W/Mos2

Quanity - 4.8 kg (11 lb)
PAE-4-62
NOTE : The following works require a professional skill
because they are the inspection and maintenance
for inside the engine. Since the adjustment also re-
quires special knowledge and skill, consult them with
an authorized dealer.
F. CHECK AND ADJUSTMENT FOR FUEL INJECTION

TIMING
This is to adjust the fuel injection timing to optimize
the engine performance.
G. CHECK AND ADJUSTMENT FOR CONTACT SUR-

FACE OF INTAKE AND EXHAUST VALVE
This is to ensure the gas-tightness on the exhaust
and intake valves to optimize the engine performance.
4-64
INSPECTION MAINTENANCE CHECK LIST
Machine Model: Serial NO.: Machine Hours: .
ITEM OK MAINT. PERFORMED ITEM OK MAINT. PERFORMED
ENGINE OIL LEVEL SLEWING REDUCTION OIL

ENGINE COOLANT LEVEL SLEWING RING GEAR
CHECK FOR FLUID LEAKS GREASE BATH LEVEL
CHECK BELT TENSION SLEWING RING PINION
CHECK FUEL LEVEL SLEWING RING SEAL
DRAIN WATER SEPARATOR SWIVEL JOINT SEALS
CHECK AIR CLEANER DRAIN WATER FROM BATH
CHECK ENGINE ELECTRICAL GREASE SLEWING RING
DRAIN WATER FROM FUEL CHANGE GREASE BATH
CHANGE ENGINE OIL CHECK BOLTS/HARDWARE
CHANGE OIL FILTER CHECK LINES FOR DAMAGE
CHANGE FUEL FILTER CHECK STEPS
CHANGE WATER SEPARATOR CHECK FRAME STRUCTURE
CHECK AIR INTAKE INDICATOR CHECK CRAWLERS
CHECK FAN ASSEMBLY CHECK SPROCKET WEAR
CHECK BELT TENSIONER CHECK IDLER WEAR
CLEAN RADIATOR CHECK ROLLER WEAR
CHANGE ENGINE COOLANT CHECK CRAWLER TENSION
AIR CLEANER ELEMENTS ADJUST CRAWLER TENSION
ADJUST VALVE CLEARANCE TRAVEL REDUCTION
HYDRAULIC OIL LEVEL CHECK BOOM & ARM
CHECK HYD FUNCTIONS BUCKET TEETH
CHECK FOR OIL LEAKS SIDE CUTTERS
CHECK HOSES/PIPINGS GREASE BOOM PINS
CLEAN SUCTION SCREEN GREASE ARM PINS
CHANGE RETURN FILTER GREASE BUCKET PINS
PILOT MANIFOLD FILTER GREASE SWING PIN
CHANGE HYDRAULIC OIL GREASE DOZER PIN
CLEAN HYDRAULIC TANK CHECK COOLANT ADDITIVE
INSPECT ALL WIRING CHECK CRAWLER SHOE
BATTERY ELECTROLYTE
BATTERY SERVICE
HYD. FUNCTION OPERATION
CHECK SWITCHES
CHECK WARNING LIGHTS
CHECK HORN
CHECK DISPLAY MONITOR
These item include non-equipped parts by the machine specification.

MECHANIC :
SIGNATURE : DATE :
4-65
NOTES
4-66
SECTION 5
TRANSPORTATION
TABLE OF CONTENTS
5.0 TRANSPORTATION ................................................................................................................................. 5-2

A. When Preparing Transportation Plans ............................................................................................. 5-2
B. Loading And Unloading the Machine ............................................................................................... 5-2
C. Securing the Machine ..................................................................................................................... 5-3
D. Lifting Procedures For the Machine Complete ................................................................................. 5-4
5-1
SECTION 5 - TRANSPORTATION
5.0 TRANSPORTATION
A. WHEN PREPARING TRANSPORTATION PLANS

Before preparing to transport the machine, refer to
Section 6, SPECIFICATIONS and check the total
weight, height, width, length, traveling speed, ground
pressure, etc.
Survey the width of roads, bridges, road surface
conditions and traffic conditions for transportation.
Obtain any permits required from proper govern-
ment agencies for the machine transportation.
B. LOADING / UNLOADING THE MACHINE
Slow speed traveling is necessary to load and un-

load the machine.
It is dangerous to use the attachment for loading
and unloading the machine. Do not take such man-
ner.
Do not operate other operating levers than the trav-
eling lever on the ramps.
Pay attention for the sudden transferring of the
center of gravity of the machine on the border be-
tween the truck/trailer and the ramps.
USE OF RAMPS
Refer to page 1-38 for cautions at loading/unload-
ing the machine.
USE OF PLATFORM OR EARTH BANKING

[1] Make the width of the earth banking (raising
the ground level) enough to the machine width.
[2] Make the earth banking strong enough in or-

der not to turn over the machine during load-
ing/unloading due to broken side slope of the
earth banking.
15û OR LESS
If necessary, provide some supporting posts
to reinforce both side of the banking.
PV5-01
[3] The height of the platform or banking must cor-
respond to that of the base of truck/trailer.
[4] At loading the machine, climb up to the truck/

trailer from front end of the machine for the case
of the machine with attachment, and from back
end for the machine without attachment.
[5] Set the machine at the center position on the

truck/trailer.
5-2
C. SECURING THE MACHINE
After the machine is loaded and positioned, fix the
machine by the following procedures.
[1] Get down the dozer.
[2] Fully extend the bucket and arm cylinders, then

slowly get down the boom.
NOTE : To prevent the bucket cylinder from damages

during transport, apply a wooden block to the edge
of bucket link in order not to get down it to the floor. PAE-1-27
[1] Pull up the safety lock lever and set to the "LOCK"
position. LOCKED (UP)
POSITION
[2] Turn OFF all switches and pull out the starter
key.
Lock all the caps and the door (CAB SPEC.). PAD FOR PAD FOR
EDGE EDGE
[3] Apply the blocks to both the front and rear of the
crawler and fix them with a wire rope of sufficient
WIRE ROPE
strength. This will prevent the machine from mov-
ing forward/backward or rolling due to vibration from PV1-89
the truck/trailer.
5-3
D. LIFTING PROCEDURES FOR THE MACHINE
COMPLETE
The wire ropes to be used for lifting the machine

should have sufficient strength against the machine
weight.
Improper lifting method and/or roping manner might
cause for a movement or slip of the machine while
it is lifted up, resulting serious injury or damages on
the machine.
Do not impose a load suddenly on the wire ropes
and slings.
When the lifting work is carried out in cooperation
with plural persons, make sure to check every situ-
ations with exchanging signals with each other.
During the lifting work, keep any persons away
from around the lifting machine, especially under
Label K
the machine
Carry out the lifting work on a level ground.
[1] Start up the engine, and slew the machine so that

the dozer blade comes to backside.
[2] Raise the dozer blade up to the most upper position.
[3] Manipulate each operating lever to take posture
as shown in the figure.
[4] When the boom is swung, operate the boom swing
pedal to face the boom direct front.
[5] Stop the engine, and make the safety lock lever to
LOCK position. Then take off the machine after
ensuring for no abnormalities around the operators
seat.
[6] Install shackles to both bores (A) provided at both
ends to the dozer blade, and put the wire ropes on
them.
[7] Put the wire ropes on the (B) portion.
[8] If any portions of the wire ropes directly get touch
with the machine when the wire ropes are pulled up,
protect the machine from damages by means of
applying a wooden piece or pad between them.
[9] Put the wire ropes from 30 to 40 degress of lifting
angle with each other. 14_05_01
[10] Slightly lift the machine to confirm the balance,

then lift up the machine.
NOTE : If wire ropes get touch with the Canopy Roof,

remove the Canopy prior to lifting.
14_05_02
5-4
SECTION 6
SPECIFICATIONS
TABLE OF CONTENTS
6.1 GENERAL SPECIFICATIONS ................................................................................................................... 6-2

A. Machine Dimensions ................................................................................................................. 6-2
B. Attachment Working Ranges ..................................................................................................... 6-3
C. Boom With Arm Cylinder ........................................................................................................... 6-4
D. Arm & Standard Bucket ............................................................................................................. 6-4
E. Arm ........................................................................................................................................... 6-4
F. Bucket ....................................................................................................................................... 6-4
G. Dozer ........................................................................................................................................ 6-4
H. Crawler Shoe ............................................................................................................................ 6-5
I. Bucket Types ............................................................................................................................ 6-5
J. Performance Specifications ....................................................................................................... 6-6
1. Speed and Gradeability ....................................................................................................... 6-6
2. Side Digging & Dozer ........................................................................................................... 6-6
3. Engine .................................................................................................................................. 6-6
4. Hydraulic Components ......................................................................................................... 6-6
5. Noise Level .......................................................................................................................... 6-6
K. Machine & Components Weight ................................................................................................ 6-7
6-1
SECTION 6 - SPECIFICATIONS
6.1 GENERAL SPECIFICATIONS
A. MACHINE DIMENSIONS
Long Arm
PEE-6-101
6-2
B. ATTACHMENT WORKING RANGES
(A)
Long Arm 0.040m3 Bucket
(A')
(G)
(C)
(H)
(D)
(E)
(X)
)Y(
(K) (L)
(F)
(B)
14_06_01
14_06_02
6-3
C. BOOM WITH ARM CYLINDER
14_06_03
D. ARM & STANDARD BUCKET
14_06_04
E. ARM
14_06_05
F. BUCKET
14_06_06
G. DOZER
14_06_07
6-4
H. CRAWLER SHOE
14_06_08
I. BUCKET TYPES
14_06_09
6-5
J. PERFORMANCE SPECIFICATIONS
14_06_10
6-6
K. MACHINE & COMPONENTS WEIGHT
14_06_11
6-7
NOTES
6-8
SECTION 7
TROUBLESHOOTING
TABLE OF CONTENTS
7.1 GENERAL TROUBLESHOOTING ............................................................................................................ 7-2

A. Operating ......................................................................................................................................... 7-2
B. Travel .........................................................................................................................................7-2, 7-3
C. Hydraulic ......................................................................................................................................... 7-3
D. Gauge Cluster Display ..................................................................................................................... 7-3
E. Engine ............................................................................................................................................. 7-4
7-1
SECTION 7 - TROUBLESHOOTING
7.1 GENERAL TROUBLESHOOTING
This troubleshooting information covers the components and systems as described in this MANUAL. Should
in depth troubleshooting, repair or replacement of components or adjustment of valves be required, contact an
authorized dealer for assistance.
7-2
7-3
7-4
SECTION 8
OPTIONAL EQUIPMENT
TABLE OF CONTENTS
8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER ........................................................................ 8-2

A. Selection of Hydraulic Breaker And Nibbler .................................................................................... 8-2
B. Before Operating Breaker and Nibbler .......................................................................................... 8-2
C. Precautions For Impurity and Hydraulic Oil ................................................................................... 8-2
D. Operation ....................................................................................................................................... 8-3
E. Connection To Hydraulic Circuit For Attachment ........................................................................... 8-3
F. Selector Valve Shifting Procedures ................................................................................................. 8-4
8.2 SAFETY PRECAUTIONS.......................................................................................................................... 8-5
A. Use for Intended Purpose ............................................................................................................... 8-5
B. Passengers ..................................................................................................................................... 8-5
C. Protective Equipment ...................................................................................................................... 8-5
D. Cylinders ......................................................................................................................................... 8-5
E. Avoid Continuous Operation ........................................................................................................... 8-5
F. Hose Surge ..................................................................................................................................... 8-6
G. Do Not Use Dropping Force ........................................................................................................... 8-6
H. Do Not Use Slew / Swing Force ...................................................................................................... 8-6
I. Do Not Lift ........................................................................................................................................ 8-6
J. Working Ranges .............................................................................................................................. 8-7
K. To Pry and Break Forcibly ............................................................................................................... 8-7
L. Arm in Vertical Position .................................................................................................................... 8-7
8.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL ..................................................................... 8-8
A. Replacement Interval ..................................................................................................................... 8-8
B. Maintenance Record Sheet (Example) .......................................................................................... 8-8
C. Pump Discharge Capacity (For Reference) ................................................................................... 8-8
8-1
SECTION 8 - OPTIONAL EQUIPMENT
8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER
A. SELECTION OF HYDRAULIC BREAKER AND NIBBLER

When installing a hydraulic breaker or nibbler to the machine, select the optimal breaker or nibbler taking the
matters into consideration such as stability, blowing force, grasping force, required hydraulic oil volume, etc.
B. BEFORE OPERATING BREAKER OR NIBBLER

Consult with an authorized dealer for the additional piping work and reinforcement for the arm to install the
breaker or nibbler to the machine.
When using the breaker or nibbler, fully understand and peruse the operation manual of its manufacturer and
the SAFETY PRECAUTIONS for the work mentioned in this MANUAL, in order to get full performance of them
paying attention to damages on the machine and hydraulic breaker or nibbler.
C. PRECAUTIONS FOR IMPURITY AND HYDRAULIC OIL

When the hydraulic breaker or nibbler is removed after its installation, apply a blinding plug to the stop valves
attached on the tip of arm and openings on the hydraulic pipings for the hydraulic breaker or nibbler to prevent
them from invasion of dust, water, etc.
Before the operation, check the looseness on the clamps which are fixing the piping for attachment, and the
leakage on connections of tubes and hoses.
D. OPERATION
There are two specifications for the machine, one is single hydraulic circuit for breaker only, and the other is
combined hydraulic circuits for both breaker and nibbler. An option pedal is provided at left front of the operator's
seat to operate them.
1. Operating Pedal
[1] Single Hydraulic Circuit for Breaker only
Release the pedal lock for the operating pedal lo-
cated at left front of driver's seat, and operate the
pedal. OPTION PEDAL
Pedal Depressing Direction Operation (B)

Left Side (A) Breaker is not operated. (A)
Right Side (B) Breaker is operated.
Breaker stops at releasing
pedal.
[2] Combined Hydraulic Circuit for Breaker and Nibbler

Release the pedal lock for the operating pedal lo- PAE-8-2
cated at left front of driver's seat, and operate the
pedal.
* Hydraulic Breaker Operation

Pedal Depressing Direction Operation
Left Side (A) Breaker is not operated.
Right Side (B) Breaker is operated.
Breaker stops at releasing
pedal.
Do not put foot on the pedal except during opera-

* Nibbler Operation tion. If you put foot on the pedal and mistakenly
Pedal Depressing Direction Operation
step foot on it, the machine may move suddenly to
Left Side (A) Grasping operation
cause a serious accident.
Right Side (B) Opening operation
8-2
2. Pedal Lock Device ( 1 ) LOCKED

This is a device to lock the pedal.
Make sure to set the pedal lock to "LOCKED" posi-

tion while the breaker or nibbler is not used.
Careless contact with UNLOCKED position of pedal
may cause severe accident and injury.
( 2 ) UNLOCKED
(1) Position ................. LOCKED
(2) Position ................. UNLOCKED
PAE-8-14
E. CONNECTION TO HYDRAULIC CIRCUIT FOR

ATTACHMENT
Connect the hydraulic circuit for the breaker and
nibbler with the following procedures.
[1] Remove the PF 1/2 blinding plugs (A) on pipings

for stop valves (2 points of left and right).
Pay attention not to give any damages on the
blinding plugs removed, or lose them.
[2] Connect the hydraulic pipings for the breaker

and nibbler to the positions where the blinding
plugs are removed at the above [1].
NOTE :
Stop valves are to stop the flow of hydraulic oil.
LOCK : The hydraulic oil flow is stopped.
PAE-8-3
FREE : The hydraulic oil flows.
When installing or removing the hydraulic breaker
or nibbler, make sure to set the stop valve at
"LOCKED" position and attach the blinding plugs.
NOTE : PAE-8-4
The engine must be operated at 85% of rated speed
while the work for breaker or nibbler.
From time to time, stop the work for a while, and
make the engine speed at idling to cool the hydrau-
lic oil.
PAE-8-5
8-3
F. SELECTOR VALVE SHIFTING PROCEDURES
When installing the hydraulic beaker or nibbler, the
selector valve (1) must be installed to the main cir-
cuit. It is necessary to shift the selector valve to ei-
ther of proper position.
NOTE :
Improper shifting of the selector valve may cause
deterioration of working efficiency and lowering the
working speed as well as damages on the machine
occasionally. Make sure to shift the selector valve
to the proper position.
The selector valve needs to be periodically shifted
every one or two times a month.
PAE-8-6
* SHIFTING PROCEDURES
NOTE : To shift the selector valve, make sure to stop
the engine and lower the attachment to the
ground making the machine at stable condi-
tions.
Tools to be used for selector valve (A)

Location ; Right side of boom
Tool ; Spanner (24 mm)
Hex. wrench key (5 mm) PAE-8-7
Selector Valve Shifting Procedure

[1] Remove the socket capscrew (B) on the selector
To tank To tank
valve (A) which is located on right side of the Perform
boom, with hexagonal wrench key (C). engraving
To To
[2] Shift the selector valve to the proper position with attachment attachment
the spanner (E).
Install the capscrew (B) to the corresponding po- To control valve To control valve
sition.
When breaker used When nibbler used
Marks on the selector valve stand for;
PM8-13
B : Breaker
N : Nibbler
8-4
8.2 SAFETY PRECAUTIONS

The following safety precautions should be used in
conjunction with all other safety precautions found
in this MANUAL.
READ, UNDERSTAND AND FOLLOW ALL SAFETY

PRECAUTIONS AND OPERATING PROCEDURES
FOUND IN THIS MANUAL BEFORE OPERATING
THE MACHINE OR ANY ATTACHMENT.
A. USE FOR INTENDED PURPOSE

Use the attachment only for its intended purpose. If
PMJ-8-6
not used in accordance with the manufactures in-
structions, the excessive pressure exerted on the
boom, arm and frame structure of the machine will
cause premature failure of the components.
B. PASSENGERS
Never allow passengers on the attachment or ma-
chine.
C. PROTECTIVE EQUIPMENT
When operating attachments that produce flying de-
bris, it is highly recommended to procure and install
protective guards on the machine and close all win- PMJ-1-1
dows to protect the operator from flying debris. Also
the operator and all personnel in the vicinity of the
machine should wear protective gear such as safety
shoes, hard hat, gloves and face shield or goggles.
D. CYLINDERS
Do not operate boom, arm or bucket cylinders at
stroke ends when using a breaker attachment. Do-
ing this can cause undue stress on the cylinder rods
and result in damage.
PMJ-8-13
E. AVOID CONTINUOUS OPERATION
Operate the nibbler/breaker in 30 sec. intervals. Op-
eration for longer than 30 sec. at a time can cause
high oil temperatures and damage the accumula-
tors, cylinder seals and possibly pump damage.
PMJ-8-7
8-5
F. HOSE SURGE
Should the hydraulic hoses begin to surge or vibrate
abnormally during operation of a Breaker or Nibbler,
immediately stop operation and contact an autho-
rized dealer for assistance. This problem often is a
result of damaged accumulators and can also re-
sult in valve failure.
PMJ-8-8
G. DO NOT USE DROPPING FORCE

Never use the dropping force of the attachment to
break or drive objects. This will cause extensive dam-
age to the attachment and machine structure.
PMJ-8-9
H. DO NOT USE SLEW/SWING FORCE

Never use the slew/swing force of the machine for
pushing or sliding objects. This will cause prema-
ture failure of the attachment and other machine
components.
PMJ-8-10
I. DO NOT LIFT
Never use an optional attachment to lift or transport
objects or material. Doing so can cause extensive
damage to the attachment, the machine structures
or cause injury or death due to slipping or dropping
of load due to improper attachment.
PA-8-1
8-6
J. WORKING RANGES
Never operate an optional attachment over the sides

of the machine. Only operate over the front or rear
of the machine.
The balance on the machine becomes unstable at

the position shown in the right figure involving a pos-
sibility of turning over the machine. Never carry out
the breaker work with this position.
NOTE :
Refer to this SECTION for the work with the other
attachment than the hydraulic breaker, too.
Use the reinforced arm for the work with the hydrau-
lic breaker, etc. The use of standard arm for such
work may cause damages on the arm.
PMJ-8-17
K. TO PRY AND BREAK FORCIBLY

Do not use the breaker to pry and break rock and
concrete.
This may damage the hydraulic breaker, and also
boom, arm and cylinder.
PMJ-8-11
L. ARM IN VERTICAL POSITION

The arm should not be operated in the vertical posi-
tion to prevent the arm cylinder from vertical shocks.
This may damage the rod packing and piston and
cause oil to leak from those sections.
PMJ-8-12
8-7
8.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL
A. REPLACEMENT INTERVAL
Contamination and deterioration of hydraulic oil will cause malfunctioning of the control valves, early wear
and seizure of the hydraulic pump and consequential failure of the entire hydraulic circuit. Operation of
breaker hasten deterioration of hydraulic oil comparing with normal operation using bucket. Replace filters
and hydraulic oil, referring to the following table :
Inspection / Replacement interval

Location
maintenance First 2nd replacement Regular
Hydraulic oil Hydraulic tank Every 600 hours
Return filter Hydraulic tank 25 hours 100 hours Every 200 hours
B. MAINTENANCE RECORD SHEET (EXAMPLE)
DATE HRS FILTER REPLACEMENT HYD. OIL CHANGE
C. PUMP DISCHARGE CAPACITY (For reference)

29.6 liters /min. X 85% of rated speed = 25.2 liters /min. (6.7gal./min.)
Note ; See page 8-3 for the 85% of rated speed.
8-8
SECTION 9
SPECIFICATIONS (EPA ENGINE)
TABLE OF CONTENTS
THE EPA REGULATIONS

1. Engine Identification ......................................................................................................................... 9-2
2. Requirements on Engine Installation Condition ................................................................................. 9-3
3. Emissions-Related Parts .................................................................................................................. 9-3
4. Maintenance Schedule ..................................................................................................................... 9-3
5. Emission System Warranty Statement ............................................................................................. 9-4
9-1
SECTION 9 - SPECIFICATIONS (EPA ENGINE)
Technical Bulletin TNE

To : All customers ISB-99-017-1
Nov. 16, 1999
THE EPA REGULATIONS

The EPA regulations For non-road engines.
(Engines which will be used in the North American market.)
The information on engines to comply with the EPA Regulations for Non-road Engines are released and you are
kindly requested to make every effort to comply with them.
The regulations covered Yanmar Engines of all TNE ENGINE MODELS.
1. ENGINE IDENTIFICATION
With the regulations on engine emission worldwide, it has become necessary to identity engines in a manner
to determine which regulations they comply with, hence.
a) Emission control label as shown below which will contain:
* Emission Control is accomplished through

Engine Modification (EM-Design)
Engine family name as assigned by EPA identifying engine family group
YYDXL2.78P4N and this identifies
Method of air aspiration

X*: 1999
Number of cylinders
Y : 2000
Combustion chamber design
1 : 2001
Displacement (liter)
2 : 2002
Non-road large Diesel
3 : 2003
Yanmar Diesel
*2000 Model Year
b) Label location :
The typical location of this label for each engine is on the exhaust side or intake side of rocker arm
cover or the top of rocker arm cover. A supplement label may be used in certain applications for
improved visibility.
9-2
2. REQUIREMENTS ON ENGINE INSTALLATION CONDITION
The followings are required from the point of view of engine installation in order to comply with the EPA
regulations. Unless otherwise satisfying these, engines exhaust gas emission will not be within the regulated
value of the EPA Regulations for Non-road Engines.
2-1) Maximum Exhaust Gas Restriction shall be

600 mm H2O or less for 2TNE68
1200 mm H2O or less for 3TNE68 and 3TNE74
1560 mm H2O or less for 3TNE78A, 3TNE82A, 3TNE84, 3TNE88
4TNE84, 4TNE88, 4TNE94, 4TNE98 and 4TNE106
600 mm H2O or less for 3TNE84T, 4TNE84T and 4TNE106T
2-2) Maximum air intake restriction shall be 635 mm H2O or less and clean air cleaner element each time when
air intake restriction exceeds 300 mm H2O at rated power condition.
3. EMISSIONS-RELATED PARTS
The EPA regulates specific emissions-related parts are warranted for the period in the following table. How-
ever, ultimate purchasers are obligated to use and maintain the engine correctly.
Warranty Periods
Power Range Other Than Constant-Speed

kW (Gross Power) Constant-Speed Under 3,000 rpm Greater than or equal to 3,000 rpm
1,500 hours or 2 years
3,000 hours or 5 years 1,500 hours or 2 years
3,000 hours or 5 years
* Actual hours or years of operation whichever occurs first is applied.

The specific emissions-related parts are 1) Fuel injection nozzle, 2) Fuel injection pump, 3) Turbocharger.
4. MAINTENANCE SCHEDULE
To maintain optimum engine performance and compliance with the EPA Regulations Non-road Engines, it is
necessary that the maintenance schedule be adhered to. Regular scheduled maintenance is a major key to
engine service life and emissions regulations compliance. It is of utmost importance that scheduled mainte-
nance, requirements are performed on a timely basis.
9-3
5. EMISSION SYSTEM WARRANTY STATEMENT
U.S. EMISSIONS CONTROL WARRANTY STATEMENT
Yanmar Diesel Engine Co., Ltd. (Hereinafter referred to as Yanmar) warrants initial owner and each subse-
quent owner that the engine is designed, built and equipped so as to conform with applicable regulations for
its warranty period.
Specific emissions-related parts and components are warranted for the period specified in 3 Emissions-
related parts whichever comes first, after the date of delivery to the initial owner. If any emission-related part
is defective during the warranty period, the part will be repaired or replaced by Yanmar.
To maintain engine performance and compliance with the regulations, the owner is responsible for the perfor-
mance of the required maintenance listed in the owners manual during the warranty period.
This emission warranty does not cover :

1. Failure caused by any of the following :
Abuse, neglect, improper maintenance or use of non-genuine parts.
Use of fuel oil and lubricating oil not recommended for the engine.
Improper application and installation.
2. Add-on or modification affecting engine emissions.
3. Incidental or consequential damage.
9-4
CASE, LLC Part Number 6-37900NA
700 STATE STREET North American English January 03
RACINE, WI 53404 U.S.A. Printed in U.S.A. Bur

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CX14

Part Number: 6-37900NA

CASE TECHNICAL MANUALS

Copyright © 2003 Case LLC. Bur 6-37900NA

Safety Precautions ................................................................................................................. Section 1

Machine Familiarization ......................................................................................................... Section 2

Basic Machine Operation ....................................................................................................... Section 3

Maintenance ........................................................................................................................... Section 4

Transportation ......................................................................................................................... Section 5

Specifications ......................................................................................................................... Section 6

Troubleshooting ...................................................................................................................... Section 7

Optional Equipment................................................................................................................ Section 8

Specifications (EPA Engine) .................................................................................................. Section 9

1.1 GENERAL SAFETY INFORMATION .................................................................................................... 1-2

1. Read and understand all Warning plates and de-

Do not operate this machine unless you have read

6. Relieve all pressure in air, oil or water systems

7. Lower the bucket, blade, or other attachments to

A. OBSERVE SAFETY PRECAUTIONS

B. WEAR PROTECTIVE CLOTHING

Do not wear the working clothes with adhered

C. READ and UNDERSTAND THE OPERATION &

D. KEEP OPERATION & MAINTENANCE MANUAL

MAINTENANCE MANUAL become lost or READ MANUAL / KEEP IN STORAGE

Prepare beforehand the communication means

KEEP FIRE AWAY FROM FUEL AND OIL

K. SURELY INSTALL SAFEGUARD

L. MOUNTING & DISMOUNTING MACHINE

MOUNTING & DISMOUNTING MACHINE

P. CONFIRM OPERATING LEVER PATTERNS

R. HOW TO HANDLE LIFE HAMMER-CAB only

S. PERFORM PRE-START INSPECTION

T. TAG OUT MACHINE DURING MAINTENANCE

LC20T01001P1. Make sure to inform the

V. AVOID HOT SURFACES & AREAS

C. HORN BEFORE STARTING ENGINE

Do not start the engine if the machine has been

D. CHECK AFTER STARTING ENGINE

F. CONFIRM OPERATING CONTROL PATTERN

G. CONFIRM TRAVEL DIRECTION CONDITION WHERE THE TRAVEL

H. DO NOT HIT THE CAB WITH ATTACHMENT

K. FROZEN & SNOW COVERED WORK SITES

P. WORKING AROUND ELECTRIC POWER LINE

R. PARKING THE MACHINE

work area warnings and markers. PARKING SAFETY

S. RESTRICTED WORK AREAS

T. DO NOT WORK UNDER PRECIPICES

V. SET LIMITS TO WORKING AREA

W. CAUTION FOR WORK IN URBAN AREAS

X. PROHIBITION TO USE NON-SERVICED

Z. STRENGTHEN SOFT GROUND

AA. LOOSENED GROUND AFTER RAIN

BB.LOOSENED GROUND AFTER EARTHQUAKE

PAY ATTENTION TO LOOSENED GROUND

DD. STABILIZE ATTACHMENTS

B. MEETING PRIOR TO WORK

C. ORGANIZE AND CLEAN UP WORKING AREA

E. TOOLS & EQUIPMENT

F. SET THE ATTACHMENT HYDRAULIC OIL LEVEL CHECK POSITION

G. CLEAN THE MACHINE

J. SUPPORT THE MACHINE

O. USE APPROVED WORK LIGHTS

USE APPROVED WORK LIGHTS

CX14 Op's Manual

CX14 Op's Manual

Confirm for safety around the working area. Also