Page 1 ® Z 1 7 GEN :2 Form No. 50940306 Revision A Feb. 2015 Com pa c t Exc avat or Se ria l N um be rs 0 0 7 0 1 a nd U p © 2015 Manitou Americas, Inc. • All Rights Reserved. • Printed in USA Courtesy of Machine.Market...
Page 2 6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment. No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein.
Page 3: Introduction
1. Introduction This Operation and Maintenance Manual is designed to provide you with important information and sug- gestions necessary for using the machine with safety and efficiency. Please be sure to read through the manual before using the machine, to make yourself familiar with the procedures and instructions for op- erating, inspecting and servicing.
Page 4: Safety Information
2. Safety Information • The following Signal Words have been used in this Manual and on the Safety Signs to indicate the se- riousness of the hazards that could be encountered by failing to comply with the applicable Product Warnings, as follows: The word "DANGER"...
Page 5: Product Overview
3. Product Overview 3-1. Intended uses The excavator is intended to perform the following tasks: • Digging • Leveling of ground The machine should not be used for unintended tasks • Shoveling • Ditching and Guttering • Loading For the details on how to work with the machine, refer to Section “13-14. Operations using the bucket“. 3-2.
Page 6: Conditions To Insure Compliance With Epa Emission Standards
3. Product Overview 3-3. Conditions to insure compliance with EPA emission standards Conditions de conformité avec les standards d’émission EPA An EPA approved engine has been mounted on this machine. The following are the conditions that must be met in order to insure that the emission during operation meets the EPA standards. Be sure to follow these. •...
Page 7: Operation License
4. Operation License Before you operate this machine, confirm the licensing requirements that are applicable to the operation of this machine. Comply with all applicable laws. Ask your dealer about licensing requirements. Courtesy of Machine.Market...
Page 8: Ordering Replacement Parts And Service Calls
5. Ordering Replacement Parts and Service Calls 5-1. Location of machine serial number plate The machine serial number plate is located on the turning frame as illustrated at the right. Never remove the plate for any reason. 020190-00X 5-2. Location of engine serial number plate The engine serial number plate is located on the top of the cylinder head cover.
Page 9: Ordering Replacement Parts And Service Calls
5. Ordering Replacement Parts and Service Calls 5-4. Ordering replacement parts and service calls When ordering replacement parts or calling for service, let your dealer know the model designation, the machine se- rial number, and the engine serial number as well as the reading of the hourmeter.
Page 10: Table Of Contents
6. Contents 1. Introduction ............................0-1 2. Safety Information ..........................0-2 3. Product Overview ..........................0-3 3-1. Intended uses ..........................0-3 3-2. Break in period.........................0-3 3-3. Conditions to insure compliance with EPA emission standards ..........0-4 4. Operation License ..........................0-5 5. Ordering Replacement Parts and Service Calls................0-6 5-1.
Page 11 6. Contents 13. Operating Instructions ........................2-18 13-1. Checking before starting the engine ..................2-18 13-2. Starting up the engine......................2-28 13-3. Operating and checking instructions after starting the engine ..........2-31 13-4. Traveling ..........................2-33 13-5. Steering..........................2-37 13-6. Stopping the machine ......................2-39 13-7. Swinging the upper structure ....................2-40 13-8.
Page 12 6. Contents MAINTENANCE 18. Precautions for Servicing .......................3-2 19. Basic Servicing Practices .......................3-5 19-1. Oils, fuel, and cooling water....................3-6 19-2. Electrical equipment.......................3-9 19-3. Hydraulic system........................3-10 20. Consumables ..........................3-11 21. Fueling, Oiling and Greasing Based on Temperature Range ............3-12 21-1. Fuel and oil ..........................3-12 21-2.
Page 13: Safety
SAFETY Never attempt to operate or service this Excavator until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual. The failure to comply with all relevant Safety Instructions could result in bodi- ly injury.
Page 14: Basic Precautions
These instructions should be strictly followed 7. Basic Precautions WARNING for the safety of you, others and your machine. Follow safety rules at your workplace • The operation and servicing of this machine is restricted to qualified persons. • When operating or servicing the machine, follow all the safety rules, precautions and procedures. •...
Page 15 7. Basic Precautions WARNING Neglecting these instructions may cause extreme hazards. Avoid unauthorized modifications • Unauthorized modifications may cause safety hazards. • When you wish to modify your machine, contact your dealer. The implementation of unauthorized modifications or the use of unauthorized attachments could result in bodily injury. Since those ac- tions would also violate the terms of the Warranty, it would be voided.
Page 16 7. Basic Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Keep fuel and oil away from sources of ignition • Open flames can ignite fuel, oil, hydraulic oil or antifreeze solutions, which are flammable and dangerous. Special attention must be paid to the following matters.
Page 17 7. Basic Precautions WARNING Neglecting these instructions may cause extreme hazards. Prevent crush injuries by the implements • Keep hands, arms and all other parts of your body away from all the moving parts, particularly between the implements and the machine and between the hydraulic cylinder and the implements, as pinch points are created in those areas.
Page 18: Operating Precautions
These instructions should be strictly followed 8. Operating Precautions WARNING for the safety of you, others and your machine. 8-1. Precautions before starting the engine Ensure the safety of your workplace • Before starting the machine, check to see if there are any haz- ards in your working area.
Page 19 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Provide adequate ventilation when working in an enclosed area Engine exhaust fumes are harmful to the human body and their in- halation is extremely hazardous. When starting the engine in an en- closed area, open the windows and doors for ventilation.
Page 20: Precautions For Starting The Engine, Working And Parking
8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. 8-2. Precautions for starting the engine, working and parking Signal before starting the engine • Check the machine carefully before initial start up for the day. •...
Page 21 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Precautions for traveling • When traveling with the machine, keep the bucket 16 to 20 in. (40 to 50 cm) above the ground with boom and arm folded as illustrated below. •...
Page 22 8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Avoid hazardous work • Undermining a cliff is dangerous as it may cause a rockslide or landslide. • Undercutting the machine is dangerous as it may cause a cave-in, resulting in the machine over- turning and falling into the excavation.
Page 23 8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. Prevent bumping the implements • When traveling through tunnels or under bridges, or working at a site near other overhead obsta- cles, operate the machine carefully so as not to bump the boom, arm or the implement against those overhead obstacles.
Page 24 8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. Working on a slope • Be aware that the machine may tip over when swinging the upper structure or swinging the implement on a slope. •...
Page 25: Precautions For Transportation
8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. 8-3. Precautions for transportation Precautions for loading and unloading the machine • Be careful in loading and unloading the machine, because it is a job of high hazard potential. •...
Page 26: Precautions For The Battery
8. Operating Precautions WARNING These instructions should be strictly followed for the safety of you, others and your machine. 8-4. Precautions for the battery Be careful in handling the battery • The battery electrolyte contains dilute sulfuric acid, which can severely burn the eyes or skin. Al- ways wear safety goggles and protective clothing when servicing the battery.
Page 27: Precautions For Towing
8. Operating Precautions WARNING Neglecting these instructions may cause extreme hazards. 8-5. Precautions for towing Hook the wire rope on the frame when towing • Improper towing procedures can cause death or serious injury. • When towing a machine with another machine, use a wire rope strong enough to sustain the ma- chine weight.
Page 28 MEMO 1-16 Courtesy of Machine.Market...
Page 29: Precautions For Servicing
Neglecting these instructions 9. Precautions for Servicing WARNING may cause extreme hazards. 9-1. Precautions before servicing Attach the "SERVICING IN PROGRESS" tag to an implement control lever • If another person should start the engine or operate the control levers while service is in progress, the service personnel can sustain serious bodily injury.
Page 30 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Periodically replace the parts essential to safety • Aging or damage to the parts listed below can cause a fire. Make sure that they are replaced periodically. • Fuel system : Fuel hose and fuel tube cap •...
Page 31: Precautions During Servicing
9. Precautions for Servicing WARNING These instructions should be strictly followed for the safety of you, others and your machine. 9-2. Precautions during servicing Keep unauthorized persons away • Never admit any persons into the work area who are not taking part in the work. Be conscious of the safety of other persons.
Page 32 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Precautions for fueling and oiling • Spilled fuel and oil could cause a fire and they are dangerously slippery. Wipe up spills immediately. • Close the fuel cap and oil cap securely. •...
Page 33 9. Precautions for Servicing WARNING These instructions should be strictly followed for the safety of you, others and your machine. Handling high-pressure hoses • Leaks of fuel and oil could cause a fire. • Do not bend a high-pressure hose forcibly, or strike it with a hard object. Because abnormally bent or damaged piping, tubes, and hoses easily burst under high pressure, never use them.
Page 34 9. Precautions for Servicing WARNING Neglecting these instructions may cause extreme hazards. Hazards from high-pressure grease when adjusting the track crawler tension High-pressure grease is enclosed in the track crawler ad- juster. Failure to use the specified procedures for adjusting the track crawler tension could cause grease plugs or nipples to eject, which could result in bodily injury.
Page 35: Safety Messages (Warning Labels)
10. Safety Messages (Warning Labels) There are a number of Warning Labels on the machine. Full descriptions of all Warning Labels and their locations are reviewed in this section. Periodically confirm whether all Warning Labels are still mounted in their correct locations and can be easily read. If a warning label is missing, damaged or cannot be read, it must be promptly replaced.
Page 36 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. WARNING FALL HAZARD! Follow proper procedures when getting on and off machine. Always face machine. Always use steps and handrails. Always maintain three-point contact with steps and handrails. Never use control and lock levers as handrails.
Page 37: Contents
10. Safety Messages (Warning Labels) WARNING These instructions should be strictly followed for the safety of you, others and your machine. WARNING WARNING BURN HAZARD! SERVER HAZARD! CONTENTS UNDER PRESSURE! MOVING FAN BLADE AND BELTS! ALWAYS stop engine and allow NEVER open engine access panel radiator to cool before removing while engine is running.
Page 38 10. Safety Messages (Warning Labels) WARNING Neglecting these instructions may cause extreme hazards. (12) (13) WARNING WARNING Lock OPERATION HAZARD! LOCK LEVERS BEFORE LEAVING SEAT! Read and understand Never leave operator’s seat unless Operation Manual before all lock levers are in locked operating, maintaining or position, and starter switch key servicing machine.
Page 39 10. Safety Messages (Warning Labels) WARNING These instructions should be strictly followed for the safety of you, others and your machine. (17) (18) WARNING WARNING ROLLOVER HAZARD! NEVER drive on slopes greater than 20 degrees. PROPER OPERATING PROCEDURE: NEVER turn on or drive across slopes. ALWAYS drive with bucket 8 to 12 inches ALWAYS wear seat belt.
Page 40 MEMO 1-28 Courtesy of Machine.Market...
Page 41: Operation
OPERATION Courtesy of Machine.Market...
Page 42: Identification Of Important Parts
11. Identification of Important Parts 11-1. Overview of the machine Arm cylinder Boom Bucket cylinder Accelerator lever Bucket link Bucket pin Lock lever Bucket Boom cylinder Rear Right Blade Left Front Canopy Boom light (Work lamp) Boom bracket Rubber crawler Boom swing cylinder Sprocket Track roller...
Page 43: Controls And Switches
11. Identification of Important Parts 11-2. Controls and switches P.T.O. pedal Travel lever Boom swing pedal Horn switch Pedal guard Pedal guard (foot rest) (foot rest) Control lever (L) Control lever (R) Lock lever Blade lever Lock lever High-speed pedal Monitor Track gauge change control lever...
Page 44: Description Of Control Devices
12. Description of Control Devices This section describes several of the control devices necessary to operate the machine. In order to en- sure safety and comfort in working with the machine, it is imperative for you to fully understand how to operate and interact with these devices.
Page 45 12. Description of Control Devices (1) Fuel gauge The fuel gauge works while the starter switch key is in the “ON” position and indicates the fuel amount in the fuel tank. When the gauge pointer indicates close to E (empty), refill fuel oil soon.
Page 46 12. Description of Control Devices (6) Preheat pilot lamp When the starter switch is turned to the "HEAT" position, the preheat pilot lamp goes on and then goes off in 15 sec- onds, which indicate it is okay to finish the preheat opera- tion.
Page 47: Switches
12. Description of Control Devices 12-2. Switches 020205-00E (1) Starter switch Use this switch to start and stop the engine. • OFF position START Turn the starter switch key to "OFF" to stop the engine and disconnect electrical circuit or remove the starter HEAT switch key.
Page 48 12. Description of Control Devices (2) Light switch The boom light goes on when the switch is turned on with the starter switch set to the “ON” position. • ON : The lamp goes on. • OFF : The lamp goes off. IMPORTANT 000328-00X Do not keep the lamp on for a long time while the en-...
Page 49: Control Levers And Pedals
12. Description of Control Devices 12-3. Control levers and pedals (10) (11) (11) (12) 020209-00X (1) Lock levers The lock levers lock the implement operation and the swing operation. When the left lock lever is pulled back, the control lever stand on the left side comes up. However, when the right lock lever is pulled back, the control lever stand on the right side does not come up.
Page 50 12. Description of Control Devices Unlock When pushing the lock levers forward, be careful not to accidentally touch the implement control le- vers. Lock lever (Left side) 020320-00E The relationship between the control lever shift configuration and the implement movement is de- tailed in this manual.
Page 51 12. Description of Control Devices (5) Travel levers and pedals Normal position The travel levers and pedals control the traveling of the machine. • If the blade is in the reverse direction, the travel Blade Sprocket levers and pedals should also be operated in re- 020210-00E verse for forward and backward travel.
Page 52 12. Description of Control Devices (8) Track gauge change control lever Use this lever to widen or narrow the track gauge for prop- er work posture. (A) : To widen the track gauge, push the lever forward. (B) : To narrow the track gauge, pull the lever back. 020215-00X •...
Page 53 12. Description of Control Devices (11) Pedal guard (foot rest) The boom swing pedal and the P.T.O. pedal have respec- Pedal guard Unlock tive pedal guards. Lock To avoid bodily injury, securely place the respec- tive pedal guard in the lock position whenever the 000347-00X boom swing pedal or the P.T.O.
Page 54: Engine Hood
12. Description of Control Devices 12-4. Engine hood Do not open the engine hood while the engine is running. Check and service the engine after it has been stopped and temperatures have cooled. (1) Opening the engine hood 1) Insert the starter switch key and turn it counterclockwise to unlock the engine hood.
Page 55: Operator's Seat
12. Description of Control Devices 12-6. Operator’s seat • Be sure to adjust the seat slide to obtain the best operating position whenever you (or a new oper- ator) starts operation. • Do not place any foreign objects within the mov- ing area of the operator’s seat.
Page 56: Fuse
12. Description of Control Devices 12-7. Fuse • When replacing a fuse, be sure to turn off the power by turning the starter switch key to the OFF position. • Using the wrong fuse or shorting out a fuse hold- er could damage the gauges, the electrical equip- ment and the wiring due to overheating.
Page 57 12. Description of Control Devices Replacing the fuses If any electrical equipment does not operate when the starter switch is set to "ON" or "START", the fuse may have been blown out. Follow the procedure below: 1) Turn the starter switch key to the “OFF” position. 2) Remove the fuse box cover to take the fuses out.
Page 58: Operating Instructions
13. Operating Instructions 13-1. Checking before starting the engine 13-1-1. Walking check (visual inspection) around the machine • If there are any combustibles in any heat build- up areas, or if there are any fuel and/or oil leaks, a fire can result. •...
Page 59 13. Operating Instructions (2) Removing dust deposits from around the engine, battery, and radiator Check to confirm that there are no dust deposits or other combustibles around the engine, on the radia- tor, or in other heat build-up areas, such as the muffler. If there are any, remove them. (3) Checking the engine and its accessories for oil or water leakage Check the engine for oil leakage and the cooling water system for water leakage.
Page 60 13. Operating Instructions 13-1-2. Checking before start-up Check the following points before initial start-up for the day. Checking and replenishing the cooling water • Normally do not open the radiator cap. • Check the cooling water level in the sub-tank when the engine is cool.
Page 61 13. Operating Instructions Checking and replenishing the engine oil • At operating temperature, oil and dipstick areas are hot. Do not allow hot oil or hot components to contact the skin, to prevent bodily injury. • Check oil level and replenish oil after engine has cooled down.
Page 62 13. Operating Instructions Checking and replenishing the fuel in the fuel tank Be careful not to overfill the fuel tank because it could cause a fire. If the tank is overfilled, com- pletely wipe off the spilled fuel. 000319-00X • Do not remove the strainer from the fuel supply port of the fuel tank when supplying fuel.
Page 63 13. Operating Instructions Checking and replenishing the hydraulic oil in the hydraulic oil tank When removing the plug of the oil supply port, slowly loosen it to gradually relieve the internal pressure in the tank, or oil may spurt from the tank. 1) Park the machine as illustrated in the figure at the right.
Page 64 13. Operating Instructions Checking and adjusting the fan belt tension Open 1) Open the cover (1) under the operator's seat. 2) Press down on the fan belt between the generator pul- ley and the crank pulley with a finger, to check the fan belt tension.
Page 65 13. Operating Instructions Greasing Implement IMPORTANT Grease the fittings thoroughly after washing the ma- chine or after operation in rain, on soft ground, or in muddy water. 1) Put the bucket and the blade on the ground and stop the engine.
Page 66 13. Operating Instructions Checking the electrical equipment If a fuse blows out frequently, contact your dealer for assistance. Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action. Check the following items after the starter switch is turned to the "ON"...
Page 67 13. Operating Instructions 13-1-3. Operating and checking instructions before starting up the engine • Accidentally operating a control lever can cause the machine to move suddenly, possibly causing a serious accident. 020339-00X • When leaving the operator's seat, be sure to place the lock levers securely in the lock posi- Lock Lock lever...
Page 68: Starting Up The Engine
13. Operating Instructions 13-2. Starting up the engine 13-2-1. Normal start-up • First check that there are no people or obstacles around the machine. Then sound the horn and start the engine. • Be sure that you are seated on the operator's 020324-00X seat when starting the engine.
Page 69 13. Operating Instructions 13-2-2. Starting the engine in cold weather • First check that there are no people or obstacles around the machine. Then sound the horn and start the engine. • Be sure that you are seated on the operator's seat when starting the engine.
Page 70 13. Operating Instructions 5) When the engine speed has increased, push the accel- Idling erator lever forward to the "IDLING" position immediate- 020326-00E IMPORTANT To protect the starter motor and the battery: 15 seconds 10 seconds 30 seconds 15 seconds •...
Page 71: Operating And Checking Instructions After Starting The Engine
13. Operating Instructions 13-3. Operating and checking instructions after starting the engine • Emergency stop. If abnormal operation occurs, turn the starter switch key to the "OFF" position, to shut off the electrical system and the engine. Then ask your dealer to check the machine.
Page 72 13. Operating Instructions 3) Unlock the lock levers, and lift the bucket from the Unlock ground. 4) Operate the bucket and arm control levers slowly to move the bucket and arm cylinders to their stroke ends. Operate the bucket for thirty seconds and the arm for Lock lever thirty seconds alternately for approximately five minutes (Left side)
Page 73: Traveling
13. Operating Instructions 13-4. Traveling 13-4-1. Traveling forward • Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
Page 74 13. Operating Instructions 3) Pull back the blade lever (3) to raise the blade. 020331-00X 4) Operate the left and right travel levers (4) or pedals (5) as follows: (Right) • When the blade is in the front of the machine; Slowly push the travel levers (4) forward or step on the (Left) front of the pedals (5) to move the machine forward.
Page 75 13. Operating Instructions 13-4-2. Traveling in reverse • Always check the position of the blade before operating the travel levers and pedals. When the blade is in the rear, the travel levers and pedals operate in the reverse of the normal operation.
Page 76 13. Operating Instructions 3) Pull back the blade lever (3) to raise the blade. 020331-00X 4) Operate the left and right travel levers (4) or pedals (5) as follows: (Right) • When the blade is in the front of the machine; Slowly pull the travel levers (4) back or unfold the exten- (Left) sion plate to step on it in order to move the machine...
Page 77: Steering
13. Operating Instructions 13-5. Steering 13-5-1. Steering (turning the machine) Always check the position of the blade before op- erating the travel levers. When the blade is in the rear, the travel levers op- erate in the reverse of the normal operation. Do not use the travel pedals to steer the machine, or the machine may not be controlled expectedly, causing a serious accident.
Page 78 13. Operating Instructions Steering the machine while traveling (the left and right travel levers are both tilted in the same direc- tion) To turn left, return the left travel lever to the neutral posi- tion. Note : To turn right, return the right travel lever to the neutral po- sition.
Page 79: Stopping The Machine
13. Operating Instructions 13-6. Stopping the machine Do not stop the machine suddenly but provide a safety margin. • Park on solid, level ground. • Do not park on a slope. If it is unavoidable to park on a slope, place solid blocks of wood behind the crawlers, place the blade on the ground, and dig the Put the bucket into the ground.
Page 80: Swinging The Upper Structure
13. Operating Instructions 13-7. Swinging the upper structure Before swinging, make sure that there are no peo- ple or obstacles within the swing range of the im- plement or the machine tail. 1) To swing the upper structure, operate the left control le- ver as illustrated in the figure at the right.
Page 81: Operating The Implement
13. Operating Instructions 13-8. Operating the implement Operating the arm <STD Pattern> • Check the area around the machine for safety and sound the horn before beginning to operate the machine. Control lever (L) • The setting of the pattern change lever alters Operating the arm <OPT Pattern>...
Page 82: Operating The Track Gauge Change
13. Operating Instructions 13-9. Operating the track gauge change • Be sure to operate the track gauge change control lever at middle engine speed to avoid hazard. • When operating the track gauge change, the crawl- ers move widthwise. Be sure to operate it from the operator’s seat only to prevent your body from being caught between the crawler and the upper structure or between the crawler and nearby obstacles.
Page 83 13. Operating Instructions 13-9-2. Changing the blade width The blade width can be adjusted to 37.4 in. or 50.4 in. (950mm or 1280mm) by changing the positions of the pins. 1) Raise the blade to its stroke end. 020348-00X 2) Change the positions of the pins as illustrated in the fig- When the blade is widened ure at the right and hold the extension blades to change the blade width.
Page 84: Precautions For Operating The Implement
13. Operating Instructions 13-10. Precautions for operating the implement • Do not operate the control levers while traveling. Stop traveling first and then operate the imple- ment. • Do not operate the implement on any rocky sur- face. Do not use the implement's swing force Do not level the ground or break down a wall by the use of swing force, and do not dig the bucket teeth into the ground while swinging.
Page 85 13. Operating Instructions Do not operate the implement by using the drop- ping force of the machine Do not excavate the ground by using the dropping force of the machine. 020351-00X Excavating a hard rock It is recommended that a hard rock first be broken into small pieces by other means.
Page 86 13. Operating Instructions Do not bump the blade against a large rock or boul- Never bump the blade against a large rock or boulder. Do- ing so may cause the blade or the hydraulic cylinder to be damaged. 000426-00X Be careful when retracting the implement When retracting the implement for travel or transport, be careful that the bucket and the blade never bump against each other.
Page 87: Precautions For Working
13. Operating Instructions 13-11. Precautions for working Precautions for traveling Driving over a stone or a stump subjects the machine (es- pecially undercarriage) to a shock, which may cause dam- age to the machine. Avoid such obstacles by driving around them, or removing Less than them.
Page 88: Precautions For Going Up And Down A Slope
13. Operating Instructions 13-12. Precautions for going up and down a slope • When traveling on a slope, place the implement in the direction of travel and raise the bucket 8 to 12 in. (20 to 30 cm) above the ground. •...
Page 89 13. Operating Instructions Braking when going down a slope When going down a slope, you can automatically brake the machine by setting the travel levers to the neutral position. When the crawler is slipping If you cannot go up a slope by operating the travel levers because the crawler is slipping, retract the arm and use the pull-back power of the implement to help you go up the slope.
Page 90: Escaping From The Mud
13. Operating Instructions 13-13. Escaping from the mud Carefully operate the machine not to allow it to get mired in mud. If the machine is mired in mud, the machine can escape as follows: 13-13-1. If only one track is mired in the mud If only one track is mired in the mud, place the bucket on the muddy side, lift the track above the ground, lay a log or a wood block under the track shoe, and raise the bucket to...
Page 91: Operations Using The Bucket
13. Operating Instructions 13-14. Operations using the bucket You can greatly widen the range of work described here by using optional attachments. 13-14-1. Backhoe operation Backhoe operation is suitable for digging the ground below the machine. Suppose that the machine is operating as illustrated in the 90 degrees figure at the right : a maximum digging force of each cylin- der can be obtained when the angle between the bucket...
Page 92: Reversing The Bucket
13. Operating Instructions 13-15. Reversing the bucket • When driving pins into the bucket with a ham- mer, metal chips may fly. If metal chips should get into your eyes, they can cause serious injury. Use goggles, a hard hat and gloves for safety when reversing the bucket.
Page 93 13. Operating Instructions IMPORTANT When using a reversed bucket, the bucket and the boom cylinder can contact each other when the arm is curled or the boom is lowered beyond the positions in- dicated in the figure at the right. Never curl the bucket too much, and never allow it to contact the boom cylinder.
Page 94: Parking The Machine
13. Operating Instructions 13-16. Parking the machine Do not stop the machine suddenly but provide a safety margin. • Park on solid, level ground. • Do not park on a slope. If it is unavoidable to park on a Place the blade on slope, place solid blocks of wood behind the crawlers, the ground...
Page 95: Inspection Requirements After Completing Operation
13. Operating Instructions 3) Place the bucket on the ground with its bottom surface in contact with the ground. 4) Place the blade on the ground. 020372-00X 5) Set the lock lever to the "LOCK" position. Lock Lock lever (Left side) 020323-00E 13-17.
Page 96: Stopping The Engine
13. Operating Instructions 13-18. Stopping the engine IMPORTANT • Stopping the engine after rotation at high speed may shorten the engine life. Do not stop the engine sud- denly except in case of emergency. • If the engine is overheated, do not stop the engine immediately.
Page 97: Inspection Requirements After Stopping The Engine
13. Operating Instructions 13-19. Inspection requirements after stopping the engine 1) Check oil and water for leaks, and visually inspect the implement, the machine, and the undercarriage by walking around them. If there are any leaks of oil or water, or any observed ab- normality, take corrective action.
Page 98: Handling The Rubber Crawlers
13. Operating Instructions 13-21. Handling the rubber crawlers 13-21-1. Using the rubber crawlers properly Rubber crawlers have some advantages over steel crawl- ers. However, you cannot take full advantage of them if you use them in the same manner as steel ones. Use care in oper- ating with rubber crawlers in accord with the conditions of the work site and the type of work.
Page 99 13. Operating Instructions 13-21-3. Precautions for using the rubber crawlers Prohibitions Observe the following prohibitions: • Do not operate or turn on surfaces or terrains that have sharp stones, a hard, uneven rock base, or that expose the crawlers to steel rods, scrap iron, or edges of iron plates.
Page 100 13. Operating Instructions 13-21-4. Other precautions for using the rubber crawlers Observe the following precautions when operating the machine: • Never spin-turn on concrete or asphalt roads. • Do not change course suddenly. Doing this will cause the rubber track to wear early or be damaged. •...
Page 101 13. Operating Instructions • Keep the crawlers in appropriate tension to prevent them from coming off. If the tension is too low, the rubber crawlers may come off under the following conditions. (Even if the tension is adequate, take care when operating the crawlers under these conditions.) •...
Page 102 13. Operating Instructions 2) If the machine is traveling in reverse, clearance may also be created between the track rollers and the rubber Idler crawlers, and between the idlers and the rubber crawl- ers, causing the rubber crawlers to come off. 000463-00E 3) Other situations to be avoided.
Page 103: Handling Hydraulic P.t.o
13. Operating Instructions 13-22. Handling hydraulic P.T.O. 13-22-1. Description of stop valve, P.T.O. selector valve, P.T.O. pedal and pedal lock 020376-00X (1) Stop valve This valve can stop the flow of the hydraulic oil. (A) Open : The hydraulic oil flows (B) Close: The hydraulic oil stops.
Page 104 13. Operating Instructions (3) P.T.O. pedal Use this pedal to operate the attachment. • Move the P.T.O. pedal to L side for operating the single acting actuator type of attachments, when the P.T.O. se- lector valve is in the single acting position. P.T.O.
Page 105 13. Operating Instructions 13-22-2. Hydraulic circuit 1) When mounting any attachment, follow the procedure below to connect the circuit. (1) Make sure the stop valves are in the closed position and remove the screw plugs. Take care not to lose or damage the removed parts.
Page 106 13. Operating Instructions 13-22-3. Operating attachment When changing the hydraulic piping connection, stop the engine and slowly loosen the connection to release the inner pressure. If you use the oil pressure for other hydraulic devices as the power source, connect the piping by using the follow- ing procedure after the engine has stopped.
Page 107 13. Operating Instructions Precautions Double acting P.T.O. • Make sure the P.T.O. selector valve is in the double act- ing position. Refer to Section "13-22-1. Description of stop valve, P.T.O. selector valve, P.T.O. pedal and pedal lock". • Make proper use of the general attachments following 020361-00E the handling instructions in the operation manual provid- ed by the manufacturer of the general attachments.
Page 108: Transportation
14. Transportation 14-1. Loading and unloading the machine For safety in transporting the machine, comply with all ap- plicable regulations and laws. • Be careful when loading and unloading the ma- chine, because it is a job of high hazard poten- tial.
Page 109 14. Transportation 1) Firmly brake the truck and apply wheel stoppers to the tires. Securely install the ramp plates on the bed of the Hook truck in a position where the center of the truck aligns Ramp plate with the center of the machine. Make sure that the left and right ramp plates are at the same level.
Page 110: Precautions For Loading The Machine
14. Transportation 14-2. Precautions for loading the machine Load or unload the machine on level, solid ground far away from the shoulder of the road. After loading the machine in a safe position on the truck, secure the machine as follows: 1) Place the blade down on the bed of the truck.
Page 111: Precautions For Transporting The Machine
14. Transportation 14-3. Precautions for transporting the machine Select a route for transporting the machine based on the road width and clearance, and the height and weight of the machine. For safer transportation, comply with all local regulations and laws. 2-71 Courtesy of Machine.Market...
Page 112: Suspending The Machine
14. Transportation 14-4. Suspending the machine • Never suspend the machine if any person is on the machine or the implement. • Use wire ropes strong enough for the weight of the machine. • Do not suspend the machine in any way other than that explained on the following page.
Page 113 14. Transportation Suspend the machine on level ground as follows: Front side Rear side 1) Swing the upper structure so that the blade is behind the operator’s seat. 2) Raise the blade to the highest limit. 3) Extend the hydraulic cylinders of the front implement (except for the boom swing cylinder) to the maximum.
Page 114: Care And Service In Cold Weather
15. Care and Service in Cold Weather 15-1. Preparing for cold weather In cold weather, you may have difficulty in starting the en- gine or the cooling water may freeze. So take measures as follows: 15-1-1. Fuel and lube oil Use low viscosity fuel and lube oil.
Page 115 15. Care and Service in Cold Weather 15-1-3. Battery • The battery generates flammable gas and it can cause a fire and an explosion. Keep sparks or flames away from the battery. • Battery electrolyte contains dilute sulfuric acid which is a strong acid.
Page 116: Precautions After A Day's Work
15. Care and Service in Cold Weather 15-2. Precautions after a day's work To prevent the machine from getting stuck in the morning due to frozen mud or water deposits on the undercarriage, be sure to observe the following precautions. •...
Page 117: Long-Term Storage
16. Long-term Storage 16-1. Before storing IMPORTANT Retract the bucket and arm cylinders to place When storing the machine, set up the machine as illus- the bucket on the ground. trated in the figure at the right, to protect the hydraulic cylinder rods from becoming corroded.
Page 118: Storing
16. Long-term Storage 16-2. Storing When you have to operate the machine indoors for the antirust procedure, be sure to ventilate the area well by opening windows and doors to pre- vent asphyxiation. Move the machine at least once a month to form new oil films on all the moving parts during long-term storage, and recharge the battery at the same time.
Page 119: Troubleshooting
17. Troubleshooting 17-1. Phenomena that do not constitute faults The following phenomena do not constitute faults: • Shaking of the bucket When the boom is raised immediately after extending the arm while curling the bucket, the bucket may shake. This phenomenon is not a fault.
Page 120: Towing
17. Troubleshooting 17-2. Towing Always safely tow a disabled machine by using the proper equipment and procedures. The use of incorrect methods or improper proce- dures could result in bodily injury. Follow the recommendations below to properly perform the towing procedure. If the machine becomes mired in muddy ground and must be towed out, or when it is necessary for the machine to tow a heavy object, attach the sling belt as illustrated at the...
Page 121: If The Battery Is Overdischarged
17. Troubleshooting 17-3. If the battery is overdischarged • Stop the engine and turn the starter switch key to the "OFF" position before checking or servicing the battery. • Flammable hydrogen gas is produced by the bat- To disconnect, begin with the negative terminal tery, which may cause ignition.
Page 122: Troubleshooting
17. Troubleshooting 17-3-1. Starting the engine using booster cables To start the engine using booster cables, do the following. Precautions for connecting and disconnecting the booster cables • When you start the engine using booster cables, wear safety goggles. Reverse •...
Page 123 17. Troubleshooting Charging with the battery mounted on the machine • Remove the battery cables from the positive and nega- tive terminals of the battery before charging it. If this is not done, abnormal voltage may be applied to the gener- ator which could damage it.
Page 124 17. Troubleshooting Connecting the booster cables Battery on Turn the starter switch to the "OFF" position, and connect normal machine the booster cables as follows: (1) Turn the starter switches on both the normal machine Battery on and the machine in trouble to the "OFF" position. machine in trouble Upperstructure of machine in trouble...
Page 125 17. Troubleshooting Disconnecting the booster cables Battery on After the engine on the machine in trouble has started, dis- normal machine connect the booster cables in the reverse order of the con- necting procedure. Battery on (1) Remove the clip of the booster cable (B) from the en- machine in trouble gine block on the machine in trouble.
Page 126 17. Troubleshooting 17-4. Troubleshooting 17-4-1. Engine and electrical equipment • Contact your dealer for assistance, regarding the mea- sures indicated in parentheses in the list below. • If any abnormalities or troubles are encountered that are not included among those shown below, ask your dealer for assistance.
Page 127 17. Troubleshooting 17-4-2. Machine body • Contact your dealer for assistance, regarding the mea- sures indicated in parentheses in the list below. • If any abnormalities or troubles are encountered that are not included among those shown below, ask your dealer for assistance.
Page 128 MEMO 2-88 Courtesy of Machine.Market...
Page 129: Maintenance
MAINTENANCE Courtesy of Machine.Market...
Page 130: Precautions For Servicing
18. Precautions for Servicing Do not use any inspection or servicing procedures that are not described and recommended in this manual. Park the machine on solid, level ground to inspect and service it. Check the hourmeter Read the hourmeter every day to check if any service item has reached the time prescribed for imple- mentation.
Page 131 18. Precautions for Servicing Attach the warning tag When the oil or the cooling water is being drained, attach the "SERVICING IN PROGRESS" tag to a con- trol lever so that other persons will not start the engine. Observe the warning labels Observe the warning labels affixed to the machine.
Page 132 18. Precautions for Servicing Check before and after working If the machine is to be used in mud, rain, snow, or on a beach, check for loose plugs and cocks before working. After working, clean the machine and check each part for cracks and damage and check for loose or missing bolts and nuts.
Page 133: Basic Servicing Practices
19. Basic Servicing Practices • Use genuine replacement parts. • Do not mix oils of different makes and types when replacing or replenishing oil. • The following types of oil, fuel and cooling water are used at the factory for shipping unless otherwise specified: Item Type...
Page 134: Oils, Fuel, And Cooling Water
19. Basic Servicing Practices 19-1. Oils, fuel, and cooling water 19-1-1. Oils • Because the oil is used in the engine and implement under extreme conditions (high temperature and pressure), it deteriorates as time elapses. Be sure to use oils of the grades which are specified in the Operation & Maintenance Manual and suit- able for the operating temperature range.
Page 135 19. Basic Servicing Practices 19-1-2. Fuel • Because the fuel injection pump is a precision device, using a fuel containing water or dust will cause problems. • Be careful that impurities will not be mixed into the fuel especially after storing the machine and refueling. •...
Page 136 19. Basic Servicing Practices 19-1-4. Grease • Grease ensures smooth operation of moving parts such as connectors and prevents operating noises. • The nipples not listed on the pages for periodic service are those used for overhaul purposes. Normally it is not necessary to refill them. Grease them if any abnormal condition arises after long term use.
Page 137: Electrical Equipment
19. Basic Servicing Practices 19-2. Electrical equipment • If electrical equipment gets wet or wiring insulation is broken, electric leaks may occur and the machine may malfunction. • Check the fan belt for tension and damage, and also check the battery for electrolyte level. •...
Page 138: Hydraulic System
19. Basic Servicing Practices 19-3. Hydraulic system • The hydraulic system is hot during and immediately after Retract the bucket and arm cylinders to place operation. It is also under high pressure during opera- the bucket on the ground. tion. Therefore, check and service the hydraulic system Upper limit carefully as follows: Lower limit...
Page 139: Consumables
20. Consumables Replace consumable parts such as filter elements and bucket teeth periodically or before they reach their wear limit. Periodic replacement prevents malfunction of the machine. When you replace a part, be sure to use an original equipment part. When ordering consumables, let us know the part numbers given in the parts catalog.
Page 140: Fueling, Oiling And Greasing Based On Temperature Range
21. Fueling, Oiling and Greasing Based on Temperature Range 21-1. Fuel and oil Select fuel and oil based on the air temperature range. The prescribed amount of oil means the total amount of oil included in the piping and equipment. The amount of oil to be changed means the amount of oil replaced in checking and servicing.
Page 141: Standard Tightening Torque For Bolts And Nuts
22. Standard Tightening Torque for Bolts and Nuts 22-1. Required tools The following tools are required for servicing: Name Q'ty Screw driver (universal system) Filter wrench 68 Filter wrench 80 Filter wrench LO Pressuring nozzle Filter wrench 92 Wrench 8 10 Wrench 12 14 Wrench 17 19 Wrench 22 24...
Page 142: Torque Table
22. Standard Tightening Torque for Bolts and Nuts 22-2. Torque table Bolts or nuts in the metric system should be tightened at the torque described below unless specified otherwise. Item Thread size pitch Tightening torque ft•lbf (N•m) Remarks Hexagon bolt (7T) Coarse 7.23 to 8.68 (9.8 to 11.8) 1) Apply 80% tightening torque...
Page 143: Replacing Essential Parts Periodically
23. Replacing Essential Parts Periodically For safe operation, the machine must be serviced periodically. To increase safety, be sure to periodically replace the parts listed in the table of safety parts on the next page. A fire could result if they deteriorate or are damaged.
Page 144 23. Replacing Essential Parts Periodically List of essential parts Essential parts to be replaced periodically Q'ty Replacement time intervals Fuel hose (fuel tank to water separator) Fuel hose (water separator to feed pump) Fuel hose (feed pump to fuel filter) Fuel hose (fuel filter to fuel injection pump) Every 2 years or every 4000 service hours, whichever first occurs.
Page 145: Maintenance Table
24. Maintenance Table Daily and periodic inspection are important to keep the machine in its best condition. The following is a summary of inspection and servicing requirements by inspection interval. Periodic inspection intervals vary depending on the use, loads, fuels and lube oils used and handling conditions, and are hard to es- tablish definitively.
Page 146 24. Maintenance Table Check and service points Page Every 50 hours Greasing the swing gear and the swing bearing 3-43 Draining the water and deposits in the fuel tank 3-43 Cleaning the water separator element 3-44 Cleaning the fuel filter element 3-45 Every 100 hours (Perform the same maintenance every 50 service hours)
Page 147 24. Maintenance Table List of periodic inspection and servicing *Applicable to models with the relevant equipment : Check : Supply : Replace : Adjust (clean) : Oil & grease Check & service items Daily Every Every Every Every Every 1000 hrs General Check falling off, breakage of parts Check loosened bolts &...
Page 148 24. Maintenance Table : Check : Supply : Replace : Adjust (clean) : Oil & grease Check & service items Daily Every Every Every Every Every 1000 2000 hrs Fuel oil Check & supply of oil to the tank Drain the fuel tank Clean the oil/water separator Replace the fuel filter element, pre-filter Lube oil...
Page 149: Service Intervals When Using The Hydraulic Breaker
24. Maintenance Table 24-2. Service intervals when using the hydraulic breaker When a hydraulic breaker is used, the hydraulic oil deteri- orates earlier than in usual bucket excavating work. Set up the service time intervals as follows: • Replacing the hydraulic oil return filter 1000 Replace the hydraulic oil return filter on the new machine once after the first 100 to 150 hours.
Page 150: Procedures For Maintenance
25. Procedures for Maintenance 25-1. First services Service a new machine at 50, 100 and 250 hours, as fol- lows. 25-1-1. At first 50 hours • Replace the engine oil and the engine oil filter. For these procedures, refer to Section "25-6. Mainte- nance every 200 service hours".
Page 151: Non-Periodic Services
25. Procedures for Maintenance 25-2. Non-periodic services 25-2-1. Checking the rubber crawlers Rubber crawlers in the following condition require repair or replacement. Ask your dealer to repair or replace them. Height of lugs • As the lug height "a" is reduced by wear, the tractive Track roller force decreases.
Page 152 25. Procedures for Maintenance Crack in the rubber crawler If a crack occurs between any lugs of the rubber crawler, repair it if the crack length reaches approximately 2.4 in. To be repaired if (60 mm). If the inside steel cord is exposed even though 2.4 in.
Page 153 25. Procedures for Maintenance 25-2-2. Checking and adjusting the rubber crawler tension • When adjusting the rubber crawler tension while raising the machine, do not support the machine with the implement only. The control levers could move or the hydraulic oil could flow out accidentally so that the ma- chine would fall.
Page 154 25. Procedures for Maintenance If the tension is improper, adjust it as follows: Adjusting the rubber crawler tension • To increase the tension Prepare a grease gun. 1) Remove the cover. Cover 2) Raise the machine using the implement and the safety blocks.
Page 155 25. Procedures for Maintenance • Loosening the tension • Grease is under high pressure. If the nipple valve (1) is opened suddenly, grease could be ejected or the valve could blow, which could cause bodi- ly injury. • Do not rely on valve appearance alone to deter- mine whether or not grease has been dis- charged, but check that by measuring the tension of the rubber crawler.
Page 156 25. Procedures for Maintenance 25-2-3. Replacing the rubber crawler • To replace the rubber crawler with a new one, work with a partner. You must operate the ma- chine in response to signs from your partner. Track roller • Because the rubber crawler is replaced with the machine in a raised position, there is a danger that the machine may accidentally fall.
Page 157 25. Procedures for Maintenance Removing the rubber crawler • It is very dangerous to discharge the grease by any procedure other than that described below. • If the tension of the rubber crawler cannot be properly adjusted, ask your dealer to repair or re- place the rubber crawler.
Page 158 25. Procedures for Maintenance Installing the rubber crawler 1) Raise the machine with the implement and the safety blocks. To do this, slowly operate the control lever. 2) Engage the rubber crawler with the sprocket, and place the rubber crawler on the idler. 020172-00X 3) Rotate the sprocket in the reverse direction to push the rubber crawler in, and then stop rotating it.
Page 159 25. Procedures for Maintenance 25-2-4. Cleaning the inside of the cooling system • The cooling water is very hot immediately after the engine has stopped. Discharging the cooling water immediately after the engine has stopped may cause burns. Start cleaning the inside of the cooling system after the engine has cooled down sufficiently.
Page 160 25. Procedures for Maintenance Table of mixing ratio of anti-freeze to water ° F Lowest temperature (° C) (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40) Qts. 0.53 0.85 1.06 1.16 1.27 1.48 1.69 1.80 Amount of anti-freeze (0.5) (0.8) (1.0) (1.1) (1.2)
Page 161 25. Procedures for Maintenance How to clean the inside of the cooling system Things to prepare • Container for cooling water Capacity : 3.70 Qts. (3.5 L) or more • Hose for supplying water 1) Swing the upper structure so that the drain plug (P) is positioned in the middle of the right and left crawlers.
Page 162 25. Procedures for Maintenance 8) After flushing with running water, stop the engine, drain the cooling system completely and then install the drain plug (P). 9) Pour water mixed with anti-freeze into the water supply port of the radiator, to fill it up. 10) To bleed air, idle the engine for 5 to 6 minutes and then run the engine without load at high speed for 5 to 6 minutes.
Page 163: Checking Before Start-Up
25. Procedures for Maintenance 25-3. Checking before start-up Check the items described here every day, before starting the engine for the first time. 25-3-1. Checking and replenishing the cooling water Normally do not open the radiator cap. Check the cooling water in the sub-tank when the engine is cool.
Page 164 25. Procedures for Maintenance 25-3-2. Checking and replenishing the engine oil • At operating temperature, the oil and dipstick ar- eas are hot. • Do not allow hot oil or hot components to contact the skin, to prevent bodily injury. Check oil level and replenish oil after engine has cooled down sufficiently.
Page 165 25. Procedures for Maintenance 25-3-3. Checking and replenishing the fuel in the fuel tank Be careful not to overfill the fuel tank because it could cause a fire. If the fuel tank is overfilled, completely wipe off the spilled fuel. •...
Page 166 25. Procedures for Maintenance 25-3-4. Checking and replenishing the hydraulic oil in the hydraulic oil tank When removing the cap of the oil supply port, slowly loosen it to gradually relieve the internal pressure in the tank, or oil may spurt from the tank. 1) Park the machine as illustrated in the figure at the right.
Page 167 25. Procedures for Maintenance 25-3-5. Checking and adjusting the fan belt tension Open • Stop the engine, take out the starter switch key, and attach the "SERVICING IN PROGRESS" tag to a control lever. • The fan belt is hot immediately after the engine is stopped.
Page 168 25. Procedures for Maintenance 5) Retighten the mounting bolt (5) to secure the generator (6). Adjust the fan belt tension by inserting a bar. 6) Check the pulleys, the V-grooves and the fan belt (7) for damage, and check that the fan belt (7) does not touch the bottom of each V-groove.
Page 169 25. Procedures for Maintenance 25-3-7. Greasing Implement IMPORTANT Grease the fittings thoroughly after washing the ma- chine or after operation in rain, on soft ground, or in muddy water. 1) Put the bucket and the blade on the ground and stop the engine.
Page 170 25. Procedures for Maintenance 25-3-8. Checking the electrical equipment If a fuse blows out frequently, contact your dealer for assistance. Check fuses for damage, wiring for poor connections or short circuits, and battery terminals for corrosion or loose fits. Take corrective action. Check the following items after the starter switch is turned to the "ON"...
Page 171: Maintenance Every 50 Service Hours
25. Procedures for Maintenance 25-4. Maintenance every 50 service hours 25-4-1. Greasing the swing gear and the swing bearing Swing bearing Do not swing the upper structure while greasing. Swing the upper structure after each stage of greas- ing is completed to avoid serious bodily injury. Swing gear 020291-00E 1) Grease the swing gear and bearing through the grease...
Page 172 25. Procedures for Maintenance 25-4-3. Cleaning the water separator element • Keep sparks, flames and lit cigarettes away. • At operating temperature, the engine compo- nents are hot and can cause a burn. • Disconnect the battery and replace the element after the engine has cooled sufficiently.
Page 173: Maintenance Every 100 Service Hours
25. Procedures for Maintenance 25-4-4. Cleaning the fuel filter element • Keep sparks, flames and lit cigarettes away. • At operating temperature, the engine compo- nents are hot and can cause a burn. • Disconnect the battery and replace the element after the engine has cooled sufficiently.
Page 174: Maintenance Every 200 Service Hours
25. Procedures for Maintenance 25-6. Maintenance every 200 service hours Also perform the maintenance every 50 and 100 service hours. 25-6-1. Replacing the engine oil and the engine oil filter • Do not replace the oil immediately after the en- gine stops to prevent bodily injury, because all the components are hot.
Page 175 25. Procedures for Maintenance 8) When mounting the new filter cartridge, turn it 2/3 of a turn after the seal surface has contacted the filter mount. 9) After replacing the oil filter cartridge, add engine oil up to the upper limit mark on the oil dipstick (G) through the oil supply port (F).
Page 176 25. Procedures for Maintenance 25-6-2. Checking and cleaning the air cleaner • Never attempt to clean and replace the air clean- er while the engine is running. Always stop the engine and allow it to cool first. • Compressed air is used to clean the element. Al- ways wear safety goggles to prevent injury to your eyes.
Page 177 25. Procedures for Maintenance 6) After cleaning, illuminate the element from inside with a light bulb and check it. If there are any small holes or thin areas, replace the element with a new one. IMPORTANT • When cleaning the element, do not tap it or strike it against other objects.
Page 178 25. Procedures for Maintenance 25-6-3. Checking and cleaning the radiator fin • Never attempt to check and clean the radiator fin while the engine is running. Always stop the engine and allow it to cool first, before checking and cleaning it. •...
Page 179: Maintenance Every 250 Service Hours
25. Procedures for Maintenance 25-6-4. Adjusting the governor lever and accelerator devices The governor lever and the accelerator devices (i.e., accel- erator lever, pedal.) are connected by an accelerator wire. If the wire becomes stretched or if the connections loose, deviation in position may result and make operation un- safe.
Page 180: Maintenance Every 400 Service Hours
25. Procedures for Maintenance 25-8. Maintenance every 400 service hours Also perform the maintenance every 50, 100, and 200 service hours. 25-8-1. Replacing the fuel filter element • Keep sparks, flames and lit cigarettes away. • At operating temperature, the engine compo- nents are hot and can cause a burn.
Page 181 25. Procedures for Maintenance How to release air: This machine is equipped with an automatic air release de- vice (a solenoid pump). Follow the air release procedure below: 1) Fill up the fuel tank. 2) Set the lock levers to the lock position and the acceler- ator lever to the "RUN"...
Page 182 25. Procedures for Maintenance 25-8-2. Replacing the air cleaner element Never attempt to replace the air cleaner element while the engine is running. Replace the air cleaner element after the engine has been stopped and has cooled sufficiently. 1) Open the engine hood. 2) Remove the clips (1) and remove the dust cup (2).
Page 183: Maintenance Every 500 Service Hours
25. Procedures for Maintenance 25-9. Maintenance every 500 service hours Also perform the maintenance every 50, 100, and 250 service hours. 25-9-1. Replacing the return filter in the hydraulic oil tank • The hydraulic oil and the tank are hot and under pressure immediately after the engine stops, and can cause bodily injury.
Page 184: Maintenance Every 1000 Service Hours
25. Procedures for Maintenance 25-10. Maintenance every 1000 service hours Also perform the maintenance every 50, 100, 250 and 500 service hours. 25-10-1. Replacing the hydraulic oil and cleaning the suction filter • The hydraulic oil and the tank are hot and under pressure at operating temperature.
Page 185 25. Procedures for Maintenance 9) Clean the area around the oil supply port (F) on the top of the hydraulic oil tank with a cloth. Slowly loosen and remove the oil supply port cap (F). 10) After draining the waste oil, install and tighten the drain plug (P).
Page 186 25. Procedures for Maintenance 25-10-2. Checking and adjusting the intake/exhaust valve clearances Ask your dealer about checking and adjusting. 25-10-3. Checking and adjusting the fuel injection valve Ask your dealer about checking and adjusting. 25-10-4. Retightening the cylinder head bolts Ask your dealer about retightening.
Page 187: Maintenance Every 2000 Service Hours
25. Procedures for Maintenance 25-11. Maintenance every 2000 service hours Also perform the maintenance every 50, 100, 250, 500 and 1000 service hours. 25-11-1. Checking and replacing fuel piping, cooling water piping Ask your dealer. 25-11-2. Lapping the intake/exhaust valves Ask your dealer.
Page 188 MEMO 3-60 Courtesy of Machine.Market...
Page 189: Specifications And Dimensional Diagrams
SPECIFICATIONS AND DIMENSIONAL DIAGRAMS Courtesy of Machine.Market...
Page 190 26. Specifications and Dimensional Diagrams Specifications Type Rubber crawler Items Canopy • Weight (in compliance with SAE standards) Operating mass lbs. (kg) 3836 (1740) Machine mass (without implement) lbs. (kg) 2900 (1315) • Working range and performance Bucket capacity, standard cu.ft (cu.m) 1.77 (0.050) Bucket width, standard...
Page 191 26. Specifications and Dimensional Diagrams Model view and working range Unit : in. (mm) 60.4(1535) (54.3(1380):at Boom Swing) 9.06 (230) 46.3 (1176) 60.0 (1525) 41.3 (1050) 28.3 / (720) 135.8 (3450) 146.1 (3710) 50.4 (1280) / 37.4 (950) 150.0 (3810) 020310-00E Courtesy of Machine.Market...
Page 192 MEMO Courtesy of Machine.Market...
Page 193: Optional Parts And Attachments
OPTIONAL PARTS AND ATTACHMENTS Courtesy of Machine.Market...
Page 194: General Precautions
27. General Precautions 27-1. Safety precautions The mounting of attachments and optional parts that are not authorized may cause accidents as well as shorten the machine life. If you need to mount any attachments other than those described in this manual, contact your dealer. If you fail to do so, the installation and use of unauthorized attachments and parts may void your Warranty.
Page 195: Precautions For Mounting An Attachment (Implement)
27. General Precautions 27-2. Precautions for mounting an attachment (implement) A long implement may throw a machine off balance, and may cause the machine to roll over when the machine descends or swings on a slope. The following operations are especially dangerous, and must never be done. •...
Page 196 MEMO Courtesy of Machine.Market...
Page 197 NOTES Courtesy of Machine.Market...
Page 198: Maintenance Log
28. Maintenance Log Maintenance log Date Machine hours Service performed Courtesy of Machine.Market...
Page 199 28. Maintenance Log Date Machine hours Service performed Courtesy of Machine.Market...
Page 200 28. Maintenance Log Date Machine hours Service performed Courtesy of Machine.Market...
Page 201 28. Maintenance Log Date Machine hours Service performed Courtesy of Machine.Market...
Page 202: Notes
29. Notes Notes Courtesy of Machine.Market...
Page 203 29. Notes Courtesy of Machine.Market...
Page 204 29. Notes Courtesy of Machine.Market...
Page 205 29. Notes Courtesy of Machine.Market...
Page 206 MEMO 6-10 Courtesy of Machine.Market...
Page 207 Courtesy of Machine.Market...
Page 208 State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery. ® Manitou Americas, Inc. P.O. Box 179 West Bend, WI 53095-0179 U.S.A www.gehl.com 50940306/AP0215 © 2015 All rights reserved. Printed in U.S.A Courtesy of Machine.Market...

Gehl Z17 GEN:2 Operator's Manual

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