Table of Contents
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Grading Operation ....................................................................... 5-12
Avoid Abusive Operation .......................................................... 5-13
Operating Tips ............................................................................... 5-14
Avoid Swinging Bucket to Move Objects ............................ 5-14
Operating Loading Shovel ........................................................ 5-15
Prohibited Operation .................................................................. 5-15
Object Handling --- If Equipped .............................................. 5-18
Overnight Storage Instructions ............................................... 5-19
TRANSPORTING .............................................................................6-1
Transporting ......................................................................................6-1
MAINTENANCE ...............................................................................7-1
Correct Maintenance and Inspection Procedures ...............7-1
Check Hour Meter Regularly .......................................................7-2
Use Correct Fuels and Lubricants ..............................................7-2
Prepare Machine for Maintenance ............................................7-3
Open Access Doors for Service ...................................................7-5
Inspection/Maintenance Lights .................................................7-6
Use a Chain to Prevent Falling Accidents ...............................7-7
Construction Outline .....................................................................7-8
Hydraulic System .......................................................................... 7-10
Periodic Replacement of Parts ................................................. 7-13
Periodic Replacement of Rubber Hoses ............................... 7-14
Maintenance Interval Guide ..................................................... 7-18
A. Greasing ...................................................................................... 7-22
Loading Shovel Front Joint Pins ........................................ 7-23
Backhoe Front Joint Pins ...................................................... 7-26
Swing Bearing .......................................................................... 7-29
Swing Internal Gear................................................................ 7-30
Center Joint ............................................................................... 7-31
Operating Lubricator ............................................................. 7-32
B. Engine .......................................................................................... 7-34
Check Engine Oil Level .......................................................... 7-35
Change Engine Oil .................................................................. 7-36
Replace Engine Oil Filters ..................................................... 7-36
C. Transmission .............................................................................. 7-38
Pump Transmission ................................................................ 7-39
Swing Reduction Gear .......................................................... 7-43
Travel Reduction Gear ........................................................... 7-45
D. Hydraulic System ..................................................................... 7-47
Inspection and Maintenance of Hydraulic
Equipment ........................................................................... 7-48
Check Hydraulic Oil Level .................................................... 7-50
Drain Hydraulic Oil Tank Sump .......................................... 7-51
Replace Full-Flow Filter and Drain Filter Element ....... 7-52
Replace Bypass Filter Element ............................................ 7-54
Replace Pilot Oil Filter Element .......................................... 7-56
Change Hydraulic Oil ............................................................. 7-58
Replace Suction Filter ............................................................ 7-58
Replace High-Pressure Filter Element ............................. 7-61
Replace Tank Air Breather Element................................... 7-62
Clean Oil Cooler Core ............................................................ 7-63
Check Hoses and Lines ......................................................... 7-64
E. Fuel System ................................................................................ 7-70
Drain Fuel Tank Sump ............................................................ 7-72
Drain Fuel Filter Sediment ................................................... 7-72
CONTENTS
Replace Fuel Filter Element ................................................. 7-73
Replace Fuel Filter ................................................................... 7-74
Check Fuel Hoses .................................................................... 7-75
Clean Fuel Cooler Core .......................................................... 7-77
Clean Fuel Tank Breather ...................................................... 7-77
Drain Fuel Pre-Filter Sediment (Optional) ...................... 7-78
Replace Fuel Pre-Filter Element (Optional) .................... 7-79
F. Air Cleaner ................................................................................... 7-80
Clean Air Cleaner Outer Element ...................................... 7-80
Replace Air Cleaner Outer and Inner Elements ........... 7-80
G. Cooling System ........................................................................ 7-82
Check Coolant Level .............................................................. 7-83
Check DCA4 Concentration in Coolant ........................... 7-84
Replace Coolant Filter ........................................................... 7-92
Change Coolant ....................................................................... 7-93
Clean Radiator, After Cooler Interior ................................ 7-93
Clean Radiator, After Cooler Core ..................................... 7-94
Check Fan Belt for Wear ........................................................ 7-94
Check Radiator Stay for Looseness ................................... 7-94
H. Air Conditioner ......................................................................... 7-95
Recirculation Air Filter ........................................................... 7-95
Ventilation Air Filter ............................................................... 7-96
Check Refrigerant Quantity ................................................. 7-97
Check Compressor Belt Tension ........................................ 7-98
Clean Condenser Core .......................................................... 7-99
Check Tightening Torque ...................................................7-100
Seasonal Maintenance ........................................................7-101
I. Electrical System ......................................................................7-102
Batteries ...................................................................................7-103
Replacing Fuses .....................................................................7-108
Check Power Source Terminal ..........................................7-111
Check High Current Fuse ....................................................7-112
Check Electrical Cables and Wire Harnesses for
Short Circuits .....................................................................7-113
Check Emergency Engine Stop Switch .........................7-115
J. Miscellaneous ..........................................................................7-116
Check Bucket Teeth ..............................................................7-117
Inspect Emergency Escape Device and Hanger ........7-123
Auto-Lubrication System ...................................................7-124
Check and Replace Seat Belt .............................................7-128
Check Windshield Washer Fluid Level ...........................7-128
Clean Air Horn Compressor Filter ....................................7-129
Check and Adjust Track Sag ..............................................7-130
Check Accumulator and Track Adjuster Cylinder
Circuit ...................................................................................7-132
Clean Side Frame Area ........................................................7-132
Check Tightening Torque of Bolts and Nuts ................7-133
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS ....................................................................................9-1
Maintenance Under Special Environmental Conditions ...9-1
STORAGE ........................................................................................ 10-1
Storing Machine............................................................................ 10-1
Removing Machine from Storage .......................................... 10-2
TRANSPORTING MACHINE ........................................................ 10-2
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