Transport .........................................4-1
Loading and unloading ............................ 4-2
Hoisting the machine ............................... 4-3
Securing the machine .............................. 4-4
Maintenance ....................................5-1
General .................................................... 5-2
Maintenance overview ......................... 5-2
Cautions on maintenance .................... 5-2
Service data ............................................ 5-4
Fuel and lubricant table ........................ 5-4
Regularly r
eplace the hydraulic oil ........ 5-6
List of consumables ............................. 5-7
List of tools .......................................... 5-8
List of tightening tor
ques ..................... 5-9
Safety-critical parts ................................ 5-10
Maintenance list ..................................... 5-12
W
alk-around inspection ......................... 5-14
Inspecting by opening the engine hood
and rear door ..................................... 5-14
Inspecting by walking ar
ound
the machine ....................................... 5-15
Inspecting while sitting in
the operator’
s seat ............................. 5-15
Daily inspection (every 10 hours) ............ 5-16
Inspecting and replenishing the coolant
... 5-16
Inspecting and replenishing the engine oil
5-17
Inspecting the water separator ........... 5-17
Inspecting the fuel level ...................... 5-18
Inspecting the hydraulic oil tank level
and r
eplenishing ................................ 5-19
Lubricating the working equipment .... 5-20
After the initial 50 hours
(only for new machines) ......................... 5-21
Replacing the engine oil and the oil filter
... 5-21
Replacing the hydraulic oil return filter 5-22
Replacing the pilot line filter
................ 5-23
Inspecting and adjusting the fan belt
.. 5-24
Inspecting and adjusting
the compr
essor belt (AC) ................... 5-25
Every 50 hours ...................................... 5-26
Inspecting and adjusting the track tension
5-26
Draining the water from the fuel tank .. 5-27
Inspecting the battery fluid level and
r
eplenishing ....................................... 5-28
Inspecting the bucket stoppers
(bolts/nuts) ......................................... 5-30
Every 100 hours .................................... 5-31
Cleaning the water separator ............. 5-31
After the initial 250 hours
(only for new machines) ......................... 5-32
Replacing the travel motor gear oil
..... 5-32
Every 250 hours .................................... 5-33
Replacing the engine oil and the oil filter
... 5-33
Inspecting and adjusting the fan belt .. 5-33
Inspecting and adjusting
the compr
essor belt (AC) ................... 5-33
Replacing the air cleaner element
...... 5-34
Cleaning the radiator fins and oil
cooler fins
.......................................... 5-35
Cleaning the condenser (AC) ............. 5-35
Cleaning the air filters (AC) ................. 5-36
Inspecting the refrigerant (gas) level (AC)
.. 5-37
Every 500 hours .................................... 5-39
Replacing the hydraulic oil r
eturn filter 5-39
Replacing the pilot line filter
................ 5-39
Replacing the travel motor gear oil
..... 5-39
Replacing the fuel filter
....................... 5-39
Adjusting or r
eplacing the bucket
stoppers (bolts/nuts) .......................... 5-40
Every 1000 hours .................................. 5-42
Cleaning the engine cooling system
... 5-42
Replacing the hydraulic oil and
cleaning the suction strainer .............. 5-44
Inspecting and adjusting the engine
valve clearance ..................................5-46
Every 3000 hours .................................. 5-47
Inspecting and cleaning the engine
fuel injectors ...................................... 5-47
Inspecting the turbocharger
(W
ash blower as necessary) ............... 5-47
When r
equired ....................................... 5-48
Replacing the bucket or attachment . 5-48
Inspecting and r
eplenishing the
windshield washer fluid
...................... 5-50
Lubricating the levers ......................... 5-50
Inspecting the rubber tracks .............. 5-51
T
ilting up the canopy (cab) ..................... 5-52
Maintenance during extended storage
period .................................................... 5-53
Troubleshooting ...............................6-1
Symptoms that are not malfunctions ....... 6-2
If the engine overheats ............................. 6-3
If the battery goes dead ........................... 6-4
If a fuse blows ......................................... 6-6
Inspecting and r
eplacing the fuse ......... 6-6
Inspecting the fusible link ..................... 6-7
Restarting after adding fuel ...................... 6-8
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