Gehl Z17 GEN:2 Operator'S Manual Download Page 208 | Manualshive

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50940306/AP0215

© 2015 All rights reserved.

Printed in U.S.A

®

Manitou Americas, Inc.

P.O. Box 179

West Bend, WI 53095-0179 U.S.A

www.gehl.com

WARNING

THIS OPERATOR'S MANUAL IS

PROVIDED FOR OPERATOR USE

DO NOT REMOVE

FROM THIS MACHINE

Do not start, operate or work on the machine until you carefully
read and thoroughly understand the contents of this Operator’s
Manual.

Failure to follow safety, operating and maintenance instructions
can result in serious injury to the operator or bystanders, poor
operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or main-
tenance of the machine, contact your dealer or the Manitou Ameri-
cas, Inc. Service Department before starting or continuing
operation.

California Proposition 65 Warnings:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and

birth defects and other reproductive harm. Battery post, terminals and related accessories contain lead and

lead compounds, chemicals known to the State of California to cause cancer and birth defects and other

reproductive harm.

Wash hands after handling battery.

Courtesy of Machine.Market

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Summary of Contents for Z17 GEN:2

Page 1: ...mpact Excavator Serial Numbers 00701 and Up Z17 GEN 2 Ope rat or s M a nua l 2015 Manitou Americas Inc All Rights Reserved Printed in USA Form No 50940306 Revision A Feb 2015 Courtesy of Machine Marke...

Page 2: ...OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW GEHL WARRANTY DOES NOT INCLUDE 1 Transportation to selling dealer s business location or at the option of the Or...

Page 3: ...using the machine must keep the manual at hand and review it periodically If the manual should be lost or damaged promptly order a new copy from the dealer When you transfer the machine to another use...

Page 4: ...first read and under stood all of the applicable Product Warnings and User Directions that are set forth in this Manual and on the Safety Signs that are affixed to this Excavator The failure to comply...

Page 5: ...100 service hours reading of the hourmeter In breaking in the machine You should warm up the engine by idling for 5 minutes before starting operations You should not operate the machine under heavy l...

Page 6: ...air cleaner element and the radiator fins Un moteur thermique agr EPA est install sur cette machine A la suite figurent les conditions d utilisation permettant de satisfaire au standard EPA il est imp...

Page 7: ...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 Cou...

Page 8: ...n the engine and engine hood as illustrated at right Never remove the plates for any reason La plaque signal tique est fix e sur le moteur voir il lustration droite En aucun cas ne retirer cette plaqu...

Page 9: ...ng 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 Machine serial number plate Hourmeter 5 4 Orde...

Page 10: ...ore starting the engine 1 6 8 2 Precautions for starting the engine working and parking 1 8 8 3 Precautions for transportation 1 13 8 4 Precautions for the battery 1 14 8 5 Precautions for towing 1 15...

Page 11: ...requirements after completing operation 2 55 13 18 Stopping the engine 2 56 13 19 Inspection requirements after stopping the engine 2 57 13 20 Locking 2 57 13 21 Handling the rubber crawlers 2 58 13...

Page 12: ...5 Procedures for Maintenance 3 22 25 1 First services 3 22 25 2 Non periodic services 3 23 25 3 Checking before start up 3 35 25 4 Maintenance every 50 service hours 3 43 25 5 Maintenance every 100 se...

Page 13: ...his 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 res...

Page 14: ...ect operation of the safety devices could cause serious bodily injury Do not wear loose clothing or jewelry that can be caught on the control levers and other machine parts Also avoid wearing working...

Page 15: ...the engine 4 Set all the locks in to the lock position 5 Be sure to take the starter switch key out of the starter switch For information on parking the machine refer to Section 13 16 Parking the mach...

Page 16: ...draining coolant or oil or replacing a filter at such a time may cause burns Allow temperatures to cool down and follow the procedures in this manual When removing the radiator cap stop the engine and...

Page 17: ...ident Know who to contact in an emergency and keep emergency tele phone numbers in a prominent place When installing or using optional attachments read the operating instructions for the attachments a...

Page 18: ...the allowable level For allowable water depth refer to Section 13 11 Precautions for working Wood chips dead leaves trash and other flammable materials in proximity to the engine are hazardous as they...

Page 19: ...be replaced if the machine is involved in an accident In addition the seat and the seat mounting must also be checked by your dealer after an accident has occurred If the seat and the seat mounting ar...

Page 20: ...ted in the back the opera tion of the travel levers is reversed For instructions on How the machine travels refer to Section 13 4 Traveling A signal person should be provided for safety when the work...

Page 21: ...machine on a slope keep the bucket 8 to 12 in 20 to 30 cm above the ground so that you can immediately lower it to the ground and stop the machine in an emergency Never turn the machine on a slope or...

Page 22: ...n below The following procedures are effective in preventing accidents or injuries 1 Wear shoes with rubber or leather soles 2 Use a signal person to warn the operator when the machine is getting too...

Page 23: ...careful removing snow as road shoulders or other hazards may be buried under snow Keep away from cliffs road shoulders or trenches if possible as the ground near them is unstable The ground may crumb...

Page 24: ...to the ground See the illustration at right If necessary to park the machine on the side of a road set up a warning flag fence or lamp that can be easily recog nized by passing cars and pedestrians bu...

Page 25: ...revent the machine from skidding on the ramp plates Do not load or unload the machine if the ramp plates are slippery because of rain snow or ice Never change travel direction while on the ramp plates...

Page 26: ...he battery which is short of battery electrolyte The shortage of bat tery electrolyte not only will reduce the life of the battery but also could cause an explosion When you start the engine using boo...

Page 27: ...Do not ride on the towing cable or on the wire rope When connecting an object to be towed make sure that no per son enters the space between the machine and the object To connect an object to be towed...

Page 28: ...MEMO 1 16 Courtesy of Machine Market...

Page 29: ...ed or worn tools or using tools inappropriate for the required application is very dangerous and may also cause damage to the machine Make sure to use the tools that are ap propriate for the specific...

Page 30: ...afety parts refer to Section 23 Replacing Es sential Parts Periodically Be sure to stop the engine before performing inspection and servicing If necessary to perform service while running the engine a...

Page 31: ...the implement on the ground in its lowest po sition Be sure to apply blocks to the tracks to lock the tracks se curely Never perform service underneath the machine if it is not completely stable Spill...

Page 32: ...led down Slowly loosen the cap to release the inner pressure before removing the cap Use an explosion proof lighting source when checking the fuel the oil the cooling water or the battery electrolyte...

Page 33: ...y obtain prompt medical treatment The engine cooling water and various lube oil systems are still under high temperature and pres sure immediately after the engine has stopped Removing caps draining o...

Page 34: ...ler ten sion refer to Section 25 2 Non periodic services Never contact the rotating radiator fan or fan belt with any object Contacting the rotating radiator fan or fan belt with any ob ject can resul...

Page 35: ...sing damaged or cannot be read it must be promptly replaced Also if a warning label was mounted on a part which is replaced a new warning label must be installed on the replaced part Contact your deal...

Page 36: ...y machine Failure to comply could result in death or serious injury DANGER 172437 03361 US EXPLOSION HAZARD Improper connection or disconnection can cause an explosion ALWAYS follow Operation Maintena...

Page 37: ...hen excavator is in motion Always bring the excavator to a level position when changing track gauge NOTE The stability of this excavator is reduced when operating with track gauge narrowed Failure to...

Page 38: ...n death or serious injury Lock Unlock WARNING 172437 03302 US OPERATION HAZARD Read and understand Operation Manual before operating maintaining or servicing machine Failure to comply could result in...

Page 39: ...EVER start engine standing on ground Inspect for overhead power lines obstructions holes and drop offs and note location of underground utility lines before operation NEVER leave operator s seat until...

Page 40: ...MEMO 1 28 Courtesy of Machine Market...

Page 41: ...2 1 OPERATION Courtesy of Machine Market...

Page 42: ...t cylinder Boom cylinder Boom light Work lamp Canopy Boom bracket Boom swing cylinder Arm cylinder Accelerator lever Lock lever Arm Boom Bucket link Bucket pin Blade Bucket Front Right Left Rear Idler...

Page 43: ...trol lever R Accelerator lever Track gauge change control lever Lock lever High speed pedal Travel pedal Travel lever Starter switch Monitor Horn switch Blade lever Boom swing pedal Pedal guard foot r...

Page 44: ...ssages as shown above When the starter switch key is in the ON position the monitor lamps 3 4 and 5 light and buzzer sounds Only the water temp alarm lamp 5 goes off in a few sec onds Normally all mon...

Page 45: ...ne oil pressure falls below the normal level the alarm lamp will turn on and the buzzer will sound In this event stop the engine and inspect it according to Section 17 4 Troubleshooting 4 Battery char...

Page 46: ...periodic servicing of the machine While the engine is running the hourmeter will continue registering even if the machine is not being operated The hourmeter reading increases by 1 per hour regard le...

Page 47: ...gine When the engine is not running and the starter switch key is in the ON position a buzzer will sound Turn the switch to the OFF position to stop the buzzer START position Turn the starter switch k...

Page 48: ...ng time while the en gine is not running The battery will run down and the engine may not start 3 Horn switch Press the switch on the top of the right control lever to sound the horn 4 Travel alarm sw...

Page 49: ...he lock posi tion If not they could slip out of the lock position Thus al ways make sure that the lock levers are in the lock position as illustrated in the figure at the right When pulling the lock l...

Page 50: ...t to accidentally touch the implement control le vers The relationship between the control lever shift configuration and the implement movement is de tailed in this manual To prevent an accident due t...

Page 51: ...ng the lock levers to the lock position Never touch the blade lever when not operating the blade A Down Push the lever forward B Up Pull the lever backward N Neutral When released the lever will retur...

Page 52: ...t B Swing left move to the left N Neutral When released the pedal will return to the neutral position and the boom is held as it is Be sure to operate the track gauge change con trol lever at middle e...

Page 53: ...erated These pedal guards can be used as foot rests 12 High speed pedal Step on this pedal to control the travel speed Step on the pedal while the travel levers are in operation to increase the travel...

Page 54: ...s shut 3 Turn the starter switch key clockwise to lock the engine hood The storage space for the operation maintenance man ual is provided under the operator s seat Pull the lever up to open the cover...

Page 55: ...backward The adjustable amount of seat movement is 5 51 in 140 mm maximum in five separate positions 12 6 Operator s seat Be sure to adjust the seat slide to obtain the best operating position wheneve...

Page 56: ...ent which flows in the circuit for large capacity current when a problem occurs such as short circuit due to breaking of wire Position of the fuse box Fuse box is on the right front of the seat mount...

Page 57: ...he fuse box cover to take the fuses out 3 If a fuse is blown out replace it with a spare fuse of rat ed capacity Blade fuse Slow blow fuse Remove the slow blow fuse to check it and replace it if nec e...

Page 58: ...areas Check the following points before initial start up for the day 1 Checking the implement hydraulic cylinders linkages and hoses for damage wear and loose connections Check the implement hydraulic...

Page 59: ...r loose bolts and oil leakage around the rollers If any breakage or wear is found correct it Retighten the bolts if necessary If oil leakage is found take corrective action 7 Checking the handrails an...

Page 60: ...ark through the water supply port of the sub tank 1 For the cooling water to be used refer to Section 21 Fueling Oiling and Greasing Based on Temperature Range 2 After replenishing securely tighten th...

Page 61: ...ve the excessive amount of oil through the drain plug P then recheck the engine oil level 6 After verifying that the amount of engine oil is appropri ate securely retighten the oil supply port cap and...

Page 62: ...ighten the fuel sup ply port cap 2 and then close the cover 1 5 Turn the starter switch key clockwise to lock the cover Note If the breather hole 3 in the fuel supply port cap is clogged the pressure...

Page 63: ...stress on its components causing a danger ous high pressure leak 3 Remove the hydraulic oil tank cover 1 and add oil to the oil supply port F if the oil level is below the lower limit For the quality...

Page 64: ...is at the midpoint between the upper and lower limit marks the battery 2 electro lyte level is appropriate 2 If the battery electrolyte level is below the lower limit mark replenish the battery elect...

Page 65: ...rain on soft ground or in muddy water 1 Put the bucket and the blade on the ground and stop the engine 2 Clean the grease nipples indicated by arrows in the fig ures at the right and grease them with...

Page 66: ...heck the monitor functions Check the fuel meter water temperature gauge and hourmeter Check the engine oil pressure alarm lamp battery charge alarm lamp and water temperature alarm lamp 2 Check that t...

Page 67: ...es off in 2 to 3 seconds If any of the alarm lamps do not go on or the buzzer does not sound it may mean that an alarm lamp has blown out or is broken Take corrective action or consult your dealer for...

Page 68: ...mmediately again but set the switch to the OFF position and wait for approximately 30 sec onds then start the engine again The swing motor brake is engaged when the engine is OFF but is released when...

Page 69: ...o the START position to start the engine 4 After the engine has started let go of the starter switch 2 key The starter switch key will return to the ON position by itself First check that there are no...

Page 70: ...f the engine fails to start do not start the engine im mediately again but set the switch to the OFF po sition and wait for approximately 30 seconds then start the engine again Traveling or operating...

Page 71: ...low this procedure 1 Idle the engine to check that the engine oil pressure alarm lamp is off 2 Pull the accelerator lever 1 to the midpoint between the IDLING and RUN positions and run the engine with...

Page 72: ...achine noise and the vibration level for abnormality If something is abnor mal take corrective action 7 Set the lock levers to the LOCK position to confirm that the implement cannot be operated and th...

Page 73: ...operate in the reverse of the normal operation A signal person should be in attendance to give signals at sites which are dangerous or not clear ly in view of the operator Clear all people from the w...

Page 74: ...machine Slowly push the travel levers 4 forward or step on the front of the pedals 5 to move the machine forward When the blade is in the rear of the machine Slowly pull the travel levers 4 back or u...

Page 75: ...should be in attendance to give signals at sites which are dangerous or not clear ly in view of the operator Clear all people from the working area Sound the horn before beginning travel to alert the...

Page 76: ...machine Slowly pull the travel levers 4 back or unfold the exten sion plate to step on it in order to move the machine backward When the blade is in the rear of the machine Slowly push the travel lev...

Page 77: ...forward to the left Pull the right travel lever back and start traveling in reverse to the left Note To turn right operate the left travel lever in the same man ner as above 13 5 Steering Always chec...

Page 78: ...ever to the neutral posi tion Note To turn right return the right travel lever to the neutral po sition Spin turning the machine when it is not traveling To spin turn left push the right travel lever...

Page 79: ...ng the machine Do not stop the machine suddenly but provide a safety margin Do not touch the control levers and pedals acci dentally Otherwise the implement or the ma chine may move unexpectedly causi...

Page 80: ...ver as illustrated in the figure at the right A Swing right B Swing left 13 7 Swinging the upper structure Before swinging make sure that there are no peo ple or obstacles within the swing range of th...

Page 81: ...ment will stop moving 13 8 Operating the implement Check the area around the machine for safety and sound the horn before beginning to operate the machine The setting of the pattern change lever alter...

Page 82: ...it carefully remove them after working 13 9 1 Changing the track gauge 1 Park the machine on level ground 2 Operate the track gauge change control lever until the crawlers stop moving 1 Push the lever...

Page 83: ...de to its stroke end 2 Change the positions of the pins as illustrated in the fig ure at the right and hold the extension blades to change the blade width IMPORTANT Installing the pin improperly may c...

Page 84: ...perating the hydraulic cylinder to the stroke end may im pose an undue force on the stopper in the hydraulic cylin der shortening the implement life Operate with a small safety margin Do not operate t...

Page 85: ...machine Do not excavate the ground by using the dropping force of the machine Excavating a hard rock It is recommended that a hard rock first be broken into small pieces by other means Doing so will...

Page 86: ...mplement for travel or transport be careful that the bucket and the blade never bump against each other Support the blade on both sides When you use the blade as an outrigger support the blade on both...

Page 87: ...t of water if the machine climbs a slope at an angle of more than 15 degrees the rear of the upper structure may submerge too deeply in the water which may damage the radiator fan Avoid this if possib...

Page 88: ...20 to 30 cm above the ground When driving over obstacles such as foot paths hold the implement close to the ground and drive the machine slowly Never turn on or traverse a slope Descend to flat ground...

Page 89: ...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 s...

Page 90: ...press on the ground with the bottom of the bucket Do not press on the ground with the bucket teeth In doing this the angle between the boom and the arm should be 90 degrees to 110 degrees The same pr...

Page 91: ...e depth of the work do not move the imple ment to the cylinder stroke end 13 14 2 Shoveling Shoveling is suitable for excavating ground that is higher than the machine bottom Install the bucket in the...

Page 92: ...from entering the pin holes 4 Remove pins A and B 5 Reverse the bucket 6 Connect the arm to hole B and then the link to hole A You can easily align the hole of the link and hole A by lifting the buck...

Page 93: ...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 al...

Page 94: ...accelerator lever 2 13 16 Parking the machine Do not stop the machine suddenly but provide a safety margin Do not touch the control levers and pedals acci dentally Otherwise the implement or the ma ch...

Page 95: ...lock lever to the LOCK position Check the monitor for the engine cooling water tempera ture 1 the engine oil pressure 2 and the residual quan tity of fuel 3 Take any actions necessary 13 17 Inspectio...

Page 96: ...mpera ture by rotating the engine at medium rotational speed before stopping the engine 1 Idle the engine for approximately five minutes with no load The engine temperature gradually lowers 2 To stop...

Page 97: ...m that the engine compartment is free of any for eign matter Combustibles or dust in the engine compartment may cause a fire Remove them if any 4 Remove mud adhering to the undercarriage of the ma chi...

Page 98: ...autions for operating and handling them to prolong their life and get the most out of them Be sure to read Sec tion 13 21 3 Precautions for using the rubber crawlers before using them 13 21 2 Warranty...

Page 99: ...g obstacles will also shorten the life of the rubber crawlers Prevent the rubber crawlers from getting exposed to oil fuel or chemical solvents If they are exposed immedi ately wipe them Also do not t...

Page 100: ...sium chloride potassium sulfate or superbiphosphate of lime Handling these materials may af fect the core metal adversely After using the machine to handle such materials clean the crawlers with water...

Page 101: ...such travel is not avoidable slow down the speed Do not travel with the crawler on one side on a slope or on convex ground causing a machine angle of more than 10 degrees and with the crawler on the...

Page 102: ...n the idler and the track rollers are misaligned from the core metal due to rubber crawler misalignment Traveling in reverse under the condition illustrated will cause the rubber crawlers to come off...

Page 103: ...ulic oil A Open The hydraulic oil flows B Close The hydraulic oil stops Set this valve at the closed position when removing and installing an attachment 2 P T O selector valve Use this valve to change...

Page 104: ...cting position Example of the P T O Tilt bucket Clamshell etc 4 P T O pedal lock for attachment control pedal Use this device to lock the P T O pedal Hand breaker position When the P T O pedal lock is...

Page 105: ...closed position and remove the screw plugs Take care not to lose or damage the removed parts 2 Install the connectors supplied by the manufacturer of the attachment and connect the hoses Oil flow sys...

Page 106: ...er The breaker operates when the P T O pedal is moved to the arrowed direction Make sure the P T O selector valve is in the single acting position Refer to Section 13 22 1 Description of stop valve P...

Page 107: ...acturer of the general attachments 13 22 4 Long term storage If the hydraulic tool is not used do the followings Close the stop valves Disconnect the hoses for the hydraulic tool Wind the screw plug R...

Page 108: ...loading or unloading the machine Use ramp plates of adequate strength having hooks Check to see that the ramp plates are wide long and thick enough to safely sustain the machine so that you can load o...

Page 109: ...ramp plates on the ba sis of the centers of the track shoes Do not operate the high speed pedal 2 Return the accelerator lever to reduce engine speed 3 Travel toward the ramp plates at a low speed and...

Page 110: ...ain or a wire rope so that the machine will not move during shipping In particular be sure to secure it to prevent skidding IMPORTANT To protect the bucket cylinder from being damaged during shipping...

Page 111: ...tion comply with all local regulations and laws 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 weigh...

Page 112: ...ough for the weight of the machine Do not suspend the machine in any way other than that explained on the following page Failure to suspend the machine as prescribed will throw the machine off balance...

Page 113: ...pe through the hole in the arm illustrated in the figure on the right and install shackles in the right and left holes in the side plate of the blade on the rear side then securely fasten the slingbel...

Page 114: ...taining methanol ethanol or propanol For the timing of cooling water change and the mixing ratio of the anti freeze refer to Section 25 2 Non periodic ser vices Note Because a long life coolant LLC is...

Page 115: ...th its tem perature and recharged condition 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...

Page 116: ...und Drain the water accumulated in the fuel system by open ing the drain cock to prevent freezing As battery performance deteriorates in low tempera tures cover the battery or move it to a warm place...

Page 117: ...LLC is added to the cooling water you need not change it until the temperature falls below 31 F 35 C If the temperature falls below 31 F 35 C refer to Sec tion 25 2 Non periodic services to control t...

Page 118: ...of storage follow the procedure below Wipe antirust off the hydraulic cylinder rods Apply generous amounts of grease or oil to the moving parts Drain water from the fuel tank the engine oil pan and th...

Page 119: ...r than the outside temperature by relief operation without traveling sometimes the machine cannot pivot turn be cause of thermal shock This phenomenon is not a fault The boom swing cylinder is extende...

Page 120: ...see that the wire ropes sling belts and shackles to be used are of sufficient strength and are free from cracks and damage 17 2 Towing Always safely tow a disabled machine by using the proper equipme...

Page 121: ...or contacts your skin flush immediately with large amounts of water and obtain medical treatment at once Be sure to wear safety goggles when handling a battery To disconnect the terminals begin with...

Page 122: ...start the engine by taking electric power from another machine do not allow contact be tween your machine and the other machine To connect the booster cables begin with the positive terminal and to d...

Page 123: ...rrupt charging Stop charging as soon as the process has been complet ed Overcharging could cause the following troubles Overheating of the battery Decrease in battery electrolyte Battery failure Do no...

Page 124: ...egative terminal on the normal machine 5 Connect the other clip of the booster cable B to the engine block of the machine in trouble Starting the engine 1 Make sure that the clips are securely connect...

Page 125: ...gine block on the machine in trouble 2 Remove the clip of the booster cable B from the neg ative terminal on the normal machine 3 Remove the clip of the booster cable A from the pos itive terminal on...

Page 126: ...r from fuel system Replace pump or nozzle Check and repair Replace fuse Check and repair Dark fumes come out of machine Clogged air cleaner element Deteriorated nozzle performance Improper compression...

Page 127: ...ng motor Swing brake has not released Check and grease Check and repair Check and repair Check and repair Temperature of hydraulic oil is too high Insufficient amount of hydraulic oil Overload Repleni...

Page 128: ...MEMO 2 88 Courtesy of Machine Market...

Page 129: ...3 1 MAINTENANCE Courtesy of Machine Market...

Page 130: ...rly clean the grease nipple breather and the oil level gauge glass to prevent dust from entering into them Be careful of high water and oil temperatures It is dangerous to replace the oil the cooling...

Page 131: ...detergent Clean mating surfaces before assembly When you have removed a part with an O ring or a gasket seal clean the mating surfaces before install ing the new part At this point do not fail to ref...

Page 132: ...autions for working in a dusty place If you use the machine in a dusty place be careful of the following Check the air cleaner for clogging Clean the air cleaner element earlier than scheduled Clean t...

Page 133: ...cing or replenishing oil The following types of oil fuel and cooling water are used at the factory for shipping unless otherwise specified Item Type Engine oil Engine oil SAE10W30 CD class Hydraulic o...

Page 134: ...chine failures are caused by impurities in the oils Be careful not to mix impurities into the oils especially after storing the machine and replenishing oils Do not mix oils of different makes and typ...

Page 135: ...el sys tem 19 1 3 Cooling water Because unpotable water may contain much calcium and impurities using it will cause water scales to build up in the engine or the radiator causing poor heat exchange an...

Page 136: ...When storing the oil or the fuel outdoors cover the drums with a waterproof sheet To avoid deterioration caused by long term storage use the oil on a first in first out basis 19 1 6 Filter The filter...

Page 137: ...vel Never disconnect or disassemble the electrical equipment mounted on the machine Do not mount any electrical equipment other than those items provided by the manufacturer Be careful not to spray wa...

Page 138: ...hydraulic hoses and piping check the O rings and the packing for damage before reinstalling them Replace them if they are damaged Bleed air after replacing or cleaning the hydraulic oil filter elemen...

Page 139: ...n the parts catalog List of consumables The parts in represent those which must be replaced at the same time Item Name Q ty Replacing time interval Engine oil filter Oil filter 1 Every 200 service hou...

Page 140: ...tem perature falls below 31 F 35 C If the temperature falls below 31 F 35 C refer to Section 25 2 Non periodic services to control the density of the cooling water 21 1 Fuel and oil 21 2 Cooling water...

Page 141: ...er wrench 80 1 4 Filter wrench LO 1 5 Pressuring nozzle 1 6 Filter wrench 92 1 7 Wrench 8 10 1 8 Wrench 12 14 2 9 Wrench 17 19 1 10 Wrench 22 24 2 11 Wrench 27 30 1 12 Wrench 32 36 1 13 Hexagon bar wr...

Page 142: ...rque when tightened to aluminum 2 Apply 60 tightening torque for 4T bolt and lock nut 3 Use fine thread screws for en gine only M8 1 25 16 6 to 21 0 22 6 to 28 4 M10 1 5 32 6 to 43 4 44 1 to 58 8 M12...

Page 143: ...ately If a hose clamp is deformed or cracked replace it immediately Check the hydraulic hoses which are not periodic replacement parts If any abnormality is found in them retighten them or replace the...

Page 144: ...ater separator to feed pump 1 3 Fuel hose feed pump to fuel filter 1 4 Fuel hose fuel filter to fuel injection pump 1 5 Fuel hose fuel filter to fuel tank 1 6 Fuel hose fuel injection pump to fuel fil...

Page 145: ...e has started to be used Replacing the engine oil and the engine oil filter 3 22 At first 250 hours only once after the new machine has started to be used Replacing the return filter in the hydraulic...

Page 146: ...es 3 51 Every 250 hours Perform the same maintenance every 50 service hours 3 51 Every 400 hours Replacing the fuel filter element 3 52 Replacing the air cleaner element 3 54 Every 500 hours Replacing...

Page 147: ...ime Q Check for abnormality of hydraulic pump Grease Check grease up positions grease Greasing the swing gears and the swing bearings Greasing the track gauge change cylinder and the link fulcrum Unde...

Page 148: ...Q Lube oil Check the quantity of engine oil c Replace the engine oil Q 1st time Q Replace the engine oil filter element Q 1st time Q Cooling water Check supply of cooling water c Clean radiator fins C...

Page 149: ...fter the first 100 to 150 hours After that replace it in accordance with the chart at the right Replacing the hydraulic oil in the hydraulic oil tank Replace the hydraulic oil in accordance with the c...

Page 150: ...r to Section 25 6 Mainte nance every 200 service hours 25 1 2 At first 250 hours Replacing the return filter in the hydraulic oil tank For this procedure refer to Section 25 9 Maintenance every 500 se...

Page 151: ...ew one Rubber crawler steel cord breakage If half or more of either of the steel cords is broken replace the rubber crawler with a new one Separation of the core metal of the rubber crawler If the cor...

Page 152: ...even though the crack is small repair the rubber crawler immediately If the crack length is less than 1 2 in 30 mm or the crack depth is less than 0 4 in 10 mm you do not need to re pair the rubber c...

Page 153: ...the right between the outside rolling surface of the sec ond track roller from the idler side and the inside surface of the rubber crawler is within the following range H 0 31 to 0 51 in 8 to 13 mm Wo...

Page 154: ...check that the tension is proper lower the machine and move the machine back and forth slightly 4 Check the rubber crawler tension again If the tension is improper adjust it again 5 Install the cover...

Page 155: ...ber crawler tension and readjust it if necessary 7 Completely wipe away all of the discharged grease IMPORTANT The rubber crawler is not grease resistant Completely wipe away all of the grease because...

Page 156: ...that the machine may accidentally fall Do not move any parts other than the rubber crawler to be replaced in doing the job The high internal pressure of the grease can cause the nipple valve to eject...

Page 157: ...e sprocket in the reverse direction When the rubber crawler is separated from the idler by the steel pipes slide the rubber crawler off It is very dangerous to discharge the grease by any procedure ot...

Page 158: ...the rubber crawler and rotate the sprocket again to place the rubber crawler on the idler 5 Stop rotating the sprocket and confirm that the rubber crawler is securely positioned on both the sprocket a...

Page 159: ...water has cooled down slowly turn the ra diator cap to relieve the internal pressure before removing it Clean the inside of the cooling system and replace the anti freeze according to the following ta...

Page 160: ...er Use a densitometer to control the mixing ratio Lowest temperature F 23 14 5 4 13 22 31 40 C 5 10 15 20 25 30 35 40 Amount of anti freeze Qts 0 53 0 85 1 06 1 16 1 27 1 48 1 69 1 80 L 0 5 0 8 1 0 1...

Page 161: ...idle the engine for 10 to 15 min utes Then stop the engine 5 After the engine has cooled down slowly loosen the drain plug P to drain the water and remove the radia tor cap 2 When the drain plug P is...

Page 162: ...6 minutes and then run the engine without load at high speed for 5 to 6 minutes While running the engine keep the radiator cap 2 removed 11 Approximately 5 minutes after stopping the engine pour wate...

Page 163: ...ank 1 For the cooling water to be used refer to Section 21 Fueling Oiling and Greasing Based on Temperature Range 2 Securely close the cap after replenishing 3 If the sub tank is empty check the sub t...

Page 164: ...ngine oil through the drain plug P and check the engine oil level again 6 If the engine oil level is proper securely close the port cap and close the engine hood Note When checking the engine oil leve...

Page 165: ...ng securely install and tighten the fuel sup ply port cap 2 and then close the cover 1 5 Turn the starter switch key clockwise to lock the cover Note If the breather hole 3 in the cap is clogged the p...

Page 166: ...ay damage the hydraulic system by placing stress on its components causing a danger ous high pressure leak 3 Remove the hydraulic oil tank cover 1 and add oil to the oil supply port F if the oil level...

Page 167: ...s seat 2 forward remove the mount ing bolts 3 and remove the cover 4 3 Loosen the generator mounting bolt 5 4 Insert a wooden bar between the generator 6 and the cylinder block and move the generator...

Page 168: ...rolyte level is proper 2 If the battery electrolyte level is below the lower limit mark replenish the battery electrolyte Fan belt size Inch Size Fan belt A35 The battery generates flammable gas and c...

Page 169: ...on in rain on soft ground or in muddy water 1 Put the bucket and the blade on the ground and stop the engine 2 Clean the grease nipples indicated by arrows in the fig ures at the right and grease them...

Page 170: ...e monitor functions Check the fuel meter water temperature gauge and hourmeter Check the engine oil pressure alarm lamp battery charge alarm lamp and water temperature alarm lamp 2 Check that the swit...

Page 171: ...the container for fuel waste under the hose 4 Move the hose clip 5 using pliers remove the flat head pin P and drain the water and dirt deposits with the fuel in the fuel tank Take care that the fuel...

Page 172: ...5 Check the O ring and if it is damaged or deformed re place it with a new one 6 Install the element and the cup and turn the cock to the open position 7 Close the engine hood Keep sparks flames and...

Page 173: ...one 6 Install the element and the cup and turn the cock to the open position 7 Close the engine hood Perform the same maintenance as indicated for every 50 service hours Keep sparks flames and lit cig...

Page 174: ...d contact your dealer if any me tallic particles or foreign objects are mixed in it 5 Reinstall the drain plug P 6 Turn the oil filter cartridge 1 counterclockwise with the filter wrench to remove it...

Page 175: ...o be used 10 Idle the engine for several minutes and then stop the engine Then check that the oil level exceeds the mid point between the upper and lower limit marks on the oil dipstick Refer to Secti...

Page 176: ...m inside the element 3 along the pleats to ini tially remove the dirt Then blow compressed air from outside the element 3 along the pleats to remove dirt Blow compressed air again from inside the elem...

Page 177: ...it against other objects Otherwise the element may be damaged Do not reuse the element if the pleat gasket or seal is damaged Replacement elements should be wrapped in clean paper and stored in a dry...

Page 178: ...the dirt has been removed completely 5 Reinstall the side cover R 2 6 Close the engine hood 1 Never attempt to check and clean the radiator fin while the engine is running Always stop the engine and...

Page 179: ...s touching the restraint bolt on the low speed side when the accelerator device is in the low speed position 3 If the governor lever does not touch the restraint bolt on either the high or low speed s...

Page 180: ...air from the fuel circuit in accordance with the procedure de scribed on the next page 6 After completing the air release procedure start the en gine and check that there are no fuel leaks or abnorma...

Page 181: ...ds The air will nor mally be released in 10 to 15 seconds 4 Turn the starter switch to the START position and start the engine IMPORTANT If the engine fails to start turn the starter switch back to th...

Page 182: ...ering 4 Clean the dust cup 2 and the inside of the body Remove the protective cloth and tape used to cover the air cleaner body 5 Install a new element 3 6 Install the dust cup 2 using the arrow mark...

Page 183: ...every 500 service hours The hydraulic oil and the tank are hot and under pressure immediately after the engine stops and can cause bodily injury Be sure to replace the filter only after the hydrau lic...

Page 184: ...e hood 2 6 Remove the side cover L 3 7 Place the container for waste oil under the drain plug P 8 Remove the drain plug P and drain the waste oil When removing the drain plug P take care that the oil...

Page 185: ...lbf 98 to 118 N m IMPORTANT Do not allow any dirt to enter the hydraulic oil tank when installing the suction filter 15 Install the hose 6 to the suction filter 5 and tighten the hose hands 4 Tighteni...

Page 186: ...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 cyli...

Page 187: ...nd 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 25 11 3 Checking and adjusting fuel pump...

Page 188: ...MEMO 3 60 Courtesy of Machine Market...

Page 189: ...4 1 SPECIFICATIONS AND DIMENSIONAL DIAGRAMS Courtesy of Machine Market...

Page 190: ...round in mm 146 1 3710 Front minimum swing radius with the boom swing right in mm 60 4 1535 54 3 1380 Boom swing angle left right degrees 42 65 Maximum digging force bucket lbs kN 3418 15 2 Travel spe...

Page 191: ...3690 103 5 2630 86 6 2200 40 4 1025 146 1 3710 135 8 3450 90 9 2 31 0 72 8 1850 150 0 3810 60 0 1525 46 3 1176 25 2 640 4 2 6 5 15 7 400 90 6 2300 60 4 1535 50 1280 10 2 260 8 1 205 4 9 125 11 4 290 3...

Page 192: ...MEMO 4 4 Courtesy of Machine Market...

Page 193: ...5 1 OPTIONAL PARTS AND ATTACHMENTS Courtesy of Machine Market...

Page 194: ...a partner define hand signals and communicate in accor dance with those signals When moving a heavy load more than 55 lbs 25 kg use a crane When removing a heavy part be sure to support it adequately...

Page 195: ...inst the object To avoid this type of accident deactivate the upper structure a little earlier than usual Because of increased inertia the implement will also drop a greater distance after it has been...

Page 196: ...MEMO 5 4 Courtesy of Machine Market...

Page 197: ...6 1 NOTES Courtesy of Machine Market...

Page 198: ...6 2 28 Maintenance Log Maintenance log Date Machine hours Service performed Courtesy of Machine Market...

Page 199: ...28 Maintenance Log 6 3 Date Machine hours Service performed Courtesy of Machine Market...

Page 200: ...28 Maintenance Log 6 4 Date Machine hours Service performed Courtesy of Machine Market...

Page 201: ...28 Maintenance Log 6 5 Date Machine hours Service performed Courtesy of Machine Market...

Page 202: ...6 6 29 Notes Notes Courtesy of Machine Market...

Page 203: ...29 Notes 6 7 Courtesy of Machine Market...

Page 204: ...29 Notes 6 8 Courtesy of Machine Market...

Page 205: ...29 Notes 6 9 Courtesy of Machine Market...

Page 206: ...MEMO 6 10 Courtesy of Machine Market...

Page 207: ...Courtesy of Machine Market...

Page 208: ...operation and costly breakdowns If you have any questions on proper operation adjustment or main tenance of the machine contact your dealer or the Manitou Ameri cas Inc Service Department before start...

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