Anda di halaman 1dari 79

MINI-EXCAVATOR

T15 S
Owners and
Operators
Manual
PUBLICATION NO. 47212, March 2001
THOMAS EQUIPMENT LIABILITYWARRANTY
THE WARRANTY IS THE ONLY OBLIGATION OF THOMAS OR ATHOMAS
DEALER TO THE PURCHASER OR ANYONE ELSE CONCERNING A
PRODUCT, ITS SERVICE, ITS USE OR PERFORMANCE OR ITS LOSS OF USE
OR FAILURE TO PERFORM. NEITHER THOMAS NOR ATHOMAS DEALER
HAVE MADE AND NEITHER WILL MAKE ANY OTHER EXPRESSED OR
IMPLIED REPRESENTATION, WARRANTY OR AGREEMENT CONCERNING
A PRODUCT. NEITHER THOMAS NOR ATHOMAS DEALER HAVE MADE OR
WILL MAKE ANY REPRESENTATION, WARRANTY OR AGREEMENT
CONCERNING A PRODUCTS MERCHANABILITY OR OTHER QUALITY, ITS
SUITABILITY FOR PURCHASERS PURPOSE (EVEN IFA PURCHASER HAS
INFORMED THOMAS OR ATHOMAS DEALER OF THAT PURPOSE), ITS
DURABILITY, PERFORMANCE OR OTHER CONDITION.
EVEN IF THOMAS OR A THOMAS DEALER WAS ADVISED OF THE
POSSIBILTY OF SUCH LOSS, NEITHER THOMAS NOR A THOMAS DEALER
WILL BE LIABLE TO PURCHASER OR ANYONE ELSE FOR ANY INDIRECT,
INCIDENTAL CONSEQUENTIAL, PUNITIVE, ECONOMIC, COMMERCIAL,
OR SPECIAL LOSS WHICH IS IN ANY WAYASSOCIATED WITH A PRODUCT.
THIS INCLUDES ANY LOSS OF USE OR NON-PERFORMANCE OF A
PRODUCT, ANY REPLACEMENT RENTAL OR ACQUISITION COST, ANY
LOSS OF REVENUE OR PROFITS, ANY FAILURE TO REALIZE EXPECTED
SAVINGS, ANY INTEREST COSTS, ANY IMPAIRMENT OF OTHER GOODS,
ANYINCONVENIENCE OR ANYLIABILITYOF PURCHASER TO ANYOTHER
PERSON.
PURCHASER MAY NOT ATTEMPT TO ENLARGE ITS RIGHTS UNDER
THE WARRANTY BY MAKING A CLAIM FOR INDEMNITY, FOR BRACH OF
CONTRACT, FOR BREACH OF COLLATERAL WARRANTY, FOR A TORT
(INCLUDING NEGLIGENCE, MISREPRESENTATION OR STRICT LIABILITY)
OR BY CLAIMING ANY OTHER CAUSE OFACTION.
THE WARRANTY IS A CONDITION OF SALE OF THE PRODUCT TO
PURCHASER AND WILL THEREFORE APPLY EVEN IF PURCHASER
ALLEGES THAT THERE IS ATOTALFAILURE OF THE PRODUCT.
N.B. Read and practice your Thomas operating and servicing instructions. Failure to
do this may void your warranty.
PUBLICATION NO. 47212, March 2001
INTRODUCTION
This operation manual describes the proper operation and maintenance methods oI
THOMAS EQUIPMENT's model T15S.
This machine was developed based on the accumulated design and manuIacturing expe-
rience using up-to-date technology. THOMAS EQUIPMENT rigorously inspects every
machine beIore shipment to ensure optimum operating conditions.
Read this manual careIully beIore operating the machine to ensure saIe and optimum
running conditions. II you do not understand any oI the points in the manual, or the
machine breaks down, contact your dealer.
The inIormation in this manual is subject to change without prior notice.
1
INTRODUCTION
This operation manual describes the proper operation and maintenance methods oI
THOMAS EQUIPMENT's model T15S.
This machine was developed based on the accumulated design and manuIacturing expe-
rience using up-to-date technology. THOMAS EQUIPMENT rigorously inspects every
machine beIore shipment to ensure optimum operating conditions.
Read this manual careIully beIore operating the machine to ensure saIe and optimum
running conditions. II you do not understand any oI the points in the manual, or the
machine breaks down, contact your dealer.
The inIormation in this manual is subject to change without prior notice.
1
INTRODUCTION
This operation manual describes the proper operation and maintenance methods oI
THOMAS EQUIPMENT's model T15S.
This machine was developed based on the accumulated design and manuIacturing expe-
rience using up-to-date technology. THOMAS EQUIPMENT rigorously inspects every
machine beIore shipment to ensure optimum operating conditions.
Read this manual careIully beIore operating the machine to ensure saIe and optimum
running conditions. II you do not understand any oI the points in the manual, or the
machine breaks down, contact your dealer.
The inIormation in this manual is subject to change without prior notice.
1
INTRODUCTION
This operation manual describes the proper operation and maintenance methods oI
THOMAS EQUIPMENT's model T15S.
This machine was developed based on the accumulated design and manuIacturing expe-
rience using up-to-date technology. THOMAS EQUIPMENT rigorously inspects every
machine beIore shipment to ensure optimum operating conditions.
Read this manual careIully beIore operating the machine to ensure saIe and optimum
running conditions. II you do not understand any oI the points in the manual, or the
machine breaks down, contact your dealer.
The inIormation in this manual is subject to change without prior notice.
1
CONTENTS
OPERATION
Page Section
5 SaIety
8 Operational Precautions
12 Ordering Parts and Servicing Guidelines
13 Part Names and Explanation oI Each Device
20 Operation
25 Transporting by Truck
25 Vehicle Traction
26 How to Hoist a Vehicle
28 Cold Weather or During-Winter Operations
29 Long-term Storage
INSPECTION AND MAINTENANCE
31 Inspections
36 Maintenance aIter the Eirst 50 Service Hours (New Machine)
37 Maintenance aIter the Eirst 100 Service Hours (New Machine)
38 Maintenance Every 50 Service Hours
39 Maintenance Every 100 Service Hours
40 Maintenance Every 250 Service Hours
41 Maintenance Every 500 Service Hours
43 Maintenance Every 1000 Service Hours
44 Inspection and Maintenance Procedures Ior Engine Parts
51 Inspection and Maintenance Procedures
54 Troubleshooting
61 Periodical Inspections and Maintenance List
63 Lubricants
OTHERS
68 Dimensions and SpeciIications
71 Electric Circuit
73 Hydraulic Circuit
74 Decals
77 Warranty
2
CONTENTS
OPERATION
Page Section
5 SaIety
8 Operational Precautions
12 Ordering Parts and Servicing Guidelines
13 Part Names and Explanation oI Each Device
20 Operation
25 Transporting by Truck
25 Vehicle Traction
26 How to Hoist a Vehicle
28 Cold Weather or During-Winter Operations
29 Long-term Storage
INSPECTION AND MAINTENANCE
31 Inspections
36 Maintenance aIter the Eirst 50 Service Hours (New Machine)
37 Maintenance aIter the Eirst 100 Service Hours (New Machine)
38 Maintenance Every 50 Service Hours
39 Maintenance Every 100 Service Hours
40 Maintenance Every 250 Service Hours
41 Maintenance Every 500 Service Hours
43 Maintenance Every 1000 Service Hours
44 Inspection and Maintenance Procedures Ior Engine Parts
51 Inspection and Maintenance Procedures
54 Troubleshooting
61 Periodical Inspections and Maintenance List
63 Lubricants
OTHERS
68 Dimensions and SpeciIications
71 Electric Circuit
73 Hydraulic Circuit
74 Decals
77 Warranty
2
CONTENTS
OPERATION
Page Section
5 SaIety
8 Operational Precautions
12 Ordering Parts and Servicing Guidelines
13 Part Names and Explanation oI Each Device
20 Operation
25 Transporting by Truck
25 Vehicle Traction
26 How to Hoist a Vehicle
28 Cold Weather or During-Winter Operations
29 Long-term Storage
INSPECTION AND MAINTENANCE
31 Inspections
36 Maintenance aIter the Eirst 50 Service Hours (New Machine)
37 Maintenance aIter the Eirst 100 Service Hours (New Machine)
38 Maintenance Every 50 Service Hours
39 Maintenance Every 100 Service Hours
40 Maintenance Every 250 Service Hours
41 Maintenance Every 500 Service Hours
43 Maintenance Every 1000 Service Hours
44 Inspection and Maintenance Procedures Ior Engine Parts
51 Inspection and Maintenance Procedures
54 Troubleshooting
61 Periodical Inspections and Maintenance List
63 Lubricants
OTHERS
68 Dimensions and SpeciIications
71 Electric Circuit
73 Hydraulic Circuit
74 Decals
77 Warranty
2
CONTENTS
OPERATION
Page Section
5 SaIety
8 Operational Precautions
12 Ordering Parts and Servicing Guidelines
13 Part Names and Explanation oI Each Device
20 Operation
25 Transporting by Truck
25 Vehicle Traction
26 How to Hoist a Vehicle
28 Cold Weather or During-Winter Operations
29 Long-term Storage
INSPECTION AND MAINTENANCE
31 Inspections
36 Maintenance aIter the Eirst 50 Service Hours (New Machine)
37 Maintenance aIter the Eirst 100 Service Hours (New Machine)
38 Maintenance Every 50 Service Hours
39 Maintenance Every 100 Service Hours
40 Maintenance Every 250 Service Hours
41 Maintenance Every 500 Service Hours
43 Maintenance Every 1000 Service Hours
44 Inspection and Maintenance Procedures Ior Engine Parts
51 Inspection and Maintenance Procedures
54 Troubleshooting
61 Periodical Inspections and Maintenance List
63 Lubricants
OTHERS
68 Dimensions and SpeciIications
71 Electric Circuit
73 Hydraulic Circuit
74 Decals
77 Warranty
2
This warning indicates
hazards or unsafe prac-
tices which COULD
result in minor personal
injury or product or
property damage.
CAUTION
This warning indicates
hazards or unsafe prac-
tices which COULD
result in severe personal
injury or death.
WARNING
This warning indicates an
immediate hazard which
WILL result in severe
personal injury or death.
DANGER
Instructions are necessary
before operating or servic-
ing this machine. Read the
operators manual and ser-
vice decals on the loader.
Follow warnings and
instructions in this manual
when making repairs,
adjustments or servicing.
Check for correct operation
after adjustments and
repairs.
IMPORTANT
This notice shows impor-
tant procedures which
must be followed to pre-
vent damage to the
loader or attachment.
IMPORTANT
FOREWORD
This book has been written to give the Owner / Operator necessary operating
servicing and preventative maintenance instructions on the machine.
Read this manual completely and know the machine beIore operating or servicing
it.
Do not do any service procedures that are not in the Operator`s manual.
Only service personnel that have had training in the service oI this machine can do
these service procedures.
Reference Information
Write the correct inIormation Ior your machine in the spaces below. Always use
these numbers when reIerring to your machine.
Model No.
Serial No.
Dealer Name
Address
Phone
Throughout this manual the terms DANGER, WARNING and CAUTION are used
to indicate the degree oI hazard in terms oI personal saIety. These words will be
used in conjunction with the SaIety - Alert symbol, a triangle with an exclamation
mark.
Throughout this manual, the term IMPORTANT is used
` To indicate that instructions are necessary beIore operating or servicing the
machine.
` To show important procedures which must be Iollowed to prevent damage to
the machine.
3
This warning indicates
hazards or unsafe prac-
tices which COULD
result in minor personal
injury or product or
property damage.
CAUTION
This warning indicates
hazards or unsafe prac-
tices which COULD
result in severe personal
injury or death.
WARNING
This warning indicates an
immediate hazard which
WILL result in severe
personal injury or death.
DANGER
Instructions are necessary
before operating or servic-
ing this machine. Read the
operators manual and ser-
vice decals on the loader.
Follow warnings and
instructions in this manual
when making repairs,
adjustments or servicing.
Check for correct operation
after adjustments and
repairs.
IMPORTANT
This notice shows impor-
tant procedures which
must be followed to pre-
vent damage to the
loader or attachment.
IMPORTANT
FOREWORD
This book has been written to give the Owner / Operator necessary operating
servicing and preventative maintenance instructions on the machine.
Read this manual completely and know the machine beIore operating or servicing
it.
Do not do any service procedures that are not in the Operator`s manual.
Only service personnel that have had training in the service oI this machine can do
these service procedures.
Reference Information
Write the correct inIormation Ior your machine in the spaces below. Always use
these numbers when reIerring to your machine.
Model No.
Serial No.
Dealer Name
Address
Phone
Throughout this manual the terms DANGER, WARNING and CAUTION are used
to indicate the degree oI hazard in terms oI personal saIety. These words will be
used in conjunction with the SaIety - Alert symbol, a triangle with an exclamation
mark.
Throughout this manual, the term IMPORTANT is used
` To indicate that instructions are necessary beIore operating or servicing the
machine.
` To show important procedures which must be Iollowed to prevent damage to
the machine.
3
This warning indicates
hazards or unsafe prac-
tices which COULD
result in minor personal
injury or product or
property damage.
CAUTION
This warning indicates
hazards or unsafe prac-
tices which COULD
result in severe personal
injury or death.
WARNING
This warning indicates an
immediate hazard which
WILL result in severe
personal injury or death.
DANGER
Instructions are necessary
before operating or servic-
ing this machine. Read the
operators manual and ser-
vice decals on the loader.
Follow warnings and
instructions in this manual
when making repairs,
adjustments or servicing.
Check for correct operation
after adjustments and
repairs.
IMPORTANT
This notice shows impor-
tant procedures which
must be followed to pre-
vent damage to the
loader or attachment.
IMPORTANT
FOREWORD
This book has been written to give the Owner / Operator necessary operating
servicing and preventative maintenance instructions on the machine.
Read this manual completely and know the machine beIore operating or servicing
it.
Do not do any service procedures that are not in the Operator`s manual.
Only service personnel that have had training in the service oI this machine can do
these service procedures.
Reference Information
Write the correct inIormation Ior your machine in the spaces below. Always use
these numbers when reIerring to your machine.
Model No.
Serial No.
Dealer Name
Address
Phone
Throughout this manual the terms DANGER, WARNING and CAUTION are used
to indicate the degree oI hazard in terms oI personal saIety. These words will be
used in conjunction with the SaIety - Alert symbol, a triangle with an exclamation
mark.
Throughout this manual, the term IMPORTANT is used
` To indicate that instructions are necessary beIore operating or servicing the
machine.
` To show important procedures which must be Iollowed to prevent damage to
the machine.
3
This warning indicates
hazards or unsafe prac-
tices which COULD
result in minor personal
injury or product or
property damage.
CAUTION
This warning indicates
hazards or unsafe prac-
tices which COULD
result in severe personal
injury or death.
WARNING
This warning indicates an
immediate hazard which
WILL result in severe
personal injury or death.
DANGER
Instructions are necessary
before operating or servic-
ing this machine. Read the
operators manual and ser-
vice decals on the loader.
Follow warnings and
instructions in this manual
when making repairs,
adjustments or servicing.
Check for correct operation
after adjustments and
repairs.
IMPORTANT
This notice shows impor-
tant procedures which
must be followed to pre-
vent damage to the
loader or attachment.
IMPORTANT
FOREWORD
This book has been written to give the Owner / Operator necessary operating
servicing and preventative maintenance instructions on the machine.
Read this manual completely and know the machine beIore operating or servicing
it.
Do not do any service procedures that are not in the Operator`s manual.
Only service personnel that have had training in the service oI this machine can do
these service procedures.
Reference Information
Write the correct inIormation Ior your machine in the spaces below. Always use
these numbers when reIerring to your machine.
Model No.
Serial No.
Dealer Name
Address
Phone
Throughout this manual the terms DANGER, WARNING and CAUTION are used
to indicate the degree oI hazard in terms oI personal saIety. These words will be
used in conjunction with the SaIety - Alert symbol, a triangle with an exclamation
mark.
Throughout this manual, the term IMPORTANT is used
` To indicate that instructions are necessary beIore operating or servicing the
machine.
` To show important procedures which must be Iollowed to prevent damage to
the machine.
3
OPERATION
4
OPERATION
4
OPERATION
4
OPERATION
4
SAFETY
PRECAUTIONARY NOTES BEFORE START
1. Always wear a hard hat and saIety shoes.
Be sure to wear a hard hat and saIety shoes
when running the machine. Goggles and ear
protectors may be necessary depending on the
type oI work. To prevent being caught in the
machine, do not wear loose clothing.
2. Check the surroundings beIore start.
Look around you to check the saIety oI the
surroundings beIore start.
3. Warm-up
BeIore starting, always warm up the machine.
4. Signal beIore start.
BeIore starting the engine, traveling or swivelling,
always signal to other workers, using the horn etc.
5. Pay attention to the ventilation.
Eor indoor work, ventilate suIIiciently to prevent
carbon monoxide poisoning Irom the exhaust.
5
SAFETY
PRECAUTIONARY NOTES BEFORE START
1. Always wear a hard hat and saIety shoes.
Be sure to wear a hard hat and saIety shoes
when running the machine. Goggles and ear
protectors may be necessary depending on the
type oI work. To prevent being caught in the
machine, do not wear loose clothing.
2. Check the surroundings beIore start.
Look around you to check the saIety oI the
surroundings beIore start.
3. Warm-up
BeIore starting, always warm up the machine.
4. Signal beIore start.
BeIore starting the engine, traveling or swivelling,
always signal to other workers, using the horn etc.
5. Pay attention to the ventilation.
Eor indoor work, ventilate suIIiciently to prevent
carbon monoxide poisoning Irom the exhaust.
5
SAFETY
PRECAUTIONARY NOTES BEFORE START
1. Always wear a hard hat and saIety shoes.
Be sure to wear a hard hat and saIety shoes
when running the machine. Goggles and ear
protectors may be necessary depending on the
type oI work. To prevent being caught in the
machine, do not wear loose clothing.
2. Check the surroundings beIore start.
Look around you to check the saIety oI the
surroundings beIore start.
3. Warm-up
BeIore starting, always warm up the machine.
4. Signal beIore start.
BeIore starting the engine, traveling or swivelling,
always signal to other workers, using the horn etc.
5. Pay attention to the ventilation.
Eor indoor work, ventilate suIIiciently to prevent
carbon monoxide poisoning Irom the exhaust.
5
SAFETY
PRECAUTIONARY NOTES BEFORE START
1. Always wear a hard hat and saIety shoes.
Be sure to wear a hard hat and saIety shoes
when running the machine. Goggles and ear
protectors may be necessary depending on the
type oI work. To prevent being caught in the
machine, do not wear loose clothing.
2. Check the surroundings beIore start.
Look around you to check the saIety oI the
surroundings beIore start.
3. Warm-up
BeIore starting, always warm up the machine.
4. Signal beIore start.
BeIore starting the engine, traveling or swivelling,
always signal to other workers, using the horn etc.
5. Pay attention to the ventilation.
Eor indoor work, ventilate suIIiciently to prevent
carbon monoxide poisoning Irom the exhaust.
5
6. Check the neutral position.
BeIore starting engine, always make sure that
each operation lever and pedal are in neutral
position. Do not place your Ioot on the pedal.
7. Prestart inspections
Do prestart inspections (See "Inspections" on page
31.)
8. BeIore digging contact your utility companies (gas,
electric, telephone, water and sewage) to Iind out where
utility lines are buried
Precautions during operation
1. Do not carry any passengers.
Do not carry other persons on the machine during
operations. It is unbalanced and dangerous.
2. Do not remove cap oI heated radiator.
Radiator cap must be removed aIter boiling
water is cooled. The boiling water will injure you.
3. Do not touch the muIIler.
Do not touch the muIIler just aIter turning oII
engine. A hot muIIler can cause personal injury.
6
6. Check the neutral position.
BeIore starting engine, always make sure that
each operation lever and pedal are in neutral
position. Do not place your Ioot on the pedal.
7. Prestart inspections
Do prestart inspections (See "Inspections" on page
31.)
8. BeIore digging contact your utility companies (gas,
electric, telephone, water and sewage) to Iind out where
utility lines are buried
Precautions during operation
1. Do not carry any passengers.
Do not carry other persons on the machine during
operations. It is unbalanced and dangerous.
2. Do not remove cap oI heated radiator.
Radiator cap must be removed aIter boiling
water is cooled. The boiling water will injure you.
3. Do not touch the muIIler.
Do not touch the muIIler just aIter turning oII
engine. A hot muIIler can cause personal injury.
6
6. Check the neutral position.
BeIore starting engine, always make sure that
each operation lever and pedal are in neutral
position. Do not place your Ioot on the pedal.
7. Prestart inspections
Do prestart inspections (See "Inspections" on page
31.)
8. BeIore digging contact your utility companies (gas,
electric, telephone, water and sewage) to Iind out where
utility lines are buried
Precautions during operation
1. Do not carry any passengers.
Do not carry other persons on the machine during
operations. It is unbalanced and dangerous.
2. Do not remove cap oI heated radiator.
Radiator cap must be removed aIter boiling
water is cooled. The boiling water will injure you.
3. Do not touch the muIIler.
Do not touch the muIIler just aIter turning oII
engine. A hot muIIler can cause personal injury.
6
6. Check the neutral position.
BeIore starting engine, always make sure that
each operation lever and pedal are in neutral
position. Do not place your Ioot on the pedal.
7. Prestart inspections
Do prestart inspections (See "Inspections" on page
31.)
8. BeIore digging contact your utility companies (gas,
electric, telephone, water and sewage) to Iind out where
utility lines are buried
Precautions during operation
1. Do not carry any passengers.
Do not carry other persons on the machine during
operations. It is unbalanced and dangerous.
2. Do not remove cap oI heated radiator.
Radiator cap must be removed aIter boiling
water is cooled. The boiling water will injure you.
3. Do not touch the muIIler.
Do not touch the muIIler just aIter turning oII
engine. A hot muIIler can cause personal injury.
6
4. Check Ior saIety beIore going under the machine.
Do not enter under the machine with the body
jacked up with the boom and arm.
5. Do not crane.
Craning with this machine should be prohibited.
6. Check the Iorward direction.
BeIore operating the traveling lever, ensure the
machine is Iacing in the right direction.
(I.E. Dozer blade to Iront)
7. Avoid turning on the slope.
Avoid turning on a steep slope as the machine
may slip.
8. Block the crawlers.
II you park or stop the machine on a steep slope, drive
the bucket teeth into the ground and block the crawlers.
9. ConIirm the set lever pattern.
Prior to start oI engine, check the set lever
pattern without Iail.
7
4. Check Ior saIety beIore going under the machine.
Do not enter under the machine with the body
jacked up with the boom and arm.
5. Do not crane.
Craning with this machine should be prohibited.
6. Check the Iorward direction.
BeIore operating the traveling lever, ensure the
machine is Iacing in the right direction.
(I.E. Dozer blade to Iront)
7. Avoid turning on the slope.
Avoid turning on a steep slope as the machine
may slip.
8. Block the crawlers.
II you park or stop the machine on a steep slope, drive
the bucket teeth into the ground and block the crawlers.
9. ConIirm the set lever pattern.
Prior to start oI engine, check the set lever
pattern without Iail.
7
4. Check Ior saIety beIore going under the machine.
Do not enter under the machine with the body
jacked up with the boom and arm.
5. Do not crane.
Craning with this machine should be prohibited.
6. Check the Iorward direction.
BeIore operating the traveling lever, ensure the
machine is Iacing in the right direction.
(I.E. Dozer blade to Iront)
7. Avoid turning on the slope.
Avoid turning on a steep slope as the machine
may slip.
8. Block the crawlers.
II you park or stop the machine on a steep slope, drive
the bucket teeth into the ground and block the crawlers.
9. ConIirm the set lever pattern.
Prior to start oI engine, check the set lever
pattern without Iail.
7
4. Check Ior saIety beIore going under the machine.
Do not enter under the machine with the body
jacked up with the boom and arm.
5. Do not crane.
Craning with this machine should be prohibited.
6. Check the Iorward direction.
BeIore operating the traveling lever, ensure the
machine is Iacing in the right direction.
(I.E. Dozer blade to Iront)
7. Avoid turning on the slope.
Avoid turning on a steep slope as the machine
may slip.
8. Block the crawlers.
II you park or stop the machine on a steep slope, drive
the bucket teeth into the ground and block the crawlers.
9. ConIirm the set lever pattern.
Prior to start oI engine, check the set lever
pattern without Iail.
7
8
OPERATIONAL PRECAUTIONS
Do not Ilatten the ground or destroy wall by swinging.
Do not let the bucket Iree-Iall when digging.
Do not Iully extend the cylinders. Always leave a margin Ior saIety.
When traveling down a steep slope, adjust the speed to a saIety range with the traveling lever.
Do not dig or use the bucket by an impact to hammer a pile into the ground.
8
OPERATIONAL PRECAUTIONS
Do not Ilatten the ground or destroy wall by swinging.
Do not let the bucket Iree-Iall when digging.
Do not Iully extend the cylinders. Always leave a margin Ior saIety.
When traveling down a steep slope, adjust the speed to a saIety range with the traveling lever.
Do not dig or use the bucket by an impact to hammer a pile into the ground.
8
OPERATIONAL PRECAUTIONS
Do not Ilatten the ground or destroy wall by swinging.
Do not let the bucket Iree-Iall when digging.
Do not Iully extend the cylinders. Always leave a margin Ior saIety.
When traveling down a steep slope, adjust the speed to a saIety range with the traveling lever.
Do not dig or use the bucket by an impact to hammer a pile into the ground.
8
OPERATIONAL PRECAUTIONS
Do not Ilatten the ground or destroy wall by swinging.
Do not let the bucket Iree-Iall when digging.
Do not Iully extend the cylinders. Always leave a margin Ior saIety.
When traveling down a steep slope, adjust the speed to a saIety range with the traveling lever.
Do not dig or use the bucket by an impact to hammer a pile into the ground.
OPERATIONAL PRECAUTIONS
Do not travel or dig with the bucket Iorked in the ground.
Eor scooping the earth, do not deeply Iork the bucket. Instead, dig with the bucket
at shallow levels at a long distance Irom the body. This gives less load on the bucket.
This machine can be used in the water iI the swing bearing is above the water
level.
When operating near overhead power lines, enclose the power lines or apply
insulating protectors around power lines.
When traveling or transporting the machine with its boom Iolded, do not let the
bucket come in contact with the dozer.
9
OPERATIONAL PRECAUTIONS
Do not travel or dig with the bucket Iorked in the ground.
Eor scooping the earth, do not deeply Iork the bucket. Instead, dig with the bucket
at shallow levels at a long distance Irom the body. This gives less load on the bucket.
This machine can be used in the water iI the swing bearing is above the water
level.
When operating near overhead power lines, enclose the power lines or apply
insulating protectors around power lines.
When traveling or transporting the machine with its boom Iolded, do not let the
bucket come in contact with the dozer.
9
OPERATIONAL PRECAUTIONS
Do not travel or dig with the bucket Iorked in the ground.
Eor scooping the earth, do not deeply Iork the bucket. Instead, dig with the bucket
at shallow levels at a long distance Irom the body. This gives less load on the bucket.
This machine can be used in the water iI the swing bearing is above the water
level.
When operating near overhead power lines, enclose the power lines or apply
insulating protectors around power lines.
When traveling or transporting the machine with its boom Iolded, do not let the
bucket come in contact with the dozer.
9
OPERATIONAL PRECAUTIONS
Do not travel or dig with the bucket Iorked in the ground.
Eor scooping the earth, do not deeply Iork the bucket. Instead, dig with the bucket
at shallow levels at a long distance Irom the body. This gives less load on the bucket.
This machine can be used in the water iI the swing bearing is above the water
level.
When operating near overhead power lines, enclose the power lines or apply
insulating protectors around power lines.
When traveling or transporting the machine with its boom Iolded, do not let the
bucket come in contact with the dozer.
9
10
OPERATIONAL PRECAUTIONS
AIter the operation in the water, always grease the pins on the bucket, swing bearing, and other immersed parts until the
old grease comes out.
Digging while Iacing backwards, prevent the boom cylinder Irom coming into contact with the dozer.
Never operate as a crane.
10
OPERATIONAL PRECAUTIONS
AIter the operation in the water, always grease the pins on the bucket, swing bearing, and other immersed parts until the
old grease comes out.
Digging while Iacing backwards, prevent the boom cylinder Irom coming into contact with the dozer.
Never operate as a crane.
10
OPERATIONAL PRECAUTIONS
AIter the operation in the water, always grease the pins on the bucket, swing bearing, and other immersed parts until the
old grease comes out.
Digging while Iacing backwards, prevent the boom cylinder Irom coming into contact with the dozer.
Never operate as a crane.
10
OPERATIONAL PRECAUTIONS
AIter the operation in the water, always grease the pins on the bucket, swing bearing, and other immersed parts until the
old grease comes out.
Digging while Iacing backwards, prevent the boom cylinder Irom coming into contact with the dozer.
Never operate as a crane.
POSTOPERATIONAL CAUTIONS
1. Be sure to remove the key. AIter the operation, stop engine. Lower the bucket on the ground. Remove and store the
key.
2. Park the machine on a level surIace. Select a saIe and level surIace when parking the machine. II it is necessary to park on a
slope, block the crawlers with chocks at right angles to the slope. Drive the bucket teeth into the ground.
3. Postoperational inspections. AIter operation, inspect the entire machine and lubricate.
11
POSTOPERATIONAL CAUTIONS
1. Be sure to remove the key. AIter the operation, stop engine. Lower the bucket on the ground. Remove and store the
key.
2. Park the machine on a level surIace. Select a saIe and level surIace when parking the machine. II it is necessary to park on a
slope, block the crawlers with chocks at right angles to the slope. Drive the bucket teeth into the ground.
3. Postoperational inspections. AIter operation, inspect the entire machine and lubricate.
11
POSTOPERATIONAL CAUTIONS
1. Be sure to remove the key. AIter the operation, stop engine. Lower the bucket on the ground. Remove and store the
key.
2. Park the machine on a level surIace. Select a saIe and level surIace when parking the machine. II it is necessary to park on a
slope, block the crawlers with chocks at right angles to the slope. Drive the bucket teeth into the ground.
3. Postoperational inspections. AIter operation, inspect the entire machine and lubricate.
11
POSTOPERATIONAL CAUTIONS
1. Be sure to remove the key. AIter the operation, stop engine. Lower the bucket on the ground. Remove and store the
key.
2. Park the machine on a level surIace. Select a saIe and level surIace when parking the machine. II it is necessary to park on a
slope, block the crawlers with chocks at right angles to the slope. Drive the bucket teeth into the ground.
3. Postoperational inspections. AIter operation, inspect the entire machine and lubricate.
11
ORDERING PARTS AND SERVICING GUIDELINES
Order of Parts
InIorm the dealer the parts name and serial
No.(SER.No.) when ordering parts.
Troubleshooting
InIorm the dealer the type name, serial number (SER.No.) and accumulated operation hours on the hour meter.
Use the hour meter as Iollows.
Write down the values beIore and
aIter the operation in the daily
report.
The hour meter indicates when to
replace the Iilter and oil.
Engine No. (identiIication plate)
MODEL NUMBER
SERIAL NUMBER
MACHINE WEIGHT
YEAR
ENGINE
CONSTANT OUTPUT
Manufactured by NAGANO KOGYO K.K.
3297-2. Yawata.Koshoku city.387.Nagano Pref..Japan
Kgf
PS
12
ORDERING PARTS AND SERVICING GUIDELINES
Order of Parts
InIorm the dealer the parts name and serial
No.(SER.No.) when ordering parts.
Troubleshooting
InIorm the dealer the type name, serial number (SER.No.) and accumulated operation hours on the hour meter.
Use the hour meter as Iollows.
Write down the values beIore and
aIter the operation in the daily
report.
The hour meter indicates when to
replace the Iilter and oil.
Engine No. (identiIication plate)
MODEL NUMBER
SERIAL NUMBER
MACHINE WEIGHT
YEAR
ENGINE
CONSTANT OUTPUT
Manufactured by NAGANO KOGYO K.K.
3297-2. Yawata.Koshoku city.387.Nagano Pref..Japan
Kgf
PS
12
ORDERING PARTS AND SERVICING GUIDELINES
Order of Parts
InIorm the dealer the parts name and serial
No.(SER.No.) when ordering parts.
Troubleshooting
InIorm the dealer the type name, serial number (SER.No.) and accumulated operation hours on the hour meter.
Use the hour meter as Iollows.
Write down the values beIore and
aIter the operation in the daily
report.
The hour meter indicates when to
replace the Iilter and oil.
Engine No. (identiIication plate)
MODEL NUMBER
SERIAL NUMBER
MACHINE WEIGHT
YEAR
ENGINE
CONSTANT OUTPUT
Manufactured by NAGANO KOGYO K.K.
3297-2. Yawata.Koshoku city.387.Nagano Pref..Japan
Kgf
PS
12
ORDERING PARTS AND SERVICING GUIDELINES
Order of Parts
InIorm the dealer the parts name and serial
No.(SER.No.) when ordering parts.
Troubleshooting
InIorm the dealer the type name, serial number (SER.No.) and accumulated operation hours on the hour meter.
Use the hour meter as Iollows.
Write down the values beIore and
aIter the operation in the daily
report.
The hour meter indicates when to
replace the Iilter and oil.
Engine No. (identiIication plate)
MODEL NUMBER
SERIAL NUMBER
MACHINE WEIGHT
YEAR
ENGINE
CONSTANT OUTPUT
Manufactured by NAGANO KOGYO K.K.
3297-2. Yawata.Koshoku city.387.Nagano Pref..Japan
Kgf
PS
12
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Boom
2. Boom cylinder
3. Arm cylinder
4. Arm
5. Bucket cylinder
6. Bucket links
7. Dump link
8. Bucket
9. Swing Irame
10. Engine cover
11. Euel tank
12. Hydraulic tank
13. RooI
14. Counter weight
15. Operator's seat
16. Crawler
17. Dozer blade
18. Dozer cylinder
19. Drive/Track motor
20. Track roller
21. Eront idler
22. Grease cylinder
23. Swing post
24. Swing cylinder
25. Operation levers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
13
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Boom
2. Boom cylinder
3. Arm cylinder
4. Arm
5. Bucket cylinder
6. Bucket links
7. Dump link
8. Bucket
9. Swing Irame
10. Engine cover
11. Euel tank
12. Hydraulic tank
13. RooI
14. Counter weight
15. Operator's seat
16. Crawler
17. Dozer blade
18. Dozer cylinder
19. Drive/Track motor
20. Track roller
21. Eront idler
22. Grease cylinder
23. Swing post
24. Swing cylinder
25. Operation levers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
13
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Boom
2. Boom cylinder
3. Arm cylinder
4. Arm
5. Bucket cylinder
6. Bucket links
7. Dump link
8. Bucket
9. Swing Irame
10. Engine cover
11. Euel tank
12. Hydraulic tank
13. RooI
14. Counter weight
15. Operator's seat
16. Crawler
17. Dozer blade
18. Dozer cylinder
19. Drive/Track motor
20. Track roller
21. Eront idler
22. Grease cylinder
23. Swing post
24. Swing cylinder
25. Operation levers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
13
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Boom
2. Boom cylinder
3. Arm cylinder
4. Arm
5. Bucket cylinder
6. Bucket links
7. Dump link
8. Bucket
9. Swing Irame
10. Engine cover
11. Euel tank
12. Hydraulic tank
13. RooI
14. Counter weight
15. Operator's seat
16. Crawler
17. Dozer blade
18. Dozer cylinder
19. Drive/Track motor
20. Track roller
21. Eront idler
22. Grease cylinder
23. Swing post
24. Swing cylinder
25. Operation levers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
13
14
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Meter unit
2. Starter switch
3. Horn switch
4. Euse box
5. Right operation lever
6. LeIt operation lever
7. Accelerator lever
8. Dozer operation lever
9. Right traveling lever
10. LeIt traveling lever
11. Aux. Hyd. pedal
12. Swing pedal
13. Operation lock lever
14. Swing lock pin
15. Aux. hyd. select lever
1
2
7
5
3
8 12 9
10
11 13
6
4
15 14
4 10
5
6
7
8
9
1
2
3
1. Water temperature meter
2. Euel gauge
3. Hour meter
4. Water temperature lamp
5. Engine oil pressure lamp
6. Charge lamp
7. Euel lamp
8. Glow lamp
9. Air Iilter lamp
10. Head light switch
14
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Meter unit
2. Starter switch
3. Horn switch
4. Euse box
5. Right operation lever
6. LeIt operation lever
7. Accelerator lever
8. Dozer operation lever
9. Right traveling lever
10. LeIt traveling lever
11. Aux. Hyd. pedal
12. Swing pedal
13. Operation lock lever
14. Swing lock pin
15. Aux. hyd. select lever
1
2
7
5
3
8 12 9
10
11 13
6
4
15 14
4 10
5
6
7
8
9
1
2
3
1. Water temperature meter
2. Euel gauge
3. Hour meter
4. Water temperature lamp
5. Engine oil pressure lamp
6. Charge lamp
7. Euel lamp
8. Glow lamp
9. Air Iilter lamp
10. Head light switch
14
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Meter unit
2. Starter switch
3. Horn switch
4. Euse box
5. Right operation lever
6. LeIt operation lever
7. Accelerator lever
8. Dozer operation lever
9. Right traveling lever
10. LeIt traveling lever
11. Aux. Hyd. pedal
12. Swing pedal
13. Operation lock lever
14. Swing lock pin
15. Aux. hyd. select lever
1
2
7
5
3
8 12 9
10
11 13
6
4
15 14
4 10
5
6
7
8
9
1
2
3
1. Water temperature meter
2. Euel gauge
3. Hour meter
4. Water temperature lamp
5. Engine oil pressure lamp
6. Charge lamp
7. Euel lamp
8. Glow lamp
9. Air Iilter lamp
10. Head light switch
14
PART NAMES AND EXPLANATION OF EACH DEVICE
1. Meter unit
2. Starter switch
3. Horn switch
4. Euse box
5. Right operation lever
6. LeIt operation lever
7. Accelerator lever
8. Dozer operation lever
9. Right traveling lever
10. LeIt traveling lever
11. Aux. Hyd. pedal
12. Swing pedal
13. Operation lock lever
14. Swing lock pin
15. Aux. hyd. select lever
1
2
7
5
3
8 12 9
10
11 13
6
4
15 14
4 10
5
6
7
8
9
1
2
3
1. Water temperature meter
2. Euel gauge
3. Hour meter
4. Water temperature lamp
5. Engine oil pressure lamp
6. Charge lamp
7. Euel lamp
8. Glow lamp
9. Air Iilter lamp
10. Head light switch
EXPLANATION OF EACH DEVICE
1. Water temperature meter
Indicates the temperature oI engine coolant. It's normal iI the meter indicates the green area aIter started engine and warmed
up. II the meter indicates the red area, open the engine hood to cool the engine. When the pointer goes down, stop engine
and check the level oI radiator tank, leakage, the dirt oI radiator core and looseness oI the Ian belt aIter the engine cooled.
2. Fuel gauge
Indicate the level oI Iuel in the tank. ReIill tank when the pointer is close to "E".
WARNING LIGHTS
3. Hour Meter
Indicates the accumulated operating time in 0.1 hours (six minutes), which is the reIerence Ior the inspection.
4. Water temperature lamp
Light when the temperature oI engine coolant rises abnormally high. II it is lit, supply the coolant to the overIlow tank.
5. Engine oil pressure lamp
Light when the engine oil pressure drops abnormally and also when the engine stops. AIter the engine stopped check the
lubricating system. (ReIer to page 31 Inspections.)
6. Charge lamp
Light when trouble occurs on the battery charging system. II the lamp is lit, check the charging system and Ian belt tension.
7. Fuel lamp
Light when Iuel remains only 5 l(1.3 U.S. gal) in the tank.
8. Glow lamp
Turning the key switch ON lights Ior six seconds. II the engine is warmed up, it does not light.
9. Air filter lamp
Light when air cleaner element clogged.
(Eor details reIer to page 51)
10. Head light switch
Press the switch to light the lamp mounted on the cabin and also light the panel illumination lamp.
15
EXPLANATION OF EACH DEVICE
1. Water temperature meter
Indicates the temperature oI engine coolant. It's normal iI the meter indicates the green area aIter started engine and warmed
up. II the meter indicates the red area, open the engine hood to cool the engine. When the pointer goes down, stop engine
and check the level oI radiator tank, leakage, the dirt oI radiator core and looseness oI the Ian belt aIter the engine cooled.
2. Fuel gauge
Indicate the level oI Iuel in the tank. ReIill tank when the pointer is close to "E".
WARNING LIGHTS
3. Hour Meter
Indicates the accumulated operating time in 0.1 hours (six minutes), which is the reIerence Ior the inspection.
4. Water temperature lamp
Light when the temperature oI engine coolant rises abnormally high. II it is lit, supply the coolant to the overIlow tank.
5. Engine oil pressure lamp
Light when the engine oil pressure drops abnormally and also when the engine stops. AIter the engine stopped check the
lubricating system. (ReIer to page 31 Inspections.)
6. Charge lamp
Light when trouble occurs on the battery charging system. II the lamp is lit, check the charging system and Ian belt tension.
7. Fuel lamp
Light when Iuel remains only 5 l(1.3 U.S. gal) in the tank.
8. Glow lamp
Turning the key switch ON lights Ior six seconds. II the engine is warmed up, it does not light.
9. Air filter lamp
Light when air cleaner element clogged.
(Eor details reIer to page 51)
10. Head light switch
Press the switch to light the lamp mounted on the cabin and also light the panel illumination lamp.
15
EXPLANATION OF EACH DEVICE
1. Water temperature meter
Indicates the temperature oI engine coolant. It's normal iI the meter indicates the green area aIter started engine and warmed
up. II the meter indicates the red area, open the engine hood to cool the engine. When the pointer goes down, stop engine
and check the level oI radiator tank, leakage, the dirt oI radiator core and looseness oI the Ian belt aIter the engine cooled.
2. Fuel gauge
Indicate the level oI Iuel in the tank. ReIill tank when the pointer is close to "E".
WARNING LIGHTS
3. Hour Meter
Indicates the accumulated operating time in 0.1 hours (six minutes), which is the reIerence Ior the inspection.
4. Water temperature lamp
Light when the temperature oI engine coolant rises abnormally high. II it is lit, supply the coolant to the overIlow tank.
5. Engine oil pressure lamp
Light when the engine oil pressure drops abnormally and also when the engine stops. AIter the engine stopped check the
lubricating system. (ReIer to page 31 Inspections.)
6. Charge lamp
Light when trouble occurs on the battery charging system. II the lamp is lit, check the charging system and Ian belt tension.
7. Fuel lamp
Light when Iuel remains only 5 l(1.3 U.S. gal) in the tank.
8. Glow lamp
Turning the key switch ON lights Ior six seconds. II the engine is warmed up, it does not light.
9. Air filter lamp
Light when air cleaner element clogged.
(Eor details reIer to page 51)
10. Head light switch
Press the switch to light the lamp mounted on the cabin and also light the panel illumination lamp.
15
EXPLANATION OF EACH DEVICE
1. Water temperature meter
Indicates the temperature oI engine coolant. It's normal iI the meter indicates the green area aIter started engine and warmed
up. II the meter indicates the red area, open the engine hood to cool the engine. When the pointer goes down, stop engine
and check the level oI radiator tank, leakage, the dirt oI radiator core and looseness oI the Ian belt aIter the engine cooled.
2. Fuel gauge
Indicate the level oI Iuel in the tank. ReIill tank when the pointer is close to "E".
WARNING LIGHTS
3. Hour Meter
Indicates the accumulated operating time in 0.1 hours (six minutes), which is the reIerence Ior the inspection.
4. Water temperature lamp
Light when the temperature oI engine coolant rises abnormally high. II it is lit, supply the coolant to the overIlow tank.
5. Engine oil pressure lamp
Light when the engine oil pressure drops abnormally and also when the engine stops. AIter the engine stopped check the
lubricating system. (ReIer to page 31 Inspections.)
6. Charge lamp
Light when trouble occurs on the battery charging system. II the lamp is lit, check the charging system and Ian belt tension.
7. Fuel lamp
Light when Iuel remains only 5 l(1.3 U.S. gal) in the tank.
8. Glow lamp
Turning the key switch ON lights Ior six seconds. II the engine is warmed up, it does not light.
9. Air filter lamp
Light when air cleaner element clogged.
(Eor details reIer to page 51)
10. Head light switch
Press the switch to light the lamp mounted on the cabin and also light the panel illumination lamp.
15
16
11. Starter switch
Use the main switch as a starter switch to start the
engine.
(Eor details reIer to page 21)
12. Horn switch
Press the switch on the right operation lever to sound
the alarm.
13. Fuse box
Turn the knob to remove the cover. Eour Iuses Ior 10A
each are Iixed on the circuit Ior saIety.
AIter turning the starter switch OEE, replace the Iuse.
EXPLANATION OF EACH DEVICE
Starter
Switch
Horn
Switch
Fuse
Box
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
14. Operation lever (Standard)
Ensure starter switch is
off before replacing fuses
WARNING
To avoid bodily injury,
operate controls from the
operator`s seat only.
WARNING
ISO Pattern
16
11. Starter switch
Use the main switch as a starter switch to start the
engine.
(Eor details reIer to page 21)
12. Horn switch
Press the switch on the right operation lever to sound
the alarm.
13. Fuse box
Turn the knob to remove the cover. Eour Iuses Ior 10A
each are Iixed on the circuit Ior saIety.
AIter turning the starter switch OEE, replace the Iuse.
EXPLANATION OF EACH DEVICE
Starter
Switch
Horn
Switch
Fuse
Box
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
14. Operation lever (Standard)
Ensure starter switch is
off before replacing fuses
WARNING
To avoid bodily injury,
operate controls from the
operator`s seat only.
WARNING
ISO Pattern
16
11. Starter switch
Use the main switch as a starter switch to start the
engine.
(Eor details reIer to page 21)
12. Horn switch
Press the switch on the right operation lever to sound
the alarm.
13. Fuse box
Turn the knob to remove the cover. Eour Iuses Ior 10A
each are Iixed on the circuit Ior saIety.
AIter turning the starter switch OEE, replace the Iuse.
EXPLANATION OF EACH DEVICE
Starter
Switch
Horn
Switch
Fuse
Box
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
14. Operation lever (Standard)
Ensure starter switch is
off before replacing fuses
WARNING
To avoid bodily injury,
operate controls from the
operator`s seat only.
WARNING
ISO Pattern
16
11. Starter switch
Use the main switch as a starter switch to start the
engine.
(Eor details reIer to page 21)
12. Horn switch
Press the switch on the right operation lever to sound
the alarm.
13. Fuse box
Turn the knob to remove the cover. Eour Iuses Ior 10A
each are Iixed on the circuit Ior saIety.
AIter turning the starter switch OEE, replace the Iuse.
EXPLANATION OF EACH DEVICE
Starter
Switch
Horn
Switch
Fuse
Box
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
14. Operation lever (Standard)
Ensure starter switch is
off before replacing fuses
WARNING
To avoid bodily injury,
operate controls from the
operator`s seat only.
WARNING
ISO Pattern
15. Selector Valve Operation
As an option, the machine can be Iitted with a selector
valve that allows the operator to choose between the
Standard ISO pattern or the optional SAE control
pattern. Change to the SAE pattern as Iollows.
1. Locate valve under leIt hand control lever.
2. Loosen the wing nut until the screw clears the
lock hole in position 1 on top oI the selector
valve.
3. Move the selector valve to position 2. Tighten
the wing nut until the lever is locked in place.
4. Check that the control lever pattern is correct
beIore operating.
EXPLANATION OF EACH DEVICE
Selector Valve
Position 2
Wing Nut
Position 1
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
SAE Pattern
17
15. Selector Valve Operation
As an option, the machine can be Iitted with a selector
valve that allows the operator to choose between the
Standard ISO pattern or the optional SAE control
pattern. Change to the SAE pattern as Iollows.
1. Locate valve under leIt hand control lever.
2. Loosen the wing nut until the screw clears the
lock hole in position 1 on top oI the selector
valve.
3. Move the selector valve to position 2. Tighten
the wing nut until the lever is locked in place.
4. Check that the control lever pattern is correct
beIore operating.
EXPLANATION OF EACH DEVICE
Selector Valve
Position 2
Wing Nut
Position 1
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
SAE Pattern
17
15. Selector Valve Operation
As an option, the machine can be Iitted with a selector
valve that allows the operator to choose between the
Standard ISO pattern or the optional SAE control
pattern. Change to the SAE pattern as Iollows.
1. Locate valve under leIt hand control lever.
2. Loosen the wing nut until the screw clears the
lock hole in position 1 on top oI the selector
valve.
3. Move the selector valve to position 2. Tighten
the wing nut until the lever is locked in place.
4. Check that the control lever pattern is correct
beIore operating.
EXPLANATION OF EACH DEVICE
Selector Valve
Position 2
Wing Nut
Position 1
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
SAE Pattern
17
15. Selector Valve Operation
As an option, the machine can be Iitted with a selector
valve that allows the operator to choose between the
Standard ISO pattern or the optional SAE control
pattern. Change to the SAE pattern as Iollows.
1. Locate valve under leIt hand control lever.
2. Loosen the wing nut until the screw clears the
lock hole in position 1 on top oI the selector
valve.
3. Move the selector valve to position 2. Tighten
the wing nut until the lever is locked in place.
4. Check that the control lever pattern is correct
beIore operating.
EXPLANATION OF EACH DEVICE
Selector Valve
Position 2
Wing Nut
Position 1
Boom up
Bucket open
Boom down
Bucket
close
Arm out
Swing leIt Swing right
Arm in
SAE Pattern
17
18
16. Traveling lever
Push this lever Iorward or rearward to start the
traveling. ConIirm which way you are Iacing to
operate the lever.
Right traveling (dozer at the front)
1. Right crawler traveling Iorward
2. Right crawler traveling backward
Left traveling (dozer at the front)
3. LeIt crawler traveling Iorward
4. LeIt crawler traveling backward
17. Dozer operation lever
1. Dozer raising
2. Dozer lowering
18. Acceleration lever
Vary the revolution oI engine. Push Iorward the lever
to reduce the revolutions and pull backward to increase
the revolutions.
19. Swing operation pedal
1. Right swing
2. LeIt swing
20. Pedal lock
1. Lock
2. Unlock
EXPLANATION OF EACH DEVICE
1
2
3
4
1
2
Hi Lo
2
1
2
1
18
16. Traveling lever
Push this lever Iorward or rearward to start the
traveling. ConIirm which way you are Iacing to
operate the lever.
Right traveling (dozer at the front)
1. Right crawler traveling Iorward
2. Right crawler traveling backward
Left traveling (dozer at the front)
3. LeIt crawler traveling Iorward
4. LeIt crawler traveling backward
17. Dozer operation lever
1. Dozer raising
2. Dozer lowering
18. Acceleration lever
Vary the revolution oI engine. Push Iorward the lever
to reduce the revolutions and pull backward to increase
the revolutions.
19. Swing operation pedal
1. Right swing
2. LeIt swing
20. Pedal lock
1. Lock
2. Unlock
EXPLANATION OF EACH DEVICE
1
2
3
4
1
2
Hi Lo
2
1
2
1
18
16. Traveling lever
Push this lever Iorward or rearward to start the
traveling. ConIirm which way you are Iacing to
operate the lever.
Right traveling (dozer at the front)
1. Right crawler traveling Iorward
2. Right crawler traveling backward
Left traveling (dozer at the front)
3. LeIt crawler traveling Iorward
4. LeIt crawler traveling backward
17. Dozer operation lever
1. Dozer raising
2. Dozer lowering
18. Acceleration lever
Vary the revolution oI engine. Push Iorward the lever
to reduce the revolutions and pull backward to increase
the revolutions.
19. Swing operation pedal
1. Right swing
2. LeIt swing
20. Pedal lock
1. Lock
2. Unlock
EXPLANATION OF EACH DEVICE
1
2
3
4
1
2
Hi Lo
2
1
2
1
18
16. Traveling lever
Push this lever Iorward or rearward to start the
traveling. ConIirm which way you are Iacing to
operate the lever.
Right traveling (dozer at the front)
1. Right crawler traveling Iorward
2. Right crawler traveling backward
Left traveling (dozer at the front)
3. LeIt crawler traveling Iorward
4. LeIt crawler traveling backward
17. Dozer operation lever
1. Dozer raising
2. Dozer lowering
18. Acceleration lever
Vary the revolution oI engine. Push Iorward the lever
to reduce the revolutions and pull backward to increase
the revolutions.
19. Swing operation pedal
1. Right swing
2. LeIt swing
20. Pedal lock
1. Lock
2. Unlock
EXPLANATION OF EACH DEVICE
1
2
3
4
1
2
Hi Lo
2
1
2
1
21. Aux. Hyd. operation pedal
Aux. Hyd. operational when pedal is depressed.
Aux. Hyd. is oII when pedal is released.
II single piping is Iitted then only one side oI pedal is
operative.
22. Operation lock lever
Pull the lever when you get on or oII the machine,
lever stand raises. To turn, lock the lever Iirmly and
check.
When lever stand raises, the machine doesn't work even
iI you operate the right and leIt operation levers. Except
right and leIt traveling, dozer and boom swing can be
worked even the lock lever is pulled.
23. Swing lock pin
Lock the swing when traveling or transporting the
machine.
Swing lock pin can be eIIective whether the upper
structure Iaces Iorward or backward.
24. Aux. Hyd. select lever
Select the lever Ior the purpose oI using Aux Hyd.
1. Breaker (to Tank)
2. Swing bucket, etc. (to Valve)
EXPLANATION OF EACH DEVICE
2
1
The swing lock pin can
be engaged whether the
upper structure faces
forward or backward
CAUTION
19
!
21. Aux. Hyd. operation pedal
Aux. Hyd. operational when pedal is depressed.
Aux. Hyd. is oII when pedal is released.
II single piping is Iitted then only one side oI pedal is
operative.
22. Operation lock lever
Pull the lever when you get on or oII the machine,
lever stand raises. To turn, lock the lever Iirmly and
check.
When lever stand raises, the machine doesn't work even
iI you operate the right and leIt operation levers. Except
right and leIt traveling, dozer and boom swing can be
worked even the lock lever is pulled.
23. Swing lock pin
Lock the swing when traveling or transporting the
machine.
Swing lock pin can be eIIective whether the upper
structure Iaces Iorward or backward.
24. Aux. Hyd. select lever
Select the lever Ior the purpose oI using Aux Hyd.
1. Breaker (to Tank)
2. Swing bucket, etc. (to Valve)
EXPLANATION OF EACH DEVICE
2
1
The swing lock pin can
be engaged whether the
upper structure faces
forward or backward
CAUTION
19
!
21. Aux. Hyd. operation pedal
Aux. Hyd. operational when pedal is depressed.
Aux. Hyd. is oII when pedal is released.
II single piping is Iitted then only one side oI pedal is
operative.
22. Operation lock lever
Pull the lever when you get on or oII the machine,
lever stand raises. To turn, lock the lever Iirmly and
check.
When lever stand raises, the machine doesn't work even
iI you operate the right and leIt operation levers. Except
right and leIt traveling, dozer and boom swing can be
worked even the lock lever is pulled.
23. Swing lock pin
Lock the swing when traveling or transporting the
machine.
Swing lock pin can be eIIective whether the upper
structure Iaces Iorward or backward.
24. Aux. Hyd. select lever
Select the lever Ior the purpose oI using Aux Hyd.
1. Breaker (to Tank)
2. Swing bucket, etc. (to Valve)
EXPLANATION OF EACH DEVICE
2
1
The swing lock pin can
be engaged whether the
upper structure faces
forward or backward
CAUTION
19
!
21. Aux. Hyd. operation pedal
Aux. Hyd. operational when pedal is depressed.
Aux. Hyd. is oII when pedal is released.
II single piping is Iitted then only one side oI pedal is
operative.
22. Operation lock lever
Pull the lever when you get on or oII the machine,
lever stand raises. To turn, lock the lever Iirmly and
check.
When lever stand raises, the machine doesn't work even
iI you operate the right and leIt operation levers. Except
right and leIt traveling, dozer and boom swing can be
worked even the lock lever is pulled.
23. Swing lock pin
Lock the swing when traveling or transporting the
machine.
Swing lock pin can be eIIective whether the upper
structure Iaces Iorward or backward.
24. Aux. Hyd. select lever
Select the lever Ior the purpose oI using Aux Hyd.
1. Breaker (to Tank)
2. Swing bucket, etc. (to Valve)
EXPLANATION OF EACH DEVICE
2
1
The swing lock pin can
be engaged whether the
upper structure faces
forward or backward
CAUTION
19
!
20
OPERATION
Machine Running-in
1. Precautions to running in the new machine
The new machine was inspected and adjusted completely on delivery Irom the Iactory. However, be sure to inspect it as
Iollows beIore use. Eor the Iirst 50 service hours, warm up at 60 to 70 oI Iull load.
Do not operate at an unreasonable load. Trouble may occur, thereby reducing the service liIe.
Body
Check iI there is any damaged or loose parts caused during transit.
Control system
Check iI there is an abnormality in the operation oI the control lever and control unit.
Cooling system
Check iI the radiator coolant is Iilled to the speciIied level and water leakage occurs or not. Check also expansion
tank level
Engine system
Check that engine is Iilled with the proper amount oI oil.
Check Ior oil and Iuel leakages.
Electric system
Check Ior loose wiring, battery Iluid level and loose terminal connections.
Greasing and lubricating
Check iI the parts are greased and lubricated suIIiciently.
Check the crawler tension.
2. Replacing engine oil and elements of the new machine
Replace engine oil and elements oI the new machine aIter 50 service hours.
Replace the line Iilter oI the new machine aIter 100 service hours.
Clean the suction Iilter oI the new machine aIter 100 service hours.
Replace the gear oil Ior the traveling and reduction gears oI the new machine
aIter 200 service hours.
Eor the lubricant and grease supplied, see 'Lubricants on page 63.
20
OPERATION
Machine Running-in
1. Precautions to running in the new machine
The new machine was inspected and adjusted completely on delivery Irom the Iactory. However, be sure to inspect it as
Iollows beIore use. Eor the Iirst 50 service hours, warm up at 60 to 70 oI Iull load.
Do not operate at an unreasonable load. Trouble may occur, thereby reducing the service liIe.
Body
Check iI there is any damaged or loose parts caused during transit.
Control system
Check iI there is an abnormality in the operation oI the control lever and control unit.
Cooling system
Check iI the radiator coolant is Iilled to the speciIied level and water leakage occurs or not. Check also expansion
tank level
Engine system
Check that engine is Iilled with the proper amount oI oil.
Check Ior oil and Iuel leakages.
Electric system
Check Ior loose wiring, battery Iluid level and loose terminal connections.
Greasing and lubricating
Check iI the parts are greased and lubricated suIIiciently.
Check the crawler tension.
2. Replacing engine oil and elements of the new machine
Replace engine oil and elements oI the new machine aIter 50 service hours.
Replace the line Iilter oI the new machine aIter 100 service hours.
Clean the suction Iilter oI the new machine aIter 100 service hours.
Replace the gear oil Ior the traveling and reduction gears oI the new machine
aIter 200 service hours.
Eor the lubricant and grease supplied, see 'Lubricants on page 63.
20
OPERATION
Machine Running-in
1. Precautions to running in the new machine
The new machine was inspected and adjusted completely on delivery Irom the Iactory. However, be sure to inspect it as
Iollows beIore use. Eor the Iirst 50 service hours, warm up at 60 to 70 oI Iull load.
Do not operate at an unreasonable load. Trouble may occur, thereby reducing the service liIe.
Body
Check iI there is any damaged or loose parts caused during transit.
Control system
Check iI there is an abnormality in the operation oI the control lever and control unit.
Cooling system
Check iI the radiator coolant is Iilled to the speciIied level and water leakage occurs or not. Check also expansion
tank level
Engine system
Check that engine is Iilled with the proper amount oI oil.
Check Ior oil and Iuel leakages.
Electric system
Check Ior loose wiring, battery Iluid level and loose terminal connections.
Greasing and lubricating
Check iI the parts are greased and lubricated suIIiciently.
Check the crawler tension.
2. Replacing engine oil and elements of the new machine
Replace engine oil and elements oI the new machine aIter 50 service hours.
Replace the line Iilter oI the new machine aIter 100 service hours.
Clean the suction Iilter oI the new machine aIter 100 service hours.
Replace the gear oil Ior the traveling and reduction gears oI the new machine
aIter 200 service hours.
Eor the lubricant and grease supplied, see 'Lubricants on page 63.
20
OPERATION
Machine Running-in
1. Precautions to running in the new machine
The new machine was inspected and adjusted completely on delivery Irom the Iactory. However, be sure to inspect it as
Iollows beIore use. Eor the Iirst 50 service hours, warm up at 60 to 70 oI Iull load.
Do not operate at an unreasonable load. Trouble may occur, thereby reducing the service liIe.
Body
Check iI there is any damaged or loose parts caused during transit.
Control system
Check iI there is an abnormality in the operation oI the control lever and control unit.
Cooling system
Check iI the radiator coolant is Iilled to the speciIied level and water leakage occurs or not. Check also expansion
tank level
Engine system
Check that engine is Iilled with the proper amount oI oil.
Check Ior oil and Iuel leakages.
Electric system
Check Ior loose wiring, battery Iluid level and loose terminal connections.
Greasing and lubricating
Check iI the parts are greased and lubricated suIIiciently.
Check the crawler tension.
2. Replacing engine oil and elements of the new machine
Replace engine oil and elements oI the new machine aIter 50 service hours.
Replace the line Iilter oI the new machine aIter 100 service hours.
Clean the suction Iilter oI the new machine aIter 100 service hours.
Replace the gear oil Ior the traveling and reduction gears oI the new machine
aIter 200 service hours.
Eor the lubricant and grease supplied, see 'Lubricants on page 63.
OPERATION
Before Starting Engine
Execute the inspection beIore starting operation. (Eor checking items, reIer to 'Inspections on page 31.)
Make sure oI the traveling lever at neutral.
Push back the acceleration lever to revolve the engine at medium speed or more.
It is normal that the lamps light up at 'ON and should go out as the engine starts
running.
Starting Procedure
1) Turn the starter switch key Irom OEE to ON, and
the charger and lamp circuits are electriIied.
Keep this position until the glow lamp light goes
out. (About six seconds)
2) Turn the key Irom ON to START. Engine starts running.
3) Immediately take your hand oII the key when the
engine starts.
4) Return the accelerator lever to the idling position
to warm up the machine.
START
OEE
ON GLOW
START
OEE
ON GLOW
21
Never turn the key to
START while the engine
is running.
IMPORTANT
OPERATION
Before Starting Engine
Execute the inspection beIore starting operation. (Eor checking items, reIer to 'Inspections on page 31.)
Make sure oI the traveling lever at neutral.
Push back the acceleration lever to revolve the engine at medium speed or more.
It is normal that the lamps light up at 'ON and should go out as the engine starts
running.
Starting Procedure
1) Turn the starter switch key Irom OEE to ON, and
the charger and lamp circuits are electriIied.
Keep this position until the glow lamp light goes
out. (About six seconds)
2) Turn the key Irom ON to START. Engine starts running.
3) Immediately take your hand oII the key when the
engine starts.
4) Return the accelerator lever to the idling position
to warm up the machine.
START
OEE
ON GLOW
START
OEE
ON GLOW
21
Never turn the key to
START while the engine
is running.
IMPORTANT
OPERATION
Before Starting Engine
Execute the inspection beIore starting operation. (Eor checking items, reIer to 'Inspections on page 31.)
Make sure oI the traveling lever at neutral.
Push back the acceleration lever to revolve the engine at medium speed or more.
It is normal that the lamps light up at 'ON and should go out as the engine starts
running.
Starting Procedure
1) Turn the starter switch key Irom OEE to ON, and
the charger and lamp circuits are electriIied.
Keep this position until the glow lamp light goes
out. (About six seconds)
2) Turn the key Irom ON to START. Engine starts running.
3) Immediately take your hand oII the key when the
engine starts.
4) Return the accelerator lever to the idling position
to warm up the machine.
START
OEE
ON GLOW
START
OEE
ON GLOW
21
Never turn the key to
START while the engine
is running.
IMPORTANT
OPERATION
Before Starting Engine
Execute the inspection beIore starting operation. (Eor checking items, reIer to 'Inspections on page 31.)
Make sure oI the traveling lever at neutral.
Push back the acceleration lever to revolve the engine at medium speed or more.
It is normal that the lamps light up at 'ON and should go out as the engine starts
running.
Starting Procedure
1) Turn the starter switch key Irom OEE to ON, and
the charger and lamp circuits are electriIied.
Keep this position until the glow lamp light goes
out. (About six seconds)
2) Turn the key Irom ON to START. Engine starts running.
3) Immediately take your hand oII the key when the
engine starts.
4) Return the accelerator lever to the idling position
to warm up the machine.
START
OEE
ON GLOW
START
OEE
ON GLOW
21
Never turn the key to
START while the engine
is running.
IMPORTANT
22
OPERATION
Precautions on Handling the Starter
Do not continue to operate the starter Ior more than 15 seconds. To do so will damage the starter.
Restarting
II engine does not start, return the key to the OEE position and try again aIter 30 seconds.
If engine does not start after several attempts, check the fuel level and
battery.
Precaution after Starting Engine
1) Idle engine until the warning lights go out.
2) Do not accelerate rapidly until the machine is warmed up.
Stopping Engine
1) Slowly work leIt and right operation levers to lower the bucket on the ground.
2) BeIore stopping engine, idle it Ior about
5 minutes to cool it down.
3) Return the accelerator lever to engine stop
position.
4) Return the starter switch to OEE and remove the
key.
START
OEE
ON GLOW
Leaving the starter
switch ON after stopping
engine will drain the
battery. Always turn off
the starter switch after
stopping engine.
IMPORTANT
22
OPERATION
Precautions on Handling the Starter
Do not continue to operate the starter Ior more than 15 seconds. To do so will damage the starter.
Restarting
II engine does not start, return the key to the OEE position and try again aIter 30 seconds.
If engine does not start after several attempts, check the fuel level and
battery.
Precaution after Starting Engine
1) Idle engine until the warning lights go out.
2) Do not accelerate rapidly until the machine is warmed up.
Stopping Engine
1) Slowly work leIt and right operation levers to lower the bucket on the ground.
2) BeIore stopping engine, idle it Ior about
5 minutes to cool it down.
3) Return the accelerator lever to engine stop
position.
4) Return the starter switch to OEE and remove the
key.
START
OEE
ON GLOW
Leaving the starter
switch ON after stopping
engine will drain the
battery. Always turn off
the starter switch after
stopping engine.
IMPORTANT
22
OPERATION
Precautions on Handling the Starter
Do not continue to operate the starter Ior more than 15 seconds. To do so will damage the starter.
Restarting
II engine does not start, return the key to the OEE position and try again aIter 30 seconds.
If engine does not start after several attempts, check the fuel level and
battery.
Precaution after Starting Engine
1) Idle engine until the warning lights go out.
2) Do not accelerate rapidly until the machine is warmed up.
Stopping Engine
1) Slowly work leIt and right operation levers to lower the bucket on the ground.
2) BeIore stopping engine, idle it Ior about
5 minutes to cool it down.
3) Return the accelerator lever to engine stop
position.
4) Return the starter switch to OEE and remove the
key.
START
OEE
ON GLOW
Leaving the starter
switch ON after stopping
engine will drain the
battery. Always turn off
the starter switch after
stopping engine.
IMPORTANT
22
OPERATION
Precautions on Handling the Starter
Do not continue to operate the starter Ior more than 15 seconds. To do so will damage the starter.
Restarting
II engine does not start, return the key to the OEE position and try again aIter 30 seconds.
If engine does not start after several attempts, check the fuel level and
battery.
Precaution after Starting Engine
1) Idle engine until the warning lights go out.
2) Do not accelerate rapidly until the machine is warmed up.
Stopping Engine
1) Slowly work leIt and right operation levers to lower the bucket on the ground.
2) BeIore stopping engine, idle it Ior about
5 minutes to cool it down.
3) Return the accelerator lever to engine stop
position.
4) Return the starter switch to OEE and remove the
key.
START
OEE
ON GLOW
Leaving the starter
switch ON after stopping
engine will drain the
battery. Always turn off
the starter switch after
stopping engine.
IMPORTANT
OPERATION
Traveling
1) Eold the boom and arm. Raise them to 40 to 50 cm (15"-20") above the ground.
2) Raise the dozer blade at Iull stroke.
3) Check the direction you want to go. Move the leIt and right crawler operation levers Iorward Ior Iorward traveling or
backward Ior reverse traveling.
Turning the Stationary Machine
Push the leIt crawler lever Iorward to turn the machine to the right. Pull the lever backward to turn the rear oI the machine to the
right.
Turning the Machine while Traveling
1) LeIt pivot-turn
Return the leIt crawler lever to neutral position
with the right crawler lever pushed Iorward.
2) Right pivot-turn
Return the right crawler lever to the neutral
position with the leIt crawler lever pushed
Iorward.
3) Spin turning
Turning the leIt crawler lever Iorward and right
crawler lever backward and the machine spins
rightward. Eor the spin leItward, operate in the
opposite way.
Turning radius
Turning radius
Stop
Do not make a spin turn
at high speed.
WARNING
23
OPERATION
Traveling
1) Eold the boom and arm. Raise them to 40 to 50 cm (15"-20") above the ground.
2) Raise the dozer blade at Iull stroke.
3) Check the direction you want to go. Move the leIt and right crawler operation levers Iorward Ior Iorward traveling or
backward Ior reverse traveling.
Turning the Stationary Machine
Push the leIt crawler lever Iorward to turn the machine to the right. Pull the lever backward to turn the rear oI the machine to the
right.
Turning the Machine while Traveling
1) LeIt pivot-turn
Return the leIt crawler lever to neutral position
with the right crawler lever pushed Iorward.
2) Right pivot-turn
Return the right crawler lever to the neutral
position with the leIt crawler lever pushed
Iorward.
3) Spin turning
Turning the leIt crawler lever Iorward and right
crawler lever backward and the machine spins
rightward. Eor the spin leItward, operate in the
opposite way.
Turning radius
Turning radius
Stop
Do not make a spin turn
at high speed.
WARNING
23
OPERATION
Traveling
1) Eold the boom and arm. Raise them to 40 to 50 cm (15"-20") above the ground.
2) Raise the dozer blade at Iull stroke.
3) Check the direction you want to go. Move the leIt and right crawler operation levers Iorward Ior Iorward traveling or
backward Ior reverse traveling.
Turning the Stationary Machine
Push the leIt crawler lever Iorward to turn the machine to the right. Pull the lever backward to turn the rear oI the machine to the
right.
Turning the Machine while Traveling
1) LeIt pivot-turn
Return the leIt crawler lever to neutral position
with the right crawler lever pushed Iorward.
2) Right pivot-turn
Return the right crawler lever to the neutral
position with the leIt crawler lever pushed
Iorward.
3) Spin turning
Turning the leIt crawler lever Iorward and right
crawler lever backward and the machine spins
rightward. Eor the spin leItward, operate in the
opposite way.
Turning radius
Turning radius
Stop
Do not make a spin turn
at high speed.
WARNING
23
OPERATION
Traveling
1) Eold the boom and arm. Raise them to 40 to 50 cm (15"-20") above the ground.
2) Raise the dozer blade at Iull stroke.
3) Check the direction you want to go. Move the leIt and right crawler operation levers Iorward Ior Iorward traveling or
backward Ior reverse traveling.
Turning the Stationary Machine
Push the leIt crawler lever Iorward to turn the machine to the right. Pull the lever backward to turn the rear oI the machine to the
right.
Turning the Machine while Traveling
1) LeIt pivot-turn
Return the leIt crawler lever to neutral position
with the right crawler lever pushed Iorward.
2) Right pivot-turn
Return the right crawler lever to the neutral
position with the leIt crawler lever pushed
Iorward.
3) Spin turning
Turning the leIt crawler lever Iorward and right
crawler lever backward and the machine spins
rightward. Eor the spin leItward, operate in the
opposite way.
Turning radius
Turning radius
Stop
Do not make a spin turn
at high speed.
WARNING
23
24
OPERATION
EMERGENCY STOP PROCEDURE LOWERING FRONT
ATTACHMENT
1. Remove boom control hose and plug the hose end.
2. Unscrew the socket bolts (1) and remove the cap (2) with care.
Move the spool (4) slowly Iorwards you so that the Iront attachment will lower down
(slowly).
OPERATIONAL PRECAUTIONS
OPERATING THE RUBBER CRAWLER
Do not Travel or Turn on a Sharp Edge or Stepped Grade.
II you travel or turn on a projecting edge or a stepped grade, the machine will put an extra load on the rubber crawler causing it to
split or cut the treads oI the rubber crawler and the inner steel cord.
Prevent Foreign Matter from Entering the Rubber Crawler
Eoreign matter will strain the crawler and cut it.
Sharp Turns
Do not turn sharply on road with a high-Iriction Iactor such as a concrete road.
Keep Oil Products Away from the Rubber Crawler
II you spill Iuel or hydraulic Iluid on the rubber crawler, clean it.
Protection from Salt
Do not operate on a beach. (Core metal will rust due to salt corrosion.)
Indoor Storage
II the machine is not used Ior a long time, keep it indoors to prevent exposure to direct sunlight and rain.
When removing the cap
be sure that the spool
keeps its position. When
the spool is coming out,
the front attachment will
fall down very quickly.
IMPORTANT
24
OPERATION
EMERGENCY STOP PROCEDURE LOWERING FRONT
ATTACHMENT
1. Remove boom control hose and plug the hose end.
2. Unscrew the socket bolts (1) and remove the cap (2) with care.
Move the spool (4) slowly Iorwards you so that the Iront attachment will lower down
(slowly).
OPERATIONAL PRECAUTIONS
OPERATING THE RUBBER CRAWLER
Do not Travel or Turn on a Sharp Edge or Stepped Grade.
II you travel or turn on a projecting edge or a stepped grade, the machine will put an extra load on the rubber crawler causing it to
split or cut the treads oI the rubber crawler and the inner steel cord.
Prevent Foreign Matter from Entering the Rubber Crawler
Eoreign matter will strain the crawler and cut it.
Sharp Turns
Do not turn sharply on road with a high-Iriction Iactor such as a concrete road.
Keep Oil Products Away from the Rubber Crawler
II you spill Iuel or hydraulic Iluid on the rubber crawler, clean it.
Protection from Salt
Do not operate on a beach. (Core metal will rust due to salt corrosion.)
Indoor Storage
II the machine is not used Ior a long time, keep it indoors to prevent exposure to direct sunlight and rain.
When removing the cap
be sure that the spool
keeps its position. When
the spool is coming out,
the front attachment will
fall down very quickly.
IMPORTANT
24
OPERATION
EMERGENCY STOP PROCEDURE LOWERING FRONT
ATTACHMENT
1. Remove boom control hose and plug the hose end.
2. Unscrew the socket bolts (1) and remove the cap (2) with care.
Move the spool (4) slowly Iorwards you so that the Iront attachment will lower down
(slowly).
OPERATIONAL PRECAUTIONS
OPERATING THE RUBBER CRAWLER
Do not Travel or Turn on a Sharp Edge or Stepped Grade.
II you travel or turn on a projecting edge or a stepped grade, the machine will put an extra load on the rubber crawler causing it to
split or cut the treads oI the rubber crawler and the inner steel cord.
Prevent Foreign Matter from Entering the Rubber Crawler
Eoreign matter will strain the crawler and cut it.
Sharp Turns
Do not turn sharply on road with a high-Iriction Iactor such as a concrete road.
Keep Oil Products Away from the Rubber Crawler
II you spill Iuel or hydraulic Iluid on the rubber crawler, clean it.
Protection from Salt
Do not operate on a beach. (Core metal will rust due to salt corrosion.)
Indoor Storage
II the machine is not used Ior a long time, keep it indoors to prevent exposure to direct sunlight and rain.
When removing the cap
be sure that the spool
keeps its position. When
the spool is coming out,
the front attachment will
fall down very quickly.
IMPORTANT
24
OPERATION
EMERGENCY STOP PROCEDURE LOWERING FRONT
ATTACHMENT
1. Remove boom control hose and plug the hose end.
2. Unscrew the socket bolts (1) and remove the cap (2) with care.
Move the spool (4) slowly Iorwards you so that the Iront attachment will lower down
(slowly).
OPERATIONAL PRECAUTIONS
OPERATING THE RUBBER CRAWLER
Do not Travel or Turn on a Sharp Edge or Stepped Grade.
II you travel or turn on a projecting edge or a stepped grade, the machine will put an extra load on the rubber crawler causing it to
split or cut the treads oI the rubber crawler and the inner steel cord.
Prevent Foreign Matter from Entering the Rubber Crawler
Eoreign matter will strain the crawler and cut it.
Sharp Turns
Do not turn sharply on road with a high-Iriction Iactor such as a concrete road.
Keep Oil Products Away from the Rubber Crawler
II you spill Iuel or hydraulic Iluid on the rubber crawler, clean it.
Protection from Salt
Do not operate on a beach. (Core metal will rust due to salt corrosion.)
Indoor Storage
II the machine is not used Ior a long time, keep it indoors to prevent exposure to direct sunlight and rain.
When removing the cap
be sure that the spool
keeps its position. When
the spool is coming out,
the front attachment will
fall down very quickly.
IMPORTANT
TRANSPORTING BY TRUCK
When loading or unloading the machine on or oII a vehicle, use a loading dock. II ramps are used, do the Iollowing.
Placing the Ramps
Use ramps capable oI supporting the machine weight. Place them on the vehicle securely.
The slope angle oI the ramps should be between 10 to 15.
Place the leIt and right ramp so that the vehicle centre is aligned with the machine centre.
Apply the parking brake oI the vehicle and block the Iront and rear tires oI the vehicle with chocks.
Going Up and Down the Ramps
Go up the ramps in reverse and go down Iorward.
Do not turn on the ramps. Align the machine crawlers with the ramps
and proceed straight. II the machine is oII course when going up the
ramps, stop and go back down and try again.
Cautions for Loading
Securely lock the operation lock lever and swing lock pin.
Check whether the machine is loaded properly on the vehicles and that the vehicle is not inclined.
AIter making sure that there are no problems with the machine on the vehicle, secure it to the vehicle. The machine may
slide during transit, thereIore, block both sides and ends oI the crawlers with chocks. Easten the chocks to the crawlers with
chains or wire ropes. It is very important that this measure is taken to prevent skidding.
Easten hold down chains to Iront corners oI blade and to the towing lug on the rear oI the machine.
When transporting the machine by vehicle, pay attention that no relevant traIIic regulations are violated.
VEHICLE TRACTION
Warnings
To tow a vehicle, use a shackle and a wire rope at least halI as strong again as the vehicle's weight. The wire rope must be
Iree Irom kinks, twists, and breaks.
While towing a vehicle, make sure that no person comes between the tractor and the vehicle being towed.
Position the wire rope horizontal, while making it Iace the truck Irame straight.
Draw the traction rope gradually, taking care not to load it abruptly.
Move the target vehicle slowly.
Towing a vehicle on a downward slope may let the vehicle run away out oI control. On a bad upward slope, watch the
wire careIully.
Always use the traction hook in the back oI the bottom Irame oI
the vehicle drawn.
Use a shackle and a wire rope at least halI as strong again as
the vehicle's weight.
II the vehicle towed is out oI order, check both tracks beIore
releasing the brakes oI the Iinal drive, thus preventing the vehicle
Irom running away. Then release the brakes oI the Iinal drive and
tow the vehicle.
25
TRANSPORTING BY TRUCK
When loading or unloading the machine on or oII a vehicle, use a loading dock. II ramps are used, do the Iollowing.
Placing the Ramps
Use ramps capable oI supporting the machine weight. Place them on the vehicle securely.
The slope angle oI the ramps should be between 10 to 15.
Place the leIt and right ramp so that the vehicle centre is aligned with the machine centre.
Apply the parking brake oI the vehicle and block the Iront and rear tires oI the vehicle with chocks.
Going Up and Down the Ramps
Go up the ramps in reverse and go down Iorward.
Do not turn on the ramps. Align the machine crawlers with the ramps
and proceed straight. II the machine is oII course when going up the
ramps, stop and go back down and try again.
Cautions for Loading
Securely lock the operation lock lever and swing lock pin.
Check whether the machine is loaded properly on the vehicles and that the vehicle is not inclined.
AIter making sure that there are no problems with the machine on the vehicle, secure it to the vehicle. The machine may
slide during transit, thereIore, block both sides and ends oI the crawlers with chocks. Easten the chocks to the crawlers with
chains or wire ropes. It is very important that this measure is taken to prevent skidding.
Easten hold down chains to Iront corners oI blade and to the towing lug on the rear oI the machine.
When transporting the machine by vehicle, pay attention that no relevant traIIic regulations are violated.
VEHICLE TRACTION
Warnings
To tow a vehicle, use a shackle and a wire rope at least halI as strong again as the vehicle's weight. The wire rope must be
Iree Irom kinks, twists, and breaks.
While towing a vehicle, make sure that no person comes between the tractor and the vehicle being towed.
Position the wire rope horizontal, while making it Iace the truck Irame straight.
Draw the traction rope gradually, taking care not to load it abruptly.
Move the target vehicle slowly.
Towing a vehicle on a downward slope may let the vehicle run away out oI control. On a bad upward slope, watch the
wire careIully.
Always use the traction hook in the back oI the bottom Irame oI
the vehicle drawn.
Use a shackle and a wire rope at least halI as strong again as
the vehicle's weight.
II the vehicle towed is out oI order, check both tracks beIore
releasing the brakes oI the Iinal drive, thus preventing the vehicle
Irom running away. Then release the brakes oI the Iinal drive and
tow the vehicle.
25
TRANSPORTING BY TRUCK
When loading or unloading the machine on or oII a vehicle, use a loading dock. II ramps are used, do the Iollowing.
Placing the Ramps
Use ramps capable oI supporting the machine weight. Place them on the vehicle securely.
The slope angle oI the ramps should be between 10 to 15.
Place the leIt and right ramp so that the vehicle centre is aligned with the machine centre.
Apply the parking brake oI the vehicle and block the Iront and rear tires oI the vehicle with chocks.
Going Up and Down the Ramps
Go up the ramps in reverse and go down Iorward.
Do not turn on the ramps. Align the machine crawlers with the ramps
and proceed straight. II the machine is oII course when going up the
ramps, stop and go back down and try again.
Cautions for Loading
Securely lock the operation lock lever and swing lock pin.
Check whether the machine is loaded properly on the vehicles and that the vehicle is not inclined.
AIter making sure that there are no problems with the machine on the vehicle, secure it to the vehicle. The machine may
slide during transit, thereIore, block both sides and ends oI the crawlers with chocks. Easten the chocks to the crawlers with
chains or wire ropes. It is very important that this measure is taken to prevent skidding.
Easten hold down chains to Iront corners oI blade and to the towing lug on the rear oI the machine.
When transporting the machine by vehicle, pay attention that no relevant traIIic regulations are violated.
VEHICLE TRACTION
Warnings
To tow a vehicle, use a shackle and a wire rope at least halI as strong again as the vehicle's weight. The wire rope must be
Iree Irom kinks, twists, and breaks.
While towing a vehicle, make sure that no person comes between the tractor and the vehicle being towed.
Position the wire rope horizontal, while making it Iace the truck Irame straight.
Draw the traction rope gradually, taking care not to load it abruptly.
Move the target vehicle slowly.
Towing a vehicle on a downward slope may let the vehicle run away out oI control. On a bad upward slope, watch the
wire careIully.
Always use the traction hook in the back oI the bottom Irame oI
the vehicle drawn.
Use a shackle and a wire rope at least halI as strong again as
the vehicle's weight.
II the vehicle towed is out oI order, check both tracks beIore
releasing the brakes oI the Iinal drive, thus preventing the vehicle
Irom running away. Then release the brakes oI the Iinal drive and
tow the vehicle.
25
TRANSPORTING BY TRUCK
When loading or unloading the machine on or oII a vehicle, use a loading dock. II ramps are used, do the Iollowing.
Placing the Ramps
Use ramps capable oI supporting the machine weight. Place them on the vehicle securely.
The slope angle oI the ramps should be between 10 to 15.
Place the leIt and right ramp so that the vehicle centre is aligned with the machine centre.
Apply the parking brake oI the vehicle and block the Iront and rear tires oI the vehicle with chocks.
Going Up and Down the Ramps
Go up the ramps in reverse and go down Iorward.
Do not turn on the ramps. Align the machine crawlers with the ramps
and proceed straight. II the machine is oII course when going up the
ramps, stop and go back down and try again.
Cautions for Loading
Securely lock the operation lock lever and swing lock pin.
Check whether the machine is loaded properly on the vehicles and that the vehicle is not inclined.
AIter making sure that there are no problems with the machine on the vehicle, secure it to the vehicle. The machine may
slide during transit, thereIore, block both sides and ends oI the crawlers with chocks. Easten the chocks to the crawlers with
chains or wire ropes. It is very important that this measure is taken to prevent skidding.
Easten hold down chains to Iront corners oI blade and to the towing lug on the rear oI the machine.
When transporting the machine by vehicle, pay attention that no relevant traIIic regulations are violated.
VEHICLE TRACTION
Warnings
To tow a vehicle, use a shackle and a wire rope at least halI as strong again as the vehicle's weight. The wire rope must be
Iree Irom kinks, twists, and breaks.
While towing a vehicle, make sure that no person comes between the tractor and the vehicle being towed.
Position the wire rope horizontal, while making it Iace the truck Irame straight.
Draw the traction rope gradually, taking care not to load it abruptly.
Move the target vehicle slowly.
Towing a vehicle on a downward slope may let the vehicle run away out oI control. On a bad upward slope, watch the
wire careIully.
Always use the traction hook in the back oI the bottom Irame oI
the vehicle drawn.
Use a shackle and a wire rope at least halI as strong again as
the vehicle's weight.
II the vehicle towed is out oI order, check both tracks beIore
releasing the brakes oI the Iinal drive, thus preventing the vehicle
Irom running away. Then release the brakes oI the Iinal drive and
tow the vehicle.
25
26
HOW TO HOIST A VEHICLE
HOW TO HOIST A VEHICLE
Method of hoisting
Vehicle hoisting procedure
1. Put the vehicle into the hoisting position.
1) Raise the blade to the stroke end oI the blade cylinder.
2) Operate the swing pedal, get the boom straight, and lock the
pedal with the lock bar.
3) With the control lever, extend the boom cylinder, bucket
cylinder, and arm cylinder to their stroke ends.
4) With the swing lever, swing the upper Irame, putting the blade
in back oI the vehicle.
5) Stop the engine, then pull up the lock lever securely to its
LOCK position. Get oII the vehicle. Close the door and cover
and lock them.
To avoid personal injury
ensure wire rope is rated
strong enough to lift the
vehicle safely.
WARNING
Before hoisting observe
all of the hoisting
procedures indicated in
the is manual.
WARNING
To prevent personal
injury ensure when
hoisting a vehicle that it
is in on a flat area and
use the Hoisting Position
otherwise the machine
may become unbalanced
WARNING
Do not hoist a vehicle
while the boom is
swinging.
WARNING
26
HOW TO HOIST A VEHICLE
HOW TO HOIST A VEHICLE
Method of hoisting
Vehicle hoisting procedure
1. Put the vehicle into the hoisting position.
1) Raise the blade to the stroke end oI the blade cylinder.
2) Operate the swing pedal, get the boom straight, and lock the
pedal with the lock bar.
3) With the control lever, extend the boom cylinder, bucket
cylinder, and arm cylinder to their stroke ends.
4) With the swing lever, swing the upper Irame, putting the blade
in back oI the vehicle.
5) Stop the engine, then pull up the lock lever securely to its
LOCK position. Get oII the vehicle. Close the door and cover
and lock them.
To avoid personal injury
ensure wire rope is rated
strong enough to lift the
vehicle safely.
WARNING
Before hoisting observe
all of the hoisting
procedures indicated in
the is manual.
WARNING
To prevent personal
injury ensure when
hoisting a vehicle that it
is in on a flat area and
use the Hoisting Position
otherwise the machine
may become unbalanced
WARNING
Do not hoist a vehicle
while the boom is
swinging.
WARNING
26
HOW TO HOIST A VEHICLE
HOW TO HOIST A VEHICLE
Method of hoisting
Vehicle hoisting procedure
1. Put the vehicle into the hoisting position.
1) Raise the blade to the stroke end oI the blade cylinder.
2) Operate the swing pedal, get the boom straight, and lock the
pedal with the lock bar.
3) With the control lever, extend the boom cylinder, bucket
cylinder, and arm cylinder to their stroke ends.
4) With the swing lever, swing the upper Irame, putting the blade
in back oI the vehicle.
5) Stop the engine, then pull up the lock lever securely to its
LOCK position. Get oII the vehicle. Close the door and cover
and lock them.
To avoid personal injury
ensure wire rope is rated
strong enough to lift the
vehicle safely.
WARNING
Before hoisting observe
all of the hoisting
procedures indicated in
the is manual.
WARNING
To prevent personal
injury ensure when
hoisting a vehicle that it
is in on a flat area and
use the Hoisting Position
otherwise the machine
may become unbalanced
WARNING
Do not hoist a vehicle
while the boom is
swinging.
WARNING
26
HOW TO HOIST A VEHICLE
HOW TO HOIST A VEHICLE
Method of hoisting
Vehicle hoisting procedure
1. Put the vehicle into the hoisting position.
1) Raise the blade to the stroke end oI the blade cylinder.
2) Operate the swing pedal, get the boom straight, and lock the
pedal with the lock bar.
3) With the control lever, extend the boom cylinder, bucket
cylinder, and arm cylinder to their stroke ends.
4) With the swing lever, swing the upper Irame, putting the blade
in back oI the vehicle.
5) Stop the engine, then pull up the lock lever securely to its
LOCK position. Get oII the vehicle. Close the door and cover
and lock them.
To avoid personal injury
ensure wire rope is rated
strong enough to lift the
vehicle safely.
WARNING
Before hoisting observe
all of the hoisting
procedures indicated in
the is manual.
WARNING
To prevent personal
injury ensure when
hoisting a vehicle that it
is in on a flat area and
use the Hoisting Position
otherwise the machine
may become unbalanced
WARNING
Do not hoist a vehicle
while the boom is
swinging.
WARNING
HOW TO HOIST A VEHICLE
2. Apply a wire rope to the vehicle, then hoist it.
1) Attach a shackle to each hoisting hole at either end oI
the blade. Attach a wire rope to the shackles.
2) Attach a shackle to the hoisting hole in the bracket in
the middle oI the boom.
3) Tension the wire rope lightly with the crane. II the
crane is oI the cab type, sandwich the waste cloth
between the wire rope and the cab, thus protecting the
cab.
4) Always level the vehicle. Make sure that the vehicle is
level and that the crane hook center is near the twirling
center oI the vehicle and that the hoisting angle is
appropriate. Then hoist the vehicle.
The hook holes on the
cab are not for hoisting
the vehicle.Hoisting the
vehicle using these holes
is very dangerous.
WARNING
27
HOW TO HOIST A VEHICLE
2. Apply a wire rope to the vehicle, then hoist it.
1) Attach a shackle to each hoisting hole at either end oI
the blade. Attach a wire rope to the shackles.
2) Attach a shackle to the hoisting hole in the bracket in
the middle oI the boom.
3) Tension the wire rope lightly with the crane. II the
crane is oI the cab type, sandwich the waste cloth
between the wire rope and the cab, thus protecting the
cab.
4) Always level the vehicle. Make sure that the vehicle is
level and that the crane hook center is near the twirling
center oI the vehicle and that the hoisting angle is
appropriate. Then hoist the vehicle.
The hook holes on the
cab are not for hoisting
the vehicle.Hoisting the
vehicle using these holes
is very dangerous.
WARNING
27
HOW TO HOIST A VEHICLE
2. Apply a wire rope to the vehicle, then hoist it.
1) Attach a shackle to each hoisting hole at either end oI
the blade. Attach a wire rope to the shackles.
2) Attach a shackle to the hoisting hole in the bracket in
the middle oI the boom.
3) Tension the wire rope lightly with the crane. II the
crane is oI the cab type, sandwich the waste cloth
between the wire rope and the cab, thus protecting the
cab.
4) Always level the vehicle. Make sure that the vehicle is
level and that the crane hook center is near the twirling
center oI the vehicle and that the hoisting angle is
appropriate. Then hoist the vehicle.
The hook holes on the
cab are not for hoisting
the vehicle.Hoisting the
vehicle using these holes
is very dangerous.
WARNING
27
HOW TO HOIST A VEHICLE
2. Apply a wire rope to the vehicle, then hoist it.
1) Attach a shackle to each hoisting hole at either end oI
the blade. Attach a wire rope to the shackles.
2) Attach a shackle to the hoisting hole in the bracket in
the middle oI the boom.
3) Tension the wire rope lightly with the crane. II the
crane is oI the cab type, sandwich the waste cloth
between the wire rope and the cab, thus protecting the
cab.
4) Always level the vehicle. Make sure that the vehicle is
level and that the crane hook center is near the twirling
center oI the vehicle and that the hoisting angle is
appropriate. Then hoist the vehicle.
The hook holes on the
cab are not for hoisting
the vehicle.Hoisting the
vehicle using these holes
is very dangerous.
WARNING
27
28
COLD WEATHER OR DURING-WINTER OPERATIONS
PRESTART PREPARATIONS
In cold weather, engine may be diIIicult to start and the radiator water and battery Iluid may be Ireezing. ThereIore, pay attention to
the Iollowing matters.
1) Lubricant
Engine oil SAE15W-40
2) Euel
Use diesel Iuel with the pour point Iive degrees lower than the lowest outdoor temperature.
3) Cooling water
Add anti-Ireeze to the cooling water to prevent the cooling system Irom Ireezing. The Iollowing table shows the Ireezing
temperatures by the amount oI added anti-Ireeze.
Lowest temperature (C) -5 -10 -15 -20 -25 -30
Amount oI anti-Ireeze (l)/(in
3
) 1.3 1.6 2.0 2.3 2.7 3.2
(79) (97) (122) (140) (165) (195)
Amount oI cooling water (l)/(in
3
) 4.3 4.0 3.6 3.3 2.9 2.4
(262) (244) (219) (201) (176) (146)
Be careIul with Iire because anti-Ireeze is Ilammable.
The total quantity oI cooling water is 5.6 l(1.2 gal, 1.4 U.S. gal, 341 in
3
) including
overIlow tank.
Supply the additional cooling water just beIore the start oI operation not aIter
the Iinish oI operation in a day to prevent Ireezing. Eor replacement oI cooling
water reIer to page 51.
The machine is Iilled with the anti-Ireeze Ior -20C when transported Irom
the Iactory.
COLD WEATHER OR DURING-WINTER OPERATIONS
4) Battery
Under low temperatures, battery capacity becomes low. II charging voltage is insuIIicient, the battery Iluid might be Irozen.
In this case, cover the battery with cloth or keep the battery in a warm place. Reinstall it in the morning.
The charging rate is as shown below.
Temp 20C 0C -10C -20C
(68E) (32E) (14E) (-4E)
Charge Rate
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
II the battery is recharged using a booster cable, make sure that earthing wire is attached and engine stopped.
Remove the Iluid cap and connect the cable to the battery.
28
COLD WEATHER OR DURING-WINTER OPERATIONS
PRESTART PREPARATIONS
In cold weather, engine may be diIIicult to start and the radiator water and battery Iluid may be Ireezing. ThereIore, pay attention to
the Iollowing matters.
1) Lubricant
Engine oil SAE15W-40
2) Euel
Use diesel Iuel with the pour point Iive degrees lower than the lowest outdoor temperature.
3) Cooling water
Add anti-Ireeze to the cooling water to prevent the cooling system Irom Ireezing. The Iollowing table shows the Ireezing
temperatures by the amount oI added anti-Ireeze.
Lowest temperature (C) -5 -10 -15 -20 -25 -30
Amount oI anti-Ireeze (l)/(in
3
) 1.3 1.6 2.0 2.3 2.7 3.2
(79) (97) (122) (140) (165) (195)
Amount oI cooling water (l)/(in
3
) 4.3 4.0 3.6 3.3 2.9 2.4
(262) (244) (219) (201) (176) (146)
Be careIul with Iire because anti-Ireeze is Ilammable.
The total quantity oI cooling water is 5.6 l(1.2 gal, 1.4 U.S. gal, 341 in
3
) including
overIlow tank.
Supply the additional cooling water just beIore the start oI operation not aIter
the Iinish oI operation in a day to prevent Ireezing. Eor replacement oI cooling
water reIer to page 51.
The machine is Iilled with the anti-Ireeze Ior -20C when transported Irom
the Iactory.
COLD WEATHER OR DURING-WINTER OPERATIONS
4) Battery
Under low temperatures, battery capacity becomes low. II charging voltage is insuIIicient, the battery Iluid might be Irozen.
In this case, cover the battery with cloth or keep the battery in a warm place. Reinstall it in the morning.
The charging rate is as shown below.
Temp 20C 0C -10C -20C
(68E) (32E) (14E) (-4E)
Charge Rate
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
II the battery is recharged using a booster cable, make sure that earthing wire is attached and engine stopped.
Remove the Iluid cap and connect the cable to the battery.
28
COLD WEATHER OR DURING-WINTER OPERATIONS
PRESTART PREPARATIONS
In cold weather, engine may be diIIicult to start and the radiator water and battery Iluid may be Ireezing. ThereIore, pay attention to
the Iollowing matters.
1) Lubricant
Engine oil SAE15W-40
2) Euel
Use diesel Iuel with the pour point Iive degrees lower than the lowest outdoor temperature.
3) Cooling water
Add anti-Ireeze to the cooling water to prevent the cooling system Irom Ireezing. The Iollowing table shows the Ireezing
temperatures by the amount oI added anti-Ireeze.
Lowest temperature (C) -5 -10 -15 -20 -25 -30
Amount oI anti-Ireeze (l)/(in
3
) 1.3 1.6 2.0 2.3 2.7 3.2
(79) (97) (122) (140) (165) (195)
Amount oI cooling water (l)/(in
3
) 4.3 4.0 3.6 3.3 2.9 2.4
(262) (244) (219) (201) (176) (146)
Be careIul with Iire because anti-Ireeze is Ilammable.
The total quantity oI cooling water is 5.6 l(1.2 gal, 1.4 U.S. gal, 341 in
3
) including
overIlow tank.
Supply the additional cooling water just beIore the start oI operation not aIter
the Iinish oI operation in a day to prevent Ireezing. Eor replacement oI cooling
water reIer to page 51.
The machine is Iilled with the anti-Ireeze Ior -20C when transported Irom
the Iactory.
COLD WEATHER OR DURING-WINTER OPERATIONS
4) Battery
Under low temperatures, battery capacity becomes low. II charging voltage is insuIIicient, the battery Iluid might be Irozen.
In this case, cover the battery with cloth or keep the battery in a warm place. Reinstall it in the morning.
The charging rate is as shown below.
Temp 20C 0C -10C -20C
(68E) (32E) (14E) (-4E)
Charge Rate
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
II the battery is recharged using a booster cable, make sure that earthing wire is attached and engine stopped.
Remove the Iluid cap and connect the cable to the battery.
28
COLD WEATHER OR DURING-WINTER OPERATIONS
PRESTART PREPARATIONS
In cold weather, engine may be diIIicult to start and the radiator water and battery Iluid may be Ireezing. ThereIore, pay attention to
the Iollowing matters.
1) Lubricant
Engine oil SAE15W-40
2) Euel
Use diesel Iuel with the pour point Iive degrees lower than the lowest outdoor temperature.
3) Cooling water
Add anti-Ireeze to the cooling water to prevent the cooling system Irom Ireezing. The Iollowing table shows the Ireezing
temperatures by the amount oI added anti-Ireeze.
Lowest temperature (C) -5 -10 -15 -20 -25 -30
Amount oI anti-Ireeze (l)/(in
3
) 1.3 1.6 2.0 2.3 2.7 3.2
(79) (97) (122) (140) (165) (195)
Amount oI cooling water (l)/(in
3
) 4.3 4.0 3.6 3.3 2.9 2.4
(262) (244) (219) (201) (176) (146)
Be careIul with Iire because anti-Ireeze is Ilammable.
The total quantity oI cooling water is 5.6 l(1.2 gal, 1.4 U.S. gal, 341 in
3
) including
overIlow tank.
Supply the additional cooling water just beIore the start oI operation not aIter
the Iinish oI operation in a day to prevent Ireezing. Eor replacement oI cooling
water reIer to page 51.
The machine is Iilled with the anti-Ireeze Ior -20C when transported Irom
the Iactory.
COLD WEATHER OR DURING-WINTER OPERATIONS
4) Battery
Under low temperatures, battery capacity becomes low. II charging voltage is insuIIicient, the battery Iluid might be Irozen.
In this case, cover the battery with cloth or keep the battery in a warm place. Reinstall it in the morning.
The charging rate is as shown below.
Temp 20C 0C -10C -20C
(68E) (32E) (14E) (-4E)
Charge Rate
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
II the battery is recharged using a booster cable, make sure that earthing wire is attached and engine stopped.
Remove the Iluid cap and connect the cable to the battery.
Before Storage
1) II you don`t use the machine Ior a long time, grease or
lubricate the spring guide, spring, yoke slide and
exposed portions oI the cylinders suIIiciently to prevent
rusting.
2) II you leave the machine outdoors park it on wooden
planks on a level ground (concrete Iloor) and cover
with sheet.
3) II you don`t use the machine Ior a long time,disconnect
the battery cable (-) side or recharge to prevent the
battery Irom being discharged.
During Storage
1) Operate engine at least once a month to lubricate engine
and hydraulic parts.
2) Recharge the battery at the same time.
(Recharging the battery, reIer to page 28)
After Storage
1) BeIore starting engine, check the engine oil,
hydraulic oil and water level.
2) Operate the cylinders three or Iour times at low
engine speeds.
LONG-TERM STORAGE
29
Sudden operations may
damage the packings. IMPORTANT
Before Storage
1) II you don`t use the machine Ior a long time, grease or
lubricate the spring guide, spring, yoke slide and
exposed portions oI the cylinders suIIiciently to prevent
rusting.
2) II you leave the machine outdoors park it on wooden
planks on a level ground (concrete Iloor) and cover
with sheet.
3) II you don`t use the machine Ior a long time,disconnect
the battery cable (-) side or recharge to prevent the
battery Irom being discharged.
During Storage
1) Operate engine at least once a month to lubricate engine
and hydraulic parts.
2) Recharge the battery at the same time.
(Recharging the battery, reIer to page 28)
After Storage
1) BeIore starting engine, check the engine oil,
hydraulic oil and water level.
2) Operate the cylinders three or Iour times at low
engine speeds.
LONG-TERM STORAGE
29
Sudden operations may
damage the packings. IMPORTANT
Before Storage
1) II you don`t use the machine Ior a long time, grease or
lubricate the spring guide, spring, yoke slide and
exposed portions oI the cylinders suIIiciently to prevent
rusting.
2) II you leave the machine outdoors park it on wooden
planks on a level ground (concrete Iloor) and cover
with sheet.
3) II you don`t use the machine Ior a long time,disconnect
the battery cable (-) side or recharge to prevent the
battery Irom being discharged.
During Storage
1) Operate engine at least once a month to lubricate engine
and hydraulic parts.
2) Recharge the battery at the same time.
(Recharging the battery, reIer to page 28)
After Storage
1) BeIore starting engine, check the engine oil,
hydraulic oil and water level.
2) Operate the cylinders three or Iour times at low
engine speeds.
LONG-TERM STORAGE
29
Sudden operations may
damage the packings. IMPORTANT
Before Storage
1) II you don`t use the machine Ior a long time, grease or
lubricate the spring guide, spring, yoke slide and
exposed portions oI the cylinders suIIiciently to prevent
rusting.
2) II you leave the machine outdoors park it on wooden
planks on a level ground (concrete Iloor) and cover
with sheet.
3) II you don`t use the machine Ior a long time,disconnect
the battery cable (-) side or recharge to prevent the
battery Irom being discharged.
During Storage
1) Operate engine at least once a month to lubricate engine
and hydraulic parts.
2) Recharge the battery at the same time.
(Recharging the battery, reIer to page 28)
After Storage
1) BeIore starting engine, check the engine oil,
hydraulic oil and water level.
2) Operate the cylinders three or Iour times at low
engine speeds.
LONG-TERM STORAGE
29
Sudden operations may
damage the packings. IMPORTANT
30
INSPECTION AND MAINTENANCE
30
INSPECTION AND MAINTENANCE
30
INSPECTION AND MAINTENANCE
30
INSPECTION AND MAINTENANCE
INSPECTIONS
Do the Iollowing inspections. Neglecting any oI the inspections may result in trouble with the machine including the hydraulic
equipment.
Prestart Inspections
Check the Iollowing items beIore operation everyday.
Eor inspection, always park the machine on Ilat ground.
1) Checking the amount oI oil in the engine oil pan. Pull out the level gauge.
Wipe the oil oII the gauge using a cloth and insert it again. II the oil
amount is insuIIicient, add engine oil through the oil port.
Use high-quality engine oil. It is recommended to use the Iollowing engine
oils.
Engine oil SAE10W-30
Capacity MAX. 3.5 l (0.9 U.S. gal)
2) Checking the amount oI water in radiator, conIirm the level oI water in
overIlow tank at the speciIied level or more without removing the
radiator cap. II it is insuIIicient, add soIt water (tap water) to the tank.
Level Gauge
Engine Oil Port
OverIlow Tank
Do not use dirty water to
prevent clogging of the
fins.
IMPORTANT
Before inspection and
maintenance, be sure to
stop engine.
WARNING
The radiator cap must
not be taken off when the
temperature of cooling
water is high. The water
will be very hot and
could cause injury if
released before cooled.
WARNING
31
INSPECTIONS
Do the Iollowing inspections. Neglecting any oI the inspections may result in trouble with the machine including the hydraulic
equipment.
Prestart Inspections
Check the Iollowing items beIore operation everyday.
Eor inspection, always park the machine on Ilat ground.
1) Checking the amount oI oil in the engine oil pan. Pull out the level gauge.
Wipe the oil oII the gauge using a cloth and insert it again. II the oil
amount is insuIIicient, add engine oil through the oil port.
Use high-quality engine oil. It is recommended to use the Iollowing engine
oils.
Engine oil SAE10W-30
Capacity MAX. 3.5 l (0.9 U.S. gal)
2) Checking the amount oI water in radiator, conIirm the level oI water in
overIlow tank at the speciIied level or more without removing the
radiator cap. II it is insuIIicient, add soIt water (tap water) to the tank.
Level Gauge
Engine Oil Port
OverIlow Tank
Do not use dirty water to
prevent clogging of the
fins.
IMPORTANT
Before inspection and
maintenance, be sure to
stop engine.
WARNING
The radiator cap must
not be taken off when the
temperature of cooling
water is high. The water
will be very hot and
could cause injury if
released before cooled.
WARNING
31
INSPECTIONS
Do the Iollowing inspections. Neglecting any oI the inspections may result in trouble with the machine including the hydraulic
equipment.
Prestart Inspections
Check the Iollowing items beIore operation everyday.
Eor inspection, always park the machine on Ilat ground.
1) Checking the amount oI oil in the engine oil pan. Pull out the level gauge.
Wipe the oil oII the gauge using a cloth and insert it again. II the oil
amount is insuIIicient, add engine oil through the oil port.
Use high-quality engine oil. It is recommended to use the Iollowing engine
oils.
Engine oil SAE10W-30
Capacity MAX. 3.5 l (0.9 U.S. gal)
2) Checking the amount oI water in radiator, conIirm the level oI water in
overIlow tank at the speciIied level or more without removing the
radiator cap. II it is insuIIicient, add soIt water (tap water) to the tank.
Level Gauge
Engine Oil Port
OverIlow Tank
Do not use dirty water to
prevent clogging of the
fins.
IMPORTANT
Before inspection and
maintenance, be sure to
stop engine.
WARNING
The radiator cap must
not be taken off when the
temperature of cooling
water is high. The water
will be very hot and
could cause injury if
released before cooled.
WARNING
31
INSPECTIONS
Do the Iollowing inspections. Neglecting any oI the inspections may result in trouble with the machine including the hydraulic
equipment.
Prestart Inspections
Check the Iollowing items beIore operation everyday.
Eor inspection, always park the machine on Ilat ground.
1) Checking the amount oI oil in the engine oil pan. Pull out the level gauge.
Wipe the oil oII the gauge using a cloth and insert it again. II the oil
amount is insuIIicient, add engine oil through the oil port.
Use high-quality engine oil. It is recommended to use the Iollowing engine
oils.
Engine oil SAE10W-30
Capacity MAX. 3.5 l (0.9 U.S. gal)
2) Checking the amount oI water in radiator, conIirm the level oI water in
overIlow tank at the speciIied level or more without removing the
radiator cap. II it is insuIIicient, add soIt water (tap water) to the tank.
Level Gauge
Engine Oil Port
OverIlow Tank
Do not use dirty water to
prevent clogging of the
fins.
IMPORTANT
Before inspection and
maintenance, be sure to
stop engine.
WARNING
The radiator cap must
not be taken off when the
temperature of cooling
water is high. The water
will be very hot and
could cause injury if
released before cooled.
WARNING
31
32
INSPECTIONS
3) Checking the amount oI oil in the hydraulic oil tank
Make sure that the hydraulic oil level is past the center oI the level gauge. II the
amount is insuIIicient, add oil. (See page 63)
Level gauge reading 30.6 l (8.1 U.S. gal,) when topping-up, use top-up hole.
4) Checking the amount oI Iuel in the Iuel tank
Make sure the Iuel level with the level gauge at the monitor panel. II the amount
is insuIIicient, add diesel Iuel.
Level gauge reading 23.6 l (6.2 U.S. gal)
5) Checking the water separator
1. Water is collected in the water separator in which the Iloat will transmit it to
the pointer.
2. The element can be pulled out by taking oII the retainer ring oI water
separator.
Clean the element with oil.
After cleaning or replacing, the contained air should be bled. (See page
50.)
6) Checking the loose parts
Check each part Ior looseness.
CareIully inspect the crawlers, carrier rollers, truck rollers, sprockets and
crawler drive units.
Tightening torque
Nut oI track roller 34.5 (250 lb-It)
Sprocket mounting position 8.4 (61 lb-It)
About pin oI attachment M8 2.2 kg-m (16 Ib-It)
M10 4.3 kg-m (31 Ib-It)
Level Gauge
Euel Port
Water Separator
32
INSPECTIONS
3) Checking the amount oI oil in the hydraulic oil tank
Make sure that the hydraulic oil level is past the center oI the level gauge. II the
amount is insuIIicient, add oil. (See page 63)
Level gauge reading 30.6 l (8.1 U.S. gal,) when topping-up, use top-up hole.
4) Checking the amount oI Iuel in the Iuel tank
Make sure the Iuel level with the level gauge at the monitor panel. II the amount
is insuIIicient, add diesel Iuel.
Level gauge reading 23.6 l (6.2 U.S. gal)
5) Checking the water separator
1. Water is collected in the water separator in which the Iloat will transmit it to
the pointer.
2. The element can be pulled out by taking oII the retainer ring oI water
separator.
Clean the element with oil.
After cleaning or replacing, the contained air should be bled. (See page
50.)
6) Checking the loose parts
Check each part Ior looseness.
CareIully inspect the crawlers, carrier rollers, truck rollers, sprockets and
crawler drive units.
Tightening torque
Nut oI track roller 34.5 (250 lb-It)
Sprocket mounting position 8.4 (61 lb-It)
About pin oI attachment M8 2.2 kg-m (16 Ib-It)
M10 4.3 kg-m (31 Ib-It)
Level Gauge
Euel Port
Water Separator
32
INSPECTIONS
3) Checking the amount oI oil in the hydraulic oil tank
Make sure that the hydraulic oil level is past the center oI the level gauge. II the
amount is insuIIicient, add oil. (See page 63)
Level gauge reading 30.6 l (8.1 U.S. gal,) when topping-up, use top-up hole.
4) Checking the amount oI Iuel in the Iuel tank
Make sure the Iuel level with the level gauge at the monitor panel. II the amount
is insuIIicient, add diesel Iuel.
Level gauge reading 23.6 l (6.2 U.S. gal)
5) Checking the water separator
1. Water is collected in the water separator in which the Iloat will transmit it to
the pointer.
2. The element can be pulled out by taking oII the retainer ring oI water
separator.
Clean the element with oil.
After cleaning or replacing, the contained air should be bled. (See page
50.)
6) Checking the loose parts
Check each part Ior looseness.
CareIully inspect the crawlers, carrier rollers, truck rollers, sprockets and
crawler drive units.
Tightening torque
Nut oI track roller 34.5 (250 lb-It)
Sprocket mounting position 8.4 (61 lb-It)
About pin oI attachment M8 2.2 kg-m (16 Ib-It)
M10 4.3 kg-m (31 Ib-It)
Level Gauge
Euel Port
Water Separator
32
INSPECTIONS
3) Checking the amount oI oil in the hydraulic oil tank
Make sure that the hydraulic oil level is past the center oI the level gauge. II the
amount is insuIIicient, add oil. (See page 63)
Level gauge reading 30.6 l (8.1 U.S. gal,) when topping-up, use top-up hole.
4) Checking the amount oI Iuel in the Iuel tank
Make sure the Iuel level with the level gauge at the monitor panel. II the amount
is insuIIicient, add diesel Iuel.
Level gauge reading 23.6 l (6.2 U.S. gal)
5) Checking the water separator
1. Water is collected in the water separator in which the Iloat will transmit it to
the pointer.
2. The element can be pulled out by taking oII the retainer ring oI water
separator.
Clean the element with oil.
After cleaning or replacing, the contained air should be bled. (See page
50.)
6) Checking the loose parts
Check each part Ior looseness.
CareIully inspect the crawlers, carrier rollers, truck rollers, sprockets and
crawler drive units.
Tightening torque
Nut oI track roller 34.5 (250 lb-It)
Sprocket mounting position 8.4 (61 lb-It)
About pin oI attachment M8 2.2 kg-m (16 Ib-It)
M10 4.3 kg-m (31 Ib-It)
Level Gauge
Euel Port
Water Separator
INSPECTIONS
7) Checking the Ian belt
Check the belt Ior 10 to 12 mm (0.4" to 0.6") oI slack by pressing a point
between Ian belt and crank pulley with a Iinger and Ior breakage.
8) Greasing each pin
Always grease the pins oI the work equipment.
Post operation Inspections
AIter the operation, always check the Iollowing items.
At this time, always park the machine on flat ground.
1) Checking Ior loose parts
Check each part Ior looseness. II some part is loose, retighten it.
2) Adding Iuel to the Iuel tank
AIter the operation, always check the Iuel amount. II it is insuIIicient, add
more diesel Iuel.
Ean Belt
Euel Port
When you find sludge or
so on the fan belt you
have to replace it with
new one.
IMPORTANT
33
INSPECTIONS
7) Checking the Ian belt
Check the belt Ior 10 to 12 mm (0.4" to 0.6") oI slack by pressing a point
between Ian belt and crank pulley with a Iinger and Ior breakage.
8) Greasing each pin
Always grease the pins oI the work equipment.
Post operation Inspections
AIter the operation, always check the Iollowing items.
At this time, always park the machine on flat ground.
1) Checking Ior loose parts
Check each part Ior looseness. II some part is loose, retighten it.
2) Adding Iuel to the Iuel tank
AIter the operation, always check the Iuel amount. II it is insuIIicient, add
more diesel Iuel.
Ean Belt
Euel Port
When you find sludge or
so on the fan belt you
have to replace it with
new one.
IMPORTANT
33
INSPECTIONS
7) Checking the Ian belt
Check the belt Ior 10 to 12 mm (0.4" to 0.6") oI slack by pressing a point
between Ian belt and crank pulley with a Iinger and Ior breakage.
8) Greasing each pin
Always grease the pins oI the work equipment.
Post operation Inspections
AIter the operation, always check the Iollowing items.
At this time, always park the machine on flat ground.
1) Checking Ior loose parts
Check each part Ior looseness. II some part is loose, retighten it.
2) Adding Iuel to the Iuel tank
AIter the operation, always check the Iuel amount. II it is insuIIicient, add
more diesel Iuel.
Ean Belt
Euel Port
When you find sludge or
so on the fan belt you
have to replace it with
new one.
IMPORTANT
33
INSPECTIONS
7) Checking the Ian belt
Check the belt Ior 10 to 12 mm (0.4" to 0.6") oI slack by pressing a point
between Ian belt and crank pulley with a Iinger and Ior breakage.
8) Greasing each pin
Always grease the pins oI the work equipment.
Post operation Inspections
AIter the operation, always check the Iollowing items.
At this time, always park the machine on flat ground.
1) Checking Ior loose parts
Check each part Ior looseness. II some part is loose, retighten it.
2) Adding Iuel to the Iuel tank
AIter the operation, always check the Iuel amount. II it is insuIIicient, add
more diesel Iuel.
Ean Belt
Euel Port
When you find sludge or
so on the fan belt you
have to replace it with
new one.
IMPORTANT
33
34
PT screw
Torque kg-m
Size (lb-It)
1/4 3.6
(26)
3/8 5.5
(40)
1/2 8.6
(62)
3/4 13.0
(94)
1 19.5
(141)
1 1/4 30.0
(217)
1 1/2 40.0
(289)
INSPECTIONS
Tightening Torque List
At prestart inspections, always check the bolts and nuts Ior looseness. II any bolt or nut is loose, retighten according to the table
below.
(kg-m) Tightening torque oI the bolt and nut (Body)
Material 4T 7T 12.9
Size (lb-It) (lb-It) (lb-It)
M6 0.4 (2.9) 0.9 (6.5) 1.8 (13)
M8 1.0 (7.2) 2.2 (16) 4.2 (30)
M10 2.0 (14) 4.3 (31) 8.4 (61)
M12 3.4 (25) 7.4 (54) 14.5 (105)
M14 5.4 (39) 11.7 (85) 22.9 (166)
M16 8.1 (59) 17.3 (125) 34.5 (250)
(kg-m) Tightening torque oI the hydraulic pipings.
UHF screw
Torque kg-m
Size (lb-It)
3/4 3.5-4.0
(25-29)
7/8 5.0-6.0
(36-43)
1 1/16 8.0-9.0
(59-65)
34
PT screw
Torque kg-m
Size (lb-It)
1/4 3.6
(26)
3/8 5.5
(40)
1/2 8.6
(62)
3/4 13.0
(94)
1 19.5
(141)
1 1/4 30.0
(217)
1 1/2 40.0
(289)
INSPECTIONS
Tightening Torque List
At prestart inspections, always check the bolts and nuts Ior looseness. II any bolt or nut is loose, retighten according to the table
below.
(kg-m) Tightening torque oI the bolt and nut (Body)
Material 4T 7T 12.9
Size (lb-It) (lb-It) (lb-It)
M6 0.4 (2.9) 0.9 (6.5) 1.8 (13)
M8 1.0 (7.2) 2.2 (16) 4.2 (30)
M10 2.0 (14) 4.3 (31) 8.4 (61)
M12 3.4 (25) 7.4 (54) 14.5 (105)
M14 5.4 (39) 11.7 (85) 22.9 (166)
M16 8.1 (59) 17.3 (125) 34.5 (250)
(kg-m) Tightening torque oI the hydraulic pipings.
UHF screw
Torque kg-m
Size (lb-It)
3/4 3.5-4.0
(25-29)
7/8 5.0-6.0
(36-43)
1 1/16 8.0-9.0
(59-65)
34
PT screw
Torque kg-m
Size (lb-It)
1/4 3.6
(26)
3/8 5.5
(40)
1/2 8.6
(62)
3/4 13.0
(94)
1 19.5
(141)
1 1/4 30.0
(217)
1 1/2 40.0
(289)
INSPECTIONS
Tightening Torque List
At prestart inspections, always check the bolts and nuts Ior looseness. II any bolt or nut is loose, retighten according to the table
below.
(kg-m) Tightening torque oI the bolt and nut (Body)
Material 4T 7T 12.9
Size (lb-It) (lb-It) (lb-It)
M6 0.4 (2.9) 0.9 (6.5) 1.8 (13)
M8 1.0 (7.2) 2.2 (16) 4.2 (30)
M10 2.0 (14) 4.3 (31) 8.4 (61)
M12 3.4 (25) 7.4 (54) 14.5 (105)
M14 5.4 (39) 11.7 (85) 22.9 (166)
M16 8.1 (59) 17.3 (125) 34.5 (250)
(kg-m) Tightening torque oI the hydraulic pipings.
UHF screw
Torque kg-m
Size (lb-It)
3/4 3.5-4.0
(25-29)
7/8 5.0-6.0
(36-43)
1 1/16 8.0-9.0
(59-65)
34
PT screw
Torque kg-m
Size (lb-It)
1/4 3.6
(26)
3/8 5.5
(40)
1/2 8.6
(62)
3/4 13.0
(94)
1 19.5
(141)
1 1/4 30.0
(217)
1 1/2 40.0
(289)
INSPECTIONS
Tightening Torque List
At prestart inspections, always check the bolts and nuts Ior looseness. II any bolt or nut is loose, retighten according to the table
below.
(kg-m) Tightening torque oI the bolt and nut (Body)
Material 4T 7T 12.9
Size (lb-It) (lb-It) (lb-It)
M6 0.4 (2.9) 0.9 (6.5) 1.8 (13)
M8 1.0 (7.2) 2.2 (16) 4.2 (30)
M10 2.0 (14) 4.3 (31) 8.4 (61)
M12 3.4 (25) 7.4 (54) 14.5 (105)
M14 5.4 (39) 11.7 (85) 22.9 (166)
M16 8.1 (59) 17.3 (125) 34.5 (250)
(kg-m) Tightening torque oI the hydraulic pipings.
UHF screw
Torque kg-m
Size (lb-It)
3/4 3.5-4.0
(25-29)
7/8 5.0-6.0
(36-43)
1 1/16 8.0-9.0
(59-65)
INSPECTIONS
(kg-m) Tightening torque oI the high-pressure plug nut.
Material kg-m
Size (lb-It)
o12 5.5-6.0
(40-43)
o15 10.5-11.0
(76-80)
(KG-M) Tightening torque oI the hose clamp
PE screw
Torque kg-m
Size (lb-It)
1/4 2.7-3.0
(20-22)
3/8 4.7-5.2
(34-38)
1/2 5.7-6.3
(41-46)
3/4 10.8-12.0
(78-87)
1 12.6-14.0
(91-101)
35
INSPECTIONS
(kg-m) Tightening torque oI the high-pressure plug nut.
Material kg-m
Size (lb-It)
o12 5.5-6.0
(40-43)
o15 10.5-11.0
(76-80)
(KG-M) Tightening torque oI the hose clamp
PE screw
Torque kg-m
Size (lb-It)
1/4 2.7-3.0
(20-22)
3/8 4.7-5.2
(34-38)
1/2 5.7-6.3
(41-46)
3/4 10.8-12.0
(78-87)
1 12.6-14.0
(91-101)
35
INSPECTIONS
(kg-m) Tightening torque oI the high-pressure plug nut.
Material kg-m
Size (lb-It)
o12 5.5-6.0
(40-43)
o15 10.5-11.0
(76-80)
(KG-M) Tightening torque oI the hose clamp
PE screw
Torque kg-m
Size (lb-It)
1/4 2.7-3.0
(20-22)
3/8 4.7-5.2
(34-38)
1/2 5.7-6.3
(41-46)
3/4 10.8-12.0
(78-87)
1 12.6-14.0
(91-101)
35
INSPECTIONS
(kg-m) Tightening torque oI the high-pressure plug nut.
Material kg-m
Size (lb-It)
o12 5.5-6.0
(40-43)
o15 10.5-11.0
(76-80)
(KG-M) Tightening torque oI the hose clamp
PE screw
Torque kg-m
Size (lb-It)
1/4 2.7-3.0
(20-22)
3/8 4.7-5.2
(34-38)
1/2 5.7-6.3
(41-46)
3/4 10.8-12.0
(78-87)
1 12.6-14.0
(91-101)
35
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine
3. Remove the drain plug oI the oil pan, and
drain the oil.
4. Remove the cartridge with a Iilter wrench.
5. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
6. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
7. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
36
MAINTENANCE AFTER THE FIRST 50 SERVICE HOURS (NEW MACHINE)
Drain Plug
Engine Oil Port
Engine Oil Eilter
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine
3. Remove the drain plug oI the oil pan, and
drain the oil.
4. Remove the cartridge with a Iilter wrench.
5. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
6. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
7. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
36
MAINTENANCE AFTER THE FIRST 50 SERVICE HOURS (NEW MACHINE)
Drain Plug
Engine Oil Port
Engine Oil Eilter
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine
3. Remove the drain plug oI the oil pan, and
drain the oil.
4. Remove the cartridge with a Iilter wrench.
5. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
6. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
7. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
36
MAINTENANCE AFTER THE FIRST 50 SERVICE HOURS (NEW MACHINE)
Drain Plug
Engine Oil Port
Engine Oil Eilter
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine
3. Remove the drain plug oI the oil pan, and
drain the oil.
4. Remove the cartridge with a Iilter wrench.
5. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
6. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
7. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
36
MAINTENANCE AFTER THE FIRST 50 SERVICE HOURS (NEW MACHINE)
Drain Plug
Engine Oil Port
Engine Oil Eilter
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
1) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace
it with new one.
2) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm (1.6")) and pull out
the element.
Clean the element with cleaning oil and remove all dirt.
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
MAINTENANCE AFTER THE FIRST 100 SERVICE HOURS (NEW MACHINE)
Line Eilter
Suction Eilter
Pilot Eilter
Before replacing the
filter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
37
1) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace
it with new one.
2) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm (1.6")) and pull out
the element.
Clean the element with cleaning oil and remove all dirt.
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
MAINTENANCE AFTER THE FIRST 100 SERVICE HOURS (NEW MACHINE)
Line Eilter
Suction Eilter
Pilot Eilter
Before replacing the
filter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
37
1) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace
it with new one.
2) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm (1.6")) and pull out
the element.
Clean the element with cleaning oil and remove all dirt.
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
MAINTENANCE AFTER THE FIRST 100 SERVICE HOURS (NEW MACHINE)
Line Eilter
Suction Eilter
Pilot Eilter
Before replacing the
filter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
37
1) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace
it with new one.
2) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm (1.6")) and pull out
the element.
Clean the element with cleaning oil and remove all dirt.
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
MAINTENANCE AFTER THE FIRST 100 SERVICE HOURS (NEW MACHINE)
Line Eilter
Suction Eilter
Pilot Eilter
Before replacing the
filter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
37
38
(PERFORM THE MAINTENANCE AT THE
SAME TIME IF IT IS CONTAINED IN THE
DAILY MAINTENANCE.)
PerIorm the Iollowing maintenance aIter the Iirst 50 service
hours.
1) Cleaning the radiator Iins
Clean the radiator Iins using pressurized air
and steam.
2) Checking the amount oI battery electrolyte
Remove the bolt and nut which Iix the battery cover to
take out the battery.
1. Visually check whether the level oI the battery
electrolyte in each block is between the
upper and lower limits.
2. II it is under the lower limit, take oII the cap to
add battery electrolyte or distilled water to the
upper limit in each block.
3) Inspecting the speciIic gravity oI the Iluid
Measure the speciIic gravity oI the electrolyte. II it
is lower than the speciIied values, recharge the battery.
At this time, clean and connect the terminals, and then
coat with grease.
4) Greasing swing bearing
Give grease to grease nipple oI swing bearing with a
grease gun.
MAINTENANCE EVERY 50 SERVICE HOURS
Radiator Ein
Grease Points
Terminal
Cap
Battery
If the fins remain dirty,
engine will overheat.
IMPORTANT
Always stop engine
during the work. Do not
coat with grease before
connecting the terminals.
WARNING
After working in water,
apply grease without
fail.
IMPORTANT
38
(PERFORM THE MAINTENANCE AT THE
SAME TIME IF IT IS CONTAINED IN THE
DAILY MAINTENANCE.)
PerIorm the Iollowing maintenance aIter the Iirst 50 service
hours.
1) Cleaning the radiator Iins
Clean the radiator Iins using pressurized air
and steam.
2) Checking the amount oI battery electrolyte
Remove the bolt and nut which Iix the battery cover to
take out the battery.
1. Visually check whether the level oI the battery
electrolyte in each block is between the
upper and lower limits.
2. II it is under the lower limit, take oII the cap to
add battery electrolyte or distilled water to the
upper limit in each block.
3) Inspecting the speciIic gravity oI the Iluid
Measure the speciIic gravity oI the electrolyte. II it
is lower than the speciIied values, recharge the battery.
At this time, clean and connect the terminals, and then
coat with grease.
4) Greasing swing bearing
Give grease to grease nipple oI swing bearing with a
grease gun.
MAINTENANCE EVERY 50 SERVICE HOURS
Radiator Ein
Grease Points
Terminal
Cap
Battery
If the fins remain dirty,
engine will overheat.
IMPORTANT
Always stop engine
during the work. Do not
coat with grease before
connecting the terminals.
WARNING
After working in water,
apply grease without
fail.
IMPORTANT
38
(PERFORM THE MAINTENANCE AT THE
SAME TIME IF IT IS CONTAINED IN THE
DAILY MAINTENANCE.)
PerIorm the Iollowing maintenance aIter the Iirst 50 service
hours.
1) Cleaning the radiator Iins
Clean the radiator Iins using pressurized air
and steam.
2) Checking the amount oI battery electrolyte
Remove the bolt and nut which Iix the battery cover to
take out the battery.
1. Visually check whether the level oI the battery
electrolyte in each block is between the
upper and lower limits.
2. II it is under the lower limit, take oII the cap to
add battery electrolyte or distilled water to the
upper limit in each block.
3) Inspecting the speciIic gravity oI the Iluid
Measure the speciIic gravity oI the electrolyte. II it
is lower than the speciIied values, recharge the battery.
At this time, clean and connect the terminals, and then
coat with grease.
4) Greasing swing bearing
Give grease to grease nipple oI swing bearing with a
grease gun.
MAINTENANCE EVERY 50 SERVICE HOURS
Radiator Ein
Grease Points
Terminal
Cap
Battery
If the fins remain dirty,
engine will overheat.
IMPORTANT
Always stop engine
during the work. Do not
coat with grease before
connecting the terminals.
WARNING
After working in water,
apply grease without
fail.
IMPORTANT
38
(PERFORM THE MAINTENANCE AT THE
SAME TIME IF IT IS CONTAINED IN THE
DAILY MAINTENANCE.)
PerIorm the Iollowing maintenance aIter the Iirst 50 service
hours.
1) Cleaning the radiator Iins
Clean the radiator Iins using pressurized air
and steam.
2) Checking the amount oI battery electrolyte
Remove the bolt and nut which Iix the battery cover to
take out the battery.
1. Visually check whether the level oI the battery
electrolyte in each block is between the
upper and lower limits.
2. II it is under the lower limit, take oII the cap to
add battery electrolyte or distilled water to the
upper limit in each block.
3) Inspecting the speciIic gravity oI the Iluid
Measure the speciIic gravity oI the electrolyte. II it
is lower than the speciIied values, recharge the battery.
At this time, clean and connect the terminals, and then
coat with grease.
4) Greasing swing bearing
Give grease to grease nipple oI swing bearing with a
grease gun.
MAINTENANCE EVERY 50 SERVICE HOURS
Radiator Ein
Grease Points
Terminal
Cap
Battery
If the fins remain dirty,
engine will overheat.
IMPORTANT
Always stop engine
during the work. Do not
coat with grease before
connecting the terminals.
WARNING
After working in water,
apply grease without
fail.
IMPORTANT
5) Eliminating the sediment in the Iuel tank
Open the drain cock to eliminate the sediment and drain
the water.
6) Checking the Iuel tank strainer
Remove the tank cap, remove any loose dirt on the
strainer and clean it with diesel Iuel.
MAINTENANCE EVERY 50 SERVICE HOURS
Drain Plug
Strainer
1) Inspecting and cleaning the air cleaner
Inspect and clean the element.
(Eor the inspection and cleaning, see page 51
replacing the air cleaner element)
MAINTENANCE EVERY 100 SERVICE HOURS
Air Cleaner Element
Never replace the air
cleaner element while
engine is running.
WARNING
39
5) Eliminating the sediment in the Iuel tank
Open the drain cock to eliminate the sediment and drain
the water.
6) Checking the Iuel tank strainer
Remove the tank cap, remove any loose dirt on the
strainer and clean it with diesel Iuel.
MAINTENANCE EVERY 50 SERVICE HOURS
Drain Plug
Strainer
1) Inspecting and cleaning the air cleaner
Inspect and clean the element.
(Eor the inspection and cleaning, see page 51
replacing the air cleaner element)
MAINTENANCE EVERY 100 SERVICE HOURS
Air Cleaner Element
Never replace the air
cleaner element while
engine is running.
WARNING
39
5) Eliminating the sediment in the Iuel tank
Open the drain cock to eliminate the sediment and drain
the water.
6) Checking the Iuel tank strainer
Remove the tank cap, remove any loose dirt on the
strainer and clean it with diesel Iuel.
MAINTENANCE EVERY 50 SERVICE HOURS
Drain Plug
Strainer
1) Inspecting and cleaning the air cleaner
Inspect and clean the element.
(Eor the inspection and cleaning, see page 51
replacing the air cleaner element)
MAINTENANCE EVERY 100 SERVICE HOURS
Air Cleaner Element
Never replace the air
cleaner element while
engine is running.
WARNING
39
5) Eliminating the sediment in the Iuel tank
Open the drain cock to eliminate the sediment and drain
the water.
6) Checking the Iuel tank strainer
Remove the tank cap, remove any loose dirt on the
strainer and clean it with diesel Iuel.
MAINTENANCE EVERY 50 SERVICE HOURS
Drain Plug
Strainer
1) Inspecting and cleaning the air cleaner
Inspect and clean the element.
(Eor the inspection and cleaning, see page 51
replacing the air cleaner element)
MAINTENANCE EVERY 100 SERVICE HOURS
Air Cleaner Element
Never replace the air
cleaner element while
engine is running.
WARNING
39
40
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes), as the
engine oil should be warm beIore replacing the
cartridge.
2. Remove the drain plug oI the oil pan, and drain
the oil.
3. Securely replace the drain plug, and add the speciIied
amount oI engine oil through the oil supply port.
4. Start and idle the engine Ior several minutes to check
Ior oil leakage. AIter the engine is stopped, check the
oil level using the level gauge. II short, add oil.
PerIorm this operation on level ground. Make certain
that dust does not enter through the oil supply port.
3.5 l (0.9 U.S. gal)
2) Eliminating the sediment in the hydraulic oil tank
Open the drain plug to eliminate the sediment and drain
the water.
MAINTENANCE EVERY 250 SERVICE HOURS
Drain Plug
Drain Plug
Engine Oil Port
40
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes), as the
engine oil should be warm beIore replacing the
cartridge.
2. Remove the drain plug oI the oil pan, and drain
the oil.
3. Securely replace the drain plug, and add the speciIied
amount oI engine oil through the oil supply port.
4. Start and idle the engine Ior several minutes to check
Ior oil leakage. AIter the engine is stopped, check the
oil level using the level gauge. II short, add oil.
PerIorm this operation on level ground. Make certain
that dust does not enter through the oil supply port.
3.5 l (0.9 U.S. gal)
2) Eliminating the sediment in the hydraulic oil tank
Open the drain plug to eliminate the sediment and drain
the water.
MAINTENANCE EVERY 250 SERVICE HOURS
Drain Plug
Drain Plug
Engine Oil Port
40
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes), as the
engine oil should be warm beIore replacing the
cartridge.
2. Remove the drain plug oI the oil pan, and drain
the oil.
3. Securely replace the drain plug, and add the speciIied
amount oI engine oil through the oil supply port.
4. Start and idle the engine Ior several minutes to check
Ior oil leakage. AIter the engine is stopped, check the
oil level using the level gauge. II short, add oil.
PerIorm this operation on level ground. Make certain
that dust does not enter through the oil supply port.
3.5 l (0.9 U.S. gal)
2) Eliminating the sediment in the hydraulic oil tank
Open the drain plug to eliminate the sediment and drain
the water.
MAINTENANCE EVERY 250 SERVICE HOURS
Drain Plug
Drain Plug
Engine Oil Port
40
1) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes), as the
engine oil should be warm beIore replacing the
cartridge.
2. Remove the drain plug oI the oil pan, and drain
the oil.
3. Securely replace the drain plug, and add the speciIied
amount oI engine oil through the oil supply port.
4. Start and idle the engine Ior several minutes to check
Ior oil leakage. AIter the engine is stopped, check the
oil level using the level gauge. II short, add oil.
PerIorm this operation on level ground. Make certain
that dust does not enter through the oil supply port.
3.5 l (0.9 U.S. gal)
2) Eliminating the sediment in the hydraulic oil tank
Open the drain plug to eliminate the sediment and drain
the water.
MAINTENANCE EVERY 250 SERVICE HOURS
Drain Plug
Drain Plug
Engine Oil Port
1) Replacing the Iuel Iilter element
You can take out the element by closing the clock
and removing the retainer ring.
Replace it with new one.
O rings must be replaced with new ones at all
times.
After replacing the element, bleed air.
(See page 50.)
2) Replacing cooling water in radiator
Remove the drain plug on radiator to replace the
cooling water.
5.6 l (1.4 U.S. gal)
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
4) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace it
with new one.
5) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm) and pull out the
element.
Clean the element with cleaning oil and remove all dirt.
MAINTENANCE EVERY 500 SERVICE HOURS
Line Eilter
Euel Eilter
Drain Plug
Suction Eilter
Pilot Eilter
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
Before replacing the fil-
ter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
41
1) Replacing the Iuel Iilter element
You can take out the element by closing the clock
and removing the retainer ring.
Replace it with new one.
O rings must be replaced with new ones at all
times.
After replacing the element, bleed air.
(See page 50.)
2) Replacing cooling water in radiator
Remove the drain plug on radiator to replace the
cooling water.
5.6 l (1.4 U.S. gal)
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
4) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace it
with new one.
5) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm) and pull out the
element.
Clean the element with cleaning oil and remove all dirt.
MAINTENANCE EVERY 500 SERVICE HOURS
Line Eilter
Euel Eilter
Drain Plug
Suction Eilter
Pilot Eilter
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
Before replacing the fil-
ter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
41
1) Replacing the Iuel Iilter element
You can take out the element by closing the clock
and removing the retainer ring.
Replace it with new one.
O rings must be replaced with new ones at all
times.
After replacing the element, bleed air.
(See page 50.)
2) Replacing cooling water in radiator
Remove the drain plug on radiator to replace the
cooling water.
5.6 l (1.4 U.S. gal)
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
4) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace it
with new one.
5) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm) and pull out the
element.
Clean the element with cleaning oil and remove all dirt.
MAINTENANCE EVERY 500 SERVICE HOURS
Line Eilter
Euel Eilter
Drain Plug
Suction Eilter
Pilot Eilter
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
Before replacing the fil-
ter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
41
1) Replacing the Iuel Iilter element
You can take out the element by closing the clock
and removing the retainer ring.
Replace it with new one.
O rings must be replaced with new ones at all
times.
After replacing the element, bleed air.
(See page 50.)
2) Replacing cooling water in radiator
Remove the drain plug on radiator to replace the
cooling water.
5.6 l (1.4 U.S. gal)
3) Cleaning the suction Iilter
Remove the suction Iilter Irom the hydraulic oil tank.
Clean the Iilter with diesel Iuel or kerosene to remove
the dirt. II the strainer is broken, replace it with new
one.
4) Replacing the line Iilter element
Remove the Iilter with a Iilter wrench and replace it
with new one.
5) Cleaning the pilot Iilter
Remove the plug Irom under the Iloor plate with a
spanner (width across Ilats:27 mm) and pull out the
element.
Clean the element with cleaning oil and remove all dirt.
MAINTENANCE EVERY 500 SERVICE HOURS
Line Eilter
Euel Eilter
Drain Plug
Suction Eilter
Pilot Eilter
To reinstall the lid, set
the O-ring securely into
the flange groove in
order to prevent a leak of
hydraulic oil.
IMPORTANT
Before replacing the fil-
ter, be sure to open the
hydraulic oil tank to
bleed the filter.
IMPORTANT
41
42
5) Replacing air cleaner element
Loosen the wing-nut, and replace the element.
(Eor the procedure, reIer to page 51 Air cleaner
element)
AIter stopping the engine, clean them.
6) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine and remove the drain plug
on the oil pan. Drain the oil.
3. Remove the cartridge with a Iilter wrench.
4. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
5. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
6. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
MAINTENANCE EVERY 500 SERVICE HOURS
Drain Plug
Engine Oil Eilter
Engine Oil Port
Air Cleaner Element
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
42
5) Replacing air cleaner element
Loosen the wing-nut, and replace the element.
(Eor the procedure, reIer to page 51 Air cleaner
element)
AIter stopping the engine, clean them.
6) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine and remove the drain plug
on the oil pan. Drain the oil.
3. Remove the cartridge with a Iilter wrench.
4. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
5. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
6. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
MAINTENANCE EVERY 500 SERVICE HOURS
Drain Plug
Engine Oil Eilter
Engine Oil Port
Air Cleaner Element
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
42
5) Replacing air cleaner element
Loosen the wing-nut, and replace the element.
(Eor the procedure, reIer to page 51 Air cleaner
element)
AIter stopping the engine, clean them.
6) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine and remove the drain plug
on the oil pan. Drain the oil.
3. Remove the cartridge with a Iilter wrench.
4. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
5. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
6. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
MAINTENANCE EVERY 500 SERVICE HOURS
Drain Plug
Engine Oil Eilter
Engine Oil Port
Air Cleaner Element
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
42
5) Replacing air cleaner element
Loosen the wing-nut, and replace the element.
(Eor the procedure, reIer to page 51 Air cleaner
element)
AIter stopping the engine, clean them.
6) Replacing engine oil Iilter cartridge
1. Warm up the engine (Ior about 10 minutes),
as the engine oil should be warm beIore
replacing the cartridge.
2. Shut oII the engine and remove the drain plug
on the oil pan. Drain the oil.
3. Remove the cartridge with a Iilter wrench.
4. Slightly coat the O-ring oI the new cartridge
with oil and Iirmly tighten the cartridge by
hand.
5. Securely replace the drain plug, and add the
speciIied amount oI engine oil through the oil
supply port.
6. Start and idle the engine Ior several minutes
to check Ior oil leakage. AIter the engine is
stopped, check the oil level using the level
gauge. II short, add oil.
MAINTENANCE EVERY 500 SERVICE HOURS
Drain Plug
Engine Oil Eilter
Engine Oil Port
Air Cleaner Element
Perform this operation
on flat ground. Make
sure that dust does not
enter through the oil
supply port.
IMPORTANT
1) Cleaning the Cooling Water Passage
Clean the inside oI the radiator and the engine water
passage.
Eor the cleaning procedure, see Replacing the Cooling
Water in the Radiator, page 51.
2) Checking the Engine Valve Clearance
Measure the clearance with a clearance gauge, and
adjust the clearance oI both the inlet and outlet valves
to 0.20 mm.
Eor the checking and adjustment, see Checking the
Engine Valve Clearance, page 44.
3) Measuring the Compression Pressure
Measure the compression pressure oI all cylinders with
a compression gauge.
Eor the checking and maintenance, see Checking the
Compression Pressure, page 47.
4) Replacing the Hydraulic Oil
Remove the drain plug and replace all hydraulic oil.
Amount oI hydraulic oil: 30.6 l (8.1 U.S. gal)
5) Replacing the Lubricating Oil in the Travel Speed
Reduction Gear.
Remove the blind plug in the speed reduction gear
cover, and replace the lubricating oil.
Eor the replacement procedure, see Repair Manual.
MAINTENANCE EVERY 1000 SERVICE HOURS
Drain Plug
43
1) Cleaning the Cooling Water Passage
Clean the inside oI the radiator and the engine water
passage.
Eor the cleaning procedure, see Replacing the Cooling
Water in the Radiator, page 51.
2) Checking the Engine Valve Clearance
Measure the clearance with a clearance gauge, and
adjust the clearance oI both the inlet and outlet valves
to 0.20 mm.
Eor the checking and adjustment, see Checking the
Engine Valve Clearance, page 44.
3) Measuring the Compression Pressure
Measure the compression pressure oI all cylinders with
a compression gauge.
Eor the checking and maintenance, see Checking the
Compression Pressure, page 47.
4) Replacing the Hydraulic Oil
Remove the drain plug and replace all hydraulic oil.
Amount oI hydraulic oil: 30.6 l (8.1 U.S. gal)
5) Replacing the Lubricating Oil in the Travel Speed
Reduction Gear.
Remove the blind plug in the speed reduction gear
cover, and replace the lubricating oil.
Eor the replacement procedure, see Repair Manual.
MAINTENANCE EVERY 1000 SERVICE HOURS
Drain Plug
43
1) Cleaning the Cooling Water Passage
Clean the inside oI the radiator and the engine water
passage.
Eor the cleaning procedure, see Replacing the Cooling
Water in the Radiator, page 51.
2) Checking the Engine Valve Clearance
Measure the clearance with a clearance gauge, and
adjust the clearance oI both the inlet and outlet valves
to 0.20 mm.
Eor the checking and adjustment, see Checking the
Engine Valve Clearance, page 44.
3) Measuring the Compression Pressure
Measure the compression pressure oI all cylinders with
a compression gauge.
Eor the checking and maintenance, see Checking the
Compression Pressure, page 47.
4) Replacing the Hydraulic Oil
Remove the drain plug and replace all hydraulic oil.
Amount oI hydraulic oil: 30.6 l (8.1 U.S. gal)
5) Replacing the Lubricating Oil in the Travel Speed
Reduction Gear.
Remove the blind plug in the speed reduction gear
cover, and replace the lubricating oil.
Eor the replacement procedure, see Repair Manual.
MAINTENANCE EVERY 1000 SERVICE HOURS
Drain Plug
43
1) Cleaning the Cooling Water Passage
Clean the inside oI the radiator and the engine water
passage.
Eor the cleaning procedure, see Replacing the Cooling
Water in the Radiator, page 51.
2) Checking the Engine Valve Clearance
Measure the clearance with a clearance gauge, and
adjust the clearance oI both the inlet and outlet valves
to 0.20 mm.
Eor the checking and adjustment, see Checking the
Engine Valve Clearance, page 44.
3) Measuring the Compression Pressure
Measure the compression pressure oI all cylinders with
a compression gauge.
Eor the checking and maintenance, see Checking the
Compression Pressure, page 47.
4) Replacing the Hydraulic Oil
Remove the drain plug and replace all hydraulic oil.
Amount oI hydraulic oil: 30.6 l (8.1 U.S. gal)
5) Replacing the Lubricating Oil in the Travel Speed
Reduction Gear.
Remove the blind plug in the speed reduction gear
cover, and replace the lubricating oil.
Eor the replacement procedure, see Repair Manual.
MAINTENANCE EVERY 1000 SERVICE HOURS
Drain Plug
43
Inspecting engine valve clearance
1) Be careIul when checking and making adjustments,
that the engine has been cooled.
To turn the Ilywheel easily, remove the glow plug oI
every cylinders Ior stop appearing the compression
pressure.
Tighten the adjust bolt by the lock nut aIter the
adjustment oI valve clearance.
When transporting by the track, use a mark on the
checking window beside the clutch housing instead oI
the punch mark on the rear end plate.
1. Remove the muIIler and the head cover.
2. Turn the 1TC mark oI the Ilywheel to the punch mark
on the rear end plate, to make the No.1 cylinder to the
top.
3. Check the clearance oI the valve marked Au on the
table and adjust by adjusting bolt iI it isn't standard
value.
4. Then turn the Ilywheel Ior 1 time, make the No.1
cylinder to overlapped.
5. Check the clearance oI the valve marked A on the
table and adjust by adjusting bolt iI it isn't standard
value.
44
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Adjust Screw
Punch Mark
Thickness Gauge
Screwdriver
Wrench
Crank Pulley
TDC Mark
Valve Clearance in Cold
Suction Valve
Exhaust Valve 0.2 mm (0.0079 in.)
Cyl No. 1 2 3
Valve order I E I E I E
Top mark Au Au Au Au
oI No.1 Cyl.
Overlap A A
oI No.1 Cyl.
Inspecting engine valve clearance
1) Be careIul when checking and making adjustments,
that the engine has been cooled.
To turn the Ilywheel easily, remove the glow plug oI
every cylinders Ior stop appearing the compression
pressure.
Tighten the adjust bolt by the lock nut aIter the
adjustment oI valve clearance.
When transporting by the track, use a mark on the
checking window beside the clutch housing instead oI
the punch mark on the rear end plate.
1. Remove the muIIler and the head cover.
2. Turn the 1TC mark oI the Ilywheel to the punch mark
on the rear end plate, to make the No.1 cylinder to the
top.
3. Check the clearance oI the valve marked Au on the
table and adjust by adjusting bolt iI it isn't standard
value.
4. Then turn the Ilywheel Ior 1 time, make the No.1
cylinder to overlapped.
5. Check the clearance oI the valve marked A on the
table and adjust by adjusting bolt iI it isn't standard
value.
44
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Adjust Screw
Punch Mark
Thickness Gauge
Screwdriver
Wrench
Crank Pulley
TDC Mark
Valve Clearance in Cold
Suction Valve
Exhaust Valve 0.2 mm (0.0079 in.)
Cyl No. 1 2 3
Valve order I E I E I E
Top mark Au Au Au Au
oI No.1 Cyl.
Overlap A A
oI No.1 Cyl.
Inspecting engine valve clearance
1) Be careIul when checking and making adjustments,
that the engine has been cooled.
To turn the Ilywheel easily, remove the glow plug oI
every cylinders Ior stop appearing the compression
pressure.
Tighten the adjust bolt by the lock nut aIter the
adjustment oI valve clearance.
When transporting by the track, use a mark on the
checking window beside the clutch housing instead oI
the punch mark on the rear end plate.
1. Remove the muIIler and the head cover.
2. Turn the 1TC mark oI the Ilywheel to the punch mark
on the rear end plate, to make the No.1 cylinder to the
top.
3. Check the clearance oI the valve marked Au on the
table and adjust by adjusting bolt iI it isn't standard
value.
4. Then turn the Ilywheel Ior 1 time, make the No.1
cylinder to overlapped.
5. Check the clearance oI the valve marked A on the
table and adjust by adjusting bolt iI it isn't standard
value.
44
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Adjust Screw
Punch Mark
Thickness Gauge
Screwdriver
Wrench
Crank Pulley
TDC Mark
Valve Clearance in Cold
Suction Valve
Exhaust Valve 0.2 mm (0.0079 in.)
Cyl No. 1 2 3
Valve order I E I E I E
Top mark Au Au Au Au
oI No.1 Cyl.
Overlap A A
oI No.1 Cyl.
Inspecting engine valve clearance
1) Be careIul when checking and making adjustments,
that the engine has been cooled.
To turn the Ilywheel easily, remove the glow plug oI
every cylinders Ior stop appearing the compression
pressure.
Tighten the adjust bolt by the lock nut aIter the
adjustment oI valve clearance.
When transporting by the track, use a mark on the
checking window beside the clutch housing instead oI
the punch mark on the rear end plate.
1. Remove the muIIler and the head cover.
2. Turn the 1TC mark oI the Ilywheel to the punch mark
on the rear end plate, to make the No.1 cylinder to the
top.
3. Check the clearance oI the valve marked Au on the
table and adjust by adjusting bolt iI it isn't standard
value.
4. Then turn the Ilywheel Ior 1 time, make the No.1
cylinder to overlapped.
5. Check the clearance oI the valve marked A on the
table and adjust by adjusting bolt iI it isn't standard
value.
44
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Adjust Screw
Punch Mark
Thickness Gauge
Screwdriver
Wrench
Crank Pulley
TDC Mark
Valve Clearance in Cold
Suction Valve
Exhaust Valve 0.2 mm (0.0079 in.)
Cyl No. 1 2 3
Valve order I E I E I E
Top mark Au Au Au Au
oI No.1 Cyl.
Overlap A A
oI No.1 Cyl.
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspecting and adjusting injection nozzle
1) Check Ior the injection starting pressure.
1. Remove the nozzle assembly Irom cylinder head and mount it on the nozzle
tester. Move the handle upward and downward to bleed the air.
2. Operate the handle the rate oI 60 cycles per min. And read the pressure
on the gauge when the injection starts.
Injection starting pressure 115~125kg / cm2 (1636~1778 psi)
3. II the injection starting pressure does not meet the standard, disassemble the
nozzle and adjust it with the adjusting shims.
Changing the thickness oI adjusting shim by 0.1 mm can change the pressure
about 10 kg / cm2.
2) Chattering
Operate the handle oI tester at the rate oI about one cycle per second.
1. Vibration oI needle valve
It is normal that while injecting with continuous sound when operating the handle oI tester, the vibration oI needle
valve is transmitted to the handle.
2. The state oI injection
Injecting straight in the nozzle axle direction is good.
Uneven injection or injection oI several lines is Iaulty. AIter the injection test, a little gas oil remaining on the
injection hole (dribbling) is normal.
This occurs in the test only.
3. Evaluation oI injection
Operate the handle oI tester at a speed oI one stroke per second to make sure the discharge is straight.
Pass Reject Reject Reject
Pass Reject Reject
45
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspecting and adjusting injection nozzle
1) Check Ior the injection starting pressure.
1. Remove the nozzle assembly Irom cylinder head and mount it on the nozzle
tester. Move the handle upward and downward to bleed the air.
2. Operate the handle the rate oI 60 cycles per min. And read the pressure
on the gauge when the injection starts.
Injection starting pressure 115~125kg / cm2 (1636~1778 psi)
3. II the injection starting pressure does not meet the standard, disassemble the
nozzle and adjust it with the adjusting shims.
Changing the thickness oI adjusting shim by 0.1 mm can change the pressure
about 10 kg / cm2.
2) Chattering
Operate the handle oI tester at the rate oI about one cycle per second.
1. Vibration oI needle valve
It is normal that while injecting with continuous sound when operating the handle oI tester, the vibration oI needle
valve is transmitted to the handle.
2. The state oI injection
Injecting straight in the nozzle axle direction is good.
Uneven injection or injection oI several lines is Iaulty. AIter the injection test, a little gas oil remaining on the
injection hole (dribbling) is normal.
This occurs in the test only.
3. Evaluation oI injection
Operate the handle oI tester at a speed oI one stroke per second to make sure the discharge is straight.
Pass Reject Reject Reject
Pass Reject Reject
45
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspecting and adjusting injection nozzle
1) Check Ior the injection starting pressure.
1. Remove the nozzle assembly Irom cylinder head and mount it on the nozzle
tester. Move the handle upward and downward to bleed the air.
2. Operate the handle the rate oI 60 cycles per min. And read the pressure
on the gauge when the injection starts.
Injection starting pressure 115~125kg / cm2 (1636~1778 psi)
3. II the injection starting pressure does not meet the standard, disassemble the
nozzle and adjust it with the adjusting shims.
Changing the thickness oI adjusting shim by 0.1 mm can change the pressure
about 10 kg / cm2.
2) Chattering
Operate the handle oI tester at the rate oI about one cycle per second.
1. Vibration oI needle valve
It is normal that while injecting with continuous sound when operating the handle oI tester, the vibration oI needle
valve is transmitted to the handle.
2. The state oI injection
Injecting straight in the nozzle axle direction is good.
Uneven injection or injection oI several lines is Iaulty. AIter the injection test, a little gas oil remaining on the
injection hole (dribbling) is normal.
This occurs in the test only.
3. Evaluation oI injection
Operate the handle oI tester at a speed oI one stroke per second to make sure the discharge is straight.
Pass Reject Reject Reject
Pass Reject Reject
45
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspecting and adjusting injection nozzle
1) Check Ior the injection starting pressure.
1. Remove the nozzle assembly Irom cylinder head and mount it on the nozzle
tester. Move the handle upward and downward to bleed the air.
2. Operate the handle the rate oI 60 cycles per min. And read the pressure
on the gauge when the injection starts.
Injection starting pressure 115~125kg / cm2 (1636~1778 psi)
3. II the injection starting pressure does not meet the standard, disassemble the
nozzle and adjust it with the adjusting shims.
Changing the thickness oI adjusting shim by 0.1 mm can change the pressure
about 10 kg / cm2.
2) Chattering
Operate the handle oI tester at the rate oI about one cycle per second.
1. Vibration oI needle valve
It is normal that while injecting with continuous sound when operating the handle oI tester, the vibration oI needle
valve is transmitted to the handle.
2. The state oI injection
Injecting straight in the nozzle axle direction is good.
Uneven injection or injection oI several lines is Iaulty. AIter the injection test, a little gas oil remaining on the
injection hole (dribbling) is normal.
This occurs in the test only.
3. Evaluation oI injection
Operate the handle oI tester at a speed oI one stroke per second to make sure the discharge is straight.
Pass Reject Reject Reject
Pass Reject Reject
45
46
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Disassembly
II the tested part is evaluated as a reject, it must be disassembled and the
deIective part must be replaced.
1) Eix the nozzle holder in a vice and loosen the retaining nut. Do not hold the retaining nut with the vice as this could
damage it.
2) Take out the pressure spring shim, distance piece and nozzle chip.
Scrape the stuck carbon off with a wooden tool and soak the parts
in gas oil.
Carefully handle the needle valve of nozzle tip not to damage it.
Inspection
Replace the deIective part.
1) Insert the nozzle chip into the retaining nut and securely set it.
2) Put the distance piece, retaining pin, pressure spring and disassembled shims on the nozzle tip.
3) Tighten the nozzle holder body with Iingers only.
4) Eix the nozzle holder in a vice and tighten the retaining nut to the speciIied torque.
(Tightening torque : 3.5 ~ 4.0 kgI-m) (25.2 ~ 28.8 Ib-It)
Nozzle nut
Nozzle piece
Distance piece
Push rod
Nozzle holder
body
Adjustment washer
Spring
46
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Disassembly
II the tested part is evaluated as a reject, it must be disassembled and the
deIective part must be replaced.
1) Eix the nozzle holder in a vice and loosen the retaining nut. Do not hold the retaining nut with the vice as this could
damage it.
2) Take out the pressure spring shim, distance piece and nozzle chip.
Scrape the stuck carbon off with a wooden tool and soak the parts
in gas oil.
Carefully handle the needle valve of nozzle tip not to damage it.
Inspection
Replace the deIective part.
1) Insert the nozzle chip into the retaining nut and securely set it.
2) Put the distance piece, retaining pin, pressure spring and disassembled shims on the nozzle tip.
3) Tighten the nozzle holder body with Iingers only.
4) Eix the nozzle holder in a vice and tighten the retaining nut to the speciIied torque.
(Tightening torque : 3.5 ~ 4.0 kgI-m) (25.2 ~ 28.8 Ib-It)
Nozzle nut
Nozzle piece
Distance piece
Push rod
Nozzle holder
body
Adjustment washer
Spring
46
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Disassembly
II the tested part is evaluated as a reject, it must be disassembled and the
deIective part must be replaced.
1) Eix the nozzle holder in a vice and loosen the retaining nut. Do not hold the retaining nut with the vice as this could
damage it.
2) Take out the pressure spring shim, distance piece and nozzle chip.
Scrape the stuck carbon off with a wooden tool and soak the parts
in gas oil.
Carefully handle the needle valve of nozzle tip not to damage it.
Inspection
Replace the deIective part.
1) Insert the nozzle chip into the retaining nut and securely set it.
2) Put the distance piece, retaining pin, pressure spring and disassembled shims on the nozzle tip.
3) Tighten the nozzle holder body with Iingers only.
4) Eix the nozzle holder in a vice and tighten the retaining nut to the speciIied torque.
(Tightening torque : 3.5 ~ 4.0 kgI-m) (25.2 ~ 28.8 Ib-It)
Nozzle nut
Nozzle piece
Distance piece
Push rod
Nozzle holder
body
Adjustment washer
Spring
46
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Disassembly
II the tested part is evaluated as a reject, it must be disassembled and the
deIective part must be replaced.
1) Eix the nozzle holder in a vice and loosen the retaining nut. Do not hold the retaining nut with the vice as this could
damage it.
2) Take out the pressure spring shim, distance piece and nozzle chip.
Scrape the stuck carbon off with a wooden tool and soak the parts
in gas oil.
Carefully handle the needle valve of nozzle tip not to damage it.
Inspection
Replace the deIective part.
1) Insert the nozzle chip into the retaining nut and securely set it.
2) Put the distance piece, retaining pin, pressure spring and disassembled shims on the nozzle tip.
3) Tighten the nozzle holder body with Iingers only.
4) Eix the nozzle holder in a vice and tighten the retaining nut to the speciIied torque.
(Tightening torque : 3.5 ~ 4.0 kgI-m) (25.2 ~ 28.8 Ib-It)
Nozzle nut
Nozzle piece
Distance piece
Push rod
Nozzle holder
body
Adjustment washer
Spring
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspection of compression pressure
1) Check the Iollowing items.
1. Engine oil, air cleaner, starting motor and battery must be in good condition.
2. Measure while the engine is warm. (temperature oI cooling water 50C)
2) Check by the Iollowing procedure.
1. Set to no injection oI Iuel.
2. Remove the glow plug, Iit the compression gauge adapter to
the cylinder you intend to inspect and mount the gauge.
3. Revolve the engine with the starter and read the pointer on
the compression gauge when it is stable.
4. AIter the measurement, remove the compression gauge and
adapter and mount the glow plug.
5. Measure the other cylinders.
Measurement oI compression pressure
Engine revolution : 250 rpm
Compression pressure : 23 kg / cm2 (455 psi)
Pressure diIIerence between each cylinder : 2.0 kgI / cm2 (42.7 psi) max.
47
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspection of compression pressure
1) Check the Iollowing items.
1. Engine oil, air cleaner, starting motor and battery must be in good condition.
2. Measure while the engine is warm. (temperature oI cooling water 50C)
2) Check by the Iollowing procedure.
1. Set to no injection oI Iuel.
2. Remove the glow plug, Iit the compression gauge adapter to
the cylinder you intend to inspect and mount the gauge.
3. Revolve the engine with the starter and read the pointer on
the compression gauge when it is stable.
4. AIter the measurement, remove the compression gauge and
adapter and mount the glow plug.
5. Measure the other cylinders.
Measurement oI compression pressure
Engine revolution : 250 rpm
Compression pressure : 23 kg / cm2 (455 psi)
Pressure diIIerence between each cylinder : 2.0 kgI / cm2 (42.7 psi) max.
47
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspection of compression pressure
1) Check the Iollowing items.
1. Engine oil, air cleaner, starting motor and battery must be in good condition.
2. Measure while the engine is warm. (temperature oI cooling water 50C)
2) Check by the Iollowing procedure.
1. Set to no injection oI Iuel.
2. Remove the glow plug, Iit the compression gauge adapter to
the cylinder you intend to inspect and mount the gauge.
3. Revolve the engine with the starter and read the pointer on
the compression gauge when it is stable.
4. AIter the measurement, remove the compression gauge and
adapter and mount the glow plug.
5. Measure the other cylinders.
Measurement oI compression pressure
Engine revolution : 250 rpm
Compression pressure : 23 kg / cm2 (455 psi)
Pressure diIIerence between each cylinder : 2.0 kgI / cm2 (42.7 psi) max.
47
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
Inspection of compression pressure
1) Check the Iollowing items.
1. Engine oil, air cleaner, starting motor and battery must be in good condition.
2. Measure while the engine is warm. (temperature oI cooling water 50C)
2) Check by the Iollowing procedure.
1. Set to no injection oI Iuel.
2. Remove the glow plug, Iit the compression gauge adapter to
the cylinder you intend to inspect and mount the gauge.
3. Revolve the engine with the starter and read the pointer on
the compression gauge when it is stable.
4. AIter the measurement, remove the compression gauge and
adapter and mount the glow plug.
5. Measure the other cylinders.
Measurement oI compression pressure
Engine revolution : 250 rpm
Compression pressure : 23 kg / cm2 (455 psi)
Pressure diIIerence between each cylinder : 2.0 kgI / cm2 (42.7 psi) max.
47
48
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR MAIN BOLTS
Screw
Diameter / Pitch mm
Mount part
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque
Remarks
Cylinder head bolt M9x1.25(0.4x0.04") 14(0.6") 5.0~5.3 36~38 49~52 Wet
Rocker cover bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Rocker shaIt bracket bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~2.0 7~15 9.7~19.7
Thermoswitch M16x1.5(0.6x0.06") 17(0.7") 1.9~2.7 13.6~19.6 18.6~26.6
CrankshaIt pulley nut M18x1.5(0.7x0.06") 27(1.1") 12.0~13.0 87~94 118~127
Main bearing cap bolt M8x1.25(0.3x0.05") 12(0.7") 2.0~2.5 14~18 20~25
Connecting rod cap nut M9x1.0(0.4x0.04") 14(0.6") 3.3~3.8 23.7~27.7 32.3~37.3
Rear plate bolt (standard) M12x1.25(0.5x0.05") 17(0.7") 5.5~7.5 40~54 54~74
Rear plate bolt (stamping) M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Elywheel bolt M10x1.25(0.4x0.05") 17(0.7") 7.0~8.0 51~58 69~78
Oil pan drain plug M14x1.5(0.6x0.06") 22(0.9") 3.5~4.5 25~33 34~44
Pressure relieI valve M22x1.5(0.9x0.06") 22(0.9") 4.5~5.5 32~40 44~54
Oil Iilter M20x1.5(0.8x0.06") 1.1~1.3 8.0~9.4 11~13
Oil pressure switch PT 1/8 26(1.0") 0.8~1.2 5.8~8.6 8~12
Euel injection pipe nut M12x1.5(0.5x0.06") 2.5~3.5 18~26 24~34
Euel leak-oII pipe nut M12x1.5(0.5x0.06") 18(0.7") 2.5~3.0 18~22 24.5~29.5
Delivery valve holder 19(0.75") 4.0~5.0 28.5~36.5 39~49
Euel inject nozzle holder M18x1.5(0.8x0.06") 21(0.8") 4.0~5.0 29~36 39~49
Retaining nut Ior delivery M16x0.75(0.6x0.03") 19(0.75") 3.5~4.0 25~29 34.5~39.5
valve holder body
Sliding sleeve shaIt M10x1.25(0.4x0.05") 14(0.6") 3.0~4.2 22~30 29~41
Special nut Ior M12x1.0(0.5x0.04") 17(0.7") 1.5~2.5 10~18 15~25
torque spring set
Glow plug M10x1.25(0.4x0.05") 12(0.5") 1.5~2.0 10.7~14.7 14.7~19.7
Glow plug conn. plate M4x0.7(0.2x0.03") 8(0.3") 0.1~0.15 0.7~1.1 1.0~1.4
Stop solenoid nut M30x1.5(1.2x0.06") 36(1.4") 4.0~5.0 28.5~36.5 39~49
Starter B terminal M8x1.25(0.3x0.05") 12(0.5") 1.0~1.2 7.3~8.8 9.8~11.8
* Coat the screw and seat with engine oil beIore mounting the parts labeled with the "wet" mark in the
remarks column.
* ReIer to the tightening torque Ior general bolts (or nuts) on the Iollowing page Ior bolts and nuts not speciIied
above.
48
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR MAIN BOLTS
Screw
Diameter / Pitch mm
Mount part
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque
Remarks
Cylinder head bolt M9x1.25(0.4x0.04") 14(0.6") 5.0~5.3 36~38 49~52 Wet
Rocker cover bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Rocker shaIt bracket bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~2.0 7~15 9.7~19.7
Thermoswitch M16x1.5(0.6x0.06") 17(0.7") 1.9~2.7 13.6~19.6 18.6~26.6
CrankshaIt pulley nut M18x1.5(0.7x0.06") 27(1.1") 12.0~13.0 87~94 118~127
Main bearing cap bolt M8x1.25(0.3x0.05") 12(0.7") 2.0~2.5 14~18 20~25
Connecting rod cap nut M9x1.0(0.4x0.04") 14(0.6") 3.3~3.8 23.7~27.7 32.3~37.3
Rear plate bolt (standard) M12x1.25(0.5x0.05") 17(0.7") 5.5~7.5 40~54 54~74
Rear plate bolt (stamping) M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Elywheel bolt M10x1.25(0.4x0.05") 17(0.7") 7.0~8.0 51~58 69~78
Oil pan drain plug M14x1.5(0.6x0.06") 22(0.9") 3.5~4.5 25~33 34~44
Pressure relieI valve M22x1.5(0.9x0.06") 22(0.9") 4.5~5.5 32~40 44~54
Oil Iilter M20x1.5(0.8x0.06") 1.1~1.3 8.0~9.4 11~13
Oil pressure switch PT 1/8 26(1.0") 0.8~1.2 5.8~8.6 8~12
Euel injection pipe nut M12x1.5(0.5x0.06") 2.5~3.5 18~26 24~34
Euel leak-oII pipe nut M12x1.5(0.5x0.06") 18(0.7") 2.5~3.0 18~22 24.5~29.5
Delivery valve holder 19(0.75") 4.0~5.0 28.5~36.5 39~49
Euel inject nozzle holder M18x1.5(0.8x0.06") 21(0.8") 4.0~5.0 29~36 39~49
Retaining nut Ior delivery M16x0.75(0.6x0.03") 19(0.75") 3.5~4.0 25~29 34.5~39.5
valve holder body
Sliding sleeve shaIt M10x1.25(0.4x0.05") 14(0.6") 3.0~4.2 22~30 29~41
Special nut Ior M12x1.0(0.5x0.04") 17(0.7") 1.5~2.5 10~18 15~25
torque spring set
Glow plug M10x1.25(0.4x0.05") 12(0.5") 1.5~2.0 10.7~14.7 14.7~19.7
Glow plug conn. plate M4x0.7(0.2x0.03") 8(0.3") 0.1~0.15 0.7~1.1 1.0~1.4
Stop solenoid nut M30x1.5(1.2x0.06") 36(1.4") 4.0~5.0 28.5~36.5 39~49
Starter B terminal M8x1.25(0.3x0.05") 12(0.5") 1.0~1.2 7.3~8.8 9.8~11.8
* Coat the screw and seat with engine oil beIore mounting the parts labeled with the "wet" mark in the
remarks column.
* ReIer to the tightening torque Ior general bolts (or nuts) on the Iollowing page Ior bolts and nuts not speciIied
above.
48
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR MAIN BOLTS
Screw
Diameter / Pitch mm
Mount part
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque
Remarks
Cylinder head bolt M9x1.25(0.4x0.04") 14(0.6") 5.0~5.3 36~38 49~52 Wet
Rocker cover bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Rocker shaIt bracket bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~2.0 7~15 9.7~19.7
Thermoswitch M16x1.5(0.6x0.06") 17(0.7") 1.9~2.7 13.6~19.6 18.6~26.6
CrankshaIt pulley nut M18x1.5(0.7x0.06") 27(1.1") 12.0~13.0 87~94 118~127
Main bearing cap bolt M8x1.25(0.3x0.05") 12(0.7") 2.0~2.5 14~18 20~25
Connecting rod cap nut M9x1.0(0.4x0.04") 14(0.6") 3.3~3.8 23.7~27.7 32.3~37.3
Rear plate bolt (standard) M12x1.25(0.5x0.05") 17(0.7") 5.5~7.5 40~54 54~74
Rear plate bolt (stamping) M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Elywheel bolt M10x1.25(0.4x0.05") 17(0.7") 7.0~8.0 51~58 69~78
Oil pan drain plug M14x1.5(0.6x0.06") 22(0.9") 3.5~4.5 25~33 34~44
Pressure relieI valve M22x1.5(0.9x0.06") 22(0.9") 4.5~5.5 32~40 44~54
Oil Iilter M20x1.5(0.8x0.06") 1.1~1.3 8.0~9.4 11~13
Oil pressure switch PT 1/8 26(1.0") 0.8~1.2 5.8~8.6 8~12
Euel injection pipe nut M12x1.5(0.5x0.06") 2.5~3.5 18~26 24~34
Euel leak-oII pipe nut M12x1.5(0.5x0.06") 18(0.7") 2.5~3.0 18~22 24.5~29.5
Delivery valve holder 19(0.75") 4.0~5.0 28.5~36.5 39~49
Euel inject nozzle holder M18x1.5(0.8x0.06") 21(0.8") 4.0~5.0 29~36 39~49
Retaining nut Ior delivery M16x0.75(0.6x0.03") 19(0.75") 3.5~4.0 25~29 34.5~39.5
valve holder body
Sliding sleeve shaIt M10x1.25(0.4x0.05") 14(0.6") 3.0~4.2 22~30 29~41
Special nut Ior M12x1.0(0.5x0.04") 17(0.7") 1.5~2.5 10~18 15~25
torque spring set
Glow plug M10x1.25(0.4x0.05") 12(0.5") 1.5~2.0 10.7~14.7 14.7~19.7
Glow plug conn. plate M4x0.7(0.2x0.03") 8(0.3") 0.1~0.15 0.7~1.1 1.0~1.4
Stop solenoid nut M30x1.5(1.2x0.06") 36(1.4") 4.0~5.0 28.5~36.5 39~49
Starter B terminal M8x1.25(0.3x0.05") 12(0.5") 1.0~1.2 7.3~8.8 9.8~11.8
* Coat the screw and seat with engine oil beIore mounting the parts labeled with the "wet" mark in the
remarks column.
* ReIer to the tightening torque Ior general bolts (or nuts) on the Iollowing page Ior bolts and nuts not speciIied
above.
48
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR MAIN BOLTS
Screw
Diameter / Pitch mm
Mount part
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque
Remarks
Cylinder head bolt M9x1.25(0.4x0.04") 14(0.6") 5.0~5.3 36~38 49~52 Wet
Rocker cover bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Rocker shaIt bracket bolt M8x1.25(0.3x0.05") 12(0.5") 1.0~2.0 7~15 9.7~19.7
Thermoswitch M16x1.5(0.6x0.06") 17(0.7") 1.9~2.7 13.6~19.6 18.6~26.6
CrankshaIt pulley nut M18x1.5(0.7x0.06") 27(1.1") 12.0~13.0 87~94 118~127
Main bearing cap bolt M8x1.25(0.3x0.05") 12(0.7") 2.0~2.5 14~18 20~25
Connecting rod cap nut M9x1.0(0.4x0.04") 14(0.6") 3.3~3.8 23.7~27.7 32.3~37.3
Rear plate bolt (standard) M12x1.25(0.5x0.05") 17(0.7") 5.5~7.5 40~54 54~74
Rear plate bolt (stamping) M8x1.25(0.3x0.05") 12(0.5") 1.0~1.3 7.2~9.4 9.8~12.8
Elywheel bolt M10x1.25(0.4x0.05") 17(0.7") 7.0~8.0 51~58 69~78
Oil pan drain plug M14x1.5(0.6x0.06") 22(0.9") 3.5~4.5 25~33 34~44
Pressure relieI valve M22x1.5(0.9x0.06") 22(0.9") 4.5~5.5 32~40 44~54
Oil Iilter M20x1.5(0.8x0.06") 1.1~1.3 8.0~9.4 11~13
Oil pressure switch PT 1/8 26(1.0") 0.8~1.2 5.8~8.6 8~12
Euel injection pipe nut M12x1.5(0.5x0.06") 2.5~3.5 18~26 24~34
Euel leak-oII pipe nut M12x1.5(0.5x0.06") 18(0.7") 2.5~3.0 18~22 24.5~29.5
Delivery valve holder 19(0.75") 4.0~5.0 28.5~36.5 39~49
Euel inject nozzle holder M18x1.5(0.8x0.06") 21(0.8") 4.0~5.0 29~36 39~49
Retaining nut Ior delivery M16x0.75(0.6x0.03") 19(0.75") 3.5~4.0 25~29 34.5~39.5
valve holder body
Sliding sleeve shaIt M10x1.25(0.4x0.05") 14(0.6") 3.0~4.2 22~30 29~41
Special nut Ior M12x1.0(0.5x0.04") 17(0.7") 1.5~2.5 10~18 15~25
torque spring set
Glow plug M10x1.25(0.4x0.05") 12(0.5") 1.5~2.0 10.7~14.7 14.7~19.7
Glow plug conn. plate M4x0.7(0.2x0.03") 8(0.3") 0.1~0.15 0.7~1.1 1.0~1.4
Stop solenoid nut M30x1.5(1.2x0.06") 36(1.4") 4.0~5.0 28.5~36.5 39~49
Starter B terminal M8x1.25(0.3x0.05") 12(0.5") 1.0~1.2 7.3~8.8 9.8~11.8
* Coat the screw and seat with engine oil beIore mounting the parts labeled with the "wet" mark in the
remarks column.
* ReIer to the tightening torque Ior general bolts (or nuts) on the Iollowing page Ior bolts and nuts not speciIied
above.
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR GENERAL BOLTS
Screw
Diameter / Pitch mm
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque Head
Mark
4 0.3-0.5 2.2-3.6 2.9-4.9
M6 X 1.0 7 10(0.4") 0.8-1.0 5.8-7.2 7.8-9.8
10 1.0-1.3 7.2-9.4 9.8-12.7
4 1.0-1.3 7.2-9.4 9.8-12.7
M8 X 1.25 7 12(0.5") 1.5-2.2 10.8-15.8 14.7-21.6
10 2.5-3.5 18-25.2 24.5-34.3
4 1.8-2.5 13-18 17.6-24.5
M10 X 1.25 7 14(0.6") 3.0-4.2 21.6-30.2 29.4-41.2
10 5.0-7.0 36-50.4 49-68.6
4 3.0-4.2 21.6-30.2 29.4-41.2
M12 X 1.25 7 17(0.7") .5-7.5 39.6-54 53.9-73.5
10 9.5-12.0 68.4-86.4 93.1-117.6
4 5.0-7.0 36-50.4 49-68.6
M14 X 1.5 7 19(0.75") 8.0-11.0 57.6-79.2 78.4-107.8
10 16.0-19.0 115.2-136.8 156.8-186.2
49
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR GENERAL BOLTS
Screw
Diameter / Pitch mm
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque Head
Mark
4 0.3-0.5 2.2-3.6 2.9-4.9
M6 X 1.0 7 10(0.4") 0.8-1.0 5.8-7.2 7.8-9.8
10 1.0-1.3 7.2-9.4 9.8-12.7
4 1.0-1.3 7.2-9.4 9.8-12.7
M8 X 1.25 7 12(0.5") 1.5-2.2 10.8-15.8 14.7-21.6
10 2.5-3.5 18-25.2 24.5-34.3
4 1.8-2.5 13-18 17.6-24.5
M10 X 1.25 7 14(0.6") 3.0-4.2 21.6-30.2 29.4-41.2
10 5.0-7.0 36-50.4 49-68.6
4 3.0-4.2 21.6-30.2 29.4-41.2
M12 X 1.25 7 17(0.7") .5-7.5 39.6-54 53.9-73.5
10 9.5-12.0 68.4-86.4 93.1-117.6
4 5.0-7.0 36-50.4 49-68.6
M14 X 1.5 7 19(0.75") 8.0-11.0 57.6-79.2 78.4-107.8
10 16.0-19.0 115.2-136.8 156.8-186.2
49
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR GENERAL BOLTS
Screw
Diameter / Pitch mm
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque Head
Mark
4 0.3-0.5 2.2-3.6 2.9-4.9
M6 X 1.0 7 10(0.4") 0.8-1.0 5.8-7.2 7.8-9.8
10 1.0-1.3 7.2-9.4 9.8-12.7
4 1.0-1.3 7.2-9.4 9.8-12.7
M8 X 1.25 7 12(0.5") 1.5-2.2 10.8-15.8 14.7-21.6
10 2.5-3.5 18-25.2 24.5-34.3
4 1.8-2.5 13-18 17.6-24.5
M10 X 1.25 7 14(0.6") 3.0-4.2 21.6-30.2 29.4-41.2
10 5.0-7.0 36-50.4 49-68.6
4 3.0-4.2 21.6-30.2 29.4-41.2
M12 X 1.25 7 17(0.7") .5-7.5 39.6-54 53.9-73.5
10 9.5-12.0 68.4-86.4 93.1-117.6
4 5.0-7.0 36-50.4 49-68.6
M14 X 1.5 7 19(0.75") 8.0-11.0 57.6-79.2 78.4-107.8
10 16.0-19.0 115.2-136.8 156.8-186.2
49
INSPECTION AND MAINTENANCE PROCEDURES FOR ENGINE PARTS
TIGHTENING TORQUE FOR GENERAL BOLTS
Screw
Diameter / Pitch mm
Width
across
flat
mm kg-m lb ft N-m
Tightening Torque Head
Mark
4 0.3-0.5 2.2-3.6 2.9-4.9
M6 X 1.0 7 10(0.4") 0.8-1.0 5.8-7.2 7.8-9.8
10 1.0-1.3 7.2-9.4 9.8-12.7
4 1.0-1.3 7.2-9.4 9.8-12.7
M8 X 1.25 7 12(0.5") 1.5-2.2 10.8-15.8 14.7-21.6
10 2.5-3.5 18-25.2 24.5-34.3
4 1.8-2.5 13-18 17.6-24.5
M10 X 1.25 7 14(0.6") 3.0-4.2 21.6-30.2 29.4-41.2
10 5.0-7.0 36-50.4 49-68.6
4 3.0-4.2 21.6-30.2 29.4-41.2
M12 X 1.25 7 17(0.7") .5-7.5 39.6-54 53.9-73.5
10 9.5-12.0 68.4-86.4 93.1-117.6
4 5.0-7.0 36-50.4 49-68.6
M14 X 1.5 7 19(0.75") 8.0-11.0 57.6-79.2 78.4-107.8
10 16.0-19.0 115.2-136.8 156.8-186.2
49
50
INSPECTION AND MAINTENANCE PROCEDURES
FOR ENGINE PARTS
Air bleeding of fuel system
AIter cleaning the Iuel Iilter water separator, replacing the element or using up the
Iuel, bleed the air in accordance with the Iollowing procedure.
1) Eully Iill the Iuel tank.
2) Open the cock oI Iuel Iilter.
3) Turning the starter switch ON automatically bleeds the air.
The air can ordinarily be bled in about one minute when the fuel filter is empty.
Euel Eilter
Euel Pump
Water Separator
50
INSPECTION AND MAINTENANCE PROCEDURES
FOR ENGINE PARTS
Air bleeding of fuel system
AIter cleaning the Iuel Iilter water separator, replacing the element or using up the
Iuel, bleed the air in accordance with the Iollowing procedure.
1) Eully Iill the Iuel tank.
2) Open the cock oI Iuel Iilter.
3) Turning the starter switch ON automatically bleeds the air.
The air can ordinarily be bled in about one minute when the fuel filter is empty.
Euel Eilter
Euel Pump
Water Separator
50
INSPECTION AND MAINTENANCE PROCEDURES
FOR ENGINE PARTS
Air bleeding of fuel system
AIter cleaning the Iuel Iilter water separator, replacing the element or using up the
Iuel, bleed the air in accordance with the Iollowing procedure.
1) Eully Iill the Iuel tank.
2) Open the cock oI Iuel Iilter.
3) Turning the starter switch ON automatically bleeds the air.
The air can ordinarily be bled in about one minute when the fuel filter is empty.
Euel Eilter
Euel Pump
Water Separator
50
INSPECTION AND MAINTENANCE PROCEDURES
FOR ENGINE PARTS
Air bleeding of fuel system
AIter cleaning the Iuel Iilter water separator, replacing the element or using up the
Iuel, bleed the air in accordance with the Iollowing procedure.
1) Eully Iill the Iuel tank.
2) Open the cock oI Iuel Iilter.
3) Turning the starter switch ON automatically bleeds the air.
The air can ordinarily be bled in about one minute when the fuel filter is empty.
Euel Eilter
Euel Pump
Water Separator
INSPECTION AND MAINTENANCE PROCEDURES
AIR CLEANER ELEMENT
Removal
By loosing the air cleaner band, and check the contamination oI the element visually.
Inspection
The inspection method varies depending on how dirty the element is.
(A) II dry dust is adhering to the air cleaner element, blow pressurized air (7kg/cm2 (2.4psi) or less) Irom inside oI the air
cleaner element to remove it.
(B) II the element is soiled with black carbon or soot, remove it with cleaning liquid.
1. Eor the cleaning liquid, dissolve 300g (10.6oz) oI air element cleaner
(ND1500) into 20 l (5.3 U.S. gal) oI water. Immerse the air cleaner element Ior about 20 minutes.
2. With the dust cap removed, Ilush the air cleaner element using tap water.
3. AIter cleaning, let the element dry in a place where air circulates Ireely.
Never use fire or pressurized air to dry the air cleaner element.
* The standard inspection is every 500 service hours. However, inspect every 250 iI the
machine is used in a dusty environment.
INSPECTION AND MAINTENANCE PROCEDURES
Replacing the cooling water of radiator
Dirt and rust in the water decreases the eIIectiveness oI the cooling system.
Replacement
1. Remove the radiator cap and open the drain plug to drain the cooling water.
2. Close the drain plug and Iill the radiator with cleaning Iluid. (A1).
3. Start the engine and keep idling Ior about 20 minutes. Open the radiator drain
plug while Ieeding Iresh water through the radiator cap. Continue this until the
clean water comes out.
4. AIter clean water comes out, close the plug, Ieed the neutralization Iluid (A2)
and start the idling Ior 5 minutes.
5. Stop the engine and open the drain plug to clean the inside oI
radiator with water.
Close the drain plug and supply cooling water to the speciIied
level.
Cleaning Iluid (A1):dissolve Sodium bisulIite oI 250g in water oI 1 l (0.3
U.S. gal).
Neutralization Iluid (A2):dissolve Sodium carbonate oI 6g in water oI 1 l
(0.3 U.S. gal).
Air Cleaner Element
Drain Plug
It is very dangerous to
remove the radiator cap
just after stopping
the engine. If you want to
remove the cap, slowly
turn the cap.
WARNING
Anti-freeze should be
fully mixed with the
water in another vessel
prior to feeding it in the
radiator. If you do not
follow the above, over-
heating may occur.
IMPORTANT
51
INSPECTION AND MAINTENANCE PROCEDURES
AIR CLEANER ELEMENT
Removal
By loosing the air cleaner band, and check the contamination oI the element visually.
Inspection
The inspection method varies depending on how dirty the element is.
(A) II dry dust is adhering to the air cleaner element, blow pressurized air (7kg/cm2 (2.4psi) or less) Irom inside oI the air
cleaner element to remove it.
(B) II the element is soiled with black carbon or soot, remove it with cleaning liquid.
1. Eor the cleaning liquid, dissolve 300g (10.6oz) oI air element cleaner
(ND1500) into 20 l (5.3 U.S. gal) oI water. Immerse the air cleaner element Ior about 20 minutes.
2. With the dust cap removed, Ilush the air cleaner element using tap water.
3. AIter cleaning, let the element dry in a place where air circulates Ireely.
Never use fire or pressurized air to dry the air cleaner element.
* The standard inspection is every 500 service hours. However, inspect every 250 iI the
machine is used in a dusty environment.
INSPECTION AND MAINTENANCE PROCEDURES
Replacing the cooling water of radiator
Dirt and rust in the water decreases the eIIectiveness oI the cooling system.
Replacement
1. Remove the radiator cap and open the drain plug to drain the cooling water.
2. Close the drain plug and Iill the radiator with cleaning Iluid. (A1).
3. Start the engine and keep idling Ior about 20 minutes. Open the radiator drain
plug while Ieeding Iresh water through the radiator cap. Continue this until the
clean water comes out.
4. AIter clean water comes out, close the plug, Ieed the neutralization Iluid (A2)
and start the idling Ior 5 minutes.
5. Stop the engine and open the drain plug to clean the inside oI
radiator with water.
Close the drain plug and supply cooling water to the speciIied
level.
Cleaning Iluid (A1):dissolve Sodium bisulIite oI 250g in water oI 1 l (0.3
U.S. gal).
Neutralization Iluid (A2):dissolve Sodium carbonate oI 6g in water oI 1 l
(0.3 U.S. gal).
Air Cleaner Element
Drain Plug
It is very dangerous to
remove the radiator cap
just after stopping
the engine. If you want to
remove the cap, slowly
turn the cap.
WARNING
Anti-freeze should be
fully mixed with the
water in another vessel
prior to feeding it in the
radiator. If you do not
follow the above, over-
heating may occur.
IMPORTANT
51
INSPECTION AND MAINTENANCE PROCEDURES
AIR CLEANER ELEMENT
Removal
By loosing the air cleaner band, and check the contamination oI the element visually.
Inspection
The inspection method varies depending on how dirty the element is.
(A) II dry dust is adhering to the air cleaner element, blow pressurized air (7kg/cm2 (2.4psi) or less) Irom inside oI the air
cleaner element to remove it.
(B) II the element is soiled with black carbon or soot, remove it with cleaning liquid.
1. Eor the cleaning liquid, dissolve 300g (10.6oz) oI air element cleaner
(ND1500) into 20 l (5.3 U.S. gal) oI water. Immerse the air cleaner element Ior about 20 minutes.
2. With the dust cap removed, Ilush the air cleaner element using tap water.
3. AIter cleaning, let the element dry in a place where air circulates Ireely.
Never use fire or pressurized air to dry the air cleaner element.
* The standard inspection is every 500 service hours. However, inspect every 250 iI the
machine is used in a dusty environment.
INSPECTION AND MAINTENANCE PROCEDURES
Replacing the cooling water of radiator
Dirt and rust in the water decreases the eIIectiveness oI the cooling system.
Replacement
1. Remove the radiator cap and open the drain plug to drain the cooling water.
2. Close the drain plug and Iill the radiator with cleaning Iluid. (A1).
3. Start the engine and keep idling Ior about 20 minutes. Open the radiator drain
plug while Ieeding Iresh water through the radiator cap. Continue this until the
clean water comes out.
4. AIter clean water comes out, close the plug, Ieed the neutralization Iluid (A2)
and start the idling Ior 5 minutes.
5. Stop the engine and open the drain plug to clean the inside oI
radiator with water.
Close the drain plug and supply cooling water to the speciIied
level.
Cleaning Iluid (A1):dissolve Sodium bisulIite oI 250g in water oI 1 l (0.3
U.S. gal).
Neutralization Iluid (A2):dissolve Sodium carbonate oI 6g in water oI 1 l
(0.3 U.S. gal).
Air Cleaner Element
Drain Plug
It is very dangerous to
remove the radiator cap
just after stopping
the engine. If you want to
remove the cap, slowly
turn the cap.
WARNING
Anti-freeze should be
fully mixed with the
water in another vessel
prior to feeding it in the
radiator. If you do not
follow the above, over-
heating may occur.
IMPORTANT
51
INSPECTION AND MAINTENANCE PROCEDURES
AIR CLEANER ELEMENT
Removal
By loosing the air cleaner band, and check the contamination oI the element visually.
Inspection
The inspection method varies depending on how dirty the element is.
(A) II dry dust is adhering to the air cleaner element, blow pressurized air (7kg/cm2 (2.4psi) or less) Irom inside oI the air
cleaner element to remove it.
(B) II the element is soiled with black carbon or soot, remove it with cleaning liquid.
1. Eor the cleaning liquid, dissolve 300g (10.6oz) oI air element cleaner
(ND1500) into 20 l (5.3 U.S. gal) oI water. Immerse the air cleaner element Ior about 20 minutes.
2. With the dust cap removed, Ilush the air cleaner element using tap water.
3. AIter cleaning, let the element dry in a place where air circulates Ireely.
Never use fire or pressurized air to dry the air cleaner element.
* The standard inspection is every 500 service hours. However, inspect every 250 iI the
machine is used in a dusty environment.
INSPECTION AND MAINTENANCE PROCEDURES
Replacing the cooling water of radiator
Dirt and rust in the water decreases the eIIectiveness oI the cooling system.
Replacement
1. Remove the radiator cap and open the drain plug to drain the cooling water.
2. Close the drain plug and Iill the radiator with cleaning Iluid. (A1).
3. Start the engine and keep idling Ior about 20 minutes. Open the radiator drain
plug while Ieeding Iresh water through the radiator cap. Continue this until the
clean water comes out.
4. AIter clean water comes out, close the plug, Ieed the neutralization Iluid (A2)
and start the idling Ior 5 minutes.
5. Stop the engine and open the drain plug to clean the inside oI
radiator with water.
Close the drain plug and supply cooling water to the speciIied
level.
Cleaning Iluid (A1):dissolve Sodium bisulIite oI 250g in water oI 1 l (0.3
U.S. gal).
Neutralization Iluid (A2):dissolve Sodium carbonate oI 6g in water oI 1 l
(0.3 U.S. gal).
Air Cleaner Element
Drain Plug
It is very dangerous to
remove the radiator cap
just after stopping
the engine. If you want to
remove the cap, slowly
turn the cap.
WARNING
Anti-freeze should be
fully mixed with the
water in another vessel
prior to feeding it in the
radiator. If you do not
follow the above, over-
heating may occur.
IMPORTANT
51
52
INSPECTION AND MAINTENANCE PROCEDURES
INSPECTING CRAWLER TENSION
Unequal tensions oI the crawlers may cause the machine to deviate Irom the
traveling path. Make sure the crawlers are equally tensioned.
II crawler is too tight, the rolling Iriction on the surIace idler sprocket
contacting with the bearing increases, scoring occurs on the crawler link pin
and the resistance is increased, resulting in the reduction oI traveling ability.
II the crawler is too slack, it may slip oII the sprocket. Resistance increases
when going in reverse and the traveling ability oI the machine is reduced.
Always adjust the tension oI the rubber crawler aIter the Iirst 10 to 20 service hours.
Inspection Method
1. Insert a grease gun into the grease nipple and pour the grease to strain the
crawler.
2. Eor loosening the crawler, loosening the cartridge valve, the grease in the
cylinder automatically comes out.
Confirmation of inspection (checking for air locks)
BeIore straining the crawler, loosen the cartridge valve and make sure grease comes out by pushing the Iront idler to the cylinder.
Then, tighten the valve and add grease again.
10mm to 15mm
52
INSPECTION AND MAINTENANCE PROCEDURES
INSPECTING CRAWLER TENSION
Unequal tensions oI the crawlers may cause the machine to deviate Irom the
traveling path. Make sure the crawlers are equally tensioned.
II crawler is too tight, the rolling Iriction on the surIace idler sprocket
contacting with the bearing increases, scoring occurs on the crawler link pin
and the resistance is increased, resulting in the reduction oI traveling ability.
II the crawler is too slack, it may slip oII the sprocket. Resistance increases
when going in reverse and the traveling ability oI the machine is reduced.
Always adjust the tension oI the rubber crawler aIter the Iirst 10 to 20 service hours.
Inspection Method
1. Insert a grease gun into the grease nipple and pour the grease to strain the
crawler.
2. Eor loosening the crawler, loosening the cartridge valve, the grease in the
cylinder automatically comes out.
Confirmation of inspection (checking for air locks)
BeIore straining the crawler, loosen the cartridge valve and make sure grease comes out by pushing the Iront idler to the cylinder.
Then, tighten the valve and add grease again.
10mm to 15mm
52
INSPECTION AND MAINTENANCE PROCEDURES
INSPECTING CRAWLER TENSION
Unequal tensions oI the crawlers may cause the machine to deviate Irom the
traveling path. Make sure the crawlers are equally tensioned.
II crawler is too tight, the rolling Iriction on the surIace idler sprocket
contacting with the bearing increases, scoring occurs on the crawler link pin
and the resistance is increased, resulting in the reduction oI traveling ability.
II the crawler is too slack, it may slip oII the sprocket. Resistance increases
when going in reverse and the traveling ability oI the machine is reduced.
Always adjust the tension oI the rubber crawler aIter the Iirst 10 to 20 service hours.
Inspection Method
1. Insert a grease gun into the grease nipple and pour the grease to strain the
crawler.
2. Eor loosening the crawler, loosening the cartridge valve, the grease in the
cylinder automatically comes out.
Confirmation of inspection (checking for air locks)
BeIore straining the crawler, loosen the cartridge valve and make sure grease comes out by pushing the Iront idler to the cylinder.
Then, tighten the valve and add grease again.
10mm to 15mm
52
INSPECTION AND MAINTENANCE PROCEDURES
INSPECTING CRAWLER TENSION
Unequal tensions oI the crawlers may cause the machine to deviate Irom the
traveling path. Make sure the crawlers are equally tensioned.
II crawler is too tight, the rolling Iriction on the surIace idler sprocket
contacting with the bearing increases, scoring occurs on the crawler link pin
and the resistance is increased, resulting in the reduction oI traveling ability.
II the crawler is too slack, it may slip oII the sprocket. Resistance increases
when going in reverse and the traveling ability oI the machine is reduced.
Always adjust the tension oI the rubber crawler aIter the Iirst 10 to 20 service hours.
Inspection Method
1. Insert a grease gun into the grease nipple and pour the grease to strain the
crawler.
2. Eor loosening the crawler, loosening the cartridge valve, the grease in the
cylinder automatically comes out.
Confirmation of inspection (checking for air locks)
BeIore straining the crawler, loosen the cartridge valve and make sure grease comes out by pushing the Iront idler to the cylinder.
Then, tighten the valve and add grease again.
10mm to 15mm
INSPECTION AND MAINTENANCE PROCEDURES
CRAWLER DRIVE UNIT
Use the recommended lubricant Ior the reduction gear.
II a diIIerent brand is used, replace all lubricant with new brand.
Engine oil SAE30-CD or equivalent is used at the time oI shipment
Eirst replacement oI lubricant 500 Hr
Second or Iollowing replacement 1,000 Hr
Amount oI lubricant 300 cc (18in3)
Eor the recommended lubricant and grease, reIer to the list on page 64.
HOW TO FILL LUBRICANT
The cover is provided with two blind plugs. With the cover set vertically against the
ground as shown in the Iigure, the top ports are Ior oil supply and inspection, and
the bottom port Ior draining.
1. Eirst remove the oil supply plug.
2. Eill the lubricant through the oil supply port.
3. Put back the plug to the oil supply ports.
* Insert the plug with sealing tape.
Oil discharge port
(PT3/8)
Port Ior oil supply
and checking oil level.
(PT3/8)
53
INSPECTION AND MAINTENANCE PROCEDURES
CRAWLER DRIVE UNIT
Use the recommended lubricant Ior the reduction gear.
II a diIIerent brand is used, replace all lubricant with new brand.
Engine oil SAE30-CD or equivalent is used at the time oI shipment
Eirst replacement oI lubricant 500 Hr
Second or Iollowing replacement 1,000 Hr
Amount oI lubricant 300 cc (18in3)
Eor the recommended lubricant and grease, reIer to the list on page 64.
HOW TO FILL LUBRICANT
The cover is provided with two blind plugs. With the cover set vertically against the
ground as shown in the Iigure, the top ports are Ior oil supply and inspection, and
the bottom port Ior draining.
1. Eirst remove the oil supply plug.
2. Eill the lubricant through the oil supply port.
3. Put back the plug to the oil supply ports.
* Insert the plug with sealing tape.
Oil discharge port
(PT3/8)
Port Ior oil supply
and checking oil level.
(PT3/8)
53
INSPECTION AND MAINTENANCE PROCEDURES
CRAWLER DRIVE UNIT
Use the recommended lubricant Ior the reduction gear.
II a diIIerent brand is used, replace all lubricant with new brand.
Engine oil SAE30-CD or equivalent is used at the time oI shipment
Eirst replacement oI lubricant 500 Hr
Second or Iollowing replacement 1,000 Hr
Amount oI lubricant 300 cc (18in3)
Eor the recommended lubricant and grease, reIer to the list on page 64.
HOW TO FILL LUBRICANT
The cover is provided with two blind plugs. With the cover set vertically against the
ground as shown in the Iigure, the top ports are Ior oil supply and inspection, and
the bottom port Ior draining.
1. Eirst remove the oil supply plug.
2. Eill the lubricant through the oil supply port.
3. Put back the plug to the oil supply ports.
* Insert the plug with sealing tape.
Oil discharge port
(PT3/8)
Port Ior oil supply
and checking oil level.
(PT3/8)
53
INSPECTION AND MAINTENANCE PROCEDURES
CRAWLER DRIVE UNIT
Use the recommended lubricant Ior the reduction gear.
II a diIIerent brand is used, replace all lubricant with new brand.
Engine oil SAE30-CD or equivalent is used at the time oI shipment
Eirst replacement oI lubricant 500 Hr
Second or Iollowing replacement 1,000 Hr
Amount oI lubricant 300 cc (18in3)
Eor the recommended lubricant and grease, reIer to the list on page 64.
HOW TO FILL LUBRICANT
The cover is provided with two blind plugs. With the cover set vertically against the
ground as shown in the Iigure, the top ports are Ior oil supply and inspection, and
the bottom port Ior draining.
1. Eirst remove the oil supply plug.
2. Eill the lubricant through the oil supply port.
3. Put back the plug to the oil supply ports.
* Insert the plug with sealing tape.
Oil discharge port
(PT3/8)
Port Ior oil supply
and checking oil level.
(PT3/8)
53
54
TROUBLESHOOTING
CONTROL VALVES
Remedy
Replace valve housing assembly.
Disassemble and clean or replace port relieI valve.
Disassemble and clean load check valve.
Replace poppet or lap valve seat.
Remove obstacles to Ilow oil throughout piping.
Change oil and clean hydraulic circuit.
Check tightening torque.
Loosen mounting bolts, check and adjust.
Remove Ioreign matter or replace valve housing
assembly.
Check with pressure gauge and adjust.
Remove link and check.
Replace valve housing assembly.
Replace return spring.
Loosen cap, align it and retighten it.
Warm up entire circuit.
Use a larger return circuit.
Remove seal and clean it.
Clean seal plate and tighten it with bolts.
Replace valve housing assembly.
Replace seal.
Remove Ioreign matter and clean circuit.
Replace cap seal.
Make link move Ireely.
Cause
Oil leaks Irom inside plunger.
Oil leaks Irom port relieI valve.
Eoreign matter is mixed in load check
valve.
Poppet or seat oI load check valve is
damaged.
Abnormal increase oI oil temperature.
Hydraulic oil is dirty.
Pipe port joints are overtightened, so valve
housing mounted distorted.
Eoreign matter is mixed in cutouts in
plunger.
Pressure is too high.
Lever or link is bent.
Plunger is bent.
Return spring is damaged.
Return spring or cap is dislocated.
Internal valve temperature distribution is
not uniIorm.
Back pressure on valve return circuit is too
high.
Eoreign matter on the seal.
Seal plate is loose.
Plunger is damaged.
Seal is cut oII or damaged.
Valve is clogged up with Ioreign matter.
Plunger cap is Iull oI oil.
Operating link is seized and does not move.
Trouble
Cannot maintain load
Load Ialls when
plunger is shiIted
Irom neutral to 'raise
position
Plunger sticks
Plunger sticks
Oil leakage Irom oil
seal
Plunger does not
move
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
54
TROUBLESHOOTING
CONTROL VALVES
Remedy
Replace valve housing assembly.
Disassemble and clean or replace port relieI valve.
Disassemble and clean load check valve.
Replace poppet or lap valve seat.
Remove obstacles to Ilow oil throughout piping.
Change oil and clean hydraulic circuit.
Check tightening torque.
Loosen mounting bolts, check and adjust.
Remove Ioreign matter or replace valve housing
assembly.
Check with pressure gauge and adjust.
Remove link and check.
Replace valve housing assembly.
Replace return spring.
Loosen cap, align it and retighten it.
Warm up entire circuit.
Use a larger return circuit.
Remove seal and clean it.
Clean seal plate and tighten it with bolts.
Replace valve housing assembly.
Replace seal.
Remove Ioreign matter and clean circuit.
Replace cap seal.
Make link move Ireely.
Cause
Oil leaks Irom inside plunger.
Oil leaks Irom port relieI valve.
Eoreign matter is mixed in load check
valve.
Poppet or seat oI load check valve is
damaged.
Abnormal increase oI oil temperature.
Hydraulic oil is dirty.
Pipe port joints are overtightened, so valve
housing mounted distorted.
Eoreign matter is mixed in cutouts in
plunger.
Pressure is too high.
Lever or link is bent.
Plunger is bent.
Return spring is damaged.
Return spring or cap is dislocated.
Internal valve temperature distribution is
not uniIorm.
Back pressure on valve return circuit is too
high.
Eoreign matter on the seal.
Seal plate is loose.
Plunger is damaged.
Seal is cut oII or damaged.
Valve is clogged up with Ioreign matter.
Plunger cap is Iull oI oil.
Operating link is seized and does not move.
Trouble
Cannot maintain load
Load Ialls when
plunger is shiIted
Irom neutral to 'raise
position
Plunger sticks
Plunger sticks
Oil leakage Irom oil
seal
Plunger does not
move
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
54
TROUBLESHOOTING
CONTROL VALVES
Remedy
Replace valve housing assembly.
Disassemble and clean or replace port relieI valve.
Disassemble and clean load check valve.
Replace poppet or lap valve seat.
Remove obstacles to Ilow oil throughout piping.
Change oil and clean hydraulic circuit.
Check tightening torque.
Loosen mounting bolts, check and adjust.
Remove Ioreign matter or replace valve housing
assembly.
Check with pressure gauge and adjust.
Remove link and check.
Replace valve housing assembly.
Replace return spring.
Loosen cap, align it and retighten it.
Warm up entire circuit.
Use a larger return circuit.
Remove seal and clean it.
Clean seal plate and tighten it with bolts.
Replace valve housing assembly.
Replace seal.
Remove Ioreign matter and clean circuit.
Replace cap seal.
Make link move Ireely.
Cause
Oil leaks Irom inside plunger.
Oil leaks Irom port relieI valve.
Eoreign matter is mixed in load check
valve.
Poppet or seat oI load check valve is
damaged.
Abnormal increase oI oil temperature.
Hydraulic oil is dirty.
Pipe port joints are overtightened, so valve
housing mounted distorted.
Eoreign matter is mixed in cutouts in
plunger.
Pressure is too high.
Lever or link is bent.
Plunger is bent.
Return spring is damaged.
Return spring or cap is dislocated.
Internal valve temperature distribution is
not uniIorm.
Back pressure on valve return circuit is too
high.
Eoreign matter on the seal.
Seal plate is loose.
Plunger is damaged.
Seal is cut oII or damaged.
Valve is clogged up with Ioreign matter.
Plunger cap is Iull oI oil.
Operating link is seized and does not move.
Trouble
Cannot maintain load
Load Ialls when
plunger is shiIted
Irom neutral to 'raise
position
Plunger sticks
Plunger sticks
Oil leakage Irom oil
seal
Plunger does not
move
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
54
TROUBLESHOOTING
CONTROL VALVES
Remedy
Replace valve housing assembly.
Disassemble and clean or replace port relieI valve.
Disassemble and clean load check valve.
Replace poppet or lap valve seat.
Remove obstacles to Ilow oil throughout piping.
Change oil and clean hydraulic circuit.
Check tightening torque.
Loosen mounting bolts, check and adjust.
Remove Ioreign matter or replace valve housing
assembly.
Check with pressure gauge and adjust.
Remove link and check.
Replace valve housing assembly.
Replace return spring.
Loosen cap, align it and retighten it.
Warm up entire circuit.
Use a larger return circuit.
Remove seal and clean it.
Clean seal plate and tighten it with bolts.
Replace valve housing assembly.
Replace seal.
Remove Ioreign matter and clean circuit.
Replace cap seal.
Make link move Ireely.
Cause
Oil leaks Irom inside plunger.
Oil leaks Irom port relieI valve.
Eoreign matter is mixed in load check
valve.
Poppet or seat oI load check valve is
damaged.
Abnormal increase oI oil temperature.
Hydraulic oil is dirty.
Pipe port joints are overtightened, so valve
housing mounted distorted.
Eoreign matter is mixed in cutouts in
plunger.
Pressure is too high.
Lever or link is bent.
Plunger is bent.
Return spring is damaged.
Return spring or cap is dislocated.
Internal valve temperature distribution is
not uniIorm.
Back pressure on valve return circuit is too
high.
Eoreign matter on the seal.
Seal plate is loose.
Plunger is damaged.
Seal is cut oII or damaged.
Valve is clogged up with Ioreign matter.
Plunger cap is Iull oI oil.
Operating link is seized and does not move.
Trouble
Cannot maintain load
Load Ialls when
plunger is shiIted
Irom neutral to 'raise
position
Plunger sticks
Plunger sticks
Oil leakage Irom oil
seal
Plunger does not
move
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
TROUBLESHOOTING
HYDRAULIC MOTOR
HYDRAULIC MOTOR
Remedy
Add oil.
Replace hydraulic pump.
Replace hydraulic motor.
Replace hydraulic motor or its worn parts.
Check load device and remove cause oI overload.
Change oil with hydraulic oil oI proper viscosity.
Disassemble and clean relieI valve Ior operating
valve or replace it.
Replace counterbalance valve.
Replace hydraulic pump.
Replace main relieI valve.
Lower oil temperature.
Add oil and retighten suction joint.
Retighten joints.
Replace hydraulic motor.
Add oil.
Retighten joint on suction side.
Lower oil temperature.
Replace hydraulic motor.
Align shaIt again.
Remove cause oI cavitation.
Replace oil seal.
Replace shaIt.
Replace oil seal and clean drain pipe.
Cause
Hydraulic oil is low.
Hydraulic pump is Iaulty.
Hydraulic motor internal oil leakage.
Hydraulic motor internal parts are worn.
Output shaIt is overloaded.
Oil viscosity is too low.
RelieI valve Ior operating valve is Iaulty.
Spool oI counterbalance sticks.
Incoming oil Ilow is not enough.
Oil Ilow is too high and oil leaking.
Air sucked into motor.
Hydraulic motor internal oil leak.
Hydraulic oil is low.
Air sucked into motor.
Oil temperature is too high.
Hydraulic motor is internally worn or
damaged.
ShaIt is improperly mounted.
Cavitation.
Oil seal is damaged.
ShaIt is damaged or worn.
Hydraulic motor case internal pressure is
too high.
Trouble
Hydraulic motor does
not run at all
Hydraulic motor runs
one way only
Hydraulic motor does
not run Iast enough
Hydraulic motor
makes abnormal noise
Oil leaks Irom shaIt
seal
Remedy
Adjust pressure.
Replace cylinder gaskets.
Replace hydraulic cylinder piston or rod.
Replace valve housing assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder rod.
Lower oil temperature.
Add oil and retighten suction joint.
Cause
RelieI valve set pressure is too low.
Hydraulic cylinder internal oil leak.
Hydraulic cylinder piston or rod is
damaged.
Operating valve internal oil leak.
Hydraulic cylinder gaskets are deIective.
Hydraulic cylinder rod is damaged.
Oil temperature is too high.
Air sucked into the motor.
Trouble
Hydraulic cylinder is
short oI power.
Hydraulic cylinder
external oil leak.
Piston does not move
smoothly.
55
TROUBLESHOOTING
HYDRAULIC MOTOR
HYDRAULIC MOTOR
Remedy
Add oil.
Replace hydraulic pump.
Replace hydraulic motor.
Replace hydraulic motor or its worn parts.
Check load device and remove cause oI overload.
Change oil with hydraulic oil oI proper viscosity.
Disassemble and clean relieI valve Ior operating
valve or replace it.
Replace counterbalance valve.
Replace hydraulic pump.
Replace main relieI valve.
Lower oil temperature.
Add oil and retighten suction joint.
Retighten joints.
Replace hydraulic motor.
Add oil.
Retighten joint on suction side.
Lower oil temperature.
Replace hydraulic motor.
Align shaIt again.
Remove cause oI cavitation.
Replace oil seal.
Replace shaIt.
Replace oil seal and clean drain pipe.
Cause
Hydraulic oil is low.
Hydraulic pump is Iaulty.
Hydraulic motor internal oil leakage.
Hydraulic motor internal parts are worn.
Output shaIt is overloaded.
Oil viscosity is too low.
RelieI valve Ior operating valve is Iaulty.
Spool oI counterbalance sticks.
Incoming oil Ilow is not enough.
Oil Ilow is too high and oil leaking.
Air sucked into motor.
Hydraulic motor internal oil leak.
Hydraulic oil is low.
Air sucked into motor.
Oil temperature is too high.
Hydraulic motor is internally worn or
damaged.
ShaIt is improperly mounted.
Cavitation.
Oil seal is damaged.
ShaIt is damaged or worn.
Hydraulic motor case internal pressure is
too high.
Trouble
Hydraulic motor does
not run at all
Hydraulic motor runs
one way only
Hydraulic motor does
not run Iast enough
Hydraulic motor
makes abnormal noise
Oil leaks Irom shaIt
seal
Remedy
Adjust pressure.
Replace cylinder gaskets.
Replace hydraulic cylinder piston or rod.
Replace valve housing assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder rod.
Lower oil temperature.
Add oil and retighten suction joint.
Cause
RelieI valve set pressure is too low.
Hydraulic cylinder internal oil leak.
Hydraulic cylinder piston or rod is
damaged.
Operating valve internal oil leak.
Hydraulic cylinder gaskets are deIective.
Hydraulic cylinder rod is damaged.
Oil temperature is too high.
Air sucked into the motor.
Trouble
Hydraulic cylinder is
short oI power.
Hydraulic cylinder
external oil leak.
Piston does not move
smoothly.
55
TROUBLESHOOTING
HYDRAULIC MOTOR
HYDRAULIC MOTOR
Remedy
Add oil.
Replace hydraulic pump.
Replace hydraulic motor.
Replace hydraulic motor or its worn parts.
Check load device and remove cause oI overload.
Change oil with hydraulic oil oI proper viscosity.
Disassemble and clean relieI valve Ior operating
valve or replace it.
Replace counterbalance valve.
Replace hydraulic pump.
Replace main relieI valve.
Lower oil temperature.
Add oil and retighten suction joint.
Retighten joints.
Replace hydraulic motor.
Add oil.
Retighten joint on suction side.
Lower oil temperature.
Replace hydraulic motor.
Align shaIt again.
Remove cause oI cavitation.
Replace oil seal.
Replace shaIt.
Replace oil seal and clean drain pipe.
Cause
Hydraulic oil is low.
Hydraulic pump is Iaulty.
Hydraulic motor internal oil leakage.
Hydraulic motor internal parts are worn.
Output shaIt is overloaded.
Oil viscosity is too low.
RelieI valve Ior operating valve is Iaulty.
Spool oI counterbalance sticks.
Incoming oil Ilow is not enough.
Oil Ilow is too high and oil leaking.
Air sucked into motor.
Hydraulic motor internal oil leak.
Hydraulic oil is low.
Air sucked into motor.
Oil temperature is too high.
Hydraulic motor is internally worn or
damaged.
ShaIt is improperly mounted.
Cavitation.
Oil seal is damaged.
ShaIt is damaged or worn.
Hydraulic motor case internal pressure is
too high.
Trouble
Hydraulic motor does
not run at all
Hydraulic motor runs
one way only
Hydraulic motor does
not run Iast enough
Hydraulic motor
makes abnormal noise
Oil leaks Irom shaIt
seal
Remedy
Adjust pressure.
Replace cylinder gaskets.
Replace hydraulic cylinder piston or rod.
Replace valve housing assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder rod.
Lower oil temperature.
Add oil and retighten suction joint.
Cause
RelieI valve set pressure is too low.
Hydraulic cylinder internal oil leak.
Hydraulic cylinder piston or rod is
damaged.
Operating valve internal oil leak.
Hydraulic cylinder gaskets are deIective.
Hydraulic cylinder rod is damaged.
Oil temperature is too high.
Air sucked into the motor.
Trouble
Hydraulic cylinder is
short oI power.
Hydraulic cylinder
external oil leak.
Piston does not move
smoothly.
55
TROUBLESHOOTING
HYDRAULIC MOTOR
HYDRAULIC MOTOR
Remedy
Add oil.
Replace hydraulic pump.
Replace hydraulic motor.
Replace hydraulic motor or its worn parts.
Check load device and remove cause oI overload.
Change oil with hydraulic oil oI proper viscosity.
Disassemble and clean relieI valve Ior operating
valve or replace it.
Replace counterbalance valve.
Replace hydraulic pump.
Replace main relieI valve.
Lower oil temperature.
Add oil and retighten suction joint.
Retighten joints.
Replace hydraulic motor.
Add oil.
Retighten joint on suction side.
Lower oil temperature.
Replace hydraulic motor.
Align shaIt again.
Remove cause oI cavitation.
Replace oil seal.
Replace shaIt.
Replace oil seal and clean drain pipe.
Cause
Hydraulic oil is low.
Hydraulic pump is Iaulty.
Hydraulic motor internal oil leakage.
Hydraulic motor internal parts are worn.
Output shaIt is overloaded.
Oil viscosity is too low.
RelieI valve Ior operating valve is Iaulty.
Spool oI counterbalance sticks.
Incoming oil Ilow is not enough.
Oil Ilow is too high and oil leaking.
Air sucked into motor.
Hydraulic motor internal oil leak.
Hydraulic oil is low.
Air sucked into motor.
Oil temperature is too high.
Hydraulic motor is internally worn or
damaged.
ShaIt is improperly mounted.
Cavitation.
Oil seal is damaged.
ShaIt is damaged or worn.
Hydraulic motor case internal pressure is
too high.
Trouble
Hydraulic motor does
not run at all
Hydraulic motor runs
one way only
Hydraulic motor does
not run Iast enough
Hydraulic motor
makes abnormal noise
Oil leaks Irom shaIt
seal
Remedy
Adjust pressure.
Replace cylinder gaskets.
Replace hydraulic cylinder piston or rod.
Replace valve housing assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder rod.
Lower oil temperature.
Add oil and retighten suction joint.
Cause
RelieI valve set pressure is too low.
Hydraulic cylinder internal oil leak.
Hydraulic cylinder piston or rod is
damaged.
Operating valve internal oil leak.
Hydraulic cylinder gaskets are deIective.
Hydraulic cylinder rod is damaged.
Oil temperature is too high.
Air sucked into the motor.
Trouble
Hydraulic cylinder is
short oI power.
Hydraulic cylinder
external oil leak.
Piston does not move
smoothly.
55
56
TROUBLESHOOTING
RELIEF VALVE
ATTACHMENT
Remedy
Disassemble, check Ior Ioreign matter and make
poppet move Ireely.
Clean all parts.
Replace damaged parts.
Disassemble, clean and eliminate surIace Ilaws.
Replace worn parts.
Adjust pressure.
Replace damaged and worn parts.
Disassemble, check that parts are Iree oI Ilaws, clean
and reassemble them.
Cause
Poppet is stuck and remains open.
Eoreign matter is mixed in valve seat.
Pilot poppet seat is damaged.
Pilot piston is stuck with main poppet.
Valve is worn by Ioreign matter.
Lock nut and adjusting screw are loose.
Valve seats are damaged, O-rings are worn.
Parts are stuck to Ioreign matter.
Trouble
Pressure does not rise
at all
RelieI valve is not
steady
RelieI valve operates
wrong
Oil leaks
Remedy
ReIer to engine manual.
Replace hydraulic pump.
Adjust pressure or replace valve.
Add oil.
Change oil with hydraulic oil oI proper viscosity.
Replace suction Iilter.
Replace hydraulic pump.
Add oil.
Adjust pressure or replace relieI valve.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace valve housing assembly.
Add oil or grease.
Replace bushing or pin.
Cause
Engine power is low.
Hydraulic pump is worn.
Main relieI valve is deIective.
Hydraulic oil is low.
Hydraulic oil viscosity is wrong.
Suction Iilter is clogged up.
Hydraulic pump is Iaulty.
Hydraulic oil is low.
Main or port relieI valve set pressure is too
low or wrong.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Operating valve internal oil leak.
Oil or grease is low.
Connecting pin is jarring.
Trouble
Overall operating
power decreases
All Iunctions are
Iaulty
Attachment power is
down
Attachment Ialls oI its
own weight
Abnormal noise Irom
attachment joint
56
TROUBLESHOOTING
RELIEF VALVE
ATTACHMENT
Remedy
Disassemble, check Ior Ioreign matter and make
poppet move Ireely.
Clean all parts.
Replace damaged parts.
Disassemble, clean and eliminate surIace Ilaws.
Replace worn parts.
Adjust pressure.
Replace damaged and worn parts.
Disassemble, check that parts are Iree oI Ilaws, clean
and reassemble them.
Cause
Poppet is stuck and remains open.
Eoreign matter is mixed in valve seat.
Pilot poppet seat is damaged.
Pilot piston is stuck with main poppet.
Valve is worn by Ioreign matter.
Lock nut and adjusting screw are loose.
Valve seats are damaged, O-rings are worn.
Parts are stuck to Ioreign matter.
Trouble
Pressure does not rise
at all
RelieI valve is not
steady
RelieI valve operates
wrong
Oil leaks
Remedy
ReIer to engine manual.
Replace hydraulic pump.
Adjust pressure or replace valve.
Add oil.
Change oil with hydraulic oil oI proper viscosity.
Replace suction Iilter.
Replace hydraulic pump.
Add oil.
Adjust pressure or replace relieI valve.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace valve housing assembly.
Add oil or grease.
Replace bushing or pin.
Cause
Engine power is low.
Hydraulic pump is worn.
Main relieI valve is deIective.
Hydraulic oil is low.
Hydraulic oil viscosity is wrong.
Suction Iilter is clogged up.
Hydraulic pump is Iaulty.
Hydraulic oil is low.
Main or port relieI valve set pressure is too
low or wrong.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Operating valve internal oil leak.
Oil or grease is low.
Connecting pin is jarring.
Trouble
Overall operating
power decreases
All Iunctions are
Iaulty
Attachment power is
down
Attachment Ialls oI its
own weight
Abnormal noise Irom
attachment joint
56
TROUBLESHOOTING
RELIEF VALVE
ATTACHMENT
Remedy
Disassemble, check Ior Ioreign matter and make
poppet move Ireely.
Clean all parts.
Replace damaged parts.
Disassemble, clean and eliminate surIace Ilaws.
Replace worn parts.
Adjust pressure.
Replace damaged and worn parts.
Disassemble, check that parts are Iree oI Ilaws, clean
and reassemble them.
Cause
Poppet is stuck and remains open.
Eoreign matter is mixed in valve seat.
Pilot poppet seat is damaged.
Pilot piston is stuck with main poppet.
Valve is worn by Ioreign matter.
Lock nut and adjusting screw are loose.
Valve seats are damaged, O-rings are worn.
Parts are stuck to Ioreign matter.
Trouble
Pressure does not rise
at all
RelieI valve is not
steady
RelieI valve operates
wrong
Oil leaks
Remedy
ReIer to engine manual.
Replace hydraulic pump.
Adjust pressure or replace valve.
Add oil.
Change oil with hydraulic oil oI proper viscosity.
Replace suction Iilter.
Replace hydraulic pump.
Add oil.
Adjust pressure or replace relieI valve.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace valve housing assembly.
Add oil or grease.
Replace bushing or pin.
Cause
Engine power is low.
Hydraulic pump is worn.
Main relieI valve is deIective.
Hydraulic oil is low.
Hydraulic oil viscosity is wrong.
Suction Iilter is clogged up.
Hydraulic pump is Iaulty.
Hydraulic oil is low.
Main or port relieI valve set pressure is too
low or wrong.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Operating valve internal oil leak.
Oil or grease is low.
Connecting pin is jarring.
Trouble
Overall operating
power decreases
All Iunctions are
Iaulty
Attachment power is
down
Attachment Ialls oI its
own weight
Abnormal noise Irom
attachment joint
56
TROUBLESHOOTING
RELIEF VALVE
ATTACHMENT
Remedy
Disassemble, check Ior Ioreign matter and make
poppet move Ireely.
Clean all parts.
Replace damaged parts.
Disassemble, clean and eliminate surIace Ilaws.
Replace worn parts.
Adjust pressure.
Replace damaged and worn parts.
Disassemble, check that parts are Iree oI Ilaws, clean
and reassemble them.
Cause
Poppet is stuck and remains open.
Eoreign matter is mixed in valve seat.
Pilot poppet seat is damaged.
Pilot piston is stuck with main poppet.
Valve is worn by Ioreign matter.
Lock nut and adjusting screw are loose.
Valve seats are damaged, O-rings are worn.
Parts are stuck to Ioreign matter.
Trouble
Pressure does not rise
at all
RelieI valve is not
steady
RelieI valve operates
wrong
Oil leaks
Remedy
ReIer to engine manual.
Replace hydraulic pump.
Adjust pressure or replace valve.
Add oil.
Change oil with hydraulic oil oI proper viscosity.
Replace suction Iilter.
Replace hydraulic pump.
Add oil.
Adjust pressure or replace relieI valve.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace hydraulic cylinder gaskets.
Replace hydraulic cylinder piston and cylinder or
change assembly.
Replace valve housing assembly.
Add oil or grease.
Replace bushing or pin.
Cause
Engine power is low.
Hydraulic pump is worn.
Main relieI valve is deIective.
Hydraulic oil is low.
Hydraulic oil viscosity is wrong.
Suction Iilter is clogged up.
Hydraulic pump is Iaulty.
Hydraulic oil is low.
Main or port relieI valve set pressure is too
low or wrong.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Hydraulic cylinder gaskets are damaged.
Hydraulic cylinder piston and cylinder are
damaged.
Operating valve internal oil leak.
Oil or grease is low.
Connecting pin is jarring.
Trouble
Overall operating
power decreases
All Iunctions are
Iaulty
Attachment power is
down
Attachment Ialls oI its
own weight
Abnormal noise Irom
attachment joint
TROUBLESHOOTING
TRAVELING
OPERATION LEVER
Remedy
Adjust pressure.
Replace counterbalance valve.
Replace hydraulic motor.
Replace swivel joint gaskets.
Replace hydraulic pump.
Replace valve housing assembly.
Adjust crawler tension.
Remove stones or Ioreign objects.
Replace counterbalance valve.
Replace hydraulic motor.
Add oil.
Adjust them to equal and proper tension.
Replace hydraulic pump.
Replace hydraulic motor.
Replace valve housing assembly.
Replace swivel joint gasket.
Adjust.
Cause
Main relieI valve set pressure is too low.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Swivel joint gaskets are damaged.
Hydraulic pump perIormance has dropped.
Operating valve internal oil leak.
Crawler tension is too high.
Stones or Ioreign objects are present.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Hydraulic motor sucks air in.
Right and leIt crawlers diIIer in tension.
Hydraulic pump perIormance has dropped.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Swivel joint gasket is damaged.
Lever links are loose.
Trouble
Running power is
down
Does not run smooth
Does not run straight
Remedy
Clean operating valve.
Replace valve housing assembly.
Oil / grease.
Oil / grease.
Cause
Eoreign matter in operating valve spool.
Valve plunger sticks.
Lever links are not well lubricated.
Lever links are too tight.
Trouble
Hard to operate levers
57
TROUBLESHOOTING
TRAVELING
OPERATION LEVER
Remedy
Adjust pressure.
Replace counterbalance valve.
Replace hydraulic motor.
Replace swivel joint gaskets.
Replace hydraulic pump.
Replace valve housing assembly.
Adjust crawler tension.
Remove stones or Ioreign objects.
Replace counterbalance valve.
Replace hydraulic motor.
Add oil.
Adjust them to equal and proper tension.
Replace hydraulic pump.
Replace hydraulic motor.
Replace valve housing assembly.
Replace swivel joint gasket.
Adjust.
Cause
Main relieI valve set pressure is too low.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Swivel joint gaskets are damaged.
Hydraulic pump perIormance has dropped.
Operating valve internal oil leak.
Crawler tension is too high.
Stones or Ioreign objects are present.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Hydraulic motor sucks air in.
Right and leIt crawlers diIIer in tension.
Hydraulic pump perIormance has dropped.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Swivel joint gasket is damaged.
Lever links are loose.
Trouble
Running power is
down
Does not run smooth
Does not run straight
Remedy
Clean operating valve.
Replace valve housing assembly.
Oil / grease.
Oil / grease.
Cause
Eoreign matter in operating valve spool.
Valve plunger sticks.
Lever links are not well lubricated.
Lever links are too tight.
Trouble
Hard to operate levers
57
TROUBLESHOOTING
TRAVELING
OPERATION LEVER
Remedy
Adjust pressure.
Replace counterbalance valve.
Replace hydraulic motor.
Replace swivel joint gaskets.
Replace hydraulic pump.
Replace valve housing assembly.
Adjust crawler tension.
Remove stones or Ioreign objects.
Replace counterbalance valve.
Replace hydraulic motor.
Add oil.
Adjust them to equal and proper tension.
Replace hydraulic pump.
Replace hydraulic motor.
Replace valve housing assembly.
Replace swivel joint gasket.
Adjust.
Cause
Main relieI valve set pressure is too low.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Swivel joint gaskets are damaged.
Hydraulic pump perIormance has dropped.
Operating valve internal oil leak.
Crawler tension is too high.
Stones or Ioreign objects are present.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Hydraulic motor sucks air in.
Right and leIt crawlers diIIer in tension.
Hydraulic pump perIormance has dropped.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Swivel joint gasket is damaged.
Lever links are loose.
Trouble
Running power is
down
Does not run smooth
Does not run straight
Remedy
Clean operating valve.
Replace valve housing assembly.
Oil / grease.
Oil / grease.
Cause
Eoreign matter in operating valve spool.
Valve plunger sticks.
Lever links are not well lubricated.
Lever links are too tight.
Trouble
Hard to operate levers
57
TROUBLESHOOTING
TRAVELING
OPERATION LEVER
Remedy
Adjust pressure.
Replace counterbalance valve.
Replace hydraulic motor.
Replace swivel joint gaskets.
Replace hydraulic pump.
Replace valve housing assembly.
Adjust crawler tension.
Remove stones or Ioreign objects.
Replace counterbalance valve.
Replace hydraulic motor.
Add oil.
Adjust them to equal and proper tension.
Replace hydraulic pump.
Replace hydraulic motor.
Replace valve housing assembly.
Replace swivel joint gasket.
Adjust.
Cause
Main relieI valve set pressure is too low.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Swivel joint gaskets are damaged.
Hydraulic pump perIormance has dropped.
Operating valve internal oil leak.
Crawler tension is too high.
Stones or Ioreign objects are present.
Counterbalance valve is deIective.
Hydraulic motor perIormance has dropped.
Hydraulic motor sucks air in.
Right and leIt crawlers diIIer in tension.
Hydraulic pump perIormance has dropped.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Swivel joint gasket is damaged.
Lever links are loose.
Trouble
Running power is
down
Does not run smooth
Does not run straight
Remedy
Clean operating valve.
Replace valve housing assembly.
Oil / grease.
Oil / grease.
Cause
Eoreign matter in operating valve spool.
Valve plunger sticks.
Lever links are not well lubricated.
Lever links are too tight.
Trouble
Hard to operate levers
57
58
TROUBLESHOOTING
HYDRAULIC PUMP
SWIVEL 1OINT
SWINGING
Remedy
Replace swivel joint gasket.
Replace swivel joint.
Replace swivel joint gasket.
Cause
Swivel joint gasket is deIective.
Swivel joint rotor is damaged.
Swivel joint gasket is deIective.
Trouble
Operating power is
down
Swivel joint external
oil leak.
Remedy
Add oil.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Replace hydraulic pump.
Add oil and check suction hose.
Adjust pressure.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Retighten suction joint or add oil
Change oil with hydraulic oil or proper viscosity.
Align them again.
Check cause oI bubbles and remove it. (Change oil
with Iresh oil)
Replace seal or replace hydraulic pump.
Cause
Hydraulic oil is low.
Suction Iilter is clogged up.
Hydraulic pump internal oil leak.
Hydraulic pump sucks air in.
Main relieI valve set pressure is too low.
Cavitation due to miss shaped suction hose
or clogged up suction Iilter.
Air is sucked in due to loose suction joint
or shortage oI hydraulic oil.
Cavitation due to hydraulic oil viscosity.
Pump and engine are not aligned.
Hydraulic oil has bubbles.
Hydraulic pump seal is deIective.
Trouble
No oil Ilow Irom
hydraulic pump
Hydraulic pump
pressure does not rise
Abnormal noise Irom
hydraulic pump
Oil leaks out Irom
hydraulic pump
Remedy
Replace hydraulic motor.
Oil/grease or replace swivel ring.
Adjust pressure
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Adjusting pressure.
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Add oil.
Add oil / grease.
Cause
Hydraulic motor perIormance has dropped.
Swivel ring is stuck.
Brake valve set pressure is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Port relieI valve or brake valve set pressure
is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Hydraulic motor sucks air in.
Swivel bearing is not well lubricated.
Trouble
Swivel power is down
Swivel brake keeps
running
Swivel runs on brake
action
Abnormal noise in
swivelling
58
TROUBLESHOOTING
HYDRAULIC PUMP
SWIVEL 1OINT
SWINGING
Remedy
Replace swivel joint gasket.
Replace swivel joint.
Replace swivel joint gasket.
Cause
Swivel joint gasket is deIective.
Swivel joint rotor is damaged.
Swivel joint gasket is deIective.
Trouble
Operating power is
down
Swivel joint external
oil leak.
Remedy
Add oil.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Replace hydraulic pump.
Add oil and check suction hose.
Adjust pressure.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Retighten suction joint or add oil
Change oil with hydraulic oil or proper viscosity.
Align them again.
Check cause oI bubbles and remove it. (Change oil
with Iresh oil)
Replace seal or replace hydraulic pump.
Cause
Hydraulic oil is low.
Suction Iilter is clogged up.
Hydraulic pump internal oil leak.
Hydraulic pump sucks air in.
Main relieI valve set pressure is too low.
Cavitation due to miss shaped suction hose
or clogged up suction Iilter.
Air is sucked in due to loose suction joint
or shortage oI hydraulic oil.
Cavitation due to hydraulic oil viscosity.
Pump and engine are not aligned.
Hydraulic oil has bubbles.
Hydraulic pump seal is deIective.
Trouble
No oil Ilow Irom
hydraulic pump
Hydraulic pump
pressure does not rise
Abnormal noise Irom
hydraulic pump
Oil leaks out Irom
hydraulic pump
Remedy
Replace hydraulic motor.
Oil/grease or replace swivel ring.
Adjust pressure
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Adjusting pressure.
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Add oil.
Add oil / grease.
Cause
Hydraulic motor perIormance has dropped.
Swivel ring is stuck.
Brake valve set pressure is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Port relieI valve or brake valve set pressure
is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Hydraulic motor sucks air in.
Swivel bearing is not well lubricated.
Trouble
Swivel power is down
Swivel brake keeps
running
Swivel runs on brake
action
Abnormal noise in
swivelling
58
TROUBLESHOOTING
HYDRAULIC PUMP
SWIVEL 1OINT
SWINGING
Remedy
Replace swivel joint gasket.
Replace swivel joint.
Replace swivel joint gasket.
Cause
Swivel joint gasket is deIective.
Swivel joint rotor is damaged.
Swivel joint gasket is deIective.
Trouble
Operating power is
down
Swivel joint external
oil leak.
Remedy
Add oil.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Replace hydraulic pump.
Add oil and check suction hose.
Adjust pressure.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Retighten suction joint or add oil
Change oil with hydraulic oil or proper viscosity.
Align them again.
Check cause oI bubbles and remove it. (Change oil
with Iresh oil)
Replace seal or replace hydraulic pump.
Cause
Hydraulic oil is low.
Suction Iilter is clogged up.
Hydraulic pump internal oil leak.
Hydraulic pump sucks air in.
Main relieI valve set pressure is too low.
Cavitation due to miss shaped suction hose
or clogged up suction Iilter.
Air is sucked in due to loose suction joint
or shortage oI hydraulic oil.
Cavitation due to hydraulic oil viscosity.
Pump and engine are not aligned.
Hydraulic oil has bubbles.
Hydraulic pump seal is deIective.
Trouble
No oil Ilow Irom
hydraulic pump
Hydraulic pump
pressure does not rise
Abnormal noise Irom
hydraulic pump
Oil leaks out Irom
hydraulic pump
Remedy
Replace hydraulic motor.
Oil/grease or replace swivel ring.
Adjust pressure
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Adjusting pressure.
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Add oil.
Add oil / grease.
Cause
Hydraulic motor perIormance has dropped.
Swivel ring is stuck.
Brake valve set pressure is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Port relieI valve or brake valve set pressure
is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Hydraulic motor sucks air in.
Swivel bearing is not well lubricated.
Trouble
Swivel power is down
Swivel brake keeps
running
Swivel runs on brake
action
Abnormal noise in
swivelling
58
TROUBLESHOOTING
HYDRAULIC PUMP
SWIVEL 1OINT
SWINGING
Remedy
Replace swivel joint gasket.
Replace swivel joint.
Replace swivel joint gasket.
Cause
Swivel joint gasket is deIective.
Swivel joint rotor is damaged.
Swivel joint gasket is deIective.
Trouble
Operating power is
down
Swivel joint external
oil leak.
Remedy
Add oil.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Replace hydraulic pump.
Add oil and check suction hose.
Adjust pressure.
Replace Iilter. II oil is dirty, change it with Iresh oil.
Retighten suction joint or add oil
Change oil with hydraulic oil or proper viscosity.
Align them again.
Check cause oI bubbles and remove it. (Change oil
with Iresh oil)
Replace seal or replace hydraulic pump.
Cause
Hydraulic oil is low.
Suction Iilter is clogged up.
Hydraulic pump internal oil leak.
Hydraulic pump sucks air in.
Main relieI valve set pressure is too low.
Cavitation due to miss shaped suction hose
or clogged up suction Iilter.
Air is sucked in due to loose suction joint
or shortage oI hydraulic oil.
Cavitation due to hydraulic oil viscosity.
Pump and engine are not aligned.
Hydraulic oil has bubbles.
Hydraulic pump seal is deIective.
Trouble
No oil Ilow Irom
hydraulic pump
Hydraulic pump
pressure does not rise
Abnormal noise Irom
hydraulic pump
Oil leaks out Irom
hydraulic pump
Remedy
Replace hydraulic motor.
Oil/grease or replace swivel ring.
Adjust pressure
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Adjusting pressure.
Clean port relieI valve or brake valve.
Replace hydraulic motor.
Replace valve housing assembly.
Add oil.
Add oil / grease.
Cause
Hydraulic motor perIormance has dropped.
Swivel ring is stuck.
Brake valve set pressure is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Port relieI valve or brake valve set pressure
is too low.
Port relieI valve or brake valve is clogged
up.
Hydraulic motor perIormance has dropped.
Operating valve internal oil leak.
Hydraulic motor sucks air in.
Swivel bearing is not well lubricated.
Trouble
Swivel power is down
Swivel brake keeps
running
Swivel runs on brake
action
Abnormal noise in
swivelling
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Repair the deIective connection and contact
positions.
Repair the Iull discharge oI battery, the Iailure oI
starter or break or looseness oI connections on
power distribution.
Inspect and repair it.
Pre-heat with air heater.
Warm the cooling water (Power hot water).
Repair.
Eully re-bleed Iuel system.
Supply Iuel.
Inspect and replace.
Clean or replace.
Repair.
Repair.
Supply Iuel.
Clean or replace.
Tighten the joints oI Iuel system pipes & re-bleed.
Supply oil.
Repair it.
Replace it.
Replace the element.
Replace it with oil suitable Ior the temperature.
AIter re-adjusting and cleaning, iI no, better replace
it.
Top up.
Check hoses and radiator.
Adjust or replace.
Repair or replace.
Replace it.
Dilute mixture.
Replace it.
Replace it.
Adjust tension.
Repair it.
Replace it.
Check connections, recharge, replace.
Replace it.
Repair or replace it.
Cause
DeIective starter switch.
DeIective starter revolution .
Improper viscosity oI engine oil.
Engine extremely cold.
Seizure oI crank shaIt, cam shaIt, piston or
bearing.
Air in Iuel system.
No Iuel in tank.
Improper quality oI Iuel.
Clogging oI Iuel Iilter.
InsuIIicient compression pressure.
DeIective Iuel injection pump.
No Iuel in tank.
Clogging oI Iuel Iilter.
Air included in Iuel system.
Oil shortage.
Oil leakage Irom joint.
DeIective oil pressure switch.
Clogging oI oil Iilter.
Low oil viscosity.
Oil pump operates deIectively.
Cooling water low.
Water leak.
Ean belt tension.
Radiator Iailure.
Ean broken.
Too rich anti-Ireeze concentration.
Thermostat Iailure.
Water pump Iailure.
Ean belt tension wrong.
Wires deIective.
Pilot lamp or ammeter Iailure.
Battery Iailure.
Regulator Iailure.
Alternator Iailure.
Trouble
Engine does not start.
Engine stopped
suddenly in running.
Oil pressure is
deIective.
Engine overheats
Charging Iailure
59
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Repair the deIective connection and contact
positions.
Repair the Iull discharge oI battery, the Iailure oI
starter or break or looseness oI connections on
power distribution.
Inspect and repair it.
Pre-heat with air heater.
Warm the cooling water (Power hot water).
Repair.
Eully re-bleed Iuel system.
Supply Iuel.
Inspect and replace.
Clean or replace.
Repair.
Repair.
Supply Iuel.
Clean or replace.
Tighten the joints oI Iuel system pipes & re-bleed.
Supply oil.
Repair it.
Replace it.
Replace the element.
Replace it with oil suitable Ior the temperature.
AIter re-adjusting and cleaning, iI no, better replace
it.
Top up.
Check hoses and radiator.
Adjust or replace.
Repair or replace.
Replace it.
Dilute mixture.
Replace it.
Replace it.
Adjust tension.
Repair it.
Replace it.
Check connections, recharge, replace.
Replace it.
Repair or replace it.
Cause
DeIective starter switch.
DeIective starter revolution .
Improper viscosity oI engine oil.
Engine extremely cold.
Seizure oI crank shaIt, cam shaIt, piston or
bearing.
Air in Iuel system.
No Iuel in tank.
Improper quality oI Iuel.
Clogging oI Iuel Iilter.
InsuIIicient compression pressure.
DeIective Iuel injection pump.
No Iuel in tank.
Clogging oI Iuel Iilter.
Air included in Iuel system.
Oil shortage.
Oil leakage Irom joint.
DeIective oil pressure switch.
Clogging oI oil Iilter.
Low oil viscosity.
Oil pump operates deIectively.
Cooling water low.
Water leak.
Ean belt tension.
Radiator Iailure.
Ean broken.
Too rich anti-Ireeze concentration.
Thermostat Iailure.
Water pump Iailure.
Ean belt tension wrong.
Wires deIective.
Pilot lamp or ammeter Iailure.
Battery Iailure.
Regulator Iailure.
Alternator Iailure.
Trouble
Engine does not start.
Engine stopped
suddenly in running.
Oil pressure is
deIective.
Engine overheats
Charging Iailure
59
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Repair the deIective connection and contact
positions.
Repair the Iull discharge oI battery, the Iailure oI
starter or break or looseness oI connections on
power distribution.
Inspect and repair it.
Pre-heat with air heater.
Warm the cooling water (Power hot water).
Repair.
Eully re-bleed Iuel system.
Supply Iuel.
Inspect and replace.
Clean or replace.
Repair.
Repair.
Supply Iuel.
Clean or replace.
Tighten the joints oI Iuel system pipes & re-bleed.
Supply oil.
Repair it.
Replace it.
Replace the element.
Replace it with oil suitable Ior the temperature.
AIter re-adjusting and cleaning, iI no, better replace
it.
Top up.
Check hoses and radiator.
Adjust or replace.
Repair or replace.
Replace it.
Dilute mixture.
Replace it.
Replace it.
Adjust tension.
Repair it.
Replace it.
Check connections, recharge, replace.
Replace it.
Repair or replace it.
Cause
DeIective starter switch.
DeIective starter revolution .
Improper viscosity oI engine oil.
Engine extremely cold.
Seizure oI crank shaIt, cam shaIt, piston or
bearing.
Air in Iuel system.
No Iuel in tank.
Improper quality oI Iuel.
Clogging oI Iuel Iilter.
InsuIIicient compression pressure.
DeIective Iuel injection pump.
No Iuel in tank.
Clogging oI Iuel Iilter.
Air included in Iuel system.
Oil shortage.
Oil leakage Irom joint.
DeIective oil pressure switch.
Clogging oI oil Iilter.
Low oil viscosity.
Oil pump operates deIectively.
Cooling water low.
Water leak.
Ean belt tension.
Radiator Iailure.
Ean broken.
Too rich anti-Ireeze concentration.
Thermostat Iailure.
Water pump Iailure.
Ean belt tension wrong.
Wires deIective.
Pilot lamp or ammeter Iailure.
Battery Iailure.
Regulator Iailure.
Alternator Iailure.
Trouble
Engine does not start.
Engine stopped
suddenly in running.
Oil pressure is
deIective.
Engine overheats
Charging Iailure
59
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Repair the deIective connection and contact
positions.
Repair the Iull discharge oI battery, the Iailure oI
starter or break or looseness oI connections on
power distribution.
Inspect and repair it.
Pre-heat with air heater.
Warm the cooling water (Power hot water).
Repair.
Eully re-bleed Iuel system.
Supply Iuel.
Inspect and replace.
Clean or replace.
Repair.
Repair.
Supply Iuel.
Clean or replace.
Tighten the joints oI Iuel system pipes & re-bleed.
Supply oil.
Repair it.
Replace it.
Replace the element.
Replace it with oil suitable Ior the temperature.
AIter re-adjusting and cleaning, iI no, better replace
it.
Top up.
Check hoses and radiator.
Adjust or replace.
Repair or replace.
Replace it.
Dilute mixture.
Replace it.
Replace it.
Adjust tension.
Repair it.
Replace it.
Check connections, recharge, replace.
Replace it.
Repair or replace it.
Cause
DeIective starter switch.
DeIective starter revolution .
Improper viscosity oI engine oil.
Engine extremely cold.
Seizure oI crank shaIt, cam shaIt, piston or
bearing.
Air in Iuel system.
No Iuel in tank.
Improper quality oI Iuel.
Clogging oI Iuel Iilter.
InsuIIicient compression pressure.
DeIective Iuel injection pump.
No Iuel in tank.
Clogging oI Iuel Iilter.
Air included in Iuel system.
Oil shortage.
Oil leakage Irom joint.
DeIective oil pressure switch.
Clogging oI oil Iilter.
Low oil viscosity.
Oil pump operates deIectively.
Cooling water low.
Water leak.
Ean belt tension.
Radiator Iailure.
Ean broken.
Too rich anti-Ireeze concentration.
Thermostat Iailure.
Water pump Iailure.
Ean belt tension wrong.
Wires deIective.
Pilot lamp or ammeter Iailure.
Battery Iailure.
Regulator Iailure.
Alternator Iailure.
Trouble
Engine does not start.
Engine stopped
suddenly in running.
Oil pressure is
deIective.
Engine overheats
Charging Iailure
59
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
60
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Reduce to the speciIied level.
Replace it with oil oI suitable, viscosity.
Put cover on the radiator or replace it.
* Re-adjust.
* Strip-down, inspect, or replace the part.
Replace it with better quality Iuel.
Adjust it.
* Adjust and replace it iI necessary.
* Strip-down inspection or replace the part.
Clean the element or replace it.
* Adjust and replace iI necessary.
* Adjust and replace iI necessary.
* Adjust and repair it or replace it with better one.
Replace it with better quality Iuel.
* Strip-down inspect and replace the parts, iI
necessary.
Clean or replace the element.
Reduce to the speciIied level.
Replace it with oil oI suitable viscosity Ior the
temperature.
Locate leak and tighten it or replace part iI
necessary.
* Strip-down inspect and replace the parts iI neces-
sary.
Cause
Too much volume oI oil.
Lower viscosity oI oil.
Over-cooling oI radiator.
Incorrect injection timing.
Compression pressure down.
Euel quality incorrect.
Improper valve clearance.
Eunction Iailure oI injection pump.
Compression pressure down.
Air intake blocked (clogging oI air cleaner).
Eunctional Iailure oI injection pump.
Injection Iailure oI nozzle.
Improper injection timing.
Euel quality incorrect.
Compression pressure insuIIicient.
Air intake blocked.
Too much oil.
Low viscosity oI oil.
Oil leak.
Cylinder piston ring worn out.
Trouble
White or blue gas is
exhausted
Black or dark grey gas
is exhausted
Euel consumption too
high
Oil consumption is
too high
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
60
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Reduce to the speciIied level.
Replace it with oil oI suitable, viscosity.
Put cover on the radiator or replace it.
* Re-adjust.
* Strip-down, inspect, or replace the part.
Replace it with better quality Iuel.
Adjust it.
* Adjust and replace it iI necessary.
* Strip-down inspection or replace the part.
Clean the element or replace it.
* Adjust and replace iI necessary.
* Adjust and replace iI necessary.
* Adjust and repair it or replace it with better one.
Replace it with better quality Iuel.
* Strip-down inspect and replace the parts, iI
necessary.
Clean or replace the element.
Reduce to the speciIied level.
Replace it with oil oI suitable viscosity Ior the
temperature.
Locate leak and tighten it or replace part iI
necessary.
* Strip-down inspect and replace the parts iI neces-
sary.
Cause
Too much volume oI oil.
Lower viscosity oI oil.
Over-cooling oI radiator.
Incorrect injection timing.
Compression pressure down.
Euel quality incorrect.
Improper valve clearance.
Eunction Iailure oI injection pump.
Compression pressure down.
Air intake blocked (clogging oI air cleaner).
Eunctional Iailure oI injection pump.
Injection Iailure oI nozzle.
Improper injection timing.
Euel quality incorrect.
Compression pressure insuIIicient.
Air intake blocked.
Too much oil.
Low viscosity oI oil.
Oil leak.
Cylinder piston ring worn out.
Trouble
White or blue gas is
exhausted
Black or dark grey gas
is exhausted
Euel consumption too
high
Oil consumption is
too high
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
60
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Reduce to the speciIied level.
Replace it with oil oI suitable, viscosity.
Put cover on the radiator or replace it.
* Re-adjust.
* Strip-down, inspect, or replace the part.
Replace it with better quality Iuel.
Adjust it.
* Adjust and replace it iI necessary.
* Strip-down inspection or replace the part.
Clean the element or replace it.
* Adjust and replace iI necessary.
* Adjust and replace iI necessary.
* Adjust and repair it or replace it with better one.
Replace it with better quality Iuel.
* Strip-down inspect and replace the parts, iI
necessary.
Clean or replace the element.
Reduce to the speciIied level.
Replace it with oil oI suitable viscosity Ior the
temperature.
Locate leak and tighten it or replace part iI
necessary.
* Strip-down inspect and replace the parts iI neces-
sary.
Cause
Too much volume oI oil.
Lower viscosity oI oil.
Over-cooling oI radiator.
Incorrect injection timing.
Compression pressure down.
Euel quality incorrect.
Improper valve clearance.
Eunction Iailure oI injection pump.
Compression pressure down.
Air intake blocked (clogging oI air cleaner).
Eunctional Iailure oI injection pump.
Injection Iailure oI nozzle.
Improper injection timing.
Euel quality incorrect.
Compression pressure insuIIicient.
Air intake blocked.
Too much oil.
Low viscosity oI oil.
Oil leak.
Cylinder piston ring worn out.
Trouble
White or blue gas is
exhausted
Black or dark grey gas
is exhausted
Euel consumption too
high
Oil consumption is
too high
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
60
TROUBLESHOOTING
ENGINE AND RELATED PARTS
Remedy
Reduce to the speciIied level.
Replace it with oil oI suitable, viscosity.
Put cover on the radiator or replace it.
* Re-adjust.
* Strip-down, inspect, or replace the part.
Replace it with better quality Iuel.
Adjust it.
* Adjust and replace it iI necessary.
* Strip-down inspection or replace the part.
Clean the element or replace it.
* Adjust and replace iI necessary.
* Adjust and replace iI necessary.
* Adjust and repair it or replace it with better one.
Replace it with better quality Iuel.
* Strip-down inspect and replace the parts, iI
necessary.
Clean or replace the element.
Reduce to the speciIied level.
Replace it with oil oI suitable viscosity Ior the
temperature.
Locate leak and tighten it or replace part iI
necessary.
* Strip-down inspect and replace the parts iI neces-
sary.
Cause
Too much volume oI oil.
Lower viscosity oI oil.
Over-cooling oI radiator.
Incorrect injection timing.
Compression pressure down.
Euel quality incorrect.
Improper valve clearance.
Eunction Iailure oI injection pump.
Compression pressure down.
Air intake blocked (clogging oI air cleaner).
Eunctional Iailure oI injection pump.
Injection Iailure oI nozzle.
Improper injection timing.
Euel quality incorrect.
Compression pressure insuIIicient.
Air intake blocked.
Too much oil.
Low viscosity oI oil.
Oil leak.
Cylinder piston ring worn out.
Trouble
White or blue gas is
exhausted
Black or dark grey gas
is exhausted
Euel consumption too
high
Oil consumption is
too high
Contact your Thomas
authorized Dealer for all
major fixes under the remedy
column except for regular
service IE: Replenish fluids,
tightening etc.
NOTE
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
Inspecting an
abnormal
exhaust
noise Irom
engine
Inspecting and
replacing engine
oil
Replacing
engine oil Iilter
cartridge
Adding Iuel and
cleaning Iuel
tank
Cleaning and
replacing Iuel
Iilter element
Inspecting water
separator
Adding and
replacing
cooling water
Cleaning
radiator Iin
Inspecting,
cleaning and
replacing air
cleaner element
Inspecting and
adjusting
tension oI Ian
belt
Inspecting and
adjusting
valve clearance
Retightening
cylinder head
bolt
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
+
+
+
`
`
`
`
`
`
`
#
#
#
Drain
Water and
Sediment
Replace
every
spring and
autumn
61
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
Inspecting an
abnormal
exhaust
noise Irom
engine
Inspecting and
replacing engine
oil
Replacing
engine oil Iilter
cartridge
Adding Iuel and
cleaning Iuel
tank
Cleaning and
replacing Iuel
Iilter element
Inspecting water
separator
Adding and
replacing
cooling water
Cleaning
radiator Iin
Inspecting,
cleaning and
replacing air
cleaner element
Inspecting and
adjusting
tension oI Ian
belt
Inspecting and
adjusting
valve clearance
Retightening
cylinder head
bolt
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
+
+
+
`
`
`
`
`
`
`
#
#
#
Drain
Water and
Sediment
Replace
every
spring and
autumn
61
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
Inspecting an
abnormal
exhaust
noise Irom
engine
Inspecting and
replacing engine
oil
Replacing
engine oil Iilter
cartridge
Adding Iuel and
cleaning Iuel
tank
Cleaning and
replacing Iuel
Iilter element
Inspecting water
separator
Adding and
replacing
cooling water
Cleaning
radiator Iin
Inspecting,
cleaning and
replacing air
cleaner element
Inspecting and
adjusting
tension oI Ian
belt
Inspecting and
adjusting
valve clearance
Retightening
cylinder head
bolt
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
+
+
+
`
`
`
`
`
`
`
#
#
#
Drain
Water and
Sediment
Replace
every
spring and
autumn
61
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
Inspecting an
abnormal
exhaust
noise Irom
engine
Inspecting and
replacing engine
oil
Replacing
engine oil Iilter
cartridge
Adding Iuel and
cleaning Iuel
tank
Cleaning and
replacing Iuel
Iilter element
Inspecting water
separator
Adding and
replacing
cooling water
Cleaning
radiator Iin
Inspecting,
cleaning and
replacing air
cleaner element
Inspecting and
adjusting
tension oI Ian
belt
Inspecting and
adjusting
valve clearance
Retightening
cylinder head
bolt
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
+
+
+
`
`
`
`
`
`
`
#
#
#
Drain
Water and
Sediment
Replace
every
spring and
autumn
61
62
Inspecting
the bolt and nut
Ior tightness
Inspecting
and greasing the
attachment pins
Check Ior loose
parts and
damaged parts
Greasing the
swing bearing
gear
Inspecting
the crawler
tension (grease
cylinder)
Inspecting
and greasing the
lower roller
Replacing the
lubricant Ior the
crawler drive
unit reduction
gears
Inspecting the
joint Ior
looseness and
oil leaks
Supplying or
replacing the
hydraulic oil
Replacing the
line Iilter
element
Cleaning or
replacing the
suction Iilter
Check wiring
Ior non-
connection short
circuit, loose
connections
Inspecting
the electrical
parts
Inspecting the
battery Iluid
level
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
#
+
`
`
`
`
`
`
#
+
#
Eirst 200
Hours
Drain
water and
sediment
+
+
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
62
Inspecting
the bolt and nut
Ior tightness
Inspecting
and greasing the
attachment pins
Check Ior loose
parts and
damaged parts
Greasing the
swing bearing
gear
Inspecting
the crawler
tension (grease
cylinder)
Inspecting
and greasing the
lower roller
Replacing the
lubricant Ior the
crawler drive
unit reduction
gears
Inspecting the
joint Ior
looseness and
oil leaks
Supplying or
replacing the
hydraulic oil
Replacing the
line Iilter
element
Cleaning or
replacing the
suction Iilter
Check wiring
Ior non-
connection short
circuit, loose
connections
Inspecting
the electrical
parts
Inspecting the
battery Iluid
level
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
#
+
`
`
`
`
`
`
#
+
#
Eirst 200
Hours
Drain
water and
sediment
+
+
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
62
Inspecting
the bolt and nut
Ior tightness
Inspecting
and greasing the
attachment pins
Check Ior loose
parts and
damaged parts
Greasing the
swing bearing
gear
Inspecting
the crawler
tension (grease
cylinder)
Inspecting
and greasing the
lower roller
Replacing the
lubricant Ior the
crawler drive
unit reduction
gears
Inspecting the
joint Ior
looseness and
oil leaks
Supplying or
replacing the
hydraulic oil
Replacing the
line Iilter
element
Cleaning or
replacing the
suction Iilter
Check wiring
Ior non-
connection short
circuit, loose
connections
Inspecting
the electrical
parts
Inspecting the
battery Iluid
level
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
#
+
`
`
`
`
`
`
#
+
#
Eirst 200
Hours
Drain
water and
sediment
+
+
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
62
Inspecting
the bolt and nut
Ior tightness
Inspecting
and greasing the
attachment pins
Check Ior loose
parts and
damaged parts
Greasing the
swing bearing
gear
Inspecting
the crawler
tension (grease
cylinder)
Inspecting
and greasing the
lower roller
Replacing the
lubricant Ior the
crawler drive
unit reduction
gears
Inspecting the
joint Ior
looseness and
oil leaks
Supplying or
replacing the
hydraulic oil
Replacing the
line Iilter
element
Cleaning or
replacing the
suction Iilter
Check wiring
Ior non-
connection short
circuit, loose
connections
Inspecting
the electrical
parts
Inspecting the
battery Iluid
level
Check
beIore
start-up
Eirst
50
hours
Eirst
100
hours
Every
50
hours
Every
100
hours
Every
250
hours
Every
500
hours
Every
800
hours
Every
1000
hours
Every
2000
hours
Remarks Period
Item
+
+
+
+
+
+
+
#
+
`
`
`
`
`
`
#
+
#
Eirst 200
Hours
Drain
water and
sediment
+
+
PERIODICAL INSPECTIONS AND MAINTENANCE LIST
+ Inspect, Add, Adjust, Grease # Clean, ` Replace
LUBRICANTS
Use the oil and grease speciIied in the table below depending on the seasons.
Table of Recommended Lubricants
NO. LUBRICANT CASTROL ESSO
1 Engine Oil RX SUPER 15W-40 LUBE MHX 15W-40
2 Gear Oil EPX 85W-140 GX 85W-140
3 Hydraulic Oil HYSPIN AWH-M-46 UNIVIS N46
4 Cup Grease SPHEEROL LEP2 BEACAN EP 2
5 AntiIreeze Anti Ereeze Anti Ereeze
6 Diesel Euel
* The engine oil SAE CD10W-30 or equivalent at the time oI shipment is used Ior the lubricating oil Ior traveling speed
reducer.
* German Hydraulic oil is Univis J32
Euel Tank
How to Read Table (Page 64 to 66)
Lubricating / Oil Eilling Point
Index Number on Table
Lubricating Interval... every hours
Lubricant / Oil Amount
Daily lubricating point.......Au
Additional Lubricating
Point...................................A
63
LUBRICANTS
Use the oil and grease speciIied in the table below depending on the seasons.
Table of Recommended Lubricants
NO. LUBRICANT CASTROL ESSO
1 Engine Oil RX SUPER 15W-40 LUBE MHX 15W-40
2 Gear Oil EPX 85W-140 GX 85W-140
3 Hydraulic Oil HYSPIN AWH-M-46 UNIVIS N46
4 Cup Grease SPHEEROL LEP2 BEACAN EP 2
5 AntiIreeze Anti Ereeze Anti Ereeze
6 Diesel Euel
* The engine oil SAE CD10W-30 or equivalent at the time oI shipment is used Ior the lubricating oil Ior traveling speed
reducer.
* German Hydraulic oil is Univis J32
Euel Tank
How to Read Table (Page 64 to 66)
Lubricating / Oil Eilling Point
Index Number on Table
Lubricating Interval... every hours
Lubricant / Oil Amount
Daily lubricating point.......Au
Additional Lubricating
Point...................................A
63
LUBRICANTS
Use the oil and grease speciIied in the table below depending on the seasons.
Table of Recommended Lubricants
NO. LUBRICANT CASTROL ESSO
1 Engine Oil RX SUPER 15W-40 LUBE MHX 15W-40
2 Gear Oil EPX 85W-140 GX 85W-140
3 Hydraulic Oil HYSPIN AWH-M-46 UNIVIS N46
4 Cup Grease SPHEEROL LEP2 BEACAN EP 2
5 AntiIreeze Anti Ereeze Anti Ereeze
6 Diesel Euel
* The engine oil SAE CD10W-30 or equivalent at the time oI shipment is used Ior the lubricating oil Ior traveling speed
reducer.
* German Hydraulic oil is Univis J32
Euel Tank
How to Read Table (Page 64 to 66)
Lubricating / Oil Eilling Point
Index Number on Table
Lubricating Interval... every hours
Lubricant / Oil Amount
Daily lubricating point.......Au
Additional Lubricating
Point...................................A
63
LUBRICANTS
Use the oil and grease speciIied in the table below depending on the seasons.
Table of Recommended Lubricants
NO. LUBRICANT CASTROL ESSO
1 Engine Oil RX SUPER 15W-40 LUBE MHX 15W-40
2 Gear Oil EPX 85W-140 GX 85W-140
3 Hydraulic Oil HYSPIN AWH-M-46 UNIVIS N46
4 Cup Grease SPHEEROL LEP2 BEACAN EP 2
5 AntiIreeze Anti Ereeze Anti Ereeze
6 Diesel Euel
* The engine oil SAE CD10W-30 or equivalent at the time oI shipment is used Ior the lubricating oil Ior traveling speed
reducer.
* German Hydraulic oil is Univis J32
Euel Tank
How to Read Table (Page 64 to 66)
Lubricating / Oil Eilling Point
Index Number on Table
Lubricating Interval... every hours
Lubricant / Oil Amount
Daily lubricating point.......Au
Additional Lubricating
Point...................................A
63
64
LUBRICANTS
Grease Supply Points - Main Frame
6 A 23.6 l (6.2 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
Euel Tank
Hydraulic Tank
Engine
4 Au
4 Au
4 Au
Swing Cylinder Head Pin
Swing Bearing Swing gear
64
LUBRICANTS
Grease Supply Points - Main Frame
6 A 23.6 l (6.2 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
Euel Tank
Hydraulic Tank
Engine
4 Au
4 Au
4 Au
Swing Cylinder Head Pin
Swing Bearing Swing gear
64
LUBRICANTS
Grease Supply Points - Main Frame
6 A 23.6 l (6.2 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
Euel Tank
Hydraulic Tank
Engine
4 Au
4 Au
4 Au
Swing Cylinder Head Pin
Swing Bearing Swing gear
64
LUBRICANTS
Grease Supply Points - Main Frame
6 A 23.6 l (6.2 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
3 A 30.61 l (8.1 U.S. gal)
Euel Tank
Hydraulic Tank
Engine
4 Au
4 Au
4 Au
Swing Cylinder Head Pin
Swing Bearing Swing gear
LUBRICANTS
Grease Supply Points - Undercarriage
Dozer Joint Pin
4 Au
4 Au
Eront Idler
Adjust Cylinder
2 2000 40cc (2.4in
3
Track Roller
2 1000 22cc (1.3in
3
Traveling Motor
2 1000 300cc (18.3in
3
65
LUBRICANTS
Grease Supply Points - Undercarriage
Dozer Joint Pin
4 Au
4 Au
Eront Idler
Adjust Cylinder
2 2000 40cc (2.4in
3
Track Roller
2 1000 22cc (1.3in
3
Traveling Motor
2 1000 300cc (18.3in
3
65
LUBRICANTS
Grease Supply Points - Undercarriage
Dozer Joint Pin
4 Au
4 Au
Eront Idler
Adjust Cylinder
2 2000 40cc (2.4in
3
Track Roller
2 1000 22cc (1.3in
3
Traveling Motor
2 1000 300cc (18.3in
3
65
LUBRICANTS
Grease Supply Points - Undercarriage
Dozer Joint Pin
4 Au
4 Au
Eront Idler
Adjust Cylinder
2 2000 40cc (2.4in
3
Track Roller
2 1000 22cc (1.3in
3
Traveling Motor
2 1000 300cc (18.3in
3
65
66
LUBRICANTS
Grease Supply Points - Attachments
4 Au
4 Au
Bucket Pin
Boom Joint Pin
4 Au
Bucket Link Pin
4 Au
Boom Arm Joint Pin
4 Au
Swing Post Pin
66
LUBRICANTS
Grease Supply Points - Attachments
4 Au
4 Au
Bucket Pin
Boom Joint Pin
4 Au
Bucket Link Pin
4 Au
Boom Arm Joint Pin
4 Au
Swing Post Pin
66
LUBRICANTS
Grease Supply Points - Attachments
4 Au
4 Au
Bucket Pin
Boom Joint Pin
4 Au
Bucket Link Pin
4 Au
Boom Arm Joint Pin
4 Au
Swing Post Pin
66
LUBRICANTS
Grease Supply Points - Attachments
4 Au
4 Au
Bucket Pin
Boom Joint Pin
4 Au
Bucket Link Pin
4 Au
Boom Arm Joint Pin
4 Au
Swing Post Pin
OTHERS
67
OTHERS
67
OTHERS
67
OTHERS
67
68
1
7
5
0
(
6
8
.
9
"
)
1
3
8
0
(
5
4
.
3
"
)
(
R
8
0

S
w
i
n
g
)
1
1
4
0
(
4
4
.
9
"
)
4 2 0 ( 1 6 . 5 " )
5
6
5
(
2
2
.
2
"
)
5
6
5
(
2
2
.
2
"
)
1
1
3
0
(
4
4
.
5
"
)
2 7 0
( 1 0 . 6 " )
1 8 5
( 7 . 3 " )
3
8
2
0
(
1
5
0
.
4
"
)
4
0
1
5
(
1
5
8
.
1
"
)
4
0
9
5
(
1
6
1
.
2
"
)
8 7 0 ( 3 4 . 3 " )
2 5 4 0 ( 1 0 0 " )
3 6 5 0 ( 1 4 3 . 7 " )
1 9 7 0 ( 7 7 . 6 " )
2 5 8 0 ( 1 0 1 . 6 " )
2 1 7 5 ( 8 5 . 6 " )
2 5 0 ( 9 . 8 " )
4
0
0
(
1
5
.
7
"
)
2
3
0
(
9
.
1
"
)
9
7
1
(
3
8
.
2
"
)
1
0
0
0
(
3
9
.
4
"
)
8
0
5
0
R
1
1
4
0
(
4
4
.
9
"
)
1 7 0
( 6 . 7 " )
68
1
7
5
0
(
6
8
.
9
"
)
1
3
8
0
(
5
4
.
3
"
)
(
R
8
0

S
w
i
n
g
)
1
1
4
0
(
4
4
.
9
"
)
4 2 0 ( 1 6 . 5 " )
5
6
5
(
2
2
.
2
"
)
5
6
5
(
2
2
.
2
"
)
1
1
3
0
(
4
4
.
5
"
)
2 7 0
( 1 0 . 6 " )
1 8 5
( 7 . 3 " )
3
8
2
0
(
1
5
0
.
4
"
)
4
0
1
5
(
1
5
8
.
1
"
)
4
0
9
5
(
1
6
1
.
2
"
)
8 7 0 ( 3 4 . 3 " )
2 5 4 0 ( 1 0 0 " )
3 6 5 0 ( 1 4 3 . 7 " )
1 9 7 0 ( 7 7 . 6 " )
2 5 8 0 ( 1 0 1 . 6 " )
2 1 7 5 ( 8 5 . 6 " )
2 5 0 ( 9 . 8 " )
4
0
0
(
1
5
.
7
"
)
2
3
0
(
9
.
1
"
)
9
7
1
(
3
8
.
2
"
)
1
0
0
0
(
3
9
.
4
"
)
8
0
5
0
R
1
1
4
0
(
4
4
.
9
"
)
1 7 0
( 6 . 7 " )
68
1
7
5
0
(
6
8
.
9
"
)
1
3
8
0
(
5
4
.
3
"
)
(
R
8
0

S
w
i
n
g
)
1
1
4
0
(
4
4
.
9
"
)
4 2 0 ( 1 6 . 5 " )
5
6
5
(
2
2
.
2
"
)
5
6
5
(
2
2
.
2
"
)
1
1
3
0
(
4
4
.
5
"
)
2 7 0
( 1 0 . 6 " )
1 8 5
( 7 . 3 " )
3
8
2
0
(
1
5
0
.
4
"
)
4
0
1
5
(
1
5
8
.
1
"
)
4
0
9
5
(
1
6
1
.
2
"
)
8 7 0 ( 3 4 . 3 " )
2 5 4 0 ( 1 0 0 " )
3 6 5 0 ( 1 4 3 . 7 " )
1 9 7 0 ( 7 7 . 6 " )
2 5 8 0 ( 1 0 1 . 6 " )
2 1 7 5 ( 8 5 . 6 " )
2 5 0 ( 9 . 8 " )
4
0
0
(
1
5
.
7
"
)
2
3
0
(
9
.
1
"
)
9
7
1
(
3
8
.
2
"
)
1
0
0
0
(
3
9
.
4
"
)
8
0
5
0
R
1
1
4
0
(
4
4
.
9
"
)
1 7 0
( 6 . 7 " )
68
1
7
5
0
(
6
8
.
9
"
)
1
3
8
0
(
5
4
.
3
"
)
(
R
8
0

S
w
i
n
g
)
1
1
4
0
(
4
4
.
9
"
)
4 2 0 ( 1 6 . 5 " )
5
6
5
(
2
2
.
2
"
)
5
6
5
(
2
2
.
2
"
)
1
1
3
0
(
4
4
.
5
"
)
2 7 0
( 1 0 . 6 " )
1 8 5
( 7 . 3 " )
3
8
2
0
(
1
5
0
.
4
"
)
4
0
1
5
(
1
5
8
.
1
"
)
4
0
9
5
(
1
6
1
.
2
"
)
8 7 0 ( 3 4 . 3 " )
2 5 4 0 ( 1 0 0 " )
3 6 5 0 ( 1 4 3 . 7 " )
1 9 7 0 ( 7 7 . 6 " )
2 5 8 0 ( 1 0 1 . 6 " )
2 1 7 5 ( 8 5 . 6 " )
2 5 0 ( 9 . 8 " )
4
0
0
(
1
5
.
7
"
)
2
3
0
(
9
.
1
"
)
9
7
1
(
3
8
.
2
"
)
1
0
0
0
(
3
9
.
4
"
)
8
0
5
0
R
1
1
4
0
(
4
4
.
9
"
)
1 7 0
( 6 . 7 " )
Model T15S
RooI rubber 1,500 kgI (3,307 lbI)
Cabin rubber 1,600 kgI (3,528 lbI)
0.04 m
3
(1.43 It
3
)
400 mm (15.7")
ISUZU 3YC1
954 cc (58.2 in
3
)
17 HP / 2,400 rpm (12.5 kW / 2,400 rpm)
2,580 mm (101.6")
1,970 mm (77.6")
3,650 mm (143.7")
2,540 mm (100.0")
4095 mm (161.2")
Rear 1,140 mm (44.9")
LeIt 50 / Right 80
2.3 KPH (1.4 MPH)
11.5 RPM
30
1,440 kgI (3,175 lbI)
3,820 mm x 1,000 mm x 2,175 (150.4"x39.4"x85.6")
1,000 x 250 mm (39.4" x 9.8")
230 x 1130 mm (9.1" x 44.5")
190 kgI/cm
2
(2,702psi) x 3
Gear x 3
15.7l (3) 4.1 U.S. gal 3}
Hydraulic pilot type
ISO
30.6l (8.1 U.S. gal)
3.5l ( 0.9 U.S. gal)
23.6l (6.2 U.S. gal)
5.6l (1.4 U.S. gal)
94 / 78 dB(A)
Machine weight
Standard bucket capacity
Standard bucket width
Type
Displacement
Constant output
Max. digging depth
Max. vertical digging depth
Max. digging height
Max. dumping height
Max. digging radius
Rear turning radius
Boom swing angle
Traveling speed
Swing speed
Gradeability
Max. digging power
Overall length X width X height
Dozer blade (width X height)
Shoe width x distance between center oI tumbler
Main relieI pressure
Hydraulic pump type
Main pump oil Ilow Quantity
Lever operation type
Lever pattern
Hydraulic oil capacity
Engine oil capacity
Euel capacity
Radiator capacity
Extra low noise
E
n
g
i
n
e
W
o
r
k
i
n
g

R
a
n
g
e
P
e
r
f
o
r
m
a
n
c
e
Dimen
sion
Under
Body
H
y
d
r
a
u
l
i
c
S
y
s
t
e
m
O
p
e
r
a
t
i
o
n
O
t
h
e
r
s
DIMENSIONS AND SPECIFICATIONS
69
Model T15S
RooI rubber 1,500 kgI (3,307 lbI)
Cabin rubber 1,600 kgI (3,528 lbI)
0.04 m
3
(1.43 It
3
)
400 mm (15.7")
ISUZU 3YC1
954 cc (58.2 in
3
)
17 HP / 2,400 rpm (12.5 kW / 2,400 rpm)
2,580 mm (101.6")
1,970 mm (77.6")
3,650 mm (143.7")
2,540 mm (100.0")
4095 mm (161.2")
Rear 1,140 mm (44.9")
LeIt 50 / Right 80
2.3 KPH (1.4 MPH)
11.5 RPM
30
1,440 kgI (3,175 lbI)
3,820 mm x 1,000 mm x 2,175 (150.4"x39.4"x85.6")
1,000 x 250 mm (39.4" x 9.8")
230 x 1130 mm (9.1" x 44.5")
190 kgI/cm
2
(2,702psi) x 3
Gear x 3
15.7l (3) 4.1 U.S. gal 3}
Hydraulic pilot type
ISO
30.6l (8.1 U.S. gal)
3.5l ( 0.9 U.S. gal)
23.6l (6.2 U.S. gal)
5.6l (1.4 U.S. gal)
94 / 78 dB(A)
Machine weight
Standard bucket capacity
Standard bucket width
Type
Displacement
Constant output
Max. digging depth
Max. vertical digging depth
Max. digging height
Max. dumping height
Max. digging radius
Rear turning radius
Boom swing angle
Traveling speed
Swing speed
Gradeability
Max. digging power
Overall length X width X height
Dozer blade (width X height)
Shoe width x distance between center oI tumbler
Main relieI pressure
Hydraulic pump type
Main pump oil Ilow Quantity
Lever operation type
Lever pattern
Hydraulic oil capacity
Engine oil capacity
Euel capacity
Radiator capacity
Extra low noise
E
n
g
i
n
e
W
o
r
k
i
n
g

R
a
n
g
e
P
e
r
f
o
r
m
a
n
c
e
Dimen
sion
Under
Body
H
y
d
r
a
u
l
i
c
S
y
s
t
e
m
O
p
e
r
a
t
i
o
n
O
t
h
e
r
s
DIMENSIONS AND SPECIFICATIONS
69
Model T15S
RooI rubber 1,500 kgI (3,307 lbI)
Cabin rubber 1,600 kgI (3,528 lbI)
0.04 m
3
(1.43 It
3
)
400 mm (15.7")
ISUZU 3YC1
954 cc (58.2 in
3
)
17 HP / 2,400 rpm (12.5 kW / 2,400 rpm)
2,580 mm (101.6")
1,970 mm (77.6")
3,650 mm (143.7")
2,540 mm (100.0")
4095 mm (161.2")
Rear 1,140 mm (44.9")
LeIt 50 / Right 80
2.3 KPH (1.4 MPH)
11.5 RPM
30
1,440 kgI (3,175 lbI)
3,820 mm x 1,000 mm x 2,175 (150.4"x39.4"x85.6")
1,000 x 250 mm (39.4" x 9.8")
230 x 1130 mm (9.1" x 44.5")
190 kgI/cm
2
(2,702psi) x 3
Gear x 3
15.7l (3) 4.1 U.S. gal 3}
Hydraulic pilot type
ISO
30.6l (8.1 U.S. gal)
3.5l ( 0.9 U.S. gal)
23.6l (6.2 U.S. gal)
5.6l (1.4 U.S. gal)
94 / 78 dB(A)
Machine weight
Standard bucket capacity
Standard bucket width
Type
Displacement
Constant output
Max. digging depth
Max. vertical digging depth
Max. digging height
Max. dumping height
Max. digging radius
Rear turning radius
Boom swing angle
Traveling speed
Swing speed
Gradeability
Max. digging power
Overall length X width X height
Dozer blade (width X height)
Shoe width x distance between center oI tumbler
Main relieI pressure
Hydraulic pump type
Main pump oil Ilow Quantity
Lever operation type
Lever pattern
Hydraulic oil capacity
Engine oil capacity
Euel capacity
Radiator capacity
Extra low noise
E
n
g
i
n
e
W
o
r
k
i
n
g

R
a
n
g
e
P
e
r
f
o
r
m
a
n
c
e
Dimen
sion
Under
Body
H
y
d
r
a
u
l
i
c
S
y
s
t
e
m
O
p
e
r
a
t
i
o
n
O
t
h
e
r
s
DIMENSIONS AND SPECIFICATIONS
69
Model T15S
RooI rubber 1,500 kgI (3,307 lbI)
Cabin rubber 1,600 kgI (3,528 lbI)
0.04 m
3
(1.43 It
3
)
400 mm (15.7")
ISUZU 3YC1
954 cc (58.2 in
3
)
17 HP / 2,400 rpm (12.5 kW / 2,400 rpm)
2,580 mm (101.6")
1,970 mm (77.6")
3,650 mm (143.7")
2,540 mm (100.0")
4095 mm (161.2")
Rear 1,140 mm (44.9")
LeIt 50 / Right 80
2.3 KPH (1.4 MPH)
11.5 RPM
30
1,440 kgI (3,175 lbI)
3,820 mm x 1,000 mm x 2,175 (150.4"x39.4"x85.6")
1,000 x 250 mm (39.4" x 9.8")
230 x 1130 mm (9.1" x 44.5")
190 kgI/cm
2
(2,702psi) x 3
Gear x 3
15.7l (3) 4.1 U.S. gal 3}
Hydraulic pilot type
ISO
30.6l (8.1 U.S. gal)
3.5l ( 0.9 U.S. gal)
23.6l (6.2 U.S. gal)
5.6l (1.4 U.S. gal)
94 / 78 dB(A)
Machine weight
Standard bucket capacity
Standard bucket width
Type
Displacement
Constant output
Max. digging depth
Max. vertical digging depth
Max. digging height
Max. dumping height
Max. digging radius
Rear turning radius
Boom swing angle
Traveling speed
Swing speed
Gradeability
Max. digging power
Overall length X width X height
Dozer blade (width X height)
Shoe width x distance between center oI tumbler
Main relieI pressure
Hydraulic pump type
Main pump oil Ilow Quantity
Lever operation type
Lever pattern
Hydraulic oil capacity
Engine oil capacity
Euel capacity
Radiator capacity
Extra low noise
E
n
g
i
n
e
W
o
r
k
i
n
g

R
a
n
g
e
P
e
r
f
o
r
m
a
n
c
e
Dimen
sion
Under
Body
H
y
d
r
a
u
l
i
c
S
y
s
t
e
m
O
p
e
r
a
t
i
o
n
O
t
h
e
r
s
DIMENSIONS AND SPECIFICATIONS
69
Wiper motor
Wiper switch
Washer motor
Room lamp
Heater switch Heater
M
M
M
Radio
Option
Speaker
Thermo
unit
Thermo
sensor
Oil
SW
Air
indicator Alternator
Starter
motor
Glow
plug
Battery
Fusible
link(0.85R)
Fusible
link(0.3w)
Stop solenoid
{ |
U
n
i
t

s
a
f
e
t
y
S
t
a
r
t
e
r

r
e
l
a
y
Engine
grounding
Fuel
pump Glow relay
COScontroller
Light relay
SRM-12C
Normal open
Flasher realy
SRM-12C
Normal close
Fuse box
Starter switch
Grounding
Horn switch
Fuel sensor
Horn
Work light
Cluster
Light
SW
Flasher
SW
WTM
FUEL
EHM
Interior
light
B

B
^

O
r

B
r

O
r

W
r

W/R
B/R
SP
R

R
R
R
B/R
B
B
Br
Br
R/G
B
L/W
Y/G
B/W
L/W
G/W
B/W
B

O
r

O
r

R/W
R/Y
L/W
Y/R
B
B
W/R
W/R
Y/G
W/G
Y/W
L
W/G
G/R
R/L
R
W/G
Y
B
R/W
B/R
Or
Y
Y

^
B

B
R
Y

^
W

B
G

B
W

B
B
Y

O
r

O
r

O
r

O
r

1
0
A
1
0
A
1
5
A
1
0
A
1
5
A
3
A
1
0
A
1
0
A
C
l
o
c
k
I
n
t
e
r
i
o
r

l
i
g
h
t
L
i
g
h
t
P
a
n
e
l
F
u
e
l
O
p
t
i
o
n
Hazard, heater
W
i
p
e
r
,

r
o
o
m

l
a
m
p
B BR ACC R2 C
OFF
Drive
Start
Terminal
Table of starter switch circuit
Color code
R Red
R/L Red/Blu
R/Y Red/Yel
R/G Red/Grn
R/W Red/Wht
R/B Red/Blk
L Blue
L/R Blu/Red
L/W Blu/Wht
L/B Blu/Blk
Y Yellow
Y/R Yel/Red
Y/L Yel/Blu
Y/G Yel/Grn
Y/W Yel/Wht
Y/B Yel/Blk
Or Orange
G Grn
G/R Grn/Red
G/W Grn/Wht
W White
W/R Wht/Red
W/L Wht/Blu
W/G Wht/Grn
W/B Wht/Blk
B Black
B/R Blk/Red
B/Y Blk/Yel
B/W Blk/Wht
B/L Blk/Blu
C
ACC
B BR
R2
M
M
M
L
L
L
L
L
L
L
M
L
i
m
i
t

s
w
i
t
c
h
Solenoid
valve
ELECTRICAL CIRCUIT
71
HYDRAULIC CIRCUIT
73
HYDRAULIC CIRCUIT
73
HYDRAULIC CIRCUIT
73
HYDRAULIC CIRCUIT
73
74
DECALS
TH43265
3
4
6 7
2
8
1
5
74
DECALS
TH43265
3
4
6 7
2
8
1
5
74
DECALS
TH43265
3
4
6 7
2
8
1
5
74
DECALS
TH43265
3
4
6 7
2
8
1
5
DECALS
75
TH43265
9
21
20
19
18
17
16
15
14
13
12
11
10
4
DECALS
75
TH43265
9
21
20
19
18
17
16
15
14
13
12
11
10
4
DECALS
75
TH43265
9
21
20
19
18
17
16
15
14
13
12
11
10
4
DECALS
75
TH43265
9
21
20
19
18
17
16
15
14
13
12
11
10
4
GENERAL WARRANTY INFORMATION
Thomas warrants Ior a speciIic period, and on the conditions set Iorth in the applicable limited war-
ranty statement Ior each product, that the product is Iree Irom deIects in materials and workmanship,
iI used, maintained and managed in accordance with the instructions contained in the Owner`s and
Operator`s Manual provided with each product. A copy oI the applicable limited warranty statement
must be supplied by the Dealer to the customer as part oI the sale documentation. A copy oI the limit-
ed warranty statement, signed by the customer must be returned to Thomas Warranty Department.
ORIGINAL CUSTOMERS
The warranty to the original retail customer commences on the date oI delivery oI the product to him
by the selling Dealer. This warranty shall be in eIIect Ior the period as stated on the printed limited war-
ranty statements.
Warranty applies only if the selling Dealer has registered the product at time of delivery to the
customer.
WARRANTY REGISTRATION
To register a Thomas serial numbered product Ior warranty coverage, the Dealer must Iill out the
appropriate Owner`s Warranty Registration & Delivery Report which is shipped with each product,
and mail it to Thomas Warranty Department immediately aIter delivering the product to the customer.
PDI AND 50 HOUR INSPECTION
The PDI Iorm, along with the Warranty Registration Iorm is to be returned to the Thomas Warranty
Department immediately aIter completion as per Pre Delivery Inspection, described in Section 3 -
'Thomas Dealers` Responsibilities and Services Required oI the Warranty Policy Handbook. The 50
Hour Inspection Eorm, also described in Section 3 oI the Warranty Policy Handbook, must be returned
to Thomas within 30 days aIter the inspection is completed to assure warranty is in eIIect.
DEMONSTRATION UNITS
Dealers are allowed up to hours oI demonstration time on Thomas skid steer loaders and 25 hours
on screening plants. AIter 50/25 hours the product is considered to have been put into service by the
Dealer and the applicable Thomas warranty period will commence at that time.
FIELD MODIFICATION PROGRAMS
When necessary, Thomas will initiate a Iield modiIication program to provide changes or modiIications
to our products. Normal warranty procedures will apply unless otherwise instructed.
WARRANTY
77
GENERAL WARRANTY INFORMATION
Thomas warrants Ior a speciIic period, and on the conditions set Iorth in the applicable limited war-
ranty statement Ior each product, that the product is Iree Irom deIects in materials and workmanship,
iI used, maintained and managed in accordance with the instructions contained in the Owner`s and
Operator`s Manual provided with each product. A copy oI the applicable limited warranty statement
must be supplied by the Dealer to the customer as part oI the sale documentation. A copy oI the limit-
ed warranty statement, signed by the customer must be returned to Thomas Warranty Department.
ORIGINAL CUSTOMERS
The warranty to the original retail customer commences on the date oI delivery oI the product to him
by the selling Dealer. This warranty shall be in eIIect Ior the period as stated on the printed limited war-
ranty statements.
Warranty applies only if the selling Dealer has registered the product at time of delivery to the
customer.
WARRANTY REGISTRATION
To register a Thomas serial numbered product Ior warranty coverage, the Dealer must Iill out the
appropriate Owner`s Warranty Registration & Delivery Report which is shipped with each product,
and mail it to Thomas Warranty Department immediately aIter delivering the product to the customer.
PDI AND 50 HOUR INSPECTION
The PDI Iorm, along with the Warranty Registration Iorm is to be returned to the Thomas Warranty
Department immediately aIter completion as per Pre Delivery Inspection, described in Section 3 -
'Thomas Dealers` Responsibilities and Services Required oI the Warranty Policy Handbook. The 50
Hour Inspection Eorm, also described in Section 3 oI the Warranty Policy Handbook, must be returned
to Thomas within 30 days aIter the inspection is completed to assure warranty is in eIIect.
DEMONSTRATION UNITS
Dealers are allowed up to hours oI demonstration time on Thomas skid steer loaders and 25 hours
on screening plants. AIter 50/25 hours the product is considered to have been put into service by the
Dealer and the applicable Thomas warranty period will commence at that time.
FIELD MODIFICATION PROGRAMS
When necessary, Thomas will initiate a Iield modiIication program to provide changes or modiIications
to our products. Normal warranty procedures will apply unless otherwise instructed.
WARRANTY
77
GENERAL WARRANTY INFORMATION
Thomas warrants Ior a speciIic period, and on the conditions set Iorth in the applicable limited war-
ranty statement Ior each product, that the product is Iree Irom deIects in materials and workmanship,
iI used, maintained and managed in accordance with the instructions contained in the Owner`s and
Operator`s Manual provided with each product. A copy oI the applicable limited warranty statement
must be supplied by the Dealer to the customer as part oI the sale documentation. A copy oI the limit-
ed warranty statement, signed by the customer must be returned to Thomas Warranty Department.
ORIGINAL CUSTOMERS
The warranty to the original retail customer commences on the date oI delivery oI the product to him
by the selling Dealer. This warranty shall be in eIIect Ior the period as stated on the printed limited war-
ranty statements.
Warranty applies only if the selling Dealer has registered the product at time of delivery to the
customer.
WARRANTY REGISTRATION
To register a Thomas serial numbered product Ior warranty coverage, the Dealer must Iill out the
appropriate Owner`s Warranty Registration & Delivery Report which is shipped with each product,
and mail it to Thomas Warranty Department immediately aIter delivering the product to the customer.
PDI AND 50 HOUR INSPECTION
The PDI Iorm, along with the Warranty Registration Iorm is to be returned to the Thomas Warranty
Department immediately aIter completion as per Pre Delivery Inspection, described in Section 3 -
'Thomas Dealers` Responsibilities and Services Required oI the Warranty Policy Handbook. The 50
Hour Inspection Eorm, also described in Section 3 oI the Warranty Policy Handbook, must be returned
to Thomas within 30 days aIter the inspection is completed to assure warranty is in eIIect.
DEMONSTRATION UNITS
Dealers are allowed up to hours oI demonstration time on Thomas skid steer loaders and 25 hours
on screening plants. AIter 50/25 hours the product is considered to have been put into service by the
Dealer and the applicable Thomas warranty period will commence at that time.
FIELD MODIFICATION PROGRAMS
When necessary, Thomas will initiate a Iield modiIication program to provide changes or modiIications
to our products. Normal warranty procedures will apply unless otherwise instructed.
WARRANTY
77
GENERAL WARRANTY INFORMATION
Thomas warrants Ior a speciIic period, and on the conditions set Iorth in the applicable limited war-
ranty statement Ior each product, that the product is Iree Irom deIects in materials and workmanship,
iI used, maintained and managed in accordance with the instructions contained in the Owner`s and
Operator`s Manual provided with each product. A copy oI the applicable limited warranty statement
must be supplied by the Dealer to the customer as part oI the sale documentation. A copy oI the limit-
ed warranty statement, signed by the customer must be returned to Thomas Warranty Department.
ORIGINAL CUSTOMERS
The warranty to the original retail customer commences on the date oI delivery oI the product to him
by the selling Dealer. This warranty shall be in eIIect Ior the period as stated on the printed limited war-
ranty statements.
Warranty applies only if the selling Dealer has registered the product at time of delivery to the
customer.
WARRANTY REGISTRATION
To register a Thomas serial numbered product Ior warranty coverage, the Dealer must Iill out the
appropriate Owner`s Warranty Registration & Delivery Report which is shipped with each product,
and mail it to Thomas Warranty Department immediately aIter delivering the product to the customer.
PDI AND 50 HOUR INSPECTION
The PDI Iorm, along with the Warranty Registration Iorm is to be returned to the Thomas Warranty
Department immediately aIter completion as per Pre Delivery Inspection, described in Section 3 -
'Thomas Dealers` Responsibilities and Services Required oI the Warranty Policy Handbook. The 50
Hour Inspection Eorm, also described in Section 3 oI the Warranty Policy Handbook, must be returned
to Thomas within 30 days aIter the inspection is completed to assure warranty is in eIIect.
DEMONSTRATION UNITS
Dealers are allowed up to hours oI demonstration time on Thomas skid steer loaders and 25 hours
on screening plants. AIter 50/25 hours the product is considered to have been put into service by the
Dealer and the applicable Thomas warranty period will commence at that time.
FIELD MODIFICATION PROGRAMS
When necessary, Thomas will initiate a Iield modiIication program to provide changes or modiIications
to our products. Normal warranty procedures will apply unless otherwise instructed.
WARRANTY
77
78
REQUEST FOR WARRANTY TRANSFER
Warranty is transIerable on equipment which has been sold and used Ior less than the warranty term
oI the new product. The remainder oI the warranty term can be transIerred to a subsequent owner.
The Dealer must submit a new Warranty Registration and PDI Iorm with the new customer inIorma-
tion. At the top oI each Iorm clearly indicate Transfer Request. In the corrective action/comments
section oI the PDI indicate machine condition, reason Ior transIer and any warranty limitations that
apply.
An administration Iee oI $50.00 will be charged Ior each warranty transIer request. The warranty end
date will remain the same as the original warranty registration - no time outs.
FALSIFICATION OF WARRANTY
Should an audit oI a warranty claim reveal that a Dealer has in any way misrepresented inIormation,
either on a Warranty Claim or in regards to a Warranty Claim, a complete audit will be made on all
claims submitted by the Dealer. A charge-back will be made covering any Ialse or improper warranty
claims.
A material misrepresentation of warranty information of any kind is grounds for Dealership
contract termination.
DEALER COMPENSATION FOR WARRANTY
Compensation Ior warranty repairs made by the Dealer is made by the processing oI the Warranty
Claim. (Eor sample Warranty Claim Iorm see Appendix A in the Warranty Policy Handbook.) This
Iorm must be submitted to Thomas within 30 days oI repair. Details on how to Iill out this Iorm are
included in Section 9 oI the Warranty Policy Handbook. Warranty Claims will be processed, as per
Thomas Warranty Policy, within 30 days oI receipt including issuing oI any credits (unless claims are
on Thomas branded attachments manuIactured by others, which will require 60 days or more, or unless
parts need to be returned Ior evaluation or unless more inIormation is requested). Warranty summary
reports will be supplied each month with the accounts receivable statements.
ISUZU ENGINES
Isuzu warrants engines installed in new Thomas products Ior the Iirst 12 months or 1800 hours,
whichever comes Iirst as per Isuzu warranty statement. A copy oI Isuzu`s Warranty and Limitation oI
Remedy and Liability can be Iound in Thomas Equipment`s Warranty Policy Handbook.
All Isuzu engine warranty issues are to be handled through Isuzu Distributors.
WARRANTY
78
REQUEST FOR WARRANTY TRANSFER
Warranty is transIerable on equipment which has been sold and used Ior less than the warranty term
oI the new product. The remainder oI the warranty term can be transIerred to a subsequent owner.
The Dealer must submit a new Warranty Registration and PDI Iorm with the new customer inIorma-
tion. At the top oI each Iorm clearly indicate Transfer Request. In the corrective action/comments
section oI the PDI indicate machine condition, reason Ior transIer and any warranty limitations that
apply.
An administration Iee oI $50.00 will be charged Ior each warranty transIer request. The warranty end
date will remain the same as the original warranty registration - no time outs.
FALSIFICATION OF WARRANTY
Should an audit oI a warranty claim reveal that a Dealer has in any way misrepresented inIormation,
either on a Warranty Claim or in regards to a Warranty Claim, a complete audit will be made on all
claims submitted by the Dealer. A charge-back will be made covering any Ialse or improper warranty
claims.
A material misrepresentation of warranty information of any kind is grounds for Dealership
contract termination.
DEALER COMPENSATION FOR WARRANTY
Compensation Ior warranty repairs made by the Dealer is made by the processing oI the Warranty
Claim. (Eor sample Warranty Claim Iorm see Appendix A in the Warranty Policy Handbook.) This
Iorm must be submitted to Thomas within 30 days oI repair. Details on how to Iill out this Iorm are
included in Section 9 oI the Warranty Policy Handbook. Warranty Claims will be processed, as per
Thomas Warranty Policy, within 30 days oI receipt including issuing oI any credits (unless claims are
on Thomas branded attachments manuIactured by others, which will require 60 days or more, or unless
parts need to be returned Ior evaluation or unless more inIormation is requested). Warranty summary
reports will be supplied each month with the accounts receivable statements.
ISUZU ENGINES
Isuzu warrants engines installed in new Thomas products Ior the Iirst 12 months or 1800 hours,
whichever comes Iirst as per Isuzu warranty statement. A copy oI Isuzu`s Warranty and Limitation oI
Remedy and Liability can be Iound in Thomas Equipment`s Warranty Policy Handbook.
All Isuzu engine warranty issues are to be handled through Isuzu Distributors.
WARRANTY
78
REQUEST FOR WARRANTY TRANSFER
Warranty is transIerable on equipment which has been sold and used Ior less than the warranty term
oI the new product. The remainder oI the warranty term can be transIerred to a subsequent owner.
The Dealer must submit a new Warranty Registration and PDI Iorm with the new customer inIorma-
tion. At the top oI each Iorm clearly indicate Transfer Request. In the corrective action/comments
section oI the PDI indicate machine condition, reason Ior transIer and any warranty limitations that
apply.
An administration Iee oI $50.00 will be charged Ior each warranty transIer request. The warranty end
date will remain the same as the original warranty registration - no time outs.
FALSIFICATION OF WARRANTY
Should an audit oI a warranty claim reveal that a Dealer has in any way misrepresented inIormation,
either on a Warranty Claim or in regards to a Warranty Claim, a complete audit will be made on all
claims submitted by the Dealer. A charge-back will be made covering any Ialse or improper warranty
claims.
A material misrepresentation of warranty information of any kind is grounds for Dealership
contract termination.
DEALER COMPENSATION FOR WARRANTY
Compensation Ior warranty repairs made by the Dealer is made by the processing oI the Warranty
Claim. (Eor sample Warranty Claim Iorm see Appendix A in the Warranty Policy Handbook.) This
Iorm must be submitted to Thomas within 30 days oI repair. Details on how to Iill out this Iorm are
included in Section 9 oI the Warranty Policy Handbook. Warranty Claims will be processed, as per
Thomas Warranty Policy, within 30 days oI receipt including issuing oI any credits (unless claims are
on Thomas branded attachments manuIactured by others, which will require 60 days or more, or unless
parts need to be returned Ior evaluation or unless more inIormation is requested). Warranty summary
reports will be supplied each month with the accounts receivable statements.
ISUZU ENGINES
Isuzu warrants engines installed in new Thomas products Ior the Iirst 12 months or 1800 hours,
whichever comes Iirst as per Isuzu warranty statement. A copy oI Isuzu`s Warranty and Limitation oI
Remedy and Liability can be Iound in Thomas Equipment`s Warranty Policy Handbook.
All Isuzu engine warranty issues are to be handled through Isuzu Distributors.
WARRANTY
78
REQUEST FOR WARRANTY TRANSFER
Warranty is transIerable on equipment which has been sold and used Ior less than the warranty term
oI the new product. The remainder oI the warranty term can be transIerred to a subsequent owner.
The Dealer must submit a new Warranty Registration and PDI Iorm with the new customer inIorma-
tion. At the top oI each Iorm clearly indicate Transfer Request. In the corrective action/comments
section oI the PDI indicate machine condition, reason Ior transIer and any warranty limitations that
apply.
An administration Iee oI $50.00 will be charged Ior each warranty transIer request. The warranty end
date will remain the same as the original warranty registration - no time outs.
FALSIFICATION OF WARRANTY
Should an audit oI a warranty claim reveal that a Dealer has in any way misrepresented inIormation,
either on a Warranty Claim or in regards to a Warranty Claim, a complete audit will be made on all
claims submitted by the Dealer. A charge-back will be made covering any Ialse or improper warranty
claims.
A material misrepresentation of warranty information of any kind is grounds for Dealership
contract termination.
DEALER COMPENSATION FOR WARRANTY
Compensation Ior warranty repairs made by the Dealer is made by the processing oI the Warranty
Claim. (Eor sample Warranty Claim Iorm see Appendix A in the Warranty Policy Handbook.) This
Iorm must be submitted to Thomas within 30 days oI repair. Details on how to Iill out this Iorm are
included in Section 9 oI the Warranty Policy Handbook. Warranty Claims will be processed, as per
Thomas Warranty Policy, within 30 days oI receipt including issuing oI any credits (unless claims are
on Thomas branded attachments manuIactured by others, which will require 60 days or more, or unless
parts need to be returned Ior evaluation or unless more inIormation is requested). Warranty summary
reports will be supplied each month with the accounts receivable statements.
ISUZU ENGINES
Isuzu warrants engines installed in new Thomas products Ior the Iirst 12 months or 1800 hours,
whichever comes Iirst as per Isuzu warranty statement. A copy oI Isuzu`s Warranty and Limitation oI
Remedy and Liability can be Iound in Thomas Equipment`s Warranty Policy Handbook.
All Isuzu engine warranty issues are to be handled through Isuzu Distributors.
WARRANTY
HYDROSTATICS
Thomas warrants hydrostatic components supplied with new Thomas product as per our limited war-
ranty policy. The hydrostatic component vendors (or their delegated Dealer network) will be respon-
sible Ior inspection and testing to determine iI a component is deIective and iI it Iailed due to deIects
in material or workmanship.
BATTERIES
Battery Iailures as a result oI deIects in material or workmanship are warranted on a pro-rated basis
as Iollows:
12 - Months in Service X 100
12
SPARE PARTS WARRANTY
Spare parts supplied by Thomas Ior use on Thomas products are warranted Ior a period oI ninety
(90) days Irom date oI Dealer invoice to customer, or the remainder oI the product warranty,
whichever is greater.
This warranty applies only to new, unused parts installed by Thomas or an authorized Thomas
Dealer. When applying Ior spare parts warranty, attach prooI oI purchase with the Warranty Claim.
(See - Claim Eiling Procedures, Section 8, Warranty Policy Handbook).
LABOR AND PARTS ALLOWANCE
Dealers are expected to replace Iailed parts covered by applicable Thomas warranty policy at no
charge to customer. During the warranty period, Thomas will issue credit to the Dealer Ior labor to
repair or replace a part acknowledged by Thomas to be deIective in material or workmanship.
NOTE: Any special arrangements or commitments made by Thomas Service or Warranty
Department personnel must be supported by a Special Arrangement Number (S.A.N.).
This S.A.N. must be issued to the Dealer at the time the special arrangements or com-
mitments are made, and must be reIerred to when the warranty claim is submitted.
Thomas personnel are to provide a written conIirmation oI S.A.N. to the Dealer which
is to include details oI the Special Arrangement agreed to.
LABOR RATE
Dealer warranty labor credits will be based on 100 oI Dealers posted shop labor rate. Dealer should
provide Thomas Warranty Department with their applicable shop labor rate at the time they are
appointed a Thomas Dealer. This may be reviewed once per year and may require substantiation.
Requests to change the shop rate should be submitted to the Thomas Warranty Department on the
appropriate Iorm, (See Appendix A).
WARRANTY
79
HYDROSTATICS
Thomas warrants hydrostatic components supplied with new Thomas product as per our limited war-
ranty policy. The hydrostatic component vendors (or their delegated Dealer network) will be respon-
sible Ior inspection and testing to determine iI a component is deIective and iI it Iailed due to deIects
in material or workmanship.
BATTERIES
Battery Iailures as a result oI deIects in material or workmanship are warranted on a pro-rated basis
as Iollows:
12 - Months in Service X 100
12
SPARE PARTS WARRANTY
Spare parts supplied by Thomas Ior use on Thomas products are warranted Ior a period oI ninety
(90) days Irom date oI Dealer invoice to customer, or the remainder oI the product warranty,
whichever is greater.
This warranty applies only to new, unused parts installed by Thomas or an authorized Thomas
Dealer. When applying Ior spare parts warranty, attach prooI oI purchase with the Warranty Claim.
(See - Claim Eiling Procedures, Section 8, Warranty Policy Handbook).
LABOR AND PARTS ALLOWANCE
Dealers are expected to replace Iailed parts covered by applicable Thomas warranty policy at no
charge to customer. During the warranty period, Thomas will issue credit to the Dealer Ior labor to
repair or replace a part acknowledged by Thomas to be deIective in material or workmanship.
NOTE: Any special arrangements or commitments made by Thomas Service or Warranty
Department personnel must be supported by a Special Arrangement Number (S.A.N.).
This S.A.N. must be issued to the Dealer at the time the special arrangements or com-
mitments are made, and must be reIerred to when the warranty claim is submitted.
Thomas personnel are to provide a written conIirmation oI S.A.N. to the Dealer which
is to include details oI the Special Arrangement agreed to.
LABOR RATE
Dealer warranty labor credits will be based on 100 oI Dealers posted shop labor rate. Dealer should
provide Thomas Warranty Department with their applicable shop labor rate at the time they are
appointed a Thomas Dealer. This may be reviewed once per year and may require substantiation.
Requests to change the shop rate should be submitted to the Thomas Warranty Department on the
appropriate Iorm, (See Appendix A).
WARRANTY
79
HYDROSTATICS
Thomas warrants hydrostatic components supplied with new Thomas product as per our limited war-
ranty policy. The hydrostatic component vendors (or their delegated Dealer network) will be respon-
sible Ior inspection and testing to determine iI a component is deIective and iI it Iailed due to deIects
in material or workmanship.
BATTERIES
Battery Iailures as a result oI deIects in material or workmanship are warranted on a pro-rated basis
as Iollows:
12 - Months in Service X 100
12
SPARE PARTS WARRANTY
Spare parts supplied by Thomas Ior use on Thomas products are warranted Ior a period oI ninety
(90) days Irom date oI Dealer invoice to customer, or the remainder oI the product warranty,
whichever is greater.
This warranty applies only to new, unused parts installed by Thomas or an authorized Thomas
Dealer. When applying Ior spare parts warranty, attach prooI oI purchase with the Warranty Claim.
(See - Claim Eiling Procedures, Section 8, Warranty Policy Handbook).
LABOR AND PARTS ALLOWANCE
Dealers are expected to replace Iailed parts covered by applicable Thomas warranty policy at no
charge to customer. During the warranty period, Thomas will issue credit to the Dealer Ior labor to
repair or replace a part acknowledged by Thomas to be deIective in material or workmanship.
NOTE: Any special arrangements or commitments made by Thomas Service or Warranty
Department personnel must be supported by a Special Arrangement Number (S.A.N.).
This S.A.N. must be issued to the Dealer at the time the special arrangements or com-
mitments are made, and must be reIerred to when the warranty claim is submitted.
Thomas personnel are to provide a written conIirmation oI S.A.N. to the Dealer which
is to include details oI the Special Arrangement agreed to.
LABOR RATE
Dealer warranty labor credits will be based on 100 oI Dealers posted shop labor rate. Dealer should
provide Thomas Warranty Department with their applicable shop labor rate at the time they are
appointed a Thomas Dealer. This may be reviewed once per year and may require substantiation.
Requests to change the shop rate should be submitted to the Thomas Warranty Department on the
appropriate Iorm, (See Appendix A).
WARRANTY
79
HYDROSTATICS
Thomas warrants hydrostatic components supplied with new Thomas product as per our limited war-
ranty policy. The hydrostatic component vendors (or their delegated Dealer network) will be respon-
sible Ior inspection and testing to determine iI a component is deIective and iI it Iailed due to deIects
in material or workmanship.
BATTERIES
Battery Iailures as a result oI deIects in material or workmanship are warranted on a pro-rated basis
as Iollows:
12 - Months in Service X 100
12
SPARE PARTS WARRANTY
Spare parts supplied by Thomas Ior use on Thomas products are warranted Ior a period oI ninety
(90) days Irom date oI Dealer invoice to customer, or the remainder oI the product warranty,
whichever is greater.
This warranty applies only to new, unused parts installed by Thomas or an authorized Thomas
Dealer. When applying Ior spare parts warranty, attach prooI oI purchase with the Warranty Claim.
(See - Claim Eiling Procedures, Section 8, Warranty Policy Handbook).
LABOR AND PARTS ALLOWANCE
Dealers are expected to replace Iailed parts covered by applicable Thomas warranty policy at no
charge to customer. During the warranty period, Thomas will issue credit to the Dealer Ior labor to
repair or replace a part acknowledged by Thomas to be deIective in material or workmanship.
NOTE: Any special arrangements or commitments made by Thomas Service or Warranty
Department personnel must be supported by a Special Arrangement Number (S.A.N.).
This S.A.N. must be issued to the Dealer at the time the special arrangements or com-
mitments are made, and must be reIerred to when the warranty claim is submitted.
Thomas personnel are to provide a written conIirmation oI S.A.N. to the Dealer which
is to include details oI the Special Arrangement agreed to.
LABOR RATE
Dealer warranty labor credits will be based on 100 oI Dealers posted shop labor rate. Dealer should
provide Thomas Warranty Department with their applicable shop labor rate at the time they are
appointed a Thomas Dealer. This may be reviewed once per year and may require substantiation.
Requests to change the shop rate should be submitted to the Thomas Warranty Department on the
appropriate Iorm, (See Appendix A).
WARRANTY
79
ITEMS NOT COVERED BY WARRANTY
In addition to the items listed as not covered on Thomas Equipment`s Limited Warranty Statement, the
Iollowing are not covered by Thomas warranty:
I. Pre Delivery Inspection and related adjustments
2. 50 Hour inspection and related adjustments.
3. Diagnostics.
4. Travel time.
Note that items covered by a manufacturer`s separate warranty, such as engines
(except Kubota diesel engines for the first 12 months or 1500 hours), tires and non-
Thomas attachments are not covered by Thomas Warranty.
WARRANTY
80
ITEMS NOT COVERED BY WARRANTY
In addition to the items listed as not covered on Thomas Equipment`s Limited Warranty Statement, the
Iollowing are not covered by Thomas warranty:
I. Pre Delivery Inspection and related adjustments
2. 50 Hour inspection and related adjustments.
3. Diagnostics.
4. Travel time.
Note that items covered by a manufacturer`s separate warranty, such as engines
(except Kubota diesel engines for the first 12 months or 1500 hours), tires and non-
Thomas attachments are not covered by Thomas Warranty.
WARRANTY
80
ITEMS NOT COVERED BY WARRANTY
In addition to the items listed as not covered on Thomas Equipment`s Limited Warranty Statement, the
Iollowing are not covered by Thomas warranty:
I. Pre Delivery Inspection and related adjustments
2. 50 Hour inspection and related adjustments.
3. Diagnostics.
4. Travel time.
Note that items covered by a manufacturer`s separate warranty, such as engines
(except Kubota diesel engines for the first 12 months or 1500 hours), tires and non-
Thomas attachments are not covered by Thomas Warranty.
WARRANTY
80
ITEMS NOT COVERED BY WARRANTY
In addition to the items listed as not covered on Thomas Equipment`s Limited Warranty Statement, the
Iollowing are not covered by Thomas warranty:
I. Pre Delivery Inspection and related adjustments
2. 50 Hour inspection and related adjustments.
3. Diagnostics.
4. Travel time.
Note that items covered by a manufacturer`s separate warranty, such as engines
(except Kubota diesel engines for the first 12 months or 1500 hours), tires and non-
Thomas attachments are not covered by Thomas Warranty.
WARRANTY
80