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 FOREWORD
This manual, which is written for engineers who service the machine, describes procedures for disassembly and as-
sembly, inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of
the specifications. Refer to this manual during daily work to improve your services. Note that the information is subject
to change without notice due to design modifications made to the machine from time to time by the manufacturer.

Directional terms: front, rear, left, right

In this manual, the “front” refers to the end of the machine where the dozer blade is mounted, while the “rear” refers to
the other end where the travel motor is mounted. The “right” or “left” refers to the side viewed by a person sitting in the
operator’s seat.

Machine serial number

The machine serial number is stamped on the identification plate. Be sure to include this number when sending a report
or inquiry or when ordering parts.

Control of manual
Appoint a person in charge of keeping the manuals up to date in your company and inform us of the person’s name
for our records. Any revisions or additions to this manual will be sent to the person.

Symbols used in this manual

The symbols used in this manual have the following meanings.

Indicates the machine serial number.

Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound.
Indicates the use of grease.

Manual structure
This manual consists of the following parts.
1. Safety
2. Service data
3. Function
4. Disassembly and assembly
5. Troubleshooting
6. Other

0B0BF00
SAFETY 1
Safety alert symbol
Safety precautions
Cautions when working
 SAFETY
SAFETY ALERT SYMBOL 1
SAFETY ALERT SYMBOL
This symbol represents the safety
alert.
The message that follows the symbol
contains important information regard-
ing human safety.
Read and understand the message to
avoid personal injury or death.

Safety label
Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the
following three types of labels.
Read the labels carefully as they are important for your
safety.

DANGER
The word “DANGER” indicates an imminently hazardous
situation which, if not avoided, is likely to result in serious
injury or death.

WARNING
The word “WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in serious inju-
ry or death.

CAUTION
The word “CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in minor or
moderate injury.

IMPORTANT: The word “IMPORTANT” is used to alert

operators and maintenance personnel about situations
which could result in damage to the machine and its com-
ponents.

This manual is intended for trained and qualified person-

nel only. Warnings or cautions described in this manual
do not necessarily cover all safety measures. It is also im-
possible to cover all hazards and risks which may be as-
sociated with the maintenance of the machine in every
environment. For maintenance work, each person must
take adequate safety precautions against possible haz-
ards in the respective working environment.

1
SAFETY ALERT SYMBOL 1A0BF00
 SAFETY
SAFETY PRECAUTIONS 1
SAFETY PRECAUTIONS Install an extinguisher and a first aid kit

Observe all safety rules

• Operation, inspection and maintenance of this ma-
chine must be performed only by a trained and quali-
fied person.
• All rules, regulations, precautions and safety proce-
dures must be understood and followed when per-
forming operation, inspection and maintenance of this
machine.
• Do not perform any operation, inspection or mainte-
nance of this machine when under the influence of al-
cohol, drugs, medication, fatigue or insufficient sleep.
1BAA02Z

Wear safe clothing and protective gear • Install an extinguisher to fight a fire, and learn how to
use it.
• Prepare a first aid kit and keep it at a designated
place.
• Decide on the procedures to be used in case of fire or
other hazards.
• Decide on and take note of the contact(s) in case of
emergency.

Place a “Do not operate” alert sign

Serious injury or death may result if an unauthorized per-
son starts the engine or touches the controls during in-
spection or maintenance.
1BAA01Z • Before performing maintenance, stop the engine, re-
• Do not wear loose clothing or any accessory that can move the key and store it in a safe place.
catch on the controls or the moving parts of the ma- • Prominently display a “Do not operate” alert sign on
chine. places such as the starter switch and the control lever.
• Do not wear clothing stained with oil or grease that can Place another sign outside of the machine as neces-
easily catch fire. sary.
• Wear protective gear such as helmet, safety shoes,
protective goggles, respirator, gloves and earmuffs, Use the correct tools
as appropriate, depending on the work involved. Es-
pecially make sure to wear protective eye-wear and
mask when working with a grinding/polishing/sanding
machine, hammer or compressed air, as metal frag-
ments or other objects could scatter in such an envi-
ronment.
• Wear hearing protectors when operating the machine.
Loud and prolonged noise can damage or destroy
your hearing.

1BAA03Z

Do not use damaged or weakened tools or tools de-

signed for other purposes. Use only the correct tools for
the work involved.

1
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
SAFETY PRECAUTIONS 1
Regularly replace the safety-critical parts When the canopy is tilted up
• Regularly replace fuel hoses to prevent a fire hazard. • If the canopy is raised or lowered while the engine is
Hoses wear out over time, even if they do not show any moving, the machine may accidentally start moving,
symptom of wear. resulting in severe injury to the maintenance person-
• Regardless of the replacement schedule, replace im- nel. Make sure that the working equipment has been
mediately if a symptom of wear is found. lowered to the ground and the engine has been turned
off before raising/lowering the canopy.
Explosionproof lighting • When the canopy is tilted up, firmly secure the canopy
with a stopper to prevent it from falling.

Keep the machine clean

1BAA04Z

To prevent an ignition or explosion, use explosion-proof

lights when inspecting fuel, oil, coolant or battery fluid.
1BAA06Z

Prohibit access by unauthorized persons • Clean the machine before performing maintenance
and try to keep it clean.
• Before washing, cover the electrical parts with vinyl to
prevent water from entering, as this could cause a
short-circuit or malfunction. Do not use water or steam
to wash the battery, sensors, connectors or the opera-
tor’s seat area.

Stop the engine before performing maintenance

Make sure the engine is stopped before starting inspec-
tion or maintenance. If maintenance must be performed
with the engine running, always work as a 2-person team,
communicating with each other.
1BAA05Z
• One of them must sit at the operator’s seat and stop
Do not allow unauthorized personnel in the work area the engine whenever necessary. He/she must take
while working. care not to touch the lever or pedal unless necessary.
Take particular care that no unauthorized person is pres- • The one who performs maintenance must make sure to
ent when grinding, welding or using a hammer. keep his/her body or clothing away from the moving
part of the machine.

Prepare the work area

• Select a level and firm ground on which to perform
maintenance work. Make sure that the work area is
light enough and well ventilated.
• Straighten any obstacle or dangerous object, remove
any spill of oil or grease and clean the work area.

2
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
SAFETY PRECAUTIONS 1
Keep clear of the moving fan and belt When working on the machine

1BAA07Z 1BAA09Z

• Any object that can be easily caught in moving parts • To prevent slipping/falling from machine, clear the
must be kept away. footing and observe the following:
• If a hand or tool becomes trapped in the fan or fan belt, a. Do not spill oil or grease on the machine.
you could lose your finger. Do not touch the fan or belt b. Keep the machine tidy and clean.
while they are moving. c. Be careful when walking around the machine.
• Never jump down from the machine. Climb up/down
When working under the machine the ladder (steps) holding the handrail to support your
weight in a three point secure stance (hand and feet).
• Wear protective gear according to the work involved.

Securing the working equipment

When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.

Secure the engine hood and guard when they are

open
Firmly secure the machine when the engine hood or
1BAA08Z
guard is left open. Do not keep the hood or guard open
• Before performing maintenance or repairs under the on a windy day or if the machine is parked on a slope.
machine, set all movable equipment against the
ground or in the lowermost position. Place heavy components in a stable position
• Place chocks under the crawler tracks to secure the
machine.
• If it is unavoidably necessary to work under the raised
machine or working equipment, be sure to firmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.

1BAA10Z

When it is necessary to temporally place a heavy compo-

nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable po-
sition.

3
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
SAFETY PRECAUTIONS 1
Caution when filling with fuel or oil Be careful with hot and pressurized components

1BAA11Z 1BAA12Z

• Keep away from heat, sparks and flame while filling Before performing inspection and maintenance, stop the
with fuel or oil. engine and allow the machine to cool down.
• Never remove the fuel cap or try to fuel when the en- • The engine, muffler, radiator, hydraulic lines, sliding
gine is running or still hot. parts and many other parts of the machine are hot im-
• Maintain control of the fuel filler nozzle when filling the mediately after the engine is stopped. Wait until it
tank. cools before making any inspection or adjustments.
• Refill with fuel or oil outdoors or in a well ventilated • The engine coolant, hydraulic oil and other oils are
place, with the engine turned off. also hot and under high pressure. Touching these liq-
• Clean up spilled fuel or oil immediately. uids will cause burns.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is Handling of radiator
lost, replace it only with the original manufacturer’s ap-
proved cap. Use of a non-approved cap without prop-
er venting may result in pressurization of the tank.
• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.

Handling of hoses
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or
hoses; otherwise, they may burst.
• Retighten loose connections.
1BAA13Z

Do not remove the radiator cap when the coolant is hot.

Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.

4
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
SAFETY PRECAUTIONS 1
Be careful with oils under pressure Be careful with grease under pressure

1BAA14Z 1BAA15Z

Pressure is maintained in the hydraulic circuit long after In the track adjuster, the grease has been injected under
the engine has been shut down. high pressure. If the tension is adjusted without following
• Do not fill with, dispose of fuel/oil, or perform the in- the prescribed procedure, the grease discharge valve
spection and maintenance until the internal pressure is may fly off, resulting in injury.
completely released. • Loosen the grease discharge valve slowly.
• The hydraulic oil escaping from a small hole can be • Do not put your face, arms, legs or body in front of the
hazardous if contacted. It is under high enough pres- grease discharge valve.
sure to penetrate the skin or eyes and cause serious
injury. If leak is suspected, protect your eyes and skin Handling of the accumulator
by wearing protective glasses and thick gloves to
search for a leak. Also use a paperboard or plywood
to keep your skin from oil spurting. If oil penetrates the
skin, it must be surgically removed within a few hours
by a doctor familiar with this type of injury.

Release internal pressure before working on the

hydraulic system
Oil may spurt out if caps or filters are removed or pipes
are disconnected before releasing the pressure in the
hydraulic system.
• Gradually loosen the vent plug to release the internal
pressure of the hydraulic oil tank. 1BAA16Z

• Move all the control levers and pedals several times in Be sure to handle the high-pressure nitrogen gas en-
all directions to release the pressure from the circuit of closed in the accumulator with care according to proce-
the working equipment (for link type controls). dure. If handled incorrectly, it could explode and cause
• When removing plugs or screws, or when disconnect- serious injury. Strictly observe the following precautions:
ing hoses, stand to the side and loosen them slowly to • Do not disassemble.
gradually release the internal pressure before remov- • Do not allow flame near it or throw it into a fire.
ing. • Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, roll-
ing or dropping.
• Before disposing of the unit, the sealed gas must be
drained. Contact your sales or service dealer for help
with this.

Disconnect the battery

Disconnect the wiring from the both terminals (+ and -)
on the battery before working on the electrical system or
doing electric welding. Otherwise, short-circuit and ex-
plosion of the battery can result.

5
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
SAFETY PRECAUTIONS 1
Use caution when handling batteries Have a service agent repair welding cracks or
other damage
Ask a service agent to make any repairs that require
welding. If the agent is unavailable, make sure the weld-
ing is done by a qualified person in a properly equipped
workplace.

Checks after maintenance

• Gradually raise the engine speed from low idle to max-
imum and check that no oil or water is leaking from the
parts serviced.
• Move the controls and check that the machine is oper-
1BAA17Z
ating properly.
• Batteries contain sulfuric acid which will damage eyes
or skin if contacted. Disposing of wastes
• If eye contact occurs, flush immediately with clean
water and get prompt medical attention.
• If accidentally swallowed, drink large quantities of
water or milk and call a physician immediately.
• If acid contacts skin or clothing, wash off immedi-
ately with a lot of water.
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which
may explode. Keep away from flame and sparks.
• Do not use or charge the battery when the electrolyte
level is lower than the lower limit: otherwise, it could
cause an explosion.
1BAA18Z
• Be sure to stop the engine by turning off the starter
• Always collect oil that is drained from the machine in
switch before inspecting or handling the battery.
containers. Improperly disposed waste oil can cause
• Be careful not to let metal tools (or any metal objects)
environmental harm.
such as a hammer or spanner come into contact with
• Follow appropriate laws and regulations when dispos-
the battery terminals.
ing of harmful objects such as oil, fuel, coolant, sol-
• When disconnecting the battery wiring, always discon-
vent, filters and batteries.
nect it from the earth side (-). When connecting, con-
nect the earth side last.
• Loose battery terminals may result in sparks. Be sure
to fasten terminals tightly.
• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the
battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (59°F) before use.

6
SAFETY PRECAUTIONS 1B0BF00
 SAFETY
CAUTIONS WHEN WORKING 1
CAUTIONS WHEN WORKING When removing/installing the hydraulic unit
• Make sure that the temperature of the hydraulic oil has
When disassembling or assembling dropped and is cool enough to work with.
• Clean the machine before disassembly. • To prevent the hydraulic oil from escaping under pres-
• Check the following items and record the results: sure, release the residual pressure in the piping.
a. Model, machine serial number, hour meter. • Be sure to install caps or plugs on all openings in the
b. Reason for repair, repair history. hydraulic unit to prevent dirt from getting into the unit
c. Are the filters dirty? through them.
d. The conditions of the fuel and oil.
e. Any damage or looseness to any part?
• Where necessary, draw alignment indicators to avoid
assembly errors. To avoid misconnection, place indi-
cators such as reference tags on pipes.
• Clean all disassembled parts and new parts, arrange
them neatly, and place indicators as necessary.
• Be sure to replace all seals and cotter pins with new
ones.
• Keep those parts that should not come in contact with
water or oil away from those with oil on the surface.
• When installing bearings, bushings and oil seals, a
press tool should be used. If a hammer is used, use a
cushioning material to avoid damage. • The hydraulic oil adhering to the unit is often mistaken
• Wipe all joining surfaces clean until there is no dirt or for an oil leak, so wipe off the unit thoroughly.
dust adhering to them. • Be sure that no damage is caused to the plating on the
• Wrap the thread tight with seal tape starting 1 or 2 rod in the hydraulic cylinder.
threads away from the thread end. The tape should be • Removal and installation of the hydraulic cylinder
overlapped by about 10 mm (0.39 in). should be done with the rod fully retracted.
• Be sure to bleed the air after installing the hydraulic
cylinder. ( “4. Disassembly and assembly: Cylin-
der”)
• Always bleed the air when hydraulic oil is changed or
a hydraulic device is replaced. ( “4. Disassembly
and assembly: Drive system”)

1
CAUTIONS WHEN WORKING 1C0BF00
 SAFETY
CAUTIONS WHEN WORKING 1
When connecting/disconnecting the hoses or Handling of seals
pipes • Clean the grooves for O-rings and remove any burrs.
• When hydraulic hoses or pipes are connected, tighten
them once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed torque.
a. Tighten the fittings after the installation surfaces fit
snugly together.
b. The above procedures do not apply to fittings with
seal tape.
• Use two spanners, one to tighten/loosen and the other
to secure the mating hose/pipe to ensure that the hose
is not twisted.

• Be careful not to twist the O-rings. If twisted, remove it

with your fingertips.
• When inserting, be careful not to damage the seal.
• Handling of the floating seal
a. After removal, wipe all oil off the O-ring and housing
of the floating seal.
b. When assembling, apply a thin coating of gear oil to
the contact surface of the housing.
c. After assembly, turn the seal two or three times to
1CAA03Z
get it to fit snugly.
• After connecting the hydraulic hoses or pipes, apply • Apply grease to the lip of the oil seal.
the maximum working pressure five or six times to a. This is to prevent wear from occurring upon first
check for leakage. start up after assembly.
• If high pressure, vibration or shock is applied to a twist-
ed hose, oil leak, hose breakage or damage to the
hose fitting can result.
• Be sure that the hydraulic hoses are not contacting
sharp objects or each other. This could cause surface
flaws on the hoses, resulting in breakage.

1CAA04Z

2
CAUTIONS WHEN WORKING 1C0BF00
SERVICE DATA 2
 SERVICE DATA
DIMENSIONAL DRAWING 2
DIMENSIONAL DRAWING
Machine dimensions

1
DIMENSIONAL DRAWING 2A0BJ00
 SERVICE DATA
DIMENSIONAL DRAWING 2
Unit: mm (in.)
Long arm
Rubber crawlers
A 4595 (180.9)
B 1460 (57.5)
C 2525 (99.3) / 2540 (100)**
D 1330 (52.4)
E 590 (23.2)
F 1440 (56.7)
G 1900 (74.9)
H 1450 (57.1)
J 300 (11.8)
K 305 (11.9)
L 1895 (74.7)
M 1505 (59.2)
P 490 (19.3)
Q 610 (23.9)
R 1450 (57.1)
S 355 (14) / 355 (14)*
T 3265 (128.5)
U 1455 (57.3) / 1480 (58.3)*
V 79°
W 58°
X 4730 (186.3) / 4755 (187.2)*

*: Angle blade specifications

**: Canopy specifications

2
DIMENSIONAL DRAWING 2A0BJ00
 SERVICE DATA
DIMENSIONAL DRAWING 2
Operating range

3
DIMENSIONAL DRAWING 2A0BJ00
 SERVICE DATA
DIMENSIONAL DRAWING 2
Unit: mm (in.)
Long arm
Rubber crawlers
A 4850 (190.9)
B 4710 (185.4)
C 2835 (111.6)
D 2165 (85.2)
E 3310 (130.4)
F 4490 (176.7)
G 3230 (127.2)
H 1020 (40.2)
J 380 (15.0) / 370 (14.5)*
K 310 (12.2) / 325 (12.9)*
*: Angle blade specifications

4
DIMENSIONAL DRAWING 2A0BJ00
 SERVICE DATA
SPECIFICATION TABLES 2
SPECIFICATION TABLES
Canopy Cab
Rubber Long
Operating mass kg (lb.) 2885 (6360) 2950 (6505)
crawler arm
Net (ISO 14396)
18.2/2400 (24.4/2400)
kW/min.-1 (hp/rpm)
Engine output
Net (ISO 9249/SAEJ1349)
17.6/2400 (23.6/2400)
kW/min.-1 (hp/rpm)
Heaped capacity m3 (ft.3) 0.068 (2.4)
Bucket capacity
Struck capacity m3 (ft.3) 0.051 (1.8)

Performance
Standard loading mass kg (lb.) 90 (203)
-1
min.
Slew speed 10.3 (10.3)
(rpm)
Rubber 1st km/h (mph) 2.9 (1.8)
Travel speed
crawler 2nd km/h (mph) 5.2 (3.23)
Maximum tractive force Rubber crawler kN (lbf) 28.2 (6340)
% 58
Gradeability
deg. 30
Ground pressure Rubber crawler kPa (psi) 29.4 (4.26) 30.1 (4.37)
Sound-power level dB (A) 93
Noise level
Sound-pressure level dB (A) 78

Dimensions of complete machine

Overall length Long arm mm (in.) 4730 (186.3)
During normal opera-
Overall width mm (in.) 1460 (57.5)
tion
Rubber Canopy mm (in.) 2540 (100)
Overall height
crawler Cab mm (in.) 2525 (99.3)

1
SPECIFICATION TABLES 2B0BJ00
 SERVICE DATA
SPECIFICATION TABLES 2
Dimensions of base machine
Overall length of base machine mm (in.) 2420 (95.3)
Overall width of base ma- During normal opera-
mm (in.) 1460 (57.5)
chine tion
Overall width of upper slewing structure mm (in.) 1460 (57.5)
Left mm (in.) 730 (28.7)
Overall width of upper slewing structure
Right mm (in.) 730 (28.7)
Cab width mm (in.) 1040 (40.9)
Overall height of base ma- Rubber Canopy mm (in.) 2540 (100)
chine crawler Cab mm (in.) 2525 (99.3)
Swing radius mm (in.) 1330 (52.4)
Rearmost distance of slewing structure from the
mm (in.) 1330 (52.4)
axis of rotation
Clearance height under
Rubber crawler mm (in.) 590 (23.2)
slewing structure
Crawler base Rubber crawler mm (in.) 1440 (56.7)
Crawler overall length Rubber crawler mm (in.) 1900 (74.9)
Undercarriage overall During normal opera-
mm (in.) 1450 (57.1)
width tion
During normal opera-
Track gauge mm (in.) 1150 (45.3)
tion
Track shoe width mm (in.) 300 (11.8)
Ground clearance of un-
Rubber crawler mm (in.) 305 (11.9)
dercarriage

2
SPECIFICATION TABLES 2B0BJ00
 SERVICE DATA
SPECIFICATION TABLES 2
Engine
Part Name Yanmar diesel engine
Yanmar 3TNV88F-EPTB1
Type
Yanmar 3TNV88F-EPTB
Number of cylinders – Internal diameter × stroke mm (in.) 3-88 (3.46) × 90 (3.54)
Total displacement mL (cu. in.) 1642 (100.2)
N·m (ft.-lb.) 83.4 to 92.2 (61.5 to 68)
Maximum torque
min-1 (rpm) 1440 (1440)
Specific fuel consumption g/(kW·h)
238 (0.391)
(at rated output) (lb./hp-hr.)
Fuel/air cleaner Centrifugal, filter paper-type
Fan Suction
Cooling system
Radiator Pressurized
Voltage V 12
Starting system
Output kW 1.7
Voltage V 12
Generator
Output kW 0.66
Voltage V 12
Battery Capacity Ah 54
Quantity 1

Hydraulic system
Hydraulic pump drive system Engine-linked
Double-gear variable discharge piston
Type
plus double gear
Quantity 1
L/min.
32.4 (8.56)
(US gal./min.)
L/min.
Hydraulic pump 32.4 (8.56)
(US gal./min.)
Delivery
L/min.
21.6 (5.71)
(US gal./min.)
L/min.
10.8 (2.85)
(US gal./min.)
Hydraulic pump control system Total horsepower control
MPa (psi) 21 (3050)
MPa (psi) 21 (3050)
Main relief valve pressure setting
MPa (psi) 20 (2900)
MPa (psi) 3.4 (490)
Hydraulic tank pressure Pressure tank
Type Directional control valve with 10 valves in series
Control valve
Operation type Hydraulic pilot-operated
Type Glass fiber filter paper-type
Hydraulic oil filter Filter precision BETA 10=6
Attachment position Return circuit (inside tank)
Hydraulic oil cooler Cooling system Air-cooled

3
SPECIFICATION TABLES 2B0BJ00