Case CX80 TIER 3 Excavator Operator's Manual - PDF DOWNLOAD

OPERATOR’S MANUAL EXCAVATOR

CX80 TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01April 08 Printed in U.S.A. • Book/Form Number 87490339 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01April 08

CX80 Tier 3 Excavator

87490339 NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

To the Owner Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. See “Official documents”. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the machine.

Use this manual as a guide. Your machine will remain a reliable working tool provided it is kept in good working condition and serviced properly.

The standard attachments and equipment available for use with this machine are intended for general earthmoving purposes, material rehandling, boring, ditch cleaning, etc. If the machine is to be used for handling loads, (concrete pipe sections, shoring material, etc.), make sure the machine is suitably equipped for this type of work. For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your CASE Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine’s technical specifications and with prevailing safety requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine’s initial conformity with safety requirements.

The machine must undergo regular inspections, the frequency of which varies according to the type of use.

Consult your CASE Dealer.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centers or from an approved organization.

2. That the operator has read and understood the instructions given in this manual.

Always keep this manual in the operator’s compartment (in the seat back, behind the operator’s seat). Make sure it is always complete and in good condition. If you wish to obtain additional manuals, or manuals in another language, consult your CASE Dealer.

Your CASE Dealer is at your disposal for any further information. He will also provide any after-sales service you may require, and genuine CASE spare parts, your guarantee of quality and match.

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E2440

Safety Labels RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms “Right”, “Left”, “Front” and “Rear” are used in this manual to indicate the sides as they are seen from the operator’s seat when the cab is over the idler wheels.

The illustration below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the upperstructure.

0-0178E

1 FRONT 2 REAR 3 RIGHT-HAND SIDE

4 LEFT-HAND SIDE 5 TRAVEL REDUCTION GEARS 6 IDLER WHEELS

Break-in This product is shipped after full inspections and conditioning, however, extremely overloaded usage at the initial stage could lead the reduction in performance and life. Therefore, approx. initial 100 hours (indicated hours on the service meter) break-in is neccessary.

Break-in should be conducted paying attention to the following points: • Try to keep idling and warming for 5 minutes after starting the engine.

• Avoid operation under heavy load or at high speeds.

• Avoid any sudden start, acceleration or unnecessary sudden stop and quick turn.

Specified Work This product is designed to use mainly in the following work: • • • • •

Excavation Land granding work Trenching work Loading work Demolition (Demolition specification vehicle only)

0-2

For Safe Driving IMPORTANT: Remove the protective (rust preventative) aluminum cover wrapped around the cylinder rods immediately after receiving the machine. If the machine is left with the covers on, water can collect on the inside of the cover, which will be the cause for rust to develop on the cylinder rod.

In the case of transportation by sea, sea water salt adheres to the machine making rust easier to develop. Immediately follow the measures below after receiving a machine that has been transported by sea. If the measures are not taken, the machine will develop rust easily.

1. Confirm that there are no salt deposits on the machine exterior. When salt deposits are suspected, wash the entire machine with water.

3. If Storage Is To Be Continued [Storage procedures for rust prevention.]

1 Grease up each part of the attachment.

CAUTION Do not use high pressure cleaning water directly on the alternator, battery and other electrical parts or wiring.

0-0003E

Storage for up to one month (1) Once a week operate each motion (attachment, swing, travel) with no load which performs rust prevention operation.

1 Put the engine in low~medium rpm and perform the warming up operation.

0-0002E

2 Slowly operate each cylinder of the front attachment five strokes each.

2. Performing Rust Prevention Operation.

Storage for more than one month

CAUTION

(1) Place each cylinder in the most retracted position and apply anti-rust oil to the exposed cylinder rod.

Start the engine after you understand the operation methods.

1 Set the engine at low~medium rpm and go through the warming up operation.

2 Slowly operate each cylinder of the front attachment five strokes each.

0-0004E

(2) Perform rust-prevention operation once a month.

1 Before performing the rust-prevention operation, remove the anti-rust oil (wipe off with kerosene, etc.).

2 After finishing the rust prevention operation, fully retract each cylinder and apply anti-rust oil to the exposed cylinder rod.

0-3

E0040

For Safe Driving SAFETY INSTRUCTIONS Your safety and that of people around you depend on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

Read this manual carefully and check that : - You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.

- You understand fully the speed, stability, braking and stability, braking and steering characteristics of the machine. If you are in any doubt, consult your CASE Dealer.

The safety messages in this manual concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

Whatever type of work is being done (earthmoving, handling, drilling, etc.), the safety measures for private or public work-sites are those which conform to current regulations in the country concerned, or the type of operation concerned (mining, quarrying, tunnelling).

The safety instructions given in this manual are a summary of the basic rules to be respected at all times and do not exempt you from insurance requirements or from abiding by the highway code.

Always keep this manual in the storage compartment “Pocket” provided for it. Make sure it is always complete and in good condition.

Pocket

0-0137E

0-4

For Safe Driving Warranty In case faults occur to the machine, the warranty is valid within the range described in the warranty document.

Model and Serial number of manufacture When ordering parts, obtaining information or assistance, always supply your CASE dealer with the type and serial number of your machine or accessories.

Write the following in the spaces below: The model number, serial number and year of manufacture of your machine, accessories and the serial number of the various hydraulic and mechanical components.

Machine CNH America LLC Racine, WI 53404 U.S.A

Made in Japan Type

KHP10690-00

3-0016E

0-0179E

Excavator Identification ___________________________________________________________________ Model Number _________________________________________________________________________ Serial Number __________________________________________________________________________

Engine Make and type _________________________________________________________________________ Serial number __________________________________________________________________________

Component serial numbers Hydrauric pump _________________________________________________________________________ Swing reduction gear ____________________________________________________________________ Travel reduction gears ___________________________________________________________________ Travel control valve ______________________________________________________________________ Attachment control valve __________________________________________________________________ Swing control valve ______________________________________________________________________

0-5

Table of Contents To the Owner ..................................................... 0-1 Safety Labels ..................................................... 0-2 For Safe Driving ................................................. 0-3

Warm-up Operation................................................. 2-8

Operations (Traveling)...................................... 2-10 Operations (Swing)........................................... 2-19 Swing Operation.................................................... 2-19

Operations (Attachment) .................................. 2-20

Safety Section ..................................... 0-7

Operations (Attachment) ....................................... 2-20

Precaution Identification Plates (DECALS) ........ 0-8

Operations........................................................ 2-21

Identification Plates inside the Cabin....................... 0-8 Outside Identification Plate.................................... 0-13 Precaution Identification Plates on Parts (Examples) ........................................................................... 0-17

Blade Operation .................................................... 2-22 Characteristics of Hydraulic Excavator.................. 2-22 Cautions for operations ......................................... 2-23 Cautions for Interference....................................... 2-23

Prior to Operation............................................. 0-18 Confirmation of Safety items ............................ 0-20 During Operation.............................................. 0-23 While Traveling ................................................ 0-27 After Operating................................................. 0-28 While Transporting ........................................... 0-29 Before Regular Inspection & Maintenance....... 0-30 Inspection and Maintenance ............................ 0-31

Operating Instructions (Cautions)..................... 2-25 Operating Instructions (Procedures) ................ 2-26 Bucket: Turning Over and Replacement .......... 2-28 Bucket: Turning Over and Replacement ............... 2-28

On Completion of Daily Operations.................. 2-30 On Completion of Daily Operations....................... 2-30

Operating in Cold Climates .............................. 2-32 Operating under Extreme Conditions ............... 2-33 Transportation .................................................. 2-34

Instruments and Controls .................. 1-0

Loading and Unloading ......................................... 2-34 Switch settings during loading and unloading ....... 2-34 Transportation ....................................................... 2-34

Location of Components .................................... 1-1 Overall View ............................................................ 1-1 Operator’s Cab ........................................................ 1-2

Storing .............................................................. 2-38

Right Console..................................................... 1-4 Right Console .......................................................... 1-4

Inspections and Maintenance ............3-0

Monitor & Switch Panel ...................................... 1-5

General Cautions ............................................... 3-1 Periodic Maintenance Check List ....................... 3-2

Monitor & Switch Panel ........................................... 1-5

Moniter Display .................................................. 1-6 Switch Panel ...................................................... 1-7 Left Console ....................................................... 1-9

Daily Inspections (Prior to Operation) ..................... 3-2 Periodic Maintenance Check List ............................ 3-3 Fuel / Lubricants for Different Ambient Temperature Settings ............................................................... 3-4 Genuine CASE Company LLC Parts and Elements 3-5 Disposable Items..................................................... 3-6

Left Console ............................................................ 1-9 Switch .................................................................... 1-10

Air Conditioner ................................................. 1-11 Air Conditioner (If equipped).................................. 1-11

Grease / Oil and Elements ................................. 3-7 Inspection Prior to Operation.............................. 3-8

Explanation of device ....................................... 1-13 Radio ..................................................................... 1-13

Inspections Prior to Operation................................. 3-8

Operation Levers.............................................. 1-15

Greasing Attachments...................................... 3-12

Operation Levers ................................................... 1-15

Greasing Front Attachment Pins ........................... 3-12

Operator’s Seat ................................................ 1-19

Fuel System ..................................................... 3-15

Operator’s Seat ..................................................... 1-19

Fuel ....................................................................... 3-15 Fuel Refilling and Fuel Level Checking ................. 3-18 Drainage of Water and Sediments in the Fuel Tank .......................................................................... 3-18 Draining Water from the Water Separator............. 3-19 Fuel Filter (Main) Replacement ............................. 3-19

Operator’s Cab................................................. 1-21 Fuses ............................................................... 1-23 Fuses..................................................................... 1-23

Explanation of device ....................................... 1-24 Battery ................................................................... 1-24 Starting the Engine by Using Booster Cables ....... 1-25

Engine .............................................................. 3-20 Engine Oil Replacement........................................ 3-20 Engine Oil Filter Replacement............................... 3-20 Cooling System ..................................................... 3-22 Inspecting and Refilling Coolant............................ 3-22 Replacing the Coolant ........................................... 3-23 Cleaning and Inspecting the Radiator Net and Fin .......................................................................... 3-24 Cleaning and Replacing the Air Cleaner (double elements) ............................................................... 3-25 Inspection and Adjustment of Fan Belt.................. 3-27

Operating Instructions ....................... 2-0 Operation of New Machine................................. 2-1 Using a New Machine.............................................. 2-1

Daily Inspections ................................................ 2-2 Daily Inspections ..................................................... 2-2

Starting and Stopping the Engine ...................... 2-4 Inspections before Starting the Engine.................... 2-4 Starting the Engine .................................................. 2-5 Inspections after Starting the Engine....................... 2-6 Stopping the Engine (Normal Operation) ................ 2-7

Bolt Torque....................................................... 3-28

Warm-up Operation............................................ 2-8

Bolt and Nut Torque .............................................. 3-28

0-6-1

Table of Contents Hydraulic Oil..................................................... 3-31

Using the Crusher (Attachment) ..............................5-7

Hydraulic Oil Level Inspection............................... 3-31 Refilling Hydraulic Oil ............................................ 3-31 Draining Water and Sediment from the Hydraulic Oil Tank .................................................................. 3-32 Hydraulic Oil Management.................................... 3-33 Hydraulic Oil Replacement.................................... 3-33 Bleeding Air from the Hydraulic Components ....... 3-34 Air Bleeding Procedures ....................................... 3-34 Air Bleeding from Hydraulic Pump ........................ 3-34 Air Bleeding from Cylinder .................................... 3-35 Air Bleeding from Swing Motor.............................. 3-35 Cleaning and Replacing Suction Filter .................. 3-36 Replacing Return Filter ......................................... 3-36 Replacing Air Breather Element............................ 3-37 Replacing Pilot Oil Filter Element.......................... 3-37 Replacement Intervals for Hydraulic Oil and Filters when Using Breaker..................................................... 3-38 Checking Hoses and Lines ................................... 3-38

Load Lifting Operation...................................... 5-10

Battery.............................................................. 3-39 Battery Inspection and Charge.............................. 3-39

Upper Frame.................................................... 3-41 Turntable Bearing Greasing .................................. 3-41 Greasing Swing Ring Gear ................................... 3-41

Travel Unit........................................................ 3-42 Travel Reduction Gear .......................................... 3-42 Oil Level Inspection and Refilling of Travel Reduction Gear .................................................................. 3-42 Oil Replacement for Travel Reduction Gear ......... 3-42 Inspecting Upper/Lower Take-up Roller (Idler Wheel) .......................................................................... 3-43 Inspection and Tightening of Shoe Plate .............. 3-43 Cleaning Crawler................................................... 3-43 Inspection and Adjustment of Track Shoe Tension .......................................................................... 3-44

Bucket .............................................................. 3-45 Replacing Bucket Teeth: Standard type (Length Pin Type) ................................................................. 3-45 Adjustment of Bucket Backlash............................. 3-47

Air Conditioner ................................................. 3-48 Inspection and Care of Air Conditioner (If Equipped) .......................................................................... 3-48

Routine Replacement Safety Parts.................. 3-52 Troubleshooting ............................................... 3-53 Contacting Us .................................................. 3-58

Specifications......................................4-0 Conversion Factors............................................ 4-1 CONVERSION FACTORS...................................... 4-1

Specifications..................................................... 4-2 CX80 ....................................................................... 4-2

Optional Components.........................5-0 Breakers............................................................. 5-1 Handling the Breaker (Attachment)......................... 5-1 When Using a Hydraulic Breaker ............................ 5-2 Operating the breaker ............................................. 5-4 Importance of Hydraulic oil Control ......................... 5-5

Crusher .............................................................. 5-7 0-6-2

Safety Section SAFETY

WARNING

You must read this safety section carefully.

This section contains important safety information.

The symbols on precaution film labels are attached to machines in order to prevent personal injury. Before starting operations, read carefully the indications on film labels with symbols.

It is a very difficult task to cover and handle all possible dangers in this manual. For this reason, the descriptions on precaution film labels do not always cover everything. Try to understand fully this manual and drive and operate properly, paying special attention to prevent damage to the machine or personal injury.

Contents of the manual • Precaution Identification Plates (DECALS) • Prior to Operation • Confirmation of Safety items • During Operation • While Traveling • After Operating • While Transporting • Before Regular Inspection & Maintenance • Inspection and Maintenance

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E0080

Safety

Precaution Identification Plates (DECALS)

Always keep the precaution ID label clear and readable.

When the plate gets dirty: Clean the plate with water or washing agent. Don’t use any gasoline or organic solvent.

If a precaution identification plate is extremely dirty and the dirt is difficult to remove, replace it with a new one.

Before changing it, make sure it is the same type.

In case Precaution Identification Plates are lost or damaged: Ask for a new precaution identification plate at the nearest approved sales shop.

Before changing it, make sure it is the same type.

Identification Plates inside the Cabin ԣ

ԥ

Ԥ

0-0180E

0-8

Safety

Precaution Identification Plates (DECALS)

1WARNING Label KHP1537 B

A

C

ELECTROCUTION HAZARD. CONTACT WITH EXCAVATOR OR GROUND MAY CAUSE DEATH OR BODILY INJURY. KEEP ALL PARTS OF MACHINE AND LOAD AT LEAST 15 FEET (4.57M) AWAY FROM ALL ELECTRICAL POWER LINES OR SUCH DISTANCE AS SPECIFIED

BY LOCAL SAFETY CODES.

IMPROPER EXCAVATOR OPERATION AND MAINTENANCE CAN CAUSE INJURY OR DEATH. READ AND STUDY THE OPERATORÕS MANUAL AND ALL SAFETY MESSAGES. LEARN AND PRACTICE SAFE USE OF CONTROLS. ALWAYS OPERATE PROPERLY. INSPECT AND MAINTAIN EXCAVATOR DAILY.

Attachment interference.

Machine damage may result.

Do not allow the attachment, load or other devices to contact the cab or machine.

KHP1537-00

0-0150E

A Electric shocks If you let the machine go too close to electric wires, you could get an electric shock.

Keep a safe distance and away from electric wires.

Guidelines for Safe Distances.

Voltage

6,600 V or less 22,000 V or less 66,000 V or less 154,000 V or less 187,000 V or less 275,000 V or less 500,000 V or less

Safe Distance

6.6 ft (2 m) or more 9.8 ft (3 m) or more 13.1 ft (4 m) or more 16.4 ft (5 m) or more 19.7 ft (6 m) or more 23.0 ft (7 m) or more 36.1 ft (11 m) or more

ELECTROCUTION HAZARD. CONTACT WITH EXCAVATOR OR GROUND MAY CAUSE DEATH OR BODILY INJURY. KEEP ALL PARTS OF MACHINE AND LOAD AT LEAST 15 FEET (4.57M) AWAY FROM ALL ELECTRICAL POWER LINES OR SUCH DISTANCE AS SPECIFIED

BY LOCAL SAFETY CODES. 0-0151E

0-9

Safety

Precaution Identification Plates (DECALS) 2Raise gatelock lever KHP1782

B Read manual before driving and maintemance

Raise lever completely to shut off controls before leaving the cab to avoid accidental control engagement and possible injury.

This is very important. You must read this carefully.

You must read the manual before driving, maintaining, disassembling/assembling or transporting your machne.

IMPROPER EXCAVATOR OPERATION AND MAINTENANCE CAN CAUSE INJURY OR DEATH. READ AND STUDY THE OPERATORÕS MANUAL AND ALL SAFETY MESSAGES. LEARN AND PRACTICE SAFE USE OF CONTROLS. ALWAYS OPERATE PROPERLY. INSPECT AND MAINTAIN EXCAVATOR DAILY.

0-0153E 0-0152E

3Caution against the fall of front C Attachment interferece with cab

window KHP1822

The bucket teeth may hit the cab, depending on the type of attachment.

Exercise care when operating a bucket near the cab.

There is a danger of an injury due to possible sliding fall of the stored front window.

Be sure to lock the front window securely at the position to be stored.

0-0154E 0-0014E

0-10

Safety

Precaution Identification Plates (DECALS)

4Lock pin KHP1802

7Emergency exit KHP1247 If the door or window cannot be opened and you must get outside in an emergency, use the hammer installed to brake the rear window and escape through it.

OPEN POSITION

CAUTION MAINTAIN THE LOCK PIN IN THE OPEN POSITION WHEN OPENING THE WINDOW. KHP1802-00

0-0155E

5Clianing the cab window KHP1540 0-0144E

8For use of cigarette lighter socket KHP1804 The cigarette lighter located in the right back of the operator's seat is of DC24V rating.

It is strictly prohibited to connect any of the equipment of 12V rating as this causes it to be damaged.

0-0156E

6Exchange od control function

24V

KHP1050

KHP1804-00

CONTROL FUNCTIONS ON THIS MACHINE ARE INTERCHANGABLE

0-0145E

ONLY AN AUTHORIZED DEALER REPRESENTATIVE IS ALLOWED TO MODIFY THE CONTROL PATTERN

912V Power socket KHP1803

WHEN A MODIFICATION HAS BEEN MADE THE REPRESENTATIVE MUST CHANGE THE DECAL TO MATCH THE NEW CONTROL PATTERN

A 12V power socket is supply power to electric equipment and accessories for automobile use.

FAILURE TO CHANGE THE DECAL COULD RESULT IN DEATH OR SERIOUS INJURY

12V

162140A1

0-0157E

KHP1803-00 1-0033

CAUTION This socket is only for use in the equipment of 12V rating.

Do not use it to supply power to the equipment of 24V rating.

0-11

Safety

Precaution Identification Plates (DECALS)

:Control pattern selector KHP1587

CLock the Pedal KHP1820

6*+5 /#%*+0' +5 '37+22'& 9+6* # %10641. 2#66'40 5'.'%614㧚 &1 016 12'4#6' 70.'55 %10641. 2#66'40 %#4& +0 6*+5 *1.&'4 /#6%*'5 5'.'%614 8#.8' 215+6+10㧚 5'4+175 +0,74; 14 &'#6* %17.& 4'57.6㧚 -*2

0-0017E

ABlade (Blade spec.) KHP1316 LOCK THE PEDAL WITH THE LEVER WHEN NOT OPERATING THE PEDAL TO AVOID ACCIDENTAL CONTROL ENGAGEMENT AND POSSIBLE INJURY. KHP1820-00

0-0182E

DAttachment Impact Hazard KHP10030 Interference between blade and boom can occur during deep digging.

KHP1316-00

0-0133E

BPoint to notice when changing control method KHP14310 IIn order to prevent an accident caused by wrong operation, be sure to operate the machine after content of the control decal in the cab matches to the function of the machine.

If not, replace the control decal before operation, or change the control method.

Be sure to stop the engine before changing the control method.

ATTACHMENT IMPACT HAZARD

Keep attachment away from cab and machine -*2

0-0183E

9#40+0) 6*+5 /#%*+0' +5 '37+22'& 9+6* # %10641. 2#66'40 5'.'%614 9*'0 6*' %10641. 2#66'40 +5 %*#0)'& 10 6*' 5'.'%614 8#.8' 6*' %10641. 2#66'40 %#4& +0 6*' %#$ /756 #.51 $' %*#0)'&‫ޓ‬61 /#6%* 6*' %10641. 2#66'40 5'.'%6'& 5'4+175 +0,74; 14 &'#6* %17.& 4'57.6 .'(6 *#0&

2#66'40

4+)*6 *#0&

5'.'%614 8#.8'

.'(6 *#0&

2#66'40

4+)*6 *#0&

5'.'%614 8#.8'

-*2

0-0181E

0-12

Safety

Precaution Identification Plates (DECALS)

Outside Identification Plate

0-0184E

0-13

Safety

Precaution Identification Plates (DECALS)

EShoe (crawler belt) tension

GBattery explosion KHP1536

KHP1014

The wrong handling of battery causes explosion itself.

You must read the manual before maintaining battery.

Plug could pop out from the shoe (crawler belt) tension adjustment device.

When releasing the shoe, read the manual and handle shoes properly.

GREASE UNDER HEAVY SPRING PRESSURE. DISASSEMBLY WITHOUT RELEASING PRESSURE MAY RESULT IN SERIOUS INJURY OR DEATH. DO NOT DISASSEMBLE TRACK CHECK COMPENSATING SYSTEM VALVE BEFORE COMPLETELY RELEASING GREASE PRESSURE. RELEASE RETAINING GREASE PRESSURE BY BRACKET LOOSENING CHECK VALVE. DO NOT REMOVE CHECK VALVE OR RETAINING BRACKET. KHP1014-00

0-0019E

FKeep out of the range of turns KHP1532 When the machine makes a turn, you may be caught in the upper part of the turning body.

Do not attempt to enter within the range of the turns.

0-0032E

HElectric shocks KHP0210 If you let the machine go too close to electric wires, you could get an electric shock.

Keep a safe distance and away from electric wires.

Guidelines for Safe Distances.

Voltage

6,600 V or less 22,000 V or less 66,000 V or less 154,000 V or less 187,000 V or less 275,000 V or less 500,000 V or less

KHP1532-00

0-0086E

Safe Distance

6.6 ft (2 m) or more 9.8 ft (3 m) or more 13.1 ft (4 m) or more 16.4 ft (5 m) or more 19.7 ft (6 m) or more 23.0 ft (7 m) or more 36.1 ft (11 m) or more

Stay away from machine if close to power lines.

Machine, load, and ground can become electrified and deadly.

1P2240

0-0020E

0-14

Safety

Precaution Identification Plates (DECALS)

IEntanglement KHP1533

KDiesel Fuel KHP11681

Entanglement in rotaing parts of the fun could cause injury.

Always stop the rotaing engine when conducting inspection and maintenance.

The location of the fuel tank.

&+'5'. (7'. 10.; 75' 10.; 6*' 4'%1//'0&'& &+'5'. (7'. )4#&' 14 '0)+0' &#/#)' /#; 1%%74 5'' 6*' 12'4#614 5 /#07#. (14 6*' 4'%1//'0&'& &+'5'. (7'. )4#&' -*2

0-0024E ROTATING FAN AND BELTS CAN SEVER FINGERS AND HANDS.

LHot surfaces KHP1535

STAY CLEAR.

The exhaust system must never be touched while the engine is running or immediately after the engine has stopped.

KHP1533-00

0-0021E

JRelieving pressure KHP1534 You can relieving the pressure from the reservoir by removing cap.

HOT SURFACES CAN BURN HANDS AND FINGERS. STAY CLEAR.

KHP1535-00

0-0025E

MDo not walk on Cover KAP0974

HOT FLUID UNDER PRESSURE CAN CAUSE SEVERE BURNS. RELIEVE PRESSURE BEFORE REMOVING CAP. SEE OPERATOR'S MANUAL FOR INSTRUCTIONS.

SLIPPERY AND UNSTABLE SURFACE.

KHP1534-00

0-0022E

DO NOT WALK ON THIS COVER. KAP0974

0-0175E

0-15

Safety

Precaution Identification Plates (DECALS)

NFall attention KHP12210 QLow Sulfur Fuel or Ultra Low Sulfur Only KHP14320 -''2 1(( 61 24'8'06 5'4+175 $1&+.; +0,74; -*2

0-0028E

OStart Engine from Operator Seat KHP0713

DANGER 0-0177E

RPall Hazard KHP10050 Starting in gear can cause death. Start engine only from operator seat with transmission control(s) in NEUTRAL 156468A1

0-0075E

FALL HAZARD

PJumper Cable Connection

Do not step on exposed cylinder

KHP0700

KHP10050-00

0-0185E

WARNING

SCrush Hazard KHP10070

WRONG JUMPER CABLE CONNECTIONS TO STARTER TERMINALS OR SHORTING ACROSS THE STARTER TERMINALS CAN CAUSE THE MACHINE TO MOVE SUDDENLY OUT OF CONTROL YOU CAN BE INJURED OR KILLED.

CRUSH HAZARD KEEP CLEAR OF THIS AREA. SWINGING BOOM CAN KILL OR SERIOUSLY INJURE YOU. START AND OPERATE MACHINE FROM OPERATORS SEAT ONLY. DO NOT PLACE ANY LOOSE OBJECTS INSIDE CAB AREA. KHP10070-00

USE THE CORRECT METHOD SHOWNIN THE OPERATORÕS MANUAL TO CONNECT JUMPER CABLES TO START THE ENGINE. 156404A1

0-0186E

0-0076E

0-16

Safety

Precaution Identification Plates (DECALS)

Precaution Identification Plates on Parts (Examples) Battery

Accumulator Filled with high pressure gas Flame throwing-in, welding and pre-arcing are prohibited.

0-0029E

(Accumulator)

This decal is on the batteries and draws attention to the risks and precautions to be taken when handling batteries. See “Batteries” in the “Electrical System” Section.

0-0030E

Radiator Cap

DENGER NEVER OPEN WHEN HOT CHECK FULL COOLAT IN RESERVE TANK

CAUTION

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0-17

Safety

Prior to Operation

Wear proper clothing, and always keep your qualification certificates with you!

Hold a meeting to coordinate operations: Operation procedures should be full discussed. If a signal man is arranged, you should make sure who is the signalman and what kind of signals are used.

● Wearing necessary protective devices is a basic safety rule.

While driving: ● Helmets ● Safety shoes ● Properly fitted clothing Use the following items, according to operations: ● Protective goggles ● Dust mask ● Earplugs ● Protective devices

0-0033

Always perform checking prior to the start of work ● Before starting operation, conduct start of work inspections (check prior to start of operation) without fail. ● Make sure that working lamps and wipers properly operate. In addition, clean the windows, working lamps, mirrors and inside the cabin. ● If any performance problems are found, immediately repair them.

0-0031

For safety operation, do not operate the machine when you are not in a good health

Follow the start of work inspections described in the “Inspection and Maintenance” section.

An operator should not operate a machine when he or she may not be able to operate it in a normal way because of fatigue, illness, drug influence, etc.

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0-0032

E0180

0-18

Safety

Prior to Operation

Be sure no danger is near the machine

Taking Care of Machine ● Clean the windows for good visibility. Replace if

● If there is a risk of falling stones, a head guard

damaged.

device should be worn. ● Check the strength of the shoulder and ground. ● Use lighting when it is dark.

● Clean dirt off the work lights to gain good lighting

Take necessary safety measures where it is in a dangerous condition.

● Clean inside the cabin, put away and organize

when it is dark. Check the lighting system.

● Clean the rear view mirrors and adjust their locations to gain good visibility. Replace if damaged. things that are not necessary to operate the machine. ● The inside of the engine room becomes very hot.

Remove dead leaves or combustibles which may cause a fire.

Recheck and make sure ● Do you fully understand all the operations? ● Do you fully understand all the signals? ● Is it all right and safe around the work area? ● Was anything overlooked while checking the ma-

0-0035

chine?

● Is your health condition and working wear appro-

Keep out of the work area (Keep others away from the work area)

priate?

● Make sure no people or obstacles are within the work area before starting operations.

● To keep away people from the work area, post “Keep Out” signs.

● In view of securing safe operation, secure the area of further 6.6 feet (2 m) around the machine working range of 360° as no admittance.

1 Working area 2 Safety area

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Ԙ

ԙ 0-0036

0-19

E0190

Safety

Confirmation of Safety items

Do not let anyone ride on the machine except for the driver

Pay attention to signals and signs ● Set up signs on the locations where there is pos-

● Do not let anyone ride on the machine except for

sible danger, like soft shoulders, slopes, etc.

● Place a guide at places where danger is foresee-

the driver.

able. The driver should pay attention to signs and follow signals by a guide.

Sit on operator’s seat to drive the vehicle ● To drive the vehicle, the driver always should sit on the operator’s seat.

● Be sure to sit on the operator’s seat and fasten the seat belt to operate the machine.

DANGER

0-0034E

0-0038

Do not use machine for other uses than the specified main usage ● Hydraulic excavators are designed for use in excavation and loading.

It is very dangerous to use machine for other than main purposes such as lifting/lowering people.

Usage other than main purposes may lead to personal injury, and damage to the machine.

Never attempt any of them.

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E0200

0-20

Safety

Confirmation of Safety items

Step and access handles

Starting and Operating the Machine ● When you start, drive and turn the machine, always push the horn switch and give signals.

Then, after checking around machine to make sure no one is near, and move the machine.

In addition, if the visibility is limited or as necessary, arrange a guide to make sure it is safe.

Ԙ

ԙ

Ԙ

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ԙ

Installing safety devices 0-0100

● Attached guards or covers according to the operation types.

To get on or off of the machine use the step 2 and access handles 1.

● Misuse of safety devices may cause personal injury or serious accident. ● Be familiar with the usage of gate lock levers and seat belts, and use in a proper manner. ● Never attempt to detach safety devices. In addition, always keep them in a normal operating condition.

Always maintain three point support getting on and off the machine.

Always maintain three point support while getting on and off the machine and entering or exiting the operators cab. A three point support system has been provided that enables a person to us simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

Do not try to modify them ● Modification sometimes may cause safety problems. ● Whenever modification is necessary, contact and consult our sales shops or service shops. ● We shall not be responsible for machine’s faults and accidents which are caused by unapproved modification.

When getting in or out of the cab, it is imperative that the upper structure frame is in line with the undercarriage.

Never jump down from the machine. When leaving the machine or the upper structure, always face the machine and use the steps and access handles.

To get in or out of the cab, never use to the left-hand control lever, the left-hand control arm or the door handle.

Clean the steps and access handles and remove all traces of grease, oil, mud and (in winter) ice.

0-21

E0210

Safety

Confirmation of Safety items

Be careful of asbestos dust ● Inhalation of asbestos dust may cause lung cancer. No asbestos is used in this machine; however, be careful when handing materials which possibly contains asbestos. ● Do not clean the machine using compressed air. ● Do not use grinders when you polish parts. ● If necessary, use dust musk or other respiratory equipment.

0-0043

Installing optional parts ● When you install optional attachments and use the parts, read the manuals for the attachments.

● Installation of attachments may cause safety problems or machine faults and reduced life; always contact and consult our sales shops or service shops. ● Depending on types of attachments to be installed, the stability of machine will change. Special attention should be paid during driving and operating the machine. ● We shall not be responsible for machine’s faults and accidents which are caused by using attachments. ● Installing and uninstalling attachments should be performed on the hard level ground.

Accumulator mounted machine ● Because an accumulator is attached, the attachment can be lowered by means of its own weight by operating the control lever even for a certain time after the engine stops. ● After stopping the engine, place the starter switch to ACC or OFF position, and the gate lock lever to lock position. ● The accumulator is filled with high pressure gas.

To handle the accumulator, follow the instructions described on the attached precaution identification plate.

E0220

0-22

Safety

During Operation

Use agreed signals to perform work needed for collaboration

Electric shocks In case your machine touches an electric wire,

● If 2 or more vehicles work together at the site,

● Warn workers around the machine “Do not touch

decide the signalman and signs.

the excavator”.

● When escaping from the excavator, do not use the steps, just jump off the machine

0-0044

0-0047

Working in urban areas ● To keep people away from the work area, post

Confirmation of the excavating location (pay attention to structures laid under ground)

“Keep Out” signs. If the work is performed in a heavy traffic area, a signalman should be placed to prevent accidents.

● Depending on the site, there may be structures laid under ground such as sewage pipes, tap water pipes, gas pipes and cables. Before starting operations, check the layout and put down clear markers, then perform the operation very carefully.

0-0045

Use special care around electric wires ● Take safety measures such as holding meetings and consulting with the electric companies, or placing signalman.

0-0048

0-0046

0-23

E0230

Safety

During Operation

Engine warm-up

If you detect an abnormality in the machine, immediately stop operation

● Warm up the engine and the hydraulic oil suffi-

● When you find something is wrong with the ma-

ciently before starting operations.

● Check that the measuring instruments are in nor-

chine during operation, immediately stop the operation, check and fix the problem. ● Do not use the machine until repairs have been finished.

mal operating condition.

Warming up!

0-0035E

0-0052

Do not dig too close to your machine You won’t be able to laugh it off by saying you “dug your own grave”.

For emergency, position the crawler at the right angle with the road shoulder, and travel motor behind the machine to easily escape.

“Open work” excavation is dangerous Do not dig a hole under an overhang because it is dangerous.

It may cause a landslide or falling rocks.

Travel motor

0-0036E 0-0053

Do not try to pass the bucket over the cabin ● For safety, do not pass the bucket containing earth over people or the cabin.

0-0051

E0240

0-24

Safety

During Operation

Working on slopes

Ventilation ● Engine exhaust fumes are dangerous. ● Take ventilation measures to prevent gas poi-

Special attention should be paid when operating the machine on slopes because the machine’s stability is significantly influenced.

soning when starting the engine in the locations where ventilation is poor such as indoors, in tunnels, or underground.

● Do not turn the bucket downward more than necessary.

● When operating on a slope, keep the footing level.

0-0043

Make sure the ground is safe

0-0054

● Be sure that the ground or passage is strong enough and there is no risk of collapsing from the machine’s weight and vibrations. ● Be careful of operating during the snow seasons since the ground is covered and not visible. ● Just after a rain fall, cliffs, grooves and road shoulders are dangerous since they tend to be softened. Keep away from them as much as possible. Landslides may occur due to the machine’s vibration or weight. ● If there are rises and falls in the ground, the machine’s operating conditions become unstable.

Try to travel the machine on flat places if possible.

Do not attempt operations beyond the machine capability ● Operations beyond the range of performances may cause damage to the machine or expose operators or workers to a risk of life. ● Perform operations within the range of machine’s performances.

0-0055

0-25

E0250

Safety

During Operation

Using a breaker

Bucket with hook, lifting operations

● When operations using a breaker are necessary,

● When perform lifting operations, special hooks

they should be performed by a person who has a certification for completion of driving skill training for construction machinery vehicles (for demolition). ● Installation of a breaker may cause safety problems or machine faults and reduce the life of the machine; always contact and consult our sales shops or service shops. ● Set relief pressure and engine rotation settings, and reinforce the attachment as necessary. ● Read the breaker sections of the manual thoroughly and perform operations carefully in order not to damage the excavator body or the breaker. ● When not operating the breaker, do not put your foot on the operating pedal. An inadvertent stepon may start breaker to operate; it is dangerous. ● Operation of the breaker at each stroke end (extended or retracted) of the cylinder may cause damage to the cylinder and/or to the machine.

Do not operate it at the stroke end of the cylinder because an unexpected accident resulting in injury or death may happen due to break of the machine.

for lifting are necessary.

● Before starting an operation, check and make sure that the hook has no cracks, deformations, or other abnormalities. ● Check also the lifting gears such as wire ropes or chains before starting the operation. ● Reduce the engine revolutions, and operate levers slowly. Especially, make turns slowly. ● DO NOT let anyone under the lifted bucket.

Using a crusher ● Installation of a crusher may cause safety problems or machine faults and reduce the life of the machine; always contact and consult our sales shops or service shops. ● The heavy weight of a crusher makes the vehicle unstable and poses a risk of overturning when making turns on slopes and hills. In addition, even if you try to stop a turn, the effect could be delayed due to the force of inertia. ● Attachment reinforcement should be done as needed. ● Crushing operation at each stroke end (extended or retracted) of the cylinder may cause damage to the cylinder and/or to the machine.

Do not operate it at the stroke end of the cylinder because an unexpected accident resulting in injury or death may happen due to break of the machine.

E0260

0-26

Safety

While Traveling

Check your route

traveling up and down hills

● You should investigate your route in advance. ● When you have to move a machine in a location

● While traveling up and down hills, travel in parallel with the line of the maximum inclination. traveling diagonally up or down a slope is dangerous.

where your vision is limited, arrange a guide who can give signals as needed. ● And also, before crossing a bridge, pay attention to allowable weight of the bridge.

0-0059 0-0056

Be careful when you change direction on a slope

Starting an operation ● When running the machine, first check the direc-

● Changing direction on a slope may cause the

tions of the travel reduction gears and operator’s cab; then, start the operation.

machine to slide sideways or overturn. When changing directions is absolutely necessary, do it only on a slope with hard ground and a low incline.

0-0057 0-0060

While traveling ● When traveling the machine, choose level

Traveling uphill and downhill (slopes)

ground as much as possible. ● Avoid obstacles, electric poles, and buildings while traveling. ● While traveling on frozen, snow covered ground, pay attention to the ground strength and slippery conditions.

● While traveling on hills, travel slowly and keep the bucket 20-30 cm above the ground level.

● When the machine becomes unstable, stop the machine by touching the bucket to the ground.

20-30 cm

Downhill running posture

20-30 cm Uphill running posture Less than 30ࠑ

Less than 30ࠑ

0-0037E 0-0058

0-27

E0270

Safety

After Operating

Parking

Before leaving the machine

● Park the machine on hard, level and safe

1.

2.

3.

4.

5.

6.

ground.

● Lower the bucket to the ground and stop the engine.

Lower the bucket to the ground.

Put the operating lever in neutral.

Shut off the engine.

Remove the engine key.

Raise the gate lock lever.

Lock the doors.

0-0062 0-0065

Parking the machine on a slope ● Lower the bucket to the ground, put the lever in

Inspection after operation

neutral, and place the braking blocks behind the crawlers (both right and left) on the downhill side. ● Engage turn locks also.

Check each part of the machine after operations (in addition to washing the machine).

● If any faults are detected, repair them immediately; do not postpone it until the following day.

● Fill the fuel tank to full after the daily operations are finished.

Especially in the following situations, perform inspection and repair procedures earlier than usual: after operations at very dusty locations in freezing or very hot weather after operations in swamps or soft ground locations.

0-0063

Parking on roads ● When parking the machine on road, put up signals or/and fences which can be seen at night from other cars. ● Lower the bucket to the ground and lock the doors to prevent some one from operating or tampering with the machine.

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0-0064

E0280

0-28

Safety

While Transporting

Loading and unloading

Removing front attachments

● When you load on or unload the machine from

● When front attachments are removed, the center

trailers or trucks, use ramps.

of gravity moves significantly towards the rear.

● Do not load and unload the machine by jacking it

● Pay special attention when travel the machine.

up.

● When traveling on ramps, apply a counterweight to the side facing the upward slope.

0-0067 0-0069

Transporting the machine ● Fix the machine firmly to prevent the body from

Towing methods

moving while transporting. ● Check the carrying capacity. ● If a permission provided for by the Road Traffic Control or Road Transportation Vehicle laws is necessary, apply for and obtain it.

● When towing the machine, use wire ropes strong enough for the traction load.

● Do not use wire ropes which have kinks, twists, or damage for towing.

● Do not allow anyone between the towing vehicle and the excavator.

● Do not tow the machine on slopes because there is a risk of the machine sliding sideways.

● Take measures to prevent damage to ropes and the excavator by placing wood protectors between the towing wire ropes and the excavator. ● Tow the machine slowly in order to lessen the impact on the machine. ● Connect the excavator and towing vehicle to form a straight line.

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0-29

E0290

Safety

Before Regular Inspection & Maintenance

Maintenance and inspection methods

Important safety parts

● Before performing inspection and maintenance,

● Parts related to safety and fire prevention are

read the “Inspection and Maintenance Section” thoroughly.

specifically referred to as “Important Safety Parts”. Replace these parts regularly. ● “Important Safety Parts” include parts which are difficult to determine the part life by their exterior appearance. Replace these parts regularly even if there are no apparent abnormalities. ● If any abnormality is found before the replacement interval, change and repair the part.

Maintenance/ Inspection Section

0-0038E

Inspect and maintain the machine on level ground 1.

2.

3.

4.

Choose a safe place with level and hard ground.

Lower the bucket to the ground, Stop engine and remove key.

Apply brakes to the shoes.

0-0071

Display a sign “Inspection Under Way” ● Hang a plate indicating “Inspection/Maintenance Under Way” on the door or operating lever.

n ectio Insp er Way Und

0-0039E

E0300

0-30

Safety

Inspection and Maintenance

Do not attempt to maintain moving parts

Opening hoods and covers ● Do not open the engine hood while the engine is

● Avoiding adjustments during driving if possible. ● Repair or adjustments are inevitable, two or

● Engage hood locks whenever you open the en-

more technicians should work jointly. ● Pay special attention and avoid entanglement of clothing in rotating parts.

● Do not open the engine hood when the wind is

running. gine hood or covers. strong.

Locked!

OK!

0-0040E 0-0073

Fire prevention The machine is very hot right after the engine stops!

● Use incombustible oils for cleaning parts. ● Extinguish flames which may cause fire hazards. ● Prepare fire extinguishing appliances such as

● All parts of the machine are very hot just after the

extinguishers.

engine stops. Touching anything may result in skin burns. ● Start inspection/maintenance after all parts have cooled down.

● Do not smoke while inspecting and maintaining the machine.

FUEL

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0-0074

0-31

E0310

Safety

Inspection and Maintenance

Use protective appliances

Holding attachments

● When carrying out maintenance, wear protective

● It is very dangerous to replace or repair joints/

goggles, helmet, safety shoes, gloves, and in accordance with the work, wear protective items such as dust mask and earplugs. ● Always wear protective appliances when doing grinding and hammering work since metal debris flies out.

hoses while holding attachment in the air.

● Always lower them to the ground or place it on blocks.

0-0079

Use tools in a proper manner.

Maintaining underneath the machine

0-0042E

● When working under the machine, use safety supports or safety blocks under the crawlers to support the machine.

Conducting maintenance work in high places ● Put everything in order around the footing area. ● Do not spill oil or grease and do not leave tools lying around.

Be careful not to slip while the machine is traveling. ● Use tools or handrails when mounting up or dismounting. Also, be careful of slippery surfaces. ● DO NOT jump from higher places. ● When working together, decide on and use signals. ● When working together, follow the instructions from the leader.

0-0080

Be prepared in case of emergency! ● Decide where to contact and how to handle the situation in case of an accident or fire. Additionally, investigate places where extinguishers and first-aid boxes are stored.

0-0078

0-0081

E0320

0-32

Safety

Inspection and Maintenance

Release oil pressure before starting maintenance ● Prior to inspection/maintenance, release air

Caution against high-pressure fuel and high-voltage charge during engine running

pressure and oil pressure in circuits after the parts have cooled down. ● When maintaining electric systems, remove the battery negative (-) terminal and start the work.

Pay attention to high-pressure fuel for the engine ● High-pressure fuel is in the fuel pipe while the engine is running or immediately after it has been stopped.

● Carry out inspection/maintenance after stopping the engine and wait for more than 2 minutes until the pressure in the pipe is dropped.

Pay attention to high-voltage charge to the engine ● High-voltage is charged to the controller and/or to the injector while the engine is running or immediately after it has been stopped.

Do not touch the controller and the injector.

If it is necessary to touch them such as in maintenance work, contact our service shops.

0-0082

Battery

High pressure oil

● Batteries emit flammable gases. Always keep

● Pipes and equipment inside of the excavator are

flames away. ● The battery electrolyte contains dilute sulfuric acid. If the fluid touches the skin, immediately wash it off with water and then wash fully with soap. If it gets in the eyes, after flushing them with plenty of water, get medical help. ● Before checking and handling the battery, turn off the power supply (by placing the starter switch to OFF). ● If you use or recharge the battery which requires added solution while the battery electrolyte is lower than the lower level indicated on the side of the battery, it may cause breakage (explosion). ● Check the level of the battery electrolyte (the type of adding solution), hydrometer (maintenance free), battery mounting conditions and the voltage, using testers, on a regular basis.

filled with high pressure oil. ● It is very dangerous to perform inspections/maintenance when oil pressure exits, because the oil could flow out. ● If leakage of high pressure oil from a small hole contacts skins or eyes, it may cause skin or eye injury. If you touch high pressure oils, get medical treatment immediately. ● If the oil is hot, it may cause burns. Wear protective goggles and gloves when conducting inspection/maintenance.

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0-0084

0-33

E0330

Safety

Inspection and Maintenance

Removing the battery.

Parts that have been removed

● Before maintaining the electric system, discon-

● Place removed parts in a stable condition, other-

nect the negative (-) battery terminal.

wise, they may fall down and become dangerous. ● Keep children and bystanders away from the parts storing area. ● When the ground is not hard and solid, parts may sink and fall down of their own weight. Arrange the parts storing area in a place which has level and hard ground. ● If soil or dirt gets inside the pipes, it could cause malfunction or errors. Plug or cap pipes of removed parts.

● Batteries emit flammable gases and may cause ignition and explosion. Battery electrolyte contains dilute sulfuric acid. Handle the battery with extreme care.

0-0085

Ventilation ● When conducting maintenance work in the poor ventilated locations such as indoors, keep doors and windows open and ventilate air to avoid gas poising.

0-0087

Use manufacturer’s genuine parts Always use the manufacturer’s genuine replacement parts, oils and greases. In addition, apply oils and greases compliant to temperature conditions.

Major inspections and maintenance work should be conducted in our Service Shop.

HYDRAULIC OIL

0-0086

ENGINE OIL

GEAR OIL

COOLANT

Handling high pressure hoses ● Kinks and cracks on high pressure hoses could

0-0043E

cause breakage. Do not use any hoses with kinks and cracks. ● If fuel hoses or hydraulic oil hoses are loose or cracked, they could cause fire. Always repair them immediately.

E0340

0-34

Safety

Inspection and Maintenance

First clean the machine, then check and repair it

Draining oil and changing filters ● It is dangerous to drain water or oil and replace filters just after the engine stops. Carry out the work after each part has cooled down (approximately 68 - 104°F (20 - 40°C)).

Cleaning machines makes it easy to detect failures and faults.

Keep the oil filler and oil level gauge clean and avoid dust and dirt entry.

● When changing oil or changing filters, inspect the drained oil and old filters and check for metal debris or foreign substances.

If a large amount of metal debris is detected, contact our Service Shops for repairs.

0-0089

Washing vehicles 1. When washing the machine, be careful not to splash the electrical equipment. ● Monitors and electrical equipment in the operator cabin. ● Do not apply steam directly to battery, connectors and other electrical equipment.

0-0091

Disposal of waste fluids ● Do not pour waste fluids onto ground, rivers,

2. Do not apply high pressure washing steam directly to the radiators.

Wash the radiator carefully and gently.

lakes and marshes. It can harm the environment.

● When disposing of oil, fuel, cooling water, solutions, filters and other harmful substances, follow the local rules and regulations.

Keep fluids free of water and dirt When adding fuel/hydraulic oil/engine oil, keep them free of water, dust and other contaminants.

Do not adding fuel or oil with the strainer removed from the filler port.

water

0-0092

dust

dirt

Use clean oil ● Use clean oil and grease to avoid introducing

0-0044E

dirt.

• Use clean oil and grease.

• Also use clean containers.

● After filling grease, wipe any spilled grease or oil.

• Extra grease on operating/rotating parts.

0-35

E0350

Safety

Inspection and Maintenance

Keep lubricants at proper levels

Do not drop tools and parts

● Either too high or too low lubricant levels are bad

● When opening inspection windows or tank filler

for proper machine operation. When checking and adding oil, maintain the proper levels.

ports for inspection, be careful not to drop bolts/ nuts and tools into them. ● Take out everything from your pockets to avoid dropping things.

Correct oil level

Oil level gauge

0-0045E

Welding and repairing ● Turn off the electric supply. (Move the starter

0-0095

switch to the OFF position). ● If an electronic part (microcomputer) is attached, remove it (electronic components such as controllers). ● Set up a ground within 3.3 feet (1 m) from the area to be welded. ● Do not apply 200 V or more continuously. ● Do not put any seals or bearings between welded area and the ground. ● When welding or heating a painted area, remove the paint first. When heat is applied to a painted area, harmful fumes will be produced. ● If heat is applied near to a section where hydraulic equipment and pipes are located, flammable fumes or vapors may be produced and ignited.

Installing O-rings When removing sealing parts containing O-rings, clean the fitting faces.

Be careful not to damage O-rings and assemble them by applying oil when attaching them.

After finishing maintenance work When working together, decide on and use signals 1. After maintenance, make sure that at low idle there is no oil or water leakage from where the maintenance work was done (for approximately 5 minutes).

2. Operate each component slowly, and make sure that they work correctly.

3. Then, increase the engine revolutions and make sure there is no water or oil leakage.

4. Operate each component and make sure that there are no abnormalities.

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0-0094

E0360

0-36

Safety

Inspection and Maintenance

Inspection and maintenance during cold seasons 1. Use fuel and lubricating oils and greases appropriate for the temperature conditions.

2. Check the battery charging rates.

3. Use anti-freeze (long-life coolant).

4. Remove mud and water attached to the machine body. Wipe off water drops on the cylinder rods.

Inspection and maintenance when the machine is used under special situations When used under extremely hot conditions 1. Check/maintain cooling water and radiators.

2. Check and adjust the fan belt tension.

When used in a rocky place Pay special attention to breakage of the shoe and recoil spring, loose bolts and nuts, cracks and wears. Loose the tension of shoes by a small amount.

When used by the ocean Wash salt off especially carefully. Take special care of electronic equipment, hydraulic cylinders, shoes and recoil spring to prevent corrosion.

When used at sites full of dust and sand 1. Check the elements of air cleaners more often, and clean or change the elements and dust cups regardless of exchange intervals.

2. Tighten caps fully to prevent dust and sand from entering the hydraulic oil tank.

When used in marshes or on soft ground Lubricate and grease the parts earlier than usual.

Grease any pins which have been submerged in muddy water every day. In addition, check and clean the shoes and recoil spring.

0-37

E3430

Instruments and Controls This INSTRUMENTS AND CONTROLS section describes the functions and proper operation of the components required to operate the machine.

For safe operation, fully understand the contents of this section.

CONTROLS

Contents • Location of Components Overall View Operator’s Cab • Right Console Right Console • Monitor & Switch Panel Monitor & Switch Panel • Moniter Display • Switch Panel • Left Console Left Console Switch • Air Conditioner Air Conditioner (If equipped) • Operation Levers Operation Levers • Operator’s Seat Operator’s Seat • Operator’s Cab • Fuses • Explanation of device Battery Starting the Engine by Using Booster Cables

To operate and control the machine, refer to the OPERATING INSTRUCTIONS Section.

1-0

E0371

Instruments/Controls

Location of Components

Overall View 1 2 3 4 5 6 7 8 9 0

Bucket Bucket Link Arm Link Bucket Cylinder Arm Arm Cylinder Swing Bracket Boom Swing Cylinder Blade

A B C D E F G H I J

Boom Cylinder Operator’s Cab Swing Unit Fuel Tank Hydrauric Tank Battery Air Cleaner Engine and Radiator Counterweight Tarntable Bearing

K L M N

Shoe (Crawler) Travel Unit Lower Roller Upper Roller O Shoe Tension Unit P Take up Roller

1-0145E

1-1

Instruments/Controls

Location of Components

Operator’s Cab

Air vent Operetor's seat

Monitor&switch panel Blade lever

Right control lever (with idle switch) Left control lever (with horn switch)

Air vent

Defroster Switch panel

Trevel lever

Air conditioner switch Foot rest

Trevel pedal Lock bar Boom swing pedal

1-0146E

1-2

Instruments/Controls

Location of Components

Operator’s Cab Left travel lever&pedal

Right travel lever&pedal

Foot rest Boom swing pedal

Lock bar

Right control lever (with idel switch)

Left control lever (with horn switch)

Air conditioner switch

ON/OFF

Blade lever

Switch panel Monitor&switch panel

A/C

Throttle volume

Start switch

Cigarette ligter Seat belt

Radio

12V power socket

Air vent

1-0147E

1-3

Instruments/Controls

Right Console

Right Console 1Starter Switch 2Throttle Volume 3Control lever (Right) (with Idle Switch) 4Monitor & Switch Panel

1-0067E

● Regulates engine r.p.m.

Starter Switch

Low speed.......... Volume mark position at START

High speed ......... Volume mark position at

ON

IMPORTANT

ACC

If the number of engine r.p.m. does not change even after turning the throttle volume switch, it is because the idle switch is ON. Push the idle switch to OFF.

OFF

1-0068E

Start Engine starting position

Idle Switch

ON Engine running position Electrical system energizing position ACC (Accessory) Accessory power supply connection.

Engine stopping position.

OFF Key inserting/removing position.

Electrical system off position.

The key is used both for opening/closing doors and opening/ closing the fuel tank cap.

1-0070E

By using this switch, the engine r.p.m can be adjusted to low idling.

Throttle Volume

● One Touch Idle Each time the Idle switch is pressed, the engine r.p.m. can be switched alternately between low idling and the original r.p.m.

1-0069E

1-4

Instruments/Controls

Monitor & Switch Panel

Monitor & Switch Panel 1

4

5

6

2

7

8

9

10

3

11

12

13

1-0071E

WARNING ● The monitor is intended to indicate the machine’s condition and to quickly alert the operator of any abnormalities by means of messages or buzzers. It is not intended to be used for inspection or maintenance. ● Follow the start of work inspection described in the “Inspection and Maintenance” Section.

1 Fuel Meter

8 Engine Electrical System Problem (not used)

2 Coolant Water Thermometer

9 Glow (pre-heat) Indication

3 Hour Meter

: Wiper Switch

4 Over Heat

A Washer Switch

5 ENG Oil Low Pressure

B Work Lamp Switch

6 Fuel amount warning

C Travel Mode Switch

7 Battery charge Fault

E0420

1-5

Instruments/Controls

Moniter Display Hour Meter

WARNING ● The monitor is intended to indicate the machine’s condition and to quickly alert the operator of any abnormalities by means of messages or buzzers. It is not intended to be used for inspection or maintenance. ● Follow the start of work inspection described in the “Inspection and Maintenance” Section. ● The monitor can be damaged by water.

Take care that it does not get wet.

1-0074E

● Indicates the operation time of the machine. The last digit corresponds to 1/10th of an hour (6 min.). ● When the engine is running, the green lamp blinks to indicate that the meter is advancing. ● The indicated time is used for the reference time of inspection and maintenance.

Fuel Meter

Over Heat

1-0072E

Indicates the amount of fuel in the tank.

F

Fuel Level High

E

Fuel Level Low

1-0075E

(The warning buzzer sounds) Indicates the engine coolant temperature or hydraulic oil temperature abnormally rises. Put the engine r.p.m. at low idling to reduce water or oil temperatures.

If the fuel meter indicates E, there is very little fuel left in the tank. Refill the machine with fuel.

Coolant Water Thermometer

Engine Oil Pressure Problem

1-0076E

1-0073E

Indicates the engine coolant water temperature.

C: Low temperature

(The warning buzzer sounds) The engine oil pressure is abnormally low or the engine oil filter is blocked.

Stop the engine, check engine oil level and add oil if the lever is too low. When the oil level is normal but the indication is turnd ON, change the engine oil and filter.

H: High temperature

If the indication is below C position, carry out engine warming-up. When the indication is in H position, reduce the load to prevent overheating.

1-6

Instruments/Controls

Switch Panel

Fuel amount warning

Wiper Switch

1-0077E

(The warning buzzer sounds) If the fuel mark is indictates, there is very little fuel left in the tank. Refill the machine with fuel.

1-0081E

When the switch is pressed, the wiper function toggles in an Intermittent/Continuous/Stop cycle.

Intermittent: Intermittent lamp [I lamp] ON Continuous: Continuous lamp [II lamp] ON Stop: Lamps OFF

Battery Charger Fault

IMPORTANT Using the wipers when the windshield is dry or dirty and when it is covered by snow can cause damage to them. Use caution in such cases.

1-0078E

(The warning buzzer sounds) Indicates battery charging system problems.

Check the electric circuits.

Washer Switch

Glow (Pre Heat) Indication

1-0082E

When the switch is pressed, washer fluid is sprayed and the wipers are activated.

1-0080E

When the outside temperature is low and the key switch is moved to ON, the indication turns on.

IMPORTANT Do not operate the wipers when there is no washer fluid, or the motor can seize.

Warning buzzer The warning buzzer stops after sounding for a few seconds.

Work Lamp Switch

Check Faulty Bulbs in the Monitor Before starting the engine, move the key switch to ON position and make sure that all bulbs in the monitor indication turn on (will be turned off in 3 minutes).

If bulbs are faulty, replace them.

1-0083E

When the switch is pressed, the work lamp will be turned on.off.

1-7

Instruments/Controls

Switch Panel

Travel Mode Change Switch

1-0084E

When the switch is pressed, the travel speed toggles between high and low.

(Indicates the TRAVEL mode is in high speed.)

WARNING When the travel modes are change during traveling, travel directions can be swerved. Stop the machine and then change the speed modes.

Low speed : Appropriate when traveling on slopes and places with bad ground conditions.

High speed : Appropriate when traveling on flat and level places with good ground conditions.

When the traveling load become high, it automatically returns to Low.

1-8

Instruments/Controls

Left Console

Left Console 1Control lever (Left) (with Horn Switch) 2Gate Lock Lever 3Travel caution Switch 4Rotating beacon 5Air conditioner 6Auxiliarty Switch

A/C ON/OFF

1-0144E

Horn Switch

Gate Lock Lever

1-0086E

When the switch located on top of the left side operation lever is pressed, the horn will sound.

CAUTION Always press the switch and sound the horn to give signals when you start, travel or swing the machine.

0-0153E

WARNING ● When not operating the machine, always raise the gate_ lock lever and lock it.

● A touch on the unlocked operation lever causes the machine to move. It is dangerous! ● Mare sure the lock lever is in the locked position and it is locked.

Unexpected machine operations can be avoided even if you inadvertently touch the operation levers when you are not operating the machine or when you get on and off the machine.

1-9

Instruments/Controls

Left Console

Switch Travel Caution Alarm switch

%106

#761 1(( 1-0126E

“ON” position the alarm sounds when the travel controls are actuated.

“AUTO OFF” position, when the travel controls are actuated, the alarm sounds for 10 seconds and then stops. Each time you stop the travel and then start again the alarm will sound for 10 seconds and then stop.

Rotating beacon

ON

OFF 1-0090E

This switch controls the rotating beacon. Press the switch once and the rotating beacon and the indicator lamp in the switch will light up. When the switch is pressed again, the rotating beacon goes out.

1-10

Instruments/Controls

Air Conditioner

Air Conditioner (If equipped) Control Panel 1Main Power Supply Switch 2Compressor Switch 3Fan Air Volume Change Switch 4Temperaure Control Switch 5Vent Change Switch 6Defroster Switch 7Inside/Outside Air Change Switch

ON/OFF

A/C

1-0092E

1 Main Power Supply Switch

3 Fan Air Volume Change Switch

This switch operates (ON) and stops (OFF) the air conditioner.

When turned ON by pressing this switch, the operation starts using the setting when the last time turned off.

When the air conditioner is running, by pressing this switch the fan air volume will be changed.

By pressing

, the air volume increases.

By pressing

, the air volume decreases.

ON/OFF

1-0093E 1-0095E

2 Compressor Switch (Air conditioner switch) 4 Temperaure Control Switch

Turns ON/OFF the compressor.

When it is turned ON, is indicated on the switch.

When the air conditioner is running, pressing this switch sets the inside temperature of the operator’s cabin.

A/C

By pressing

, the temperature increases.

By pressing

, the temperature decreases.

1-0094E

1-0096E

1-11

Instruments/Controls

Air Conditioner

5 Vent Change Switch By pressing this switch the vent change will be changed to vent function.

1-0097E

6 Vent Change Switch By pressing this switch, the vent change will be changed to defroster function.

1-0098E

7 Inside/Outside Air Change Switch Each time the switch is pressed, the inner air circulation/ outer air induction are changed over and the following indication appears on the switch.

1-0099E

1-12

Instruments/Controls

Explanation of device

Radio

1-0051

AM/FM Radio 6 Preset buttons (1~6)

IMPORTANT

One station each in the FM and MW bands, respectively, can be preset for each of these keys, 1 to 6 Refer to the section "Preseting desired stations"

● When water gets inside the speakers or radio, it can cause unrepairable damage. Do not get it wet. Especially under rainy weather or when washing the machine, close the windows. ● Do not use benzine, thinner or other solvents for cleaning the scale plate or knobs. ● Wipe with a soft and dry cloth. ● Do not disassemble the radio.

7 SEEK button When this button is pressed, the radio automatially, searches for a receivable station, and automatically stops searching once a station is picked-up.

1 Power switch /volume control

8 Band select switch

Turn this knob clockwise. The "click" sound indicates that the power supply is turned on.

Further turning increase the sound volume.

Pressing this switch changes over between FM and MW. The display indicates the receiving band and frequency.

Note : MW only models do not have this function.

2 Tone control Turning this knob counter-clockwise decrease high frequency sound level and clockwise to increase high sound level.

9 Tuning buttons Pressing either UP or DOWN buttons shifts the receiving frequency step by step. Pressing eitllre of these buttons continuously, allows continuous shifting of the receiving frequency.

3 Display The display indicates the receiving frequency, tlme ard / or operating functions.

4 CLOCK button

Listen to the radio

Pressing this button to indicate current time.

Pressing this button again to resume freqpency display.

Note : Battery back-up models (B-type) do not have clock function and this button is disabled.

1. Turn on ACC switch to ON position and turn ON the radio switch.

2. Select desired band MW or FM by band switch.

3. Select desired frequency by pre-set button, SEEK button, or tuning button.

5 AST (Auto-store memory) button This button has two functions depending on pressing time. Pressing this button and release within two seconds, it will work as Preset-Memory-Scan and the radio will receive pre-programed stations for a few seconds and change to another stations. Pressing this button again to stop scanning. Pressing this button longer than two seconds, it will be Auto-store Memory.

E0640

4. Adjust desired volume level and tone by the controls accordingly 5. To turn off the radio, turn volume control knob to counter-clockwise until "click" sounds.

1-13

Instruments/Controls

Explanation of device

SEEK tuning

Time set

When this button is pressed, the radio automatically shift receiving frequency upward and searches for a receivable station.

And automatically stops searching once a station is picked-up.

1. Turn on ACC switch to ON position and turn ON the radio switch.

2. Press “CLOCK” button, if display is indicating frequency, and indicate time.

3. Pressing “M” button while depressing “CLOCK” button will increase MINUTES. Pressing “H” button while depressing “CLOCK” button will increase HOUR.

Manual tuning Pressing either UP or DOWN buttons shifts the receiving frequency step by step Pressing either of these buttons continuously, allows cuntinuous shifting of the receiving frequency.

4. Releasing “M” / “H” and “CLOCK” button will set the time. [depressing]

Presetting desired station into memory 1. Select desired station by manual or seek tuning.

2. Press desired number of memory button for more than two seconds.

Adjustment of minutes

3. Repeat 1-2 to preset other stations into preset memory.

Adjustment of hours

• Follow same method to change previously stored station to other station.

• In case battery back-up line is cut of due to replacing battery or any other reason, previously stored memory will be erased and the presetting procedure should be done again.

• The radio is capable to store 6 stations of MW and 6 stations of FM band.

1-0042E

Muting switch A muting switch by which the volume of the radio sound can be muted is provided on the console lever on the left.

Auto-store memory Pressing AST button more than two seconds, radio starts automatically to search receivable stations and store the frequency automatically into each memories.

1-14

Instruments/Controls

Operation Levers

Operation Levers Blade Lever

WARNING ● Do not hang anything on the operation le-

2 Raise Blade lever

vers. It may cause misoperation. ● The Auto Idle indicator on the monitor display indicates ON. The operation lever is used to return the engine automatically to its previous r.p.m. level.

1 Lower

Travel Lever

1-0102E

Push the lever, and the blade will lower.

①

Push the lever, and the blade will raise.

③

④

② 1-0100E

WARNING ● Before operating the travel lever, confirm the direction of the lower frame (forward or backward).

The travel unit is in the back and the travel lever is pushed, the machine moves forward and if it is pulled towards you the machine moves backward. ● When not traveling, do not place your feet on the travel pedals.

1 Press the right and left travel levers at the same time to move the machine forward.

2 Pull the right and left travel levers at the same time to move the machine backward.

3 Press the left travel lever to make a right turn.

4 Press the right travel pedal to make a left turn.

40 - 50cm Travel unit

1-0148E

1-15

Instruments/Controls

Operation Levers

Operation Levers

Operation Name Plate

WARNING ● Even if the lever is put into neutral, the

川 泉

swing may continue briefly due to inertia.

Therefore, keep enough distance not to hit anything during swing operations. ● The operation method of levers varies according to the machine specification. Verify the operation procedure nameplate attached inside the cab. Master and be familiar with the operation levers before operating the machine. ● The operation of the excavator attachment is the reverse of that of the bucket. Caution should be taken when performing this operation.

1-0127E

DANGER ● Before beginning operations, verify that the operation method described in the operation nameplate is the same as the actual movements of the machine. ● When verifying each operation, perform it slowly. ● The operation method may different depending on the specifications. ● When the operation method on the nameplate and the actual movements do not match, either change the pipeline connections so that the movements match the nameplate or change the nameplate to match the machine movements.

1-0103E

Arm out

Boom, arm, bucket and swing operations can be controlled individually or simultaneously. The operation speed varies according to the operation lever stroke. When the hand is released from the operation lever, the lever automatically returns to neutral.

Swing left

Boom down Swing right

Bucket in

Arm in

Bucket out Boom up 1-0019E

This machine adopts ISO (JIS) operation method.

Operation Name Plate

KAP0859

1-0107E

1-16

Instruments/Controls

Operation Levers

WARNING THIS MACHINE IS EQUIPPED WITH A CONTROL PATTERN SELECTOR. DO NOT OPERATE UNLESS CONTROL PATTERN CARD IN THIS HOLDER MATCHES SELECTOR VALVE POSITION. KHP1587-00 SERIOUS INJURY OR DEATH COULD RESULT.

CONTROL FUNCTIONS ON THIS MACHINE ARE INTERCHANGABLE ONLY AN AUTHORIZED DEALER REPRESENTATIVE IS ALLOWED TO MODIFY THE CONTROL PATTERN

1-0128E

WHEN A MODIFICATION HAS BEEN MADE THE REPRESENTATIVE MUST CHANGE THE DECAL TO MATCH THE NEW CONTROL PATTERN FAILURE TO CHANGE THE DECAL COULD RESULT IN DEATH OR SERIOUS INJURY 162140A1

1-0129E

LEFT HAND

SELECTOR VALVE

RIGHT HAND

KHP1588-00

LEFT HAND

SELECTOR VALVE

RIGHT HAND

1-0136E

1-17

Instruments/Controls

Operation Levers

Boom Swing Pedal Press the pedal (in direction 1), and the right boom will swing.

Press the pedal (in direction 2), and the left boom will swing.

WARNING When the pedal is not used, lock it in position.

LOCK THE PEDAL WITH THE LEVER WHEN NOT OPERATING THE PEDAL TO AVOID ACCIDENTAL CONTROL ENGAGEMENT AND POSSIBLE INJURY.

● Caution against interference be-

tween the bucket and the operator’s cab

KHP1820-00

When the attachment is fully rotated toward the Left, the bucket comes close to the operator’s cab, the mirror, and the head guard.

0-0182E

• When changing the bucket, confirm that no interference with the bucket will be found.

• If the bucket can interferes with something, provide operators with a caution plate warning that it can be interfered.

ATTACHMENT IMPACT HAZARD

Keep attachment away from cab and machine -*2

0-0183E

1-0149E

- * 2

1-0150E

1-18

Instruments/Controls

Operator’s Seat

Operator’s Seat A.Seat height adjustment

WARNING

• Adjust the seat height by shifting the lever 7 as follows.

Raise: Pull up the lever.

Lower: Push down the lever.

Before adjusting the seat, lower the bucket to the ground and stop the engine or put the machine in a lever locked condition.

Always verify that the seat is locked after adjusting it.

B.Forward/backward Seat adjustment

Adjust the seat to allow the operator to easily reach the operation pedals and levers.

• Pull the slide lever 2 to adjust the seat position forward/ backward.

• When the forward/backward adjustment is completed, release the lever 2 to lock the seat.

C.Reclining adjustment • Pull the reclining adjustment lever 3 to adjust the backrest angle.

• When the reclining adjustment is completed, release the lever 3 to lock the backrest.

4

D.Arm Rest • Turn the adjustment dial 4 located under the arm rest to adjust the angle.

• Lift the arm rest so that it springs up at the side of the back seat.

3 8

1

E. Suspension Support Adjustment (If equipped)

7 2

1-0108E

• While sitting in the seat, turn the handle 1 to the right to adjust the support hardness.

F. Console & Seat Slide Position Adjustment • Pull the slide lever 5 to adjust the position as a whole.

• When the adjustment is completed, release the lever 5 to lock the seat.

G.Seat pocket • The pocket is located at the back side of the backrest.

• Use this pocket to store the instruction manual and others.Operator’s Seat

5 1-0109E

1-19

Instruments/Controls

Operator’s Seat

H. Seatbelt • Before starting operations, put on the seat belts.

• Mare sure the seat belt does not have any twists, and then insert it into its buckle.

• Always verify that the seat belt is firmly locked.

CAUTION Be sure to inspect the seatbelt for damage before starting operation of the machine.

If damaged, replace it with a new seat belt.

I. Head Rest • Hold the headrest with your both hands to move it up, down, forward, or backward gently for adjustment.

J. Lumber support adjustment • Press the bulb 8 to fill air into the lumbar support which in turn protrudes the waist support.

• Press the button at the base of the bulb 8 to deflate the lumbar support which in turn returns to its initial position.

1-20

Instruments/Controls

Operator’s Cab

Front Window

Opening WARNING

Front

When opening and closing the front window: 5. On a level site, lower the bucket to the ground and stop the engine.

6. When opening and closing the window, do it slowly with care to avoid getting fingers or hands caught.

7. Securely lock the window in place before starting the operation.

1

1-0111E

Upper Window CAUTION Be careful! The stored front window may fall down.

You could get injured when the stored front window could slide and fall off.

Make sure the front window is locked in the stored position.

The front window (upper window) can be stored into the top of the operator’s cab.

Rear

2 -A 2 -B Front

CAUTION

1-0112E

Do not touch by hand the front window upper part on the cab side (figure below) because the wiper contact point is there. If touched by hand, the contact may worsen, causing incorrect operations.

1. Move to the right the autolock 1 lever located at the upper side of the upper window to release the lock.

2. Hold the lower grip with the left hand and the upper grip with the right hand. Slowly pull up the upper window.

Wiper Contact Point

3. After verifying that the window is fixed by the center autolock 2-A located at the rear top of the cab, securely lock the window with the lock pin 2-B.

1-0110E

1-0131E

1-21

Instruments/Controls

Operator’s Cab

Closing

Door Lock

1. Release the lock of the lock pin at the back side of the cab, and turn the lock pin inward.

2. Remove the autolock at the rear top of the cab.

3. Hold the front window side grip with the left hand and the rear window side grip with the right hand.

4. Lower the front window slowly.

5. By pushing both hands onto the upper windows, confirm that the window is fixed by the autolock located on the upper side of the front window.

Door Release Lever

1-0116E

Lower Window

This is used to keep the door open.

Lower Window Opening/ Closing

Fully open the cab door and push it into the lock to lock it open.

To close the door, press down the door release lever which is located at the left side of the operator’s seat.

Cab Light Switch ON

1-0114E

With the upper window of the front window is opened, the lower window can be removed.

OFF

1-0117E

The cab light switch is located inside the roof of cab.

Hinged Roof Panel Hinged Roof Panel Lock

Recessed area

1-0113E

1. Store the removed lower window into the left side of the rear inside cab. a) For storage, align the lower side and the opposite side with the each recessed area for the storage position at the rear. b) Firmly press the front side to the lock to secure it. Interior Light Switch

1-0118E

NOTE (When cleaning) Wipe with a damp cloth for wiping with a dry cloth may cause clouding because the hinged roof panel is made of resin glass.

1-22

Instruments/Controls

Fuses

Fuses Fuses protect the electrical components and cables from overheating.

If any lamp or electrical component does not operate, it may be the result of a blown fuse.

When replacing a fuse, select one of the proper amperage.

Fuse Replacement CAUTION Before replacing the fuse, be sure to turn off the power supply (turn the starter switch to OFF).

Fuse box location (rear console) 1. Stop the engine. (Turn the starter switch to OFF.) 2. Obtain a fuse of the proper amperage for the socket where the blown fuse was placed.

Purchase specified rating fuses indicated for automobile use at a car shop or gas station.

3. Replace the blown fuse with a new one.

4. Install the fuse cover.

If the reason for the blown fuse is unknown or the fuse blows out repeatedly, have the machine inspected at a Service Shop to determine the cause.

1-0151E

1-23

Instruments/Controls

Explanation of device

Battery Installation and Removal of Battery

WARNING

● For removal, first disconnect the ground side ter-

Before inspecting and handling the battery, be sure to turn off the power supply (turn the starter switch to OFF).

Since the battery generates inflammable hydrogen gas, it may catch fire and explode.

minal ((-) terminal side).

If any tool or other object should come into contact with the (+) terminal, there is the danger that a spark may be caused. ● For installation, connect the ground side terminal ((-) terminal side) last.

● Do not use any matches, cigarettes, or other sources of fire or sparks near the battery. ● Before charging the battery, remove it from the machine and remove all the plugs. Select a well ventilated area.

Terminal side

Sulfuric acid is used as the electrolyte. It is dangerous because it can cause burns or loss of eyesight.

● If the battery fluid comes into contact with

Removal

skin or clothes, immediately wash it off with lots of water. ● If the battery fluid gets into your eyes, immediately wash your eyes with lots of water and have your eyes treated by a doctor.

1-0141E

● Do not connect the battery with the terminal connections reversed (connection of (+) to (-) or (-) to (+). It may cause damage to the generator or others.

Terminal side

Installation 1-0142E

0-0032E

1-24

Instruments/Controls

Explanation of device

Starting the Engine by Using Booster Cables 3. Removing the Booster Cables Remove the booster cables in the order of 1 to 4:

WARNING When connecting the cables, never allow the (+) and (-) terminals to touch.

Using the booster cables to start the engine can lead to accident if not done properly. Use extreme caution.

a) Remove the booster cables connected to the swing frame of the faulty machine. b) Remove the black cable connected to the terminal of the normal machine. c) Remove the red cable connected to the terminal of the normal machine.

1. Connecting Booster Cables a) Stop the engine.

d) Remove the red cable connected to the terminal of the faulty machine.

b) Connect the booster cables in the order of 1 to 4:

1 Connect one terminal of the red cable to the

Red cable

(+) terminal of the faulty machine.

2 Connect the other terminal of the red cable to the (+) terminal of a normal machine.

3 Connect one terminal of the black cable to the (-) terminal of the normal machine.

4 Connect the other terminal of the black cable to the faulty machine’s swing frame at a place away from the battery.

Terminal

c)

d)

b)

Normal machine battery Black cable

Faulty machine battery Terminal

a)

Faulty machine’s engine block or iron shoe 1-0036E

Red cable

Normal machine battery Black cable

Terminal

Faulty machine battery Terminal

Faulty machine’s engine block or iron shoe 1-0035E

2. Starting the Engine a) Make sure that the booster cables are connected correctly. b) Start the engine of the normal machine and wait for 4 to 5 minutes. c) Start the engine of the faulty machine.

(After cracking for 20 seconds and the engine does not start, wait for 2 to 3 minutes and try again.)

E0741

1-25

Instruments/Controls

Explanation of device 3. Check the battery regularly.

WARNING

a) When you use the battery which requires added solution, check the solution level and always fill it up if the level is low. b) Check the terminals and fixtures. c) Checking voltage using a tester is also recommended.

When using or charging the battery which requires added solution at the electrolyte level below the “LOWER Level” indicated at the side of battery, it may cause damage (exposition) to the battery.

IMPORTANT

The battery which requires added solution

If the battery which requires added solution is continued to be used with the electrolyte level below the “LOWER Level” indicated at the side of battery, it may deteriorate the battery quicker.

1. The battery requires added solution.

However it is unnecessary to add solution at the new machine because it equips it with the maintenance free battery.

After being used for a given period, the solution inside the battery (dilute sulfuric acid) will decrease.

If the solution level is close to the LOWER level, add distilled water or regular battery solution up to the UPPER level. (if the label indication is not attached, verify it by using an indicator)

The solution level is too low and the polar plates are exposed.

The filled hydrogen gas gets short circuited

Explosion!

Electrolyte level is low

1-0038E

Do not add the solution above the UPPER level line.

1-0037E

2. Explosion Accident Example a) If the battery which requires added solution is left with the solution level low, hydrogen gas tends to be generated and fill the inside of the battery. b) If the cells are exposed and deteriorated, the plus (+) polar plate and negative (-) polar plate easily get short-circuited. c) When the sparks caused by the short circuit ignite the inner gas, the battery may explode.

1-26

E0750

Operating Instructions This OPERATING INSTRUCTIONS section describes the proper operation of the machine.

All operators should always operate the machine carefully and safely to prevent personal injuries and damage to the machine.

Contents • Operation of New Machine • Daily Inspections • Starting and Stopping the Engine

OPERATING

• Warm-up Operation • Operations (Traveling) • Operations (Swing) • Operations (Attachment) • Operations • Operating Instructions (Cautions) • Operating Instructions (Procedures) • Bucket: Turning Over and Replacement • On Completion of Daily Operations • Operating in Cold Climates • Operating under Extreme Conditions • Transportation • Storing

* For operations of the instruments and controls, refer to the INSTRUMENTS AND CONTROLS section.

WARNING ● If any problem is found, immediately correct the problem.

Do not run or operate any machine which is not properly maintained. ● Before starting operations, check the job site conditions and take the necessary measures to ensure safe operations. ● Use extreme care in dangerous places. ● Make sure that unauthorized people can not enter the job site.

2-0

E0780

Operating

Operation of New Machine

Using a New Machine 4. Check if the machine is running properly.

Although a new machine is inspected and adjusted before being delivered, operating it under severe conditions before the end of the break-in period will affect its performance and shorten the service life.

5. Avoid running or swinging the machine rapidly.

6. Avoid giving the machine a shock by suddenly stopping the boom when lowering it, etc.

IMPORTANT Be sure to break in the machine for 50 to 100 hours (indicated by the hour meter) before working under full load conditions.

If the machine is operated at full load before it has been broken-in, seizing or scuffing may occur, resulting in shortening of the machine’s service life. Therefore, caution should be taken to prevent this from happening.

2-0003

Breaking-in procedure (up to 50 to 100 hours)

7. Conduct the new machine 50 hours maintenance.

1. Conduct the daily inspection and check for any oil, fuel, and coolant water leaks.

8. Grease the front pins everyday (for greasing type machines).

2. Always warm up the engine before operation.

Warming up!

Hours of operation Element

2-0001E

2-0002E

3. Keep the speed of the engine below 80% of the maximum.

2-0002

E0790

2-1

Operating

Daily Inspections Check after starting the engine

To ensure the safety of the operator and to extend the service life of the machine, perform the following daily inspections.

1. Horn and operation of all gauges.

2. Engine start condition, noise and exhaust color.

3. Leakage of oil, fuel and coolant.

2-0005

WARNING

2-0006

Perform inspections before starting.

If any problem is found during the inspection, immediately identify the cause and adjust or repair the machine to prevent further trouble.

If the machine is operated with the problem uncorrected, it may cause more serious problems or severe accidents.

Daily Inspections Visual check Visually check the machine before starting the engine.

Thoroughly check the surroundings and the bottom of the machine for the following: 1. Leakage of oil, fuel and coolant.

2. Loose bolts and nuts.

3. • Make sure there are no electrical short circuits.

• Check the battery connections are properly tightened.

4. Oil stain.

5. Accumulation of foreign materials.

2-2

E0800

Operating

Daily Inspections

Item to check daily Check Item General

1.

2.

3.

4.

5.

Check for coolant and oil leakage.

Check bolts and nuts for looseness.

Eliminate accumulated dust (from engine/inside cab).

Check pysical exterior damage.

Check if the cab and the window are clean.

Check before Starting Engine

1. Engine 1) Oil and coolant levels and their cleanliness.

2) Leakage of oil and water, damage of hoses and lines.

3) Damage and clogging of radiator and oil cooler.

4) Tightness of fan belts.

5) Clogging of air cleaner.

6) Draining the water and sediments from the fuel filter (main and pre) 2. Upper Structure 1) Oil level, leakage and water drainage from fuel tank.

2) Oil level, cleanliness of hydraulic oil tank.

3) Leakage of oil and water, damage of hoses and lines.

4) Looseness of bolts and nuts.

5) Deformation and damage of any area.

6) • Make sure there are no electrical short circuits.

• Check the battery connections are properly tightened.

7) Adjustment of rear view mirrors.

3. Tracks 1) Looseness, wear and damage of shoes.

2) Oil leakage and wear of the upper and lower rollers.

3) Looseness and loss of mounting bolts.

4. Working Equipment 1) Oil leakage and damage on the cylinders, lines, hoses, etc.

2) Wear and damage of bucket.

3) Looseness, wear and breakage of bucket teeth.

4) Lubrication of the front attachment.

5) Looseness and loss of mounting bolts.

5. Outer Appearance 1) Damage and deformation.

Check after Starting Engine

1.

2.

3.

4.

5.

Engine running state, exhaust color and abnormal noise.

Operation and abnormal noise in hydraulic devices.

Leakage of water and oil in any area.

Check horn, buzzer, working lamp and monitor.

Check if readings of water and hydraulic oil thermometers are correct.

6. Inspection of each operation. (travel, swing, attachment)

Refer to the next section "Inspection and Maintenance" for inspection procedure details.

E0810

2-3

Operating

Starting and Stopping the Engine

Inspections before Starting the Engine warm up operation.

Note: If the engine runs at low r.p.m., vibration may occur. In this case, slightly increase the r.p.m. and the vibration will stop.

Before starting the engine, perform the daily inspection outlined in the previous section (Daily Inspection).

2-0006

Perform inspections before starting.

Basic operation before starting the engine WARNING Check that the gate lock lever at the locked position.

1. After verifying that there are no problems with the machine and checking the surroundings, sit in the operator’s seat.

2. Put the gate lock lever at the locked position.

3. Sit in the operator’s seat and adjust the position so that the levers and pedals can be easily operated.

4. Put the operation levers into neutral.

Cautions for starting the engine 1. When it is cold, the engine becomes harder to start because the oil viscosity increases and the battery performance decreases. Start the engine at the first trial if possible.

2. Sound the horn to alert people in the surrounding area.

IMPORTANT When cold: In winter or when it is cold, before starting the engine the monitor shows readings and the engine will be automatically preheated.

Start the engine after completing preheating.

3. After starting the engine, always perform the

2-4

E0821

Operating

Starting and Stopping the Engine

Starting the Engine After performing the basic operations described in “Before Starting the Engine” section, start the engine.

Basic operation for starting the engine 1. Put the gate lock lever at the locked position.

2. Insert the key into the starter switch and turn the key to the “ON” position. Check on the monitor for any problems.

3. Press the horn switch (on the top of the left operation lever) to 4. sound the horn to alert people in the surrounding area.Check to see that there are not people at the rear the muffler.

5. Turn the key from the “ON” position to the “START” position.

Starter swtch ON ACC OFF

2-0057E

IMPORTANT If the engine can not start in one try, operate the starter for up to 10 seconds then wait for 1 or 2 minutes before trying again.

When it is cold, the engine is sometimes hard to start, but do not continue running the starter for more than 10 seconds.

The engine has been designed environment friendly so that it take longer time then conventional engine to start the engine.

6. After starting the engine, perform warm up operations.

2-5

Operating

Starting and Stopping the Engine

Inspections after Starting the Engine WARNING If any problem is found, immediately stop the engine, identify the cause and correct it immediately.

Basic operation after starting the engine Warming up!

2-0001E

After starting the engine, inspect and verify the following while warm up operation (see the “Warm Up Operation” section) is being done.

1. Engine running state, exhaust color and abnormal noise.

2. Operation and abnormal noise in hydraulic devices.

3. Leakage of water and oil in any area.

4. Check horn, buzzer, working lamp and monitor.

5. Check if readings of water and hydraulic oil thermometers are correct.

Right temperature

2-0058E

6. Check that all operations (travel, swing and attachment) are normal.

2-6

Operating

Starting and Stopping the Engine

Stopping the Engine (Normal Operation) 1. Park the machine on flat, solid ground and lower the bucket to the ground.

2-0009

2. When stopping the engine, keep the engine in low idling mode for about 5 minutes to lower the water temperature.

● Stopping the engine suddenly without cooling it off can cause damage to the engine parts.

Low

2-0059E

3. Turn the key in the starter switch to “OFF” position to stop the engine.

Pull out the key.

Starter switch ON ACC OFF 2-0060E

2-7

Operating

Warm-up Operation

Warm-up Operation Warm-up procedures

WARNING

1. Warm up the engine Neglecting the warm-up operation may cause delayed starting and stopping of each operation.

a) Warm up the engine Until the reading comes to “C” position in water thermometer.

Water thermometer

CAUTION ● Be sure to perform warm-up operation to prevent damage to the hydraulics as well as for safe operation. ● After warming up, be sure to confirm that the boom, arm, bucket, swing and travel operations can be properly performed before working the machine. ● Warm up the machine sufficiently in the winter or in cold areas.

2-0061E

b) Manual Warm-up Put the throttle volume to low-medium position and run for about 5-10 minutes.

The operating temperature of the hydraulic oil in this machine is 122-170°F (50-80°C) (the center of the oil thermometer.). If the machine is operated when the oil temperature is less than 68°F (20°C) [the second graduation of the gauge], the hydraulic components may be damaged.

After starting the engine and before beginning work, warm up the oil temperature to 68°F (20°C) (the second graduation of the gauge) by following the procedures.

2-8

E0860

Operating

Warm-up Operation 3. Confirm each operation

2. Warm up the hydraulics.

a) Repeat the following operations 3-5 times slowly to check whether they are normal or not.

If any abnormal operation such as delayed response occurs in any operation, warm up the hydraulics as described in step 2 again.

CAUTION ● Operating attachments should be done avoiding the interference with the machine’s body or the ground. ● Always verify the operation method before operating the machine. ● Do not run any component except bucket operation during warm up operation. ● Do not relieve for more than 30 seconds.

● Bucket operation

a) After warming up the engine, put the throttle control to medium position. b) Release gate lock. c) Slowly operate the arm (bucket) operation lever and bring the cylinder to stroke end. d) Relieve it for less than 30 seconds. e) Slowly operate the arm (bucket) operation lever and bring the arm and bucket to the opposite end. f ) Relieve it for less than 30 seconds.

2-0013

● Arm operation

2-0014

● Boom operation

2-0011 2-0015

g) Replace steps c) through f) and warm up the hydraulics for about ten minuets.

● Swing operation

2-0016

● Travel operation

2-0017

2-9

Operating

Operations (Traveling) 5. Check the safety of the machine surroundings and sound the horn (give a signal), push the left and right travel levers slowly forward (travel forward) or pull them towards you (travel backward) to travel the machine.

This section explains the starting and stopping procedures of the machine.

How to start 1. Turn the throttle volume and increase the speed of the engine.

WARNING If the throttle volume is turned to high speed and the travel levers are operated rapidly, the machine will start rapidly.

Use extreme care when starting to more.

2-0062E

2. Fold the attachment so that it is 16-20 inches (40-50 cm) above the ground.

2-0064E

F Forward B Backward

40 - 50cm Travel unit

2-0110E

3. Raise the blade.

4. Check the direction of the crawler.

CAUTION When the travel unit is in the rear and the travel lever is pushed forward, the machine moves forward. When the travel lever is pulled towards you, the machine moves backward.

2-10

Operating

Operations (Traveling)

How to stop IMPORTANT

CAUTION

For stopping the engine, refer to the section on starting and stopping the engine.

Park the machine on a hard, level and safe ground.

If it must be stopped on a slope, dig the bucket into the ground and block both tracks and take other necessary safety precautions.

1. Shift the travel lever into neutral.

2-0065E

N Neutral 2. Turn the throttle volume to slow down the engine speed.

2-0066E

3. Lower the bucket to the ground.

2-0009

2-11

Operating

Operations (Traveling)

Travel lever When the travel unit is in the rear,

CAUTION

1. By pushing the right and left travel levers simultaneously, the machine travels forward.

● Avoid rapidly turning the machine if possible. Before spin turning the machine, come to a full stop. ● Traveling the machine on rough ground can cause damage and cause a shock loading to the machine.

Reduce the engine speed and travel slowly.

2. By pulling the left and right travel levers simultaneously, the machine will travel backward.

3. By pushing the left travel lever forward, the machine will turn right.

4. By pushing the right travel lever forward, the machine will turn left.

● By operating the left and right travel levers in opposite directions, the machine will turn around on the spot......Spin turn.

2-0068E

Right pivot turn (forward) Left pivot turn (backward)

2-0064E

F Forward B Backward

WARNING ● Before operating the travel levers, verify the direction of the tracks.

When the travel unit is in the rear and the travel lever is pushed forward, the machine moves forward. When the travel lever is pulled towards you, the machine moves backward. ● When not traveling, do not place your feet on the travel pedals.

2-0069E

Left pivot turn (forward) Right pivot turn (backward)

2-0070E

● Spin turn (left) Forward Backward

2-0067E

● An oil damper is equipped in the travel levers on

Forward Backward

this machine. In extremely cold weather, the oil viscosity decreases and operation of the travel levers may seem harder, but this is not abnormal.

2-12

Operating

Operations (Traveling)

Travel Mode Change Switch CAUTION Do not change travel modes during traveling.

Stop the machine and then change speeds.

Indication ON at high speed.

When the switch is pressed, the travel speed toggles between high and low.

0-0058

High : Use when the ground is level.

6. Check the route you will be traveling.

• Routes should be investigated in advance.

Low : Use when climbings or descending a slope or when the ground is rough.

7. When moving the machine in an area of poor visibility, always have a signal man who sends signals to the operator.

And also, before crossing a bridge, pay attention to allowable weight of the bridge.

2-0071E

Cautions for traveling

0-0056

CAUTION

8. When traveling on paved roads, avoid damaging the road surface by placing boards, etc.

Place signs at dangerous places or signal men and take other necessary safety precautions.

9. When traveling on a ground abundant in gravel and pebbles, reduce the speed and loose the tension of track shoes a bit for traveling.

1. Before traveling, check the position of the travel motor.

2. When you run, select flat and firm ground as much as possible.

3. During traveling, avoid obstacles.

IMPORTANT Particularly for the machine used wider shoes, avoid traveling on rough terrain.

The wider shoes are more prone to deformation and crack of the shoe.

4. When traveling on rough ground, reduce the travel speed.

5. When changing direction, take care to make the largest possible turn. Avoid making rapid pivot turns or spin turns as much as possible.

2-13

Operating

Operations (Traveling)

Driving uphill and downhill (slopes) 6. Parking or stopping on a slope is dangerous. Do not park or stop on a slope.

If parking or stopping on a slope is unavoidable, dig the bucket into the ground, put the levers in neutral and block both the tracks on the downhill side.

WARNING Traveling on a slope with attachments raised is very dangerous. It may cause a turn over. ● Travel at low speed and position the bucket 8-12" (20-30 cm) above the ground level. ● When the machine becomes unstable, ground the bucket and stop the machine.

8-12" (20-30 cm)

0-0063

8-12" (20-30 cm)

Downhill running

Uphill running 30˚ or less

30˚ or less

0-0059E

1. Climb up and down the slope at a right angle.

(Climbing slopes at an angle is very dangerous.)

2. Put the machine in low travel mode.

3. It is very dangerous to change the direction or swing the upper structure on a slope.

It is also very dangerous in particular to swing it towards the down side of slope with the bucket loaded with soil and the like.

(The machine may slide or turn over.)

4. Before traveling on a slope, clean the shoe if it is clogged and take other precautions to prevent slipping.

5. The maximum slope climbing ability is 35° (70%). This value varies depending on the shoe type and the road surface, limit traveling to slopes of 30° or less.

CAUTION Do not operate the engine with the machine at 35°.

The engine or hydraulic devices may be damaged.

2-14

Operating

Operations (Traveling)

Escape method from soft ground

2. Both sides If both sides sink, place logs or boards, etc. under both tracks in the same manner as above.

Press the bucket into the front ground in front of the machine and fold the arm in the same manner as when digging. Then operate the travel levers to pull the machine out.

On soft ground, take precautions to prevent the machine from sinking.

If the machine can not travel because the bottom comes into contact with soft ground or the track becomes filled with mud or gravel, push the boom and arm on the ground to clear one track from the ground.

When the machine is raised by using the boom and arm, push the ground with the bottom of the bucket.

Keep the angle between the boom and arm between 90° and 110°. This also applies to the shovel.

2-0028

2-0026

1. Only one side If only one side of the machine sinks, press the bucket against the ground on the low side to raise the track. Then place a log or board, etc. under the shoe and pull the machine out.

2-0027

E0930

2-15

Operating

Operations (Traveling)

Cautions for operation at the allowable water depth or on soft ground 1. Before moving the machine into the water for operations, check the water depth.

“Water up to the upper roller is allowable.”

Allowable water depth Machine Type

80

Measurement A (mm)

500

A

2-0111E

2. On soft ground, the machine may sink gradually during excavation operations.

Take care that it does not sink too much.

2-0030

3. If the machine sinks in water or soil up to the swing body, grease replacement and maintenance is necessary. Stop operations and contact to our service station in your local area.

4. After operating the machine in water or on soft ground, grease the attachment and turntable bearing.

Clean and check the crawler.

2-16

Operating

Operations (Traveling)

Towing Method 2. Towing heavy objects (less than 4 tons)

WARNING

a) Attach wire rope to the towing lug on the lower frame using shackles. b) Position the rope in-line with the lower frame. c) To prevent collisions, tow slowly at low speed.

Use of an unsuitable wire rope and/or improper towing may invite a serious accident resulting in injury or death. ● When towing the machine, use wire ropes strong enough for the traction load. ● Do not use wire ropes which have kinks, twists, or damage for towing. ● Do not allow anyone between the towing vehicle and the excavator. ● Do not tow the machine on slopes because there is a risk of the machine sliding sideways. ● Take measures to prevent damage to ropes and the excavator by placing wood protectors between the towing wire ropes and the excavator. ● Tow the machine slowly in order to lessen the impact on the machine. ● Connect the excavator and towing vehicle to form a straight line.

2-0074E

CAUTION Tow the machine slowly as to not to impact the machine. Collisions can cause damage to the lower frame and also accidents.

1. How to tow the machine when it can not pull out of soft ground. a) Attach wire rope to the lower frame. b) To prevent damage to the wire rope, always use padding on sharp edges. c) To prevent collisions, tow slowly at low speed.

2-0073E

A Wire Rope B Padding

2-17

Operating

Operations (Traveling)

Caution for use of rubber shoe CAUTION ● Be careful of slipping and work with caution.

• When there is water, graval, ice or snow on the travel surface.

• Especially when loading and unloading the machine.

2-0077E

● The rubber shoes should be used on paved roads, If it is used on rough of soft ground, the rubber will rapidly wear out.

Avoid using the rubber shoe on such surfaces. Steering may be difficult on some sufaces (especially asphalt).

Spin turn (left) Forward Backward

● Careful operation Avoid changing direction at a rapid speed. The rubber shoe will wear faster than normal.

● [In order to use it safely] • If the excavator is climbed on the projection or step of the road and is traveled or swing there, a partial load will be applied, causing cracks, edge tear or internal steel cord breakage.

Caution for storage of rubber shoe Long time storage

• Refrain from using outside the temperature range of -13°F to 131°F (-25°C to ＋ 55°C), due to the properties of the rubber used.

When storing the rubber shoe, prevent exposure to direct sunlight, oil and moisture, and store it in a well-ventilated plate.

Maintenance Using a neutral detergent, clean the rubber shoe of oil and mud.

[Do not leave the rubber shoes with oil on them. Oil will deteriorate the rubber.]

2-0075E

Right pivot turn (forward) Left pivot turn (backward)

2-0076E

Left pivot turn (forward) Right pivot turn (backward

2-18

Operating

Operations (Swing)

Swing Operation

3. Since the swing continues for a while due to inertia even after the operation lever is returned to neutral, try to stop the swing safely before it hits anything.

WARNING ● Before the operation, verify the operating instructions.

● Make sure that unauthorized people can ● ●

● ●

not enter the swinging job site.

Before swinging, verify that the surrounding areas are safe.

When using the machine equipped with a long arm or heavy weight attachments, stopping swinging may be delayed due to inertial force.

Swinging on a slope may cause the machine to become unstable resulting in turning over.

Avoid swinging on a slope because it may cause turning over or sliding. It is dangerous to swing on a slow towards the down side of slope with dirt loaded on the machine because it increases inertial force.

2-0033

Do not enter the swinging area.

CAUTION Flattening earth or sweeping away rocks causes excessive force to be applied to booms and arms, and it may cause damage to the machine.

Do not press the bucket teeth into the ground during swinging.

When operating on slopes, keep the footing level.

KHP1532-00

0-0086E

Do not enter the swinging area.

When the machine makes a turn, you may be caught in the upper part of swinging body.

Do not attempt to enter within the range of the swing.

2-0035

Never work with swing force.

Swing Operation Procedure 1. Press the horn switch which is located on the top of the left operation lever to alert people in the job site.

2. After checking the surroundings for safety, operate the levers for the swing operation.

2-0034

Swinging on a slope is dangerous.

2-19

Operating

Operations (Attachment)

Operations (Attachment) Arm Operation

WARNING Always verify the operation methods.

The machine is operated by the right and left operation levers.

ISO (JIS) Operation Method Right Operation Lever...

Boom and bucket operation Left Operation Lever...

Arm and swing operation When you release your hand from the lever, it returns to the neutral position and the machine maintains that position.

2-0080E

Bucket Operation Arm out

Boom down

Swing right Swing left

Bucket in Arm in

Bucket out

Boom up

ISO (JIS) Standard Operation Method

2-0078E

Swing Operation

2-0081E

Boom Operation

2-0079E

2-0082E

2-20

Operating

Operations

Attachment swing Operation ● Depression of the swing pedal forward allows the attachment to move to the right. ● Depression of the swing pedal backward allows the attachment to move to the right.

CRUSH HAZARD KEEP CLEAR OF THIS AREA. SWINGING BOOM CAN KILL OR SERIOUSLY INJURE YOU. START AND OPERATE MACHINE FROM OPERATORS SEAT ONLY. DO NOT PLACE ANY LOOSE OBJECTS INSIDE CAB AREA.

WARNING When the pedal is not used, lock it in position.

KHP10070-00

● Caution against interference be-

0-0186E

tween the bucket and the operator’s cab When the attachment is fully rotated toward the right, the bucket comes close to the operator’s cab, the mirror, and the head guard.

• When changing the bucket, confirm that no interference with the bucket will be found.

• If the bucket can interferes with something, provide operator’s with a caution plate warning that it can be interfered.

Left

Right

Swing Pedal

2-0112E

LOCK THE PEDAL WITH THE LEVER WHEN NOT OPERATING THE PEDAL TO AVOID ACCIDENTAL CONTROL ENGAGEMENT AND POSSIBLE INJURY. KHP1820-00

0-0182E

2-21

Operating

Operations Characteristics of Hydraulic Excavator

Blade Operation Caution for blade operation

The following are characteristics of the machine excavator and not problems.

Blade is for light duty work such as pushing soft dirt or mud only.

● Do not push down hard on the blade or it may cause damage to the blade and foot.

● To avoid damage to the blade, do not side load

● When the arm or bucket is operated in the air, it

the blade. ● When using the blade to support the front of the machine during operation, ensure that the blade is firmly supported over the full length of the blade. This will prevent damage to the blade.

Blade Operation Lever

may stop suddenly. This is because the pump discharge can not keep up with the movement of the cylinder caused by the attachment weight. ● During swing or travel, or when starting or stopping, some sound may be heard in the hydraulic circuit. This sound comes from the brake valve. ● The reason the swing does not stop immediately after returning the swing lever to neutral is that the machine is being protected from shock and operator fatigue is being reduced. ● When lowering the boom, the sound heard is that of the oil flowing inside the valve.

Up

Down

2-0083E

2-22

Operating

Operations

Cautions for operations

Cautions for Interference

1. Listen for unusual noise from the engine, hydraulic equipment, reduction gear, travel unit and front attachment area. a) Creaking from any parts b) Wearing noise c) Vibration noise d) Striking noise at constant intervals e) Irregular noise of hydraulic devices

Watch out for interference with the cab.

WARNING The bucket teeth may hit the cab, depending on the type of attachment. Exercise care when operating a bucket near the cab.

2. If the 8 lights on the hydraulic oil and water thermometer gauge light up, slow down the engine speed and stop operations for the unit to cool.

Check coolant water and radiator.

● Special care is necessary when reversing the bucket or when a plate is attached to the bucket teeth.

3. If water or oil leakage is found or any problem with the meters, monitor or operation levers is found, stop and check and make repairs.

WARNING If an abnormality is detected in the machine, immediately stop the operation.

When you find something is wrong with the machine while operating, immediately stop the operation, check and repair the problem.

Do not use the machine until repairs have been finished.

2-0041

Watch out for interference with the boom. ● Depending on the arm, the bucket may hit boom when the arm is folded under the boom, so be careful.

0-0052

2-0042

2-23

Operating

Operations

Watch out for interference when digging deep.

Watch out for interference with the blade.

● Special care should be taken that the bottom of

● Take care when digging and folding the attach-

the boom, bucket cylinder hosed, etc. do not hit the ground. ● Take special care that the boom does not hit the blade.

ment for traveling or transporting because the bucket may hit the blade. ● Swing the upper 180° and place the atrtachment opposite the blade when transporting a machine with a long arm attachment.

Be careful of interferehce

2-0043

2-0113E

Watch out for interference with the tracks. ● Take care when digging at right angles or diagonal to the crawler because the attachment may hit the shoes.

2-0044

2-24

Operating

Operating Instructions (Cautions)

Cautions for operations Never strike the bucket forcefully!!

1. Do not use this machine except for permitted applications.

Hydraulic shovels are designed for use in excavation and loading. Usage other than applications for vehicle type construction machine is prohibited.

Never use the bucket as a hammer. It will damage the machine.

2. Never drive or operate this machine in a rough manner!!

All operators should always operate the machine carefully and safely to prevent injury to themselves and others and to prevent damage to the machine.

3. Open work excavation is dangerous!

Digging a hole under an overhanging land is dangerous. Never do it.

2-0048

4. Do not dig too much near around your machine!!

Do not operate the hydraulic cylinder at the stroke end

Operating on slopes

During the operation, do not run the cylinder up to the stroke end but keep some clearance. If the cylinder is used at the stroke end, it may damage.

When operating on slopes, keep the footing level.

Clearance

2-0046 2-0006E

Never travel the machine with the bucket pressed into the ground!

Never work with swing force!

Travelling with the bucket pressed into the ground or digging with reduced falling force of the machine body could cause excessive force applied on the machine resulting in the damage to the excavator.

Doing so will cause excessive force applied on the attachments and machine body.

2-0035 2-0047

E1020

2-25

Operating

Operating Instructions (Procedures)

Digging Operations

Dumping

For digging work, position the bucket at the target spot with the boom and arm and use the arm for digging.

Operate the bucket so that it scoops up the dirt as fast as possible.

Digging is done mainly with the arm.

The arm is most efficiently used for digging in the range from 90° forward to 30-45° toward the cab.

For digging, align the bucket teeth in the digging direction and run the bucket at full stroke.

After digging, raise the boom and when swinging is necessary, swing after the boom is raised. Just before returning the swing lever into neutral, raise the arm. Half of the time required for dumping is used in swinging.

Work can be done most efficiently if the swing angle is kept at a minimum, depending on the terrain.

2-0052

2-0050

When dumping dirt into a truck, do not dump the load from a position which is higher than necessary.

Position the truck at such a position that the swing angle and reach are minimized for dumping.

Position the machine lengthwise with the truck and load dirt from the front of the truck. Such operations can speed up the work.

When dumping, make sure that the load is evenly spread to prevent excess burden on the truck’s rear tires.

When the dirt does not fall easily, move the bucket lever 2-3 times to dump the dirt.

(Do not use the shock of the bucket end to dump the dirt.)

Operating Instructions (Operating Procedures).

For trenching, align the machine travelling direction with that of the trench, and gradually travel the machine backward as digging progresses.

For a wide trench, first dig both sides, then dig the center last.

2-0051

2-0053

2-26

E1030

Operating

Operating Instructions (Procedures)

Backfilling

Shovel Operation

After digging, fill back and level the ground by moving the bucket horizontally back and forth.

When levelling toward the machine, slowly pull the arm toward the machine and slightly raise the boom.

If the arm passes the vertical position, slowly lower the boom and maneuver so the bucket can move horizontally.

Bucket movement can also be added.

Shovel operation procedures (when the bucket is reversed) differ from that for back hoe digging.

Because the bucket is reversed, bucket operations are opposite.

Digging is done mainly with the arm cylinder.

Be careful of interference with the cab.

Digging power is slightly reduced compared to back hoe digging.

2-0056

2-0054

Boom Operation When lowering the boom, lower it as smoothly as possible to reduce shock loading.

2-0055

E1040

2-27

Operating

Bucket: Turning Over and Replacement

Bucket: Turning Over and Replacement 4. Keep sand or mud off the removed pin.

CAUTION

a) Removal Remove the ring 1 with a screwdriver 2 and pull out the lock pin 3. b) Installation After inserting the lock pin 3, install the ring rock 1.

● Park the machine on flat, solid ground.

When working with others, check that signals to be used are well understood. When performing hammer operations, use protective gear (safety glasses, safety shoes, etc.) ● After turning over or replacing the bucket, adjust the backlash of the bucket and check the operation before use.

ԙ

Ԙ

Removal 1. Position the back of the bucket 1 parallel to the ground.

Ԛ

2. Remove the lock pin 3 on the bucket link 2 and pull out the pin.

Ԛ

3. Remove the lock pin 5 on the arm side 4 and pull out the pin.

Removal/installation of lock pin

2-0058

Turning the bucket over 1. Remove the bucket. ԙ

ԛ

2. Slightly raise the arm and turn the bucket 180°.

Ԝ

3. Put on the bucket.

Ԛ

IMPORTANT When the bucket is turned over, it works as a shovel. The operation of the bucket levers (digging and dumping) are reversed compared to that of back hoe work.

Ԙ 2-0057

IMPORTANT ● When the pin is difficult to remove, it may be because the weight of the load is on it. ● Be careful not to damage the O-ring and dust seals when removing the pins.

ࠑ 2-0059

2-28

E1050

Operating

Bucket: Turning Over and Replacement

Installing the bucket 1. Clean the pin and pin hole of each area and grease them well.

2. Replace the O-rings and dust seals.

3. Align the bucket with the hole on the arm side 1 and insert the pin 2.

4. Align the bucket with the hole on the bucket link side 3 and insert the pin 4.

5. Install the lock pins and grease the pins.

(EM system type should be greased also.)

Ԛ

Ԙ ԙ

ԛ

2-0060

E1060

2-29

Operating

On Completion of Daily Operations

On Completion of Daily Operations Parking the machine

CAUTION

1. Stop the machine on level and solid ground which is free from the danger of falling rocks or standing water.

When parking the machine on the road, put up signals and/ or barricades which can be seen at night from other cars.

2. Position the arm vertically and lower the bucket to the ground.

0-0064 2-0009

3. Pull the gate lock lever to lock the bucket.

4. Idle the engine at low speed for about 5 minutes and cool down the engine.

5. Stop the engine and remove the key.

0-0065

6. Close the windows and raise the left console box and gate lock.

7. Lock the cab door to prevent unauthorized persons from entering the machine.

2-30

E1070

Operating

On Completion of Daily Operations

Inspections after finishing operations 1. Cleaning and inspection Check each area for oil and water leakage and any damage.

Also wash the machine as part of the inspection.

In particular, clean dirt and sand from the crawler.

(When washing the machine, be careful to avoid splashing the electrical parts.)

WARNING Do not have flames near by while refueling.

2. Filling the fuel tank Stop the engine to fill the fuel tank. When filling the tank, take care to prevent dust or water from getting into the fuel tank.

● When it is cold (outdoor temperature less than +32°F [0°C]), drain the water which has collected in the space fuel system (fuel tank and fuel filter) to prevent freezing.

(Wipe off any spilled fuel.)

Check each part of the machine after operations. (including washing the machine).

● If any problem is found, correct it immediately! ● Fill the fuel tank to the full after daily operation is finished.

Specially, in the following situations, perform inspection and repair procedures: After operations at the seaside After operations at very dusty locations In freezing or very hot weather After operations in swamps or locations with soft ground

0-0066

E1081

2-31

Operating

Operating in Cold Climates Anti-freeze mixing

When the temperature drops, the engine may become hard to start or the coolant may freeze. Take the following precautions in cold weather.

Anti-freeze is used to prevent the engine coolant from freezing during the winter or in cold areas. Mix it with water according to the lowest expected temperature.

Fuel and lubricants

Anti-freeze Mixing Ratio

Replace the lubricants for each device with that of lower viscosity. For the designated viscosity, refer to the section on “Fuel and Lubricants According to Ambient Temperature.”

As for fuel, use fuel with fluid point of 41°F (5°C) lower than the ambient temperature.

ࠑ F Lower Temp.(͠) Mixing Ratio (%)

Battery

10.4 3.2 -4 -13 -22 -32.8 -45.4 (-12)(-16)(-20)(-25)(-30)(-36)(-43)

Anti-freeze 30 35 40 45 50 55 60 Water

70 65 60 55 50 45 40

Anti-freeze mixing ratio The machine has long-life coolant (LBX Company LLC genuine coolant - Clean Coolant) when it is shipped from the factory.

When the temperature is below 14°F (-10°C), refer to the anti-freeze mixture percentage chart and adjust the concentration.

WARNING Battery produces flammable gases, always keep flames away.

The battery liquid is dangerous. Prevent it from getting into the eyes or on the skin. If you spill it on your skin or get it into your eyes, wash it off with lots of water and see a doctor for treatment.

● It is recommended that the mixture ratio be controlled by coolant concentration gauge.

CAUTION When the temperature lowers, the battery charge also lowers. If the battery charging rate is low, the battery solution may freeze.

Keep the charging rate close to 100% to prevent freezing.

Use of anti-freeze ● The concentration of the anti-freeze should be in the range of 30-60%. If the concentration is weak, the rust-proof performance is adversely affected. ● When water is reduced naturally, fill with 50% diluted water. ● Use always coolant with ASTM D3306 or equivalent, and do not mix with other kinds. ● Anti-freeze is flammable. Do not have open flames near it. ● Always use soft water for coolant.

The maintenance free battery ● Check the hydrometer of battery. (Refer to the section “Maintenance”)

The battery which requires added solution ● Measure the specific gravity and calculate the charging rate using the table below.

When the weather gets warmer

Liquid Temperature Charging Rate

68ࠑ F (20͠)

32ࠑ F (0͠)

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

When the seasons change and the weather gets warmer,

14ࠑ F -4ࠑ F (-10͠) (-20͠)

● Change the lubricants for each device to the proper viscosity. ● Completely drain the anti-freeze (unless permanent type is used), flush the cooling system and add clean soft water.

● When adding distilled water, add just before beginning operations to prevent freezing.

2-32

E1090

Operating

Operating under Extreme Conditions 4. Frequently check the level of electrolyte in the battery and add distilled water as necessary.

Refer to the section on “Fuel and Lubricants According to Ambient Temperature” to choose the suitable items.

5. During operations notice the water temperature and hydraulic oil thermometer. Do not allow these systems to overheat.

Operating in cold weather (below 32°F [0°C])

Operating in dusty or sandy areas

1. In winter or cold weather, warm up the machine with special care.

Extend the warm up time and cover the front of the radiator and oil cooler. After warming up, remove the covers.

1. Check Air Cleaner Frequently check the elements of air cleaners, and clean or change the elements and dust cups regardless of exchange intervals.

2. Until the machine is sufficiently warmed up, never attempt to rapidly swing the upper or operate the travel motor.

If any rapid operations attempted when the machine is not warmed up, the hydraulic components may be damaged.

2. Securely tighten the breather cap of the hydraulic oil tank to prevent sand and dust from entering the hydraulic circuit.

3. After warm up, be sure to confirm that the boom, arm, bucket, swing and travel operations can be properly performed before working the machine.

4. Clean radiator fin, oil cooler fin, and radiator grill.

3. Always keep the lubricated parts such as the pins and bushings clean. Clean the grease fittings before greasing them.

Operating near the ocean

4. A time lag may result when the operation levers are operated in the winter or in cold weather.

This is due to the hydraulic oil not being warmed.

1. Check that the drain valves, cocks, bolts, etc. are properly tightened to prevent any salt entry.

2. After operations, wash salt off from the machine thoroughly. Especially, take special care when cleaning electric devices and hydraulic cylinders to prevent erosion.

5. When the machine is left outside for more than 12 hours or longer in extremely cold weather, remove the battery and store it in a warm place.

6. Drain the water collected in the fuel system to prevent it from freezing.

Operating in wet or on soft ground

7. After operation, clean the tracks and place the machine on wooden blocks to prevent the tracks from freezing to the ground.

Minimize the exposed portion of the cylinder rods.

Wipe off any water on the exposed cylinder rod.

1. Moisture or mud will cause the paint, wiring and metallic parts to deteriorate. When operating the machine, keep it as dry as possible and grease it.

Operating in areas with the danger of falling objects

Operating in hot weather (above 95°F [35°C])

1. Attach the head guard for the cab.

1. Always fill the coolant to the specified amount, check cooling system for leakage, replace the coolant to flush the cooling system and prevent deposits or rust as required.

2. Keep the cooling fins of the radiator clean.

3. Always keep the belt on the water pump adjusted properly.

E1100

2-33

Operating

Transportation

Loading and Unloading

Switch settings during loading and unloading

WARNING WARNING

1. Designate a signal man and follow his commands when loading and unloading the machine.

2. When loading and unloading, select level, solid ground and keep sufficient distance from a shoulder.

Be sure to apply the parking brake and block the tires of the transport truck.

3. The ramp used (to the track platform) should be strong enough to support the weight of the machine. Use hooked ramps which will not slip off the platform.

4. When it is raining or when there is snow, carry out measures to prevent slipping.

1. Put the machine in medium or low travel mode.

(If it is in high, the travel speed is faster which may cause shock loading on the machine and is dangerous when loading or unloading.)

2. Do not operate the idle switch.

(The engine speed changes, so do not operate it.)

3. Do not operate any lever other than the travel level when on a ramp.

1

2-0085E

Turning off the indicator is confirmed

Transportation CAUTION 1. Investigate road width, bridge, rode and traffic condition for planned routes in advance.

2-34

Operating

Transportation

Loading and Unloading 3. Do not steer the machine on the ramp. Drive up the machine at a low speed without stopping.

WARNING ● Never attempt to load or unload the ma-

DANGER

chine by jacking it up with the boom just because the trailer floor is low. ● Clean the mud off the shoes to prevent the machine from slipping on the ramps. ● When climbing the ramp with the front attachment removed, position the counterweight upward.

Never attempt to steer the machine on the ramps. If it must be steered, drive it off the ramps first and correct the direction.

4. When the machine reaches the top of the ramps and it is about to touch the floor of the trailer, the center of gravity changes suddenly. Keep control of the machine.

2-0114E

A 15° or less B Support C Blade is raised ● Before loading or unloading the machine, warm up the machine sufficiently.

1. Apply the brake of the trailer and block the tires to prevent the trailer from moving. Position and secure the ramps so that the centers of the machine and the trailer are aligned.

• Use ramps which are wide, long and thick enough to assure safe loading and unloading.

If the ramps deflect excessively, support them with blocks or similar objects.

2. Align the centers of the machine to be loaded and the trailer platform. In addition, align the centers of the ramps and the shoes.

A

B

C

E

D 2-0063

A Center of trailer platform and loaded machine B Trailer platform C Center of ramps and shoes D Tracks E Ramps 2-35

Operating

Transportation

Tie down on transport vehicle

2-0115E

A Wire Rope B Block C Stop Block D Padding E Blade is lowered 1. Check that the machine is properly loaded in position and that the trailer is level.

2. Fold the bucket and then fold the arm. Place wooden blocks on the platform of the trailer.

Lower the boom slowly and adjust the wooden blocks so that the bucket and arm rest upon them.

3. Stop the engine.

• Make sure that the radio antenna is lowered.

• Adjust the mirror so that it will not hit against an object around the machine during transportation.

4. Lock the doors (the operator’s cab on both sides).

5. After verifying that there are no problems with the machine, block the tracks and tie down the machine with chains, wire ropes, etc. so that it does not move during transportation.

6. Verify that everything is blocked and tied down before transporting the machine.

CAUTION Movement of the machine during transportation is dangerous.

Secure the machine firmly with wire rope or the like so that it won’t move from vibration.

2-36

Operating

Transportation

CX80 Outer Dimensions (units: mm)

‫ޞ ޝ‬

‫ޞ ޝ‬

) .

‫ޞ ޝ‬ *'+)*6 1( )4175'4 5*1' .7)

2-0116E

Values are measured when equipped with a standard arm (1.71m).

Values《

》are measured when equipped with a long arm (2.12m).

2-37

Operating

Storing During Storage

If the machine will be stored for a month or longer, make sure the followings to prevent decrease in machine performance for the next time it is operated.

If the machine is stored for a month or longer, check the operation of each function and drive rust prevention every month. This will prevent rust in the engine, deterioration at the seals and rusting in hydraulic parts. Check if there is any coolant.

Before Storing 1. Wash off the machine, especially the crawler.

● Before operating the machine, wipe off the anti-

2. Lubricate each part.

• Grease the attachment and turntable bearing.

rust oil from the hydraulic cylinder rods.

● Carry out the operation of attachment, swinging,

3. Check the lubricant amount and cleanliness.

• Add if low.

• Replace when excessively dirty.

and traveling slowly with the engine running at a low speed.

4. Refer to the storage instructions in the operator’s manual for the engine. If the temperature is low with the possibility that the coolant may freeze, mix it with anti-freeze or drain it completely.

WARNING If the rust-prevention operation must be performed indoors, open the windows and doors for ventilation to prevent gas poisoning.

5. After cleaning and washing, store the machine in a dry, indoor site. If it must be stored outdoors, lay timber on the ground under the machine and protect the machine with covers.

2-0065

(Outdoor storage) a) Select a well drained, ventilated area. b) The floor should be of level concrete, broken rocks or gravel or place a suitable wooden block under the tracks to prevent the machine from being in direct contact with the ground. c) After following steps 6-9 below, cover the machine to prevent rain from entering the house to prevent rust.

6. Lower the bucket to the ground and block the tracks.

7. Coat the exposed area of the piston rod of all hydraulic cylinders with anti-rust coating.

8. Put all the operation levers into neutral.

9. Remove the battery, completely charge it and store it or remove one terminal ((-) terminal).

2-38

E1160

Operating

Storing

After Storage (when the machine is used again) 1. Check the levels of oil and water and fill as necessary.

Especially check carefully if the coolant is in.

Since the lubricants and grease deteriorate during storage, check them carefully when the machine is used again.

2. Completely wipe off the anti-rust oil.

3. After starting the engine, take enough time to warm it up and repeat the travel, swing and digging operations several times each.

Warming up!

2-0001E

● If the machine is stored without the monthly rustpreventing operation, contact the nearest distributor for instructions.

E1170

2-39

Inspections and Maintenance Inspections and appropriate maintenance of the machine is vital to keep it performing at its best longest and to prevent it from running down.

This section covers the regular checkup, maintenance, and adjustment procedures of the machine.Follow each step of the procedure carefully and safely when you work on the machine.

Contents • General Cautions • Periodic Maintenance Check List • Inspection Prior to Operation • Greasing Attachments • Fuel System • Engine • Bolt Torque • Hydraulic Oil

MAINTENANCE

• Battery • Upper Frame • Travel Unit • Bucket • Air Conditioner • Routine Replacement Safety Parts • Troubleshooting • Contacting Us

For specific details regarding the engine, refer to the manufacturer's Instruction for Use also.

3-0

E1180

Maintenance

General Cautions Release the hydraulic pressure prior to servicing or inspecting the machine.

Before you start working on the machine, study this section thoroughly to duly perform the service procedures.

For specific details regarding the engine, refer to the manufacturer's Instruction for Use also.

Safety WARNING Pay close attention sections marked with the symbol. They contain very important safety issues.

0-0082

To release hydraulic pressure

Self-initiated periodical inspections

1. Lower the attachment to the ground.

You must also have the hydraulic shovel adjusted thoroughly because this optimizes its functionality as well as stretching its life.

2. Turn the starter switch to the "OFF" position and stop the engine.

3. Turn the starter switch to the "ON" position.

4. Gate lock lever must be released (to the operating position).

Inspection and maintenance schedule Monitor the hour meter readings in the cab to guide you in keeping the regular service intervals. The recommended intervals are determined under normal working conditions. When you overload your machine, operate in severe weather, or operate under demanding conditions, you need to inspect the machine more frequently. Inspect when your machine has operated for the number of hours recommended for inspection, or the number of months recommended for inspection, whichever comes first.

5. Move the right and left operational levers back and forth, and left to right, for approximately ten times.

6. Turn the starter switch to the "OFF" position.

7. Release the pressure from the hydraulic oil tank.

(To release pressure, push in the tip 1 of breather rubber cap at the top of hydraulic oil tank.)

Ԙ

General cautions when performing inspections For crucial inspections and maintenance (i.e. adjusting/servicing hydraulic components or electronic components), your machine must go in a service shop.

3-0001

WARNING

CAUTION

Release the hydraulic pressure when you service or inspect the machine.

E3440

Hot hydraulic fluids may cause severe burns and bodily injury.

Before removing hydraulic tank cap, shut off engine and completely release tank pressure by opening.

3-1

Maintenance

Periodic Maintenance Check List

Daily Inspections (Prior to Operation) Inspections and maintenance

Procedure

Grease / oil (replacement parts)

Reference

Check prior to starting the engine Overall 1.

2.

3.

4.

5.

Check any water or oil leakage Check to ensure nuts & bolts are secure Eliminate accumulated dust (from engine / inside cab) Check physical exterior damage Check inside the cab and window glass for cleanliness

Bolts

Tighten and secure Clean

Engine 1.

2.

3.

4.

5.

6.

Check engine oil level, and see if it needs changed Check coolant level Check radiator and oil cooler to see if damaged or plugged Check the fan belt tension Check if air cleaner element is clean / if it is clogged Check parts for water / oil leakage, check hoses and pipes for breakage 7. Draining the water and sediments from the fuel filter (main and pre)

Refill or change Refill Repair or clean

Engine oil Soft water

Clean or replace

Element

Engine Engine Engine Engine Engine

Fuel

Swing Unit 1.

2.

3.

4.

5.

Check fuel level in fuel tank Drainage of the water and sediments in the fuel tank Check oil level in hydraulic oil tank Check if hydraulic oil is clean Check components for water / oil leakage, check hoses and pipes for integrity 6. Check components for physical damage or distortion 7. Check electrical wiring for short circuits Ensure terminals are secure 8. Adjust rear view mirror

Refill

Diesel Fuel

Refill

Hydraulic oil

Fuel Fuel Hydraulic oil

Track Travel Unit Travel Unit

1. Check shoe (track roller) for looseness, wear, or breakage 2. Check upper / lower rollers and idlers for oil leakage or wear 3. Ensure bolts are all secure, and not missing Work Unit 1.

2.

3.

4.

Check cylinders, hoses for oil leakage or breakage Check bucket for wear or breakage Check if bucket teeth are loose, worn, or missing Ensure components around front of machine are properly greased or oiled 5. Ensure bolts are all secure and not missing

Bucket Bucket Extreme pressure grease Attachments

Check after starting the engine Overall 1. Check if engine starts fine, check exhaust hue, listen for any abnormal noise 2. Check hydraulic components, check any abnormal noise 3. Check components for oil / water leakage 4. Check horns, buzzers, working lights, windshield wipers, and monitors for proper operation 5. Check units for proper operation (travel, swing, and attachments) 6. Check swing brake for proper operation

Refer to the Daily Inspection Prior to Operation section for check procedures for major components.

3-2

E1200

Maintenance

Periodic Maintenance Check List

Periodic Maintenance Check List For the recommended service interval hour figures in the table, refer to the following descriptions also. Whichever precedes the other in a set is when you need to service the machine.

10 hours 50 hours 250 hours 500 hours 1000 hours 2000 hours 5000 hours 10000 hours

(or Inspections prior to operation) (or every week) (or every month) (or every three months) (or every six months) (or every 18 months) (or every 30 months) (or every 60 months)

Areas to be checked or serviced

Service interval 10

(other than EM System)

■

(EM System specifications)

■

Grease attachments

Drain water from fuel tank

50

250 ◯

Engine

×

Engine oil pan

■

Engine oil filters Check and adjust fan belt

◎

Element

◎

Engine oil

◎

Element

■ ■

Every 2 years (when using long life coolant)

Clean radiator net and fan

□

Retighten nuts & bolts

△

■ ×

■

◎ △

◎

Element

Return filter

△

◎

Element

Swing unit

Suction filter

□

Air breather

◎

Element Element

◎ ■ ■

Check batteries Turntable bearing

◯

Extreme pressure grease

Swing ring gear

◯

Extreme pressure grease

Gear oil of swing reduction gear

△■

Gear oil

◎

Grease swing reduction gear Crawler

Hydraulic oil

Pilot oil filter

◯

Gear oil of travel reduction gear

△■

Extreme pressure grease Gear oil

◎

Upper roller, take-up roller

■

Engine oil

Lower roller

■

Gear oil

Air conditioner

□

■

Adjust clearances of bucket installer pins

When necessary

Adjust tension of track shoeDrain water from fuel

When necessary

○：Grease △：Check or replace when brand new ◎：Change oil or replace element □：Clean ×：Drain water / sediment ■：Retighten, check, and adjust

E2760

*2

Element

◎

Replace hydraulic oil

Miscellaneous

Long life coolant

□

Air cleaner element

Retighten hoses

*1

×

Water separator

Drain sediment out of hydraulic oil tank

Extreme pressure grease

◯

Fuel filter (Main)

Radiator coolant

Grease / oil Notes 500 1000 2000 5000 10000 (Replacement parts)

◎

Notes: *1 Grease daily if you work in wet or damp conditions.

Grease every 10 hours if not equipped with our genuine bucket. *2 Replace every 500 hours if you use tap water.

3-3

Maintenance

Periodic Maintenance Check List

Fuel / Lubricants for Different Ambient Temperature Settings IMPORTANT Consult your distributor for recommended fuel / lubricants when you operate the machine outside the temperatures ranging between 32°F and 104°F (-20°C and 40°C).

Fuel / Oil Refer to the table for proper fuel / oil according to the temperature range.

Refer to Grease /Oil and Element for proper oil level.

Antifreeze Add antifreeze when the temperatures falls below 32°F (0°C).

As for the ratio, refer to the section for cold weather conditions.

What to use according to different temperature settings Where to refill

Type of oil

+14 (-10)

+32 (0)

+50 (+10)

+68 (+20)

SAE 30 CD Engine oil SAE 10W-30 CD SAE 15W-40 CD Swing reduction gear Gear oil

SAE 90

Hydrauric oil tank

Hydrauric oil

ISO-VG46

Fuel tank

Diesel fuel ASTM-D-975

Travel reduction gear

No. 2D No. 1D Water+Antifreeze Cooling system

Water+Long Life Coolant

Add antifreeze Depends on mixing ratio

3-4

+104 ゜ F (+40) (℃)

SAE 40 CD

SAE 10W-20 CD

Engine oil pan

+86 (+30)

Maintenance

Periodic Maintenance Check List

Genuine CASE Company LLC Parts and Elements Listed below is our genuine oil. We guarantee the premium quality for heavy machinery use.

We recommend that you use our genuine products to fully enhance the performance of you machine.

IMPORTANT We strongly recommend that you refill your hydraulic tank using the identical product (same product ID, same manufacturer) that you initially had in your tank.

Mixing two different products will lower the functionality of the oil, and causes your hydraulic components to run down.

E2880

3-5

Maintenance

Periodic Maintenance Check List

Disposable Items Replace disposable items, such as filter elements and bucket teeth, either when the service intervals recommend or before they reach maximum life span.

We recommend that you use our genuine parts / elements guaranteed for premium quality.

Monitor those disposable items and replace when necessary. This will save your money in the long run.

The few items in parentheses ( ) in the list need to be replaced with the matching item to be replaced.

Name of disposable item

Quantity

Engine oil filter

Part ID No.

When to replace

1

KAH11150

Every 500 hrs.

1

KNH0404

Every 500 hrs.

Fuel tank filter

1

KHN0290

‑‑‑‑‑‑‑

Pilot oil filter element

1

KHJ17730

Every 2000 hrs.

Return filter element

1

KAJ11040

Every 2000 hrs.

1

Outer element KAH1386

Every 1000 hrs.

1

Inner element KAH1219

Every 1000 hrs.

1

KRJ3461

Every 1000 hrs.

1

KRJ3463

‑‑‑‑‑‑‑

1

KAJ10630

Every 5000 hrs.

Fuel filter element

Main

Air cleaner element (Double type)

Air breather element Packing Suction filter element

3-6

Maintenance

Grease / Oil and Elements

3-7

Maintenance

Inspection Prior to Operation

Inspections Prior to Operation Walk-through checks

Attachments (work unit)

Check prior to starting the engine.

Visually check the areas around and under the machine, and

1. Check oil leakage on high-pressure hoses and at linkage, and on hydraulic cylinders.

1. Check to see if there is any leakage of oil / fuel / coolant from any component.

1 Check to see if bucket teeth and side cutter

2. Check and ensure all nuts & bolts are secure.

2 Check condition of grease on and around

2. Around bucket are loose, worn, or missing. linkage. Check if bucket play is appropriate.

(Refer to the section on bucket for specific instructions for adjusting play.)

3. Check if there is any wire breakage or short circuit in electrical wiring. Ensure battery terminals are secure.

4. Check if oil / grease is clean in related components.

5. Eliminate accumulated dust and clean the area.

3-0271E

0-0034

3-8

Maintenance

Inspections Prior to Operation

Inspection prior to starting engine

2. Checking coolant level / refilling Check the coolant level in reservoir tank. If low, remove the cap and refill with coolant.

An emptied reservoir tank may cause water leakage. After inspection, repair it if found faulty.

1. Checking oil level / refilling

Ԙ ԙ

3-0006 3-0222E

1 Full 2 Low

1 Dipstick 2 Oil filler port 3 Fan belt

WARNING Never open the radiator cap when the coolant is hot. You may get splashed with boiling coolant.

● Perform oil level check either prior to starting the engine, or thirty minutes or more after turning off the engine.

Use the dipstick to check if the oil level is appropriate.

If low, refill engine oil through oil filler port.

Recheck the oil level after 10-15 minutes.

3. Checking the fan belt tension Push in between the fan pulley 1 and the Generator Pulley 2. If the deflection is within (0.390.59 in (10-15 mm)) responding to the force of approximately 98N, it is normal.

If the deflection falls outside the specified range above, refer to the section on “adjusting fan belt tension and adjust tension”.

Ԙ ԙ

0.39～0.59 in {10～15 mm} 98N{10kgf}

3-0005

1 Appropriate oil level 2 Dipstick

①

②

③

1 Fan pulley (Water pump) 2 Generator pulley (Alternator) 3 Crank pulley (Crank shaft)

3-9

3-0122E

Maintenance

Inspections Prior to Operation

4. Checking the air cleaner Clean the air cleaner if you observe a red signal in the dust indicater window.

When checking hidrauric oil

3-0272E

3-0223E

1 Hydraulic oil filler 2 Fuel filler port 3 Hydraulic oil level gauge

1 Cover 2 Element 3 Vacuator Valve 4 Indicator 5 Reset button 6 Window signal

b) Checking the hydraulic oil level / refilling When checking the hydraulic oil level, keep the machine on a level surface and place it in the checking position. ● Check and ensure that the hydraulic oil level is around the middle of the level gauge.

If the oil level is found low, refill the tank with hydraulic oil by referring to “hydraulic oil” illustrated in the section, Inspection/Maintenance.

5. Swing unit a) Checking the fuel level

WARNING Do not overfill the fuel tank (never to the top of fuel tank).

Level gauge

Check the fuel level on the display gauge. If low, refuel from the fuel filler port 2 of the fuel tank.

Refill the tank at the end of each work day, and make this a habit.

3-0125E

c) Check and ensure that the bolts on the fuel tank / hydraulic oil tank are secure. Also check if any fuel / hydraulic oil leakage exists. d) Check to see if the bolts on electrical components and batteries are secure. Also check wiring for short circuits.

1-0072E

3-10

Maintenance

Inspections Prior to Operation Inspection after starting the engine

6. Crawler a) Check the shoe (track roller) to see if it is loose. Also check for wear or breakage. b) Check to see if there is any oil leakage from travel unit, upper / lower rollers, and take-up roller. Also check for wear. c) Check components and ensure that bolts are all secure and not missing.

a) Check the horn and gauges for proper operation. b) Check to see if the engine starts fine. Check the exhaust hue, and listen for any abnormal noise. c) Check for any oil / fuel /coolant leakage

WARNING Immediately investigate anything unusual that you encounter during inspection. When you find the source of the problem, fix it or make the necessary adjustment on the spot. This will keep your machine from running down.

Please be aware that you are risking your machine into bigger failures or major accidents if you leave the problems unattended and keep operating it.

3-0273E

1 Take-up roller 2 Upper roller 3 Lower roller 4 Shoe 5 Travel unit 2-0005

3-11

Maintenance

Greasing Attachments

Greasing Front Attachment Pins • Maintenance: every 250 hours • Maintenance for EM System: every 1000 hours CAUTION ● Always grease after completing work in water or extreme wet conditions.

(Particularly around the bucket pins) Use E.P. grease No. 2

● When using an attachment other than a genuine bucket (breaker, hammer, etc.), grease the mounting pins every 10 hours.

Front attachment pin's greasing points (21 points) (No.) Reference drawing

Mono boom Greasing points

Boom Foot Pin [EMS]

Ԙ

1

Boom Cylinder, Foot Pin

ԙ

1

Bucket Cylinder Top, Foot Pin Bucket Cylinder to Bucket Linkage, Pin Bucket Linkage to Bucket, Pin Arm to Bucket Linkage, Pin Arm to Bucket, Pin

Ԛ

6

Bucket Cylinder, Foot Pin Arm Cylinder, Top Pin Boom to Arm, Connecting Pin [EMS]

ԛ

3

Boom Cylinder, Top Pin (Arm Cylinder, Foot Pin)

Ԝ

2

Blade [Every 50 hours]

ԝ

4

Swing cylinder [EMS]

Ԟ

2

Swing bracket [EMS]

ԟ

2

Greasing Points

3-0274E

3-12

Maintenance

Greasing Attachments

1 Boom Foot Pin (Total of 1 points)

4

2Boom cylinder, Foot Pin (Total of 1 points)

Bucket Cylinder Foot Pin Arm Cylinder Top Pin Boom to Arm Connecting Pin (3 points)

1

2

3-0275E

3 Bucket and related (Total of 6 points) 3-0276E

Bucket Cylinder Top Pin Bucket Cylinder to Bucket Linkage, Pin Bucket Linkage to Bucket, Pin Arm to Bucket Linkage, Pin Arm to Bucket, Pin

5 Boom Cylinder, Top Pin (1 point) Arm Cylinder, Foot Pin (Total 1 points)

3-0116E 3-0229E

3-13

Maintenance

Greasing Attachments

6 Blade (2 points) [Every 50 hours] Blade Cylinder (Foot Pin) (2 Points) Blade Cylinder (Top Pin) (1 Points) Blade Foot Pin (1 Points) (Total 4 Points)

3-0231E

7 Swing Cylinder (2 points) (Total 10 Points)

3-0277E

8 Swing Bracket (2 points)

3-0278E

3-14

Maintenance

Fuel System

Fuel WARNING ● Sufficient care is necessary during inspection and maintenance. ● Be especially careful about fire. (Do not smoke while working.) ● Wipe off any diesel fuel that is spilled during refilling, inspection or maintenance, because it may cause a fire.

● Fuel leaking from the fuel hose, injection pump, fuel filter or joint may result in a fire. If any fuel leakage is found, repair the area immediately. ● Do not use any substitute fuel because it may cause poor performance or even a fire.

Engine fuel and maintenance of fuel filters

2. Applicable standards for diesel fuel

In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine.

As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

Applicable Standard

Recommendation

ASTM (AMERICAN SOCIETY TESTING AND MATERIALS)

D 975

JIS (JAPANESE INDUSTRIAL STANDARD)

NO.2

DIN (DEUTSCHE INDUSTRIE NORMEN)

DIN 51601

SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE-J-313C

NO.2-D

BS (BRITISH STANDARD) Based on BS/2869-197

Class A-1

If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.

3. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life.

Be sure to observe the following requirements for selecting fuel.

Fuel to be applied 1. Selection of fuel Following conditions must be met for the diesel engines, that is the one; (1) In which no dust even fine one is mixed, (2) With proper viscosity, (3) With high cetane rating, (4) With good flow properties in lower temperature, (5) With not much sulfur content, and (6) With less content of carbon residue.

Sulfur content

500 ppm or less

HFRR*

460 μm or less

Water content

0.05 wt% or less

* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.

Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions.

HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used.

IMPORTANT

EPA Regulation Low sulfur fuel or ultra low sulfur fuel only.

3-15

Maintenance

Fuel System 2. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.

Be sure to use the genuine fuel filters and replace them at a periodic intervals.

Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above.

Replacement criteria Every 250 hour of use Every 500 hour of use Pre-filter Main filter

○ ○

Since the pre-filter and main filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements.

3. Time to replace filters may be advanced according to properties of the fuel being supplied.

Running the engine with the fuel filter blocked may cause the engine to be stopped due to establishment of engine error code.

If much foreign objects are found in the fuel, carry out earlier inspection and regular replacement of the filters.

IMPORTANT If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited.

Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control.

4. If dust or water get mixed with the fuel, It may cause the engine trouble and an accident.

Therefore, take measures to prevent dust and/ or water from being entered in the fuel tank when supplying fuel.

When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate.

If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel.

Maintenance of fuel filters 1. Be sure to use the genuine fuel filters.

The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment.

If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time.

5. Water drain cock is provided on the bottom side of the fuel tank.

Drain water before starting the engine every morning.

In addition, remove the cover under the tank once a year to clean up inside of the tank.

6. Do not pour a moisuture elimination agent (water draining agent) available on the market into the fuel tank.

Pouring it in the tank may cause the engine to be damaged.

IMPORTANT If a fuel filter other than the genuine filter is used, guarantee will not be applied to a fault caused by the use of a wrong filter.

3-16

E1340

Maintenance

Fuel System 7. Maintenance of electromagnetic feeding pump

IMPORTANT It you use diesel fuel which contains much sulfur content more than 2500ppm, be sure to follow the items below for the engine oil selection and maintenance of engine parts.

Guarantee will not be given to breakdowns caused by not to follow these items.

ԛ Ԝ Ԙ ԝ ԙ

(1) Selection of engine oil Use API grade CF-4 or JASO grade DH-1.

Ԛ 3-0098

(2) Exchange the engine oil and engine oil filter element by periodical interval below.

Engine oil -- Every 250 hour of use Engine oil filter element -- Every 250 hour of use

3 Filter(KHP11890) 2,4 Gasket(KHH11900) (Electromagnetic feeding pump is located near the pre-fuel filter.)

(3) Inspect and exchange the EGR parts and fuel injector parts of engine by periodical interval below.

EGR(*) parts -- Every 3000 hour of use Fuel injector parts -- Every 3000 hour of use *EGR : Exhaust Gas Recirculation

● Points to notice when carrying out maintenance of built-in filter Check the metal mesh filter 3 for external damage and/or for defects to clean it with a light oil (or blowing air lightly is possible).

If it is found damaged and/or defective, replace it with the new mesh filter.

After disassembly in addition, be sure to replace both gaskets 2, 4 with new gaskets and thoroughly remove dirt and stains stuck on the cover 1 and the magnet 6, the body 5 and inside of the body to assemble then.

During cleaning, pay special attention that any dirt and dust will not enter into the body 5 inside.

Also, be sure to carry out thorough airtight check. ● Disassembly and assembly Unfasten the cover 1 counter-clockwise with a spanner (17mm) to remove it.

After removal of the cover, the gasket (large size) 2, the metal mesh filter 3, and the gasket (small size) 4 can be removed in this order.

When carrying out assembly, do it in reverse order in disassembly described above.

In this, Mount the gasket (large size) 2 into the cover 1 and tighten up the cover 1 to the body securely with a spanner (17mm) .

For the detail of inspection and replacement for the above engine parts, please contact your nearest service factory outlet.

(4) In addition above, if the value of HFRR(*) or water content in the fuel you use is more than limitation in above table of this manual, please also contact your nearest service factory outlet. *HFRR (High-Frequency Reciprocating Rig.) : An index showing lubricating properties of the fuel.

E3831

3-17

Maintenance

Fuel System

Fuel Refilling and Fuel Level Checking WARNING Do not overfill the fuel tank (never to the top of fuel tank).

Check the fuel level on the display gauge. If low, refuel from the fuel filler port 2 of the fuel tank.

Refill the tank at the end of each work day, and make this a habit.

1-0072E

Drainage of Water and Sediments in the Fuel Tank • Maintenance: every 10 hours

3-0279E

1 Strainer 2 Fuel filler port 3 Fuel tank 4 Drain valve

1. Obtain a container to collect the drained contaminants.

(Performing drainage before starting the engine in the morning is the most effective method.)

2. Loosen the drain valve 4 located at the bottom of the tank and drain the accumulated sediment and water.

3. After draining, tighten the drain valve.

IMPORTANT Remove the fuel strainer 1 from the fuel filler port 2 for cleaning.

3-18

Maintenance

Fuel System Fuel Filter (Main) Replacement • Maintenance: every 500 hours

Draining Water from the Water Separator • As Necessary

WARNING Completely wipe off any spilled diesel fuel after replacing an element or air bleeding.

3-0234E

1 Plug 2 Drain plug 1. Loosen the plug 1 and also drain plug 2 and drain the water and sediments.

3-0235E

2. When the float sinks to the bottom, tighten the plug 1 and the drain plug 2.

Tightening torque: Plug 1 : 10 ± 2 N•m Moisture may be frozen up in cold temperature.

Drain water after the frozen moisture has thoroughly melted.

1 Fuel filter cartrige (Refer to operator's manual for the engine.)

1. Using a tool, turn the fuel filter counterclockwise and remove it.

(Replace the entire cartrige.)

(Do not spill the fuel which is inside the filter.)

(Completely wipe off any spilled diesel fuel.)

3. Verify that no fuel leaks.

WARNING

2. Install a new fuel filter.

3. For installation, put a thin coat of engine oil on the packing and tighten it with a specified touque of 13.7 ± 0.3 N•m

Completely wipe off any spilled diesel fuel. It may cause a fire.

It is so designed that bleeding air is to be carried out automatically when the engine has been started.

3-19

Maintenance

Engine

Engine Oil Replacement • Maintenance: every 500 hours Engine Oil Filter Replacement • Maintenance: every 500 hours (Refer to operator's manual for the engine.)

WARNING

Draining engine oil

Just after the engine is stopped, each part (main body, muffler, oil, etc.) may be very hot.

Do not touch any of them because it may cause a burn.

Wait until all parts have cooled down before beginning the inspection/maintenance work.

1. Wipe clean around the oil filler cap B taking care so that no foreign particles entry. Remove the filler cap B. 2. Loosen the cap F of oil drain cock and remove it. Connect the oil drain hose G to the oil drain cock D and drain the oil.

It is advisable that draining be done while the engine is warm, to minimize the draining time.

CAUTION If the engine oil is contaminated or extremely deteriorated, replace it regardless of the maintenance interval.

Specified Lubricants

D

Use engine oil of API rating Class CD or higher which is suitable for the temperature.

G

F

3-0018 Selection Depending on Temperature

Refilling Point

Oil Type

-14

+32

(-10)

(0)

+50 (+10)

3. After the completion of draining disconnect

ࠑF

+86 +104

+68 (+20)

the hose G and wipe off the oil on the drain cock D.

͠

(+30) (+40)

SAE 10W-20 CD Engine oil pan

4. Turn the cap F of oil drain cock slightly and settle it. From that position, turn more about 60 to 90 degrees.

SAE 30 CD

Engine oil

SAE 10W-30 CD SAE 15W-40 CD

CAUTION Use a receptacle to receive the drained oil so that the engine and equipment may not be stained with the drained oil.

3-0236E

ADipstick BOil filler cap COil pan

DDrain plug EOil filter

3-20

Maintenance

Engine

Main oil filter element removal Main oil filter (Spin-on type)

Engine oil refilling 1. Disconnect the oil drain hose and reinstall the cap of drain cock.

Set a wrench at the hexagonal section of the second stage above the cartridge, and remove the main of filter.

There may remain the used engine oil in the cartridge, and care should be taken not to spill it when removing the filter.

Discard the used filter.

2. Fill with new engine oil by the oil filler port.

Wait about fifteen minutes until the oil gets down to the oil pan.

Then check the oil level with a dipstick.

Do not insert the dipstick by force. The dipstick may be broken.

Check after Oil and Filter Changes Oil leakage check Idle the engine to raise the oil pressure, then check for oil leakage.

Oil level recheck Stop the engine and keep it stationary about twenty minutes.

Use the dipstick to recheck the oil level.

Replenish with engine oil, if necessary, to the specified level.

3-0237E

CAUTION

Oil filter element installation

When the engine started, the level will slightly drop from the initial level as the oil fully comes into the entire oil circuit.

1. Apply lightly engine oil to the O-ring.

3-0093

2. Turn in new cartridge until its sealed face comes in contact with the O-ring.

3. Use a filter wrench to further turn in the cartridge by one full turn.

E1410

3-21

Maintenance

Engine

Cooling System

Inspecting and Refilling Coolant • Daily Inspection

WARNING When the radiator water temperature is high, do not remove the radiator cap.

Hot water may come out forcefully.

Wait until all parts have cooled down before beginning the inspection/maintenance work.

Check the level of coolant in the reserve tank. If low, remove the cap, and add the coolant (long-life coolant). (The proper level is between FULL and LOW.)

Ԙ

CAUTION

ԙ

When the overheat warning is displayed on the monitor and the buzzer sounds, check the coolant level, radiator clogging and V-belt tension.

Mix the coolant with anti-freeze (long-life coolant) according to the ambient temperature.

3-0006

1 Full 2 Low

WARNING Since the coolant is toxic, do not swallow it, put it on the skin, and get it in the eye.

Make it vomit if swallowed and wash well it off with water if in contact with skin or eye, then see a doctor for medical treatment.

3-22

E1420

Maintenance

Engine

Replacing the Coolant • Long-Life Coolant: Every 2 Years • When Anti-Freeze is Used, Twice a Year: Spring and Autumn 2. Loosen the sarmosensar 3 on the engine and drain the coolant.

(Refer to operator's manual for the engine.)

CAUTION ● Since discharged coolant is harmful, do not discharge it into a draining trench.

● Consult an expert company or a our authorized service shop for disposal of the coolant to be discharged.

1. Remove the radiator cap 1, loosen the drain valves 2 on the radiator and drain the coolant.

3-0239E

3. Close the drain valves 2, sarmosensar 3, fill the radiator with tap water (warm water is preferable), run the engine at slightly higher speed than idling speed for about 10 minutes raising the temperature to over 170°F (about 80°C) and then drain the water.

CAUTION Be careful not to get burned when draining the hot coolant.

Repeat the radiator cleaning until the drained water is clear.

3-0238E

4. Fill the radiator to the radiator cap 1 with coolant water (long-life coolant), run the engine for about 10 minutes and sufficiently expel air from the cooling system.

5. Stop the engine and check the coolant level. Refill if low. For the mixture ratio of the long-life coolant, refer to section on “Operating in Cold Climates”.

6. Add coolant into the reserve tank until the level reaches to the “FULL” line.

3-23

Maintenance

Engine

Cleaning and Inspecting the Radiator Net and Fin • Maintenance: every 500 hours WARNING Wear safety goggles when using compressed air.

CAUTION When using pressured washing steam, keep a distance from the fin. Using the pressured washing steam near the object causes the deformation of the radiator fin.

Clogging in the radiator net, radiator fin, and oil cooler fin can lead to overheating.

Blow away any mud and debris clogged on the net and fin using compressed air. Steam or pressured water can be used instead of compressed air.

3-0240E

Cleaning the radiator net Remove the radiator net and clean it.

When working mainly in dusty sites, check the clogging on the net every day, and clean the net if it is clogged.

Cleaning the radiator fin and oil cooler fin Clean the oil cooler fin and also the radiator fin.

3-24

Maintenance

Engine

Cleaning and Replacing the Air Cleaner (double elements) • Cleaning: every 250 hours • Replacement: every 1000 hours 3. Clean the outer element.

CAUTION

a) When using compressed air, Blow compressed air (0.69MPa (100 psi) or less) to the element along its flutes from the inside.

● Before maintaining the element, stop the engine.

● When cleaning the outer element, do not hit it or knock it against other objects. ● When the air cleaner filter clogging warning signal is indicated on the monitor system 4, clean or replace the element. ● Do not clean the inner element.

WARNING When using compressed air, use safety goggles.

Cleaning the Air Cleaner (Outer element) 1. Remove the cover 1 and take out the element 2.

2. Before cleaning inside the body, cover the engine intake port so contaminants do not get inside.

3-0021

b) When washing with water, (1) If the element is contaminated due to smoke, soot, oily materials, etc., wash it with element detergent (Donaldson Brand ND-1500, etc). Use of warm water of about 100°F (40°C) makes washing more effective.

(2) After washing off the dirt and detergent with clean water, dry the element in a wellventilated place.

Use a fan to speed up drying.

Do not use heat for drying.

Since it takes time to dry the element after washing, it is recommended that a spare element be used for replacement.

(3) After cleaning, project a light from the inside of the element.

Do not reuse if there are holes, damage or thin area.

3-0223E

1 Cover 2 Element 3 Vacuator Valve 4 Indicator 5 Reset button 6 Window signal

3-0022

3-25

Maintenance

Engine

IMPORTANT ● When an outer element is cleaned 6 times or used for 1000 hours, replace it with a new one.

Installing the air cleaner 1. Installing the element.

2. Attach the cover according to the direction shown on the label.

Fit the element securely with the cover.

Replacing inner element ● Replace the inner element every 1,000 hours. ● Do not reuse an inner element by cleaning.

Replace the inner element with a new element together with the outer element when it is replacing. ● Replace the inner element speedily.

3-26

E1460

Maintenance

Engine

Inspection and Adjustment of Fan Belt • Maintenance: every 250 hours 2. Tension Adjustment a) Loosen the upper and lower mounting bolts 1 and 2 on the generator. Turn adjusting bolts 3 of the generator and move the generator to adjust the tension. b) After adjustment, securely tighten the bolts.

WARNING Be sure to stop the engine before carrying out inspection/adjustment of belt tension.

Otherwise, your finger might be cut off.

(Refer to operator's manual for the engine.)

Ԛ

Fan belt

Ԙ

If the belt is loose, it will cause the battery to be insufficiently charged, the engine to be overheated or the belt to wear out early.

ԙ 1. Inspection Check to see if the belt tension is adequate.

Press the belt at the center between the fan alternator 2 and the fan pulley 3 with your finger with a force of about 98 N (10 kgf). Deflection of about 0.39 - 0.59 in (10 - 15 mm) is normal.

CAUTION ● After adjustment, it is important to securely tighten the bolts and nuts, but overtightening will damage the bolts or bearings. ● Take care to prevent grease from sticking to the belt. The belt will slip and service life will be shortened. ● If the belt is stretched so long that there are no adjustment marks or if it is cracked or cut, replace it. ● When two belts are used, replace both belts at the same time.

After replacing the belt(s), run the machine for about one hour and then recheck the tension of the belt(s).

Ԙ

ԙ

Ԛ

3-0024

3-0023

1 About 0.39 - 0.59 in (10 - 15 mm) at center (Push down force: about 98 N <10 kgf>)

2 Fan pulley 3 Generator pulley

3-27

Maintenance

Bolt Torque

Bolt and Nut Torque • After the first 50 hours/Maintenance: every 250 hours Tighten the bolts and nuts according to the table. After daily work, check the bolts and nuts for looseness and for any missing. Tighten if loose and replace if missing.

Tighten the bolts and nuts after the first 50 hours of operation and every 250 hours thereafter.

Tightening Torque Table No.

Tightening Point

Tightening Torque

Bolt Diameter

Wrench

①

Travel Motor

M16

24mm

267-312

②

Drive Sprocket

M14

22mm

173-202

③

Take-up Roller

M10

17mm

63-73

④

Upper (Carrier) Roller

M16

24mm

267-312

⑤ 6

Lower (Track) Roller

M20

30mm

521-608

Shoe Bolt

M14

22mm

245±25

7

Counterweight

M24

46mm

850-992

8

Turntable Bearing (Lower Frame)

M16

24mm

252-283

9

Turntable Bearing (Swing Frame)

M16

24mm

252-283

⑩

Swing Equipment

M16

24mm

272-317

⑪

Engine (Engine Mount)

M16

24mm

265-313

⑫ 13

Engine Bracket

M10

17mm

64-74

Radiator

M12

19mm

64-74

⑭ ⑮

Hydraulic Pump

M10 M12

17mm Hex. Socket

64-73 109-126

⑯

Hydraulic Oil Tank

M12

19mm

67-78

⑰

Fuel Tank

M12

19mm

98-108

⑱

Control Valve

M12

19mm

59

⑲

Rotating Joint

M12

19mm

88-107

⑳

Rotating Joint

M12

19mm

109-127

[N•m]

Note: Use Loctite No. 262 (adhesive) equivalent on those marked with 〇 and tighten to the torque listed in the above table.

Tightening torque is N•m ÷ 9.8=kgf•m

The tightening torque for the bolts and nuts not listed above are as follows: Bolt Diameter (size) Wrench

M6 ［mm］

M8

M10

M12

M14

M16

M18

M20

10

13

17

19

22

24

27

30

6.9

19.6

39.2

58.8

98.1

157.0

196.0

274.0

5

6

8

10

12

14

14

17

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.03

Hex. Bolt Tightening Torque ［N･m］ Hex. Socket Head Bolt

Wrench

［mm］

Tightening Torque ［N･m］

3-28

Maintenance

Bolt Torque

3-0280E

1,2

8,9 8

1

2

9 3-0246E

3-0243E

3,4,5,6

7 4

3

6

5

3-0244E 3-0245E

3-29

Maintenance

Bolt Torque

:

A,B

10

3-0248E

3-0247E

D,E

13

3-0250E

3-0249E

F

G

3-0281E

3-0251E

H

I,J

19

18 20

3-0254E 3-0253E

3-30

Maintenance

Hydraulic Oil Refilling Hydraulic Oil

WARNING

1. Put the machine in the position for hydraulic oil check.

During inspection, strictly observe the following points: ● Release the hydraulic pressure from the circuit.

Refer to the “Procedure for Releasing the Hydraulic Pressure”. ● The hydraulic oil is hot just after stopping the engine. Wait until the oil cools down (less than 100°F (40°C)) before beginning work.

2. Remove the 4 bolts 1 to remove the cover 2 and O-ring 3 from the hydraulic oil filler port.

3. Refill oil through the filler port.

4. Observing the level gauge 4 on the side of the tank, check that the oil level is proper.

5. After refilling, replace the filler port cover 2 and O-ring 3.

Types of hydraulic oil Use the our recommended oil range: WEB0150 (20 ) (ISO-VG46).

Hydraulic Oil Level Inspection • Daily Inspection 1. Park the machine on a level ground in the position for hydraulic oil check to inspect the oil level of the hydraulic oil tank.

2. Check if the hydraulic oil level is between the high and low marks on the oil level gauge 2. If low, refill through the hydraulic oil filler port 1.

● When the oil level is low, unusual noise may be heard from the hydraulic devices.

● Oil is sometimes trapped at the bottom of the hydraulic oil level gauge. Use care to read the gauge properly.

When checking hydraulic oil

3-0256E

CAUTION When refilling hydraulic oil, prevent dust, water, sand or other contaminants from entering the tank.

3-0282E

1 Hydraulic oil filler port 2 Hydraulic oil level gauge 3-31

Maintenance

Hydraulic Oil

Draining Water and Sediment from the Hydraulic Oil Tank • Maintenance: every 250 hours 1. Press the rubber cap on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Loosen the drain plug 2 on the lower part of the tank to drain the sediment and water at the bottom of the tank. (Have a drain pan ready.)

3. After draining, tighten the drain plug 2.

4. Check the hydraulic oil level and add oil if the level is low.

3-0257E

3-32

Maintenance

Hydraulic Oil

Hydraulic Oil Management • Maintenance: every 1,000 hours Hydraulic Oil Replacement • Maintenance: every 5,000 hours 9. Install the O-ring 3 and filler port cover 2.

If the O-ring 3 is damaged, replace it with a new one.

WARNING The temperature of the hydraulic oil is hot right after stopping the engine. Wait until the oil cools down (less than 100°F (40°C)) before beginning the maintenance.

10. Bleed air from the hydraulic components.

11. Start the engine and run it for about 5 minutes without load.

Operate the travel and swing functions, and all hydraulic cylinders slowly several times. Then, put the machine in the oil check position, and stop the engine.

CAUTION ● When replacing the hydraulic oil, take care

12. Check if the hydraulic oil level is within the proper range.

to prevent dust, water, sand or other contaminants from entering the tank. ● Always replace with new filters and elements when the replacing the hydraulic oil. ● When using the hydraulic breaker, the deterioration and or contamination of hydraulic oil progresses faster compared to ordinary digging work. Be sure to carry out the full hydraulic oil maintenance more often. ● Hydraulic oil management at every 1,000 hours Check oil for the contamination and deterioration by sampling.

1. Place the machine in the hydraulic oil check position.

2. Press the rubber cap of the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

3. Remove the 4 bolts on the filler port to detach the filler port cover 2 and O-ring 3.

4. Using a pump, discharge the hydraulic oil into an empty waste container.

5. Remove the drain plug 5 on the bottom of the tank and drain the remaining oil from the tank.

(Have a drain pan ready beforehand.)

3-0258E

6. Remove the suction filter 4 and return filter 6, and install new ones. (Refer to the replacing suction filter and return filter) 7. Tighten the drain plug 5 securely.

8. Refill with the specified hydraulic oil to the specified level.

3-33

Maintenance

Hydraulic Oil ● Follow the procedures below for air bleeding.

Bleeding Air from the Hydraulic Components

Air bleeding procedures

IMPORTANT

Air bleeding Air bleeding Air bleeding from swing from pump from cylinder motor

Check

‫ڈ‬

‫ڈ‬

Hydrauric oil/pump replacement

After replacing the hydraulic oil, bleed air from the hydraulic components.

‫ڈ‬

Cylinder replacement

‫ڈ‬

Swing motor replacement

Air bleeding procedures after replacing the hydraulic oil

‫ڈ‬

‫ڈ‬ ‫ڈ‬

‫ڈ‬

Air Bleeding from Hydraulic Pump

1. Bleed air from the hydraulic pump.

2. Bleed air from the cylinders.

3. Bleed air from the swing motor.

4. Bleed air from the whole circuit by slowly operating each function (travel, swing and each cylinder).

CAUTION If air is not completely bled, the life of the pump will be reduced or serious problems can occur.

5. Stop the engine and check that no air bubbles remain in the hydraulic oil tank.

WARNING

1. Stop the Engine.

Loosen the plug 1 to check that oil comes from the drain port.

Release internal air pressure from the tank before beginning work.

The hydraulic oil is hot just after stopping the engine.

Wait until it cools down (less than 100°F[40°C]) before beginning work.

2. If oil does not come out, remove the plug 1 and fill hydraulic oil into the pump case through the filler port.

3. Temporarily tighten the plug 1.

4. Start the engine and low speed it without load until oil comes out from the drain port.

CAUTION

5. Stop the Engine.

6. Tighten the drain plug 1 fully.

If any metallic powder or chips are found when the filter or element is replaced, contact our approved Service Shop. If left unattended, it may lead to serious problems.

Avoid dropping any tools or small parts into the tank.

Air Bleeding Procedures CAUTION After replacing hydraulic oil, repairing or replacing hydraulic components or removing hydraulic lines, bleed air from the hydraulic circuit.

3-0259E

2 To engine 3 Outer side

3-34

Maintenance

Hydraulic Oil

Air Bleeding from Cylinder 2. If no oil comes out, stop the engine, remove the air plug 1 and the hydraulic oil is filled from the air port 1 to the motor case.

CAUTION If air is not bled from the cylinder, the piston packing and other parts may be damaged.

3. Temporarily tighten the air plug 1.

4. Idle the engine at low speed and continue to run it until oil comes out from the air plug 1.

1. Idle the engine at low speed, and extend and retract each cylinder 4 or 5 times without reaching the stroke end (about 4 inches (100 mm) before the end of the cylinder).

5. Tighten the air plug 1 fully.

6. Idle the engine at low speed and slowly swing the machine left to right evenly 2 turns or more.

2. Then, operate each cylinder 3 or 4 times to the stroke end to bleed air completely.

Check After air bleeding is completed, stop the engine for 5 minutes and check that no air bubbles remain in the oil in the hydraulic oil tank.

Air Bleeding from Swing Motor CAUTION If air is not completely bled from the swing motor, the motor bearing or other parts may be damaged.

1. Idle the engine at low speed, loosen the air plug 1 and check the oil comes out from the air port 1.

At this time, do not attempt to swing the machine.

3-0260E

3-35

Maintenance

Hydraulic Oil Replacing Return Filter • Initial change after the first 250 hours • Maintenance: every 2,000 hours

Cleaning and Replacing Suction Filter • Cleaning: every 2,000 hours • Replacement: every 5,000 hours

1. Press the rubber cap top on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

1. Press the rubber cap top on the breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Remove the cover A and O-ring B. 3. Take out the spring C, valve D and return filter E from the tank.

2. Remove the cover 2 and O-ring 3.

3. Remove the suction filter 5 from the tank

4. Replace the filter with a new one. Wash the spring and valve and assemble them.

4. Wash filter with cleaning solution, dry completely and check the filter.

If there is any damage on the surface, replace it with a new one.

5. Check the O-ring B. If it is worn or damaged, replace it with a new one.

6. Install the cover A.

IMPORTANT Replace the suction filter with a new one every 5,000 hours or when the hydraulic oil is replaced.

5. Assemble the spring 4 to the filter and put them in place inside the tank.

6. Check the O-ring 3. If it is worn or damaged, replace it with a new one.

7. Install the cover 2.

3-0261E

3-36

Maintenance

Hydraulic Oil

Replacing Air Breather Element • Maintenance: every 1,000 hours

Replacing Pilot Oil Filter Element • Initial change after the first 250 hours • Maintenance: every 2,000 hours

WARNING The hydraulic oil is hot right after stopping the engine. Wait until the oil cools (less than 100°F [40°C]) before beginning work.

WARNING Be sure to release the hydraulic pressure in the circuit.

(Refer to the "Procedure for Releasing Hydraulic Pressure" )

1. Press the rubber cap top on the air breather 1 located at the upper part of the hydraulic tank to release the pressure inside the tank.

2. Remove in following order: rubber cap 1 hexagonal nut 2 cover 3.

1. The bottom of the filter cartridge 2 (hexagonal part) is loosend with a spanner.

3. Replace the old filter element 4 with a new one.

When installing the new filter element, put the sponge packing B on top.

2. Remove the filter cartridge 2 by the hand.

3. Apply clean hydraulic oil to a new filter cartridge and install it in the filter base 1.

4. Adjust the notch portion A, install the cover 3 and install the hexagonal nut 2, then rubber cap 1.

4. Tighten 1/3 rotation by the hand when the filter cartridge 2 is installed in the filter base 1.

Ԙ ԙ A Ԛ B ԛ

①

A

② 3-0033 3-0032

E1591

3-37

Maintenance

Hydraulic Oil

Replacement Intervals for Hydraulic Oil and Filters when Using Breaker IMPORTANT ● If the breaker work continues during a short pe-

tion and/or contamination of hydraulic oil progresses faster compared to ordinary digging work. Be sure to carry out the maintenance more often. In addition, when replacing the hydraulic filters, also measure the cleanliness and deterioration of the oil. ● Replace the hydraulic oil and filter element, using the graph as a guideline, depending on the operation frequency of the breaker.

riod of time and the hour meter exceeds 100 hours during the period, replace the element every 100 hours. ● Replace the return filter for the breaker at the same interval as the element. Additionally, if using a filter with indicator, change the filter according to the indicator's indication.

Average operation rate of hydraulic breaker (%)

● When using the hydraulic breaker, the deteriora-

100 80 60

Filter element replacement interval

40

Hydraulic oil replacement interval

20 0

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

Excavator operation time (hr)

Checking Hoses and Lines • Daily inspections • Maintenance: every 50 hours Check the hydraulic system hoses, pipes, plugs, connectors and fittings for oil leakage and the mounting bolts and nuts for looseness. If any faults are found, rectify them by repairing, replacing and additional tightening as required.

3-38

E1600

Maintenance

Battery Battery Inspection and Charge • Maintenance: every 250 hours

④ ②

CAUTION

⑤

③

● Do not touch the battery when your body is statically charged. Static electricity may cause ignition leading to an explosion.

Touch a metal part of the machine body with bare hand to let charged static electricity escape before carrying out inspection or maintenance. ● Use a piece of rug wetted with water for cleaning of the battery, do not use a dry rug for this purpose. Otherwise, it may be ignited by static electricity leading to an explosion. ● Do not clean the battery with organic solvent such as benzene, thinner and gasoline, or with a detergent and a chemical scrubbing cloth. Battery may be damaged causing leakage of battery electrolyte. ● When an unusual smell is felt around the battery during operation of the vehicle, do not continue operation with this situation left as it is. Otherwise, it may cause a fire or an explosion.

① 3-0080E

1 Hydrometer 2 Negative (–) terminal 3 Positive (+) terminal 4 Handle 5 Caution label

WARNING ● Be sure to read the instructions on the caution label stuck on the battery top for proper use of it.

● Be sure to carry out inspection and service of ●

● ● ●

●

the battery after turning off the power (starter switch OFF).

When using or charging the battery with the hydrometer in the battery indicated in black, the battery generates flammable hydrogen gas which in turn may cause damage (such as explosion) to it.

Do not bring an open flame such as of match and of cigarette near the battery or produce sparks.

Since dilute sulfuric acid is used in the electrolyte of battery, carry out inspection and service very carefully.

If the electrolyte is stuck to the skin or to the clothes, wash it away with water immediately then wash well it off by using soap.

In addition, in case of getting it in the eye, wash well it off with plenty of water then see a doctor for medical treatment.

The battery can be used at an ambient temperature range between 5°F~140°F (-5°C~60°C) continuously and between -22°~167° (-30°C~75°C) for a short time.

Use of the battery beyond the temperature range described above may cause freezing or overheat by which may result in damage or deformation.

E3590

• Check that no crack, split, chipping, and leaking of liquid is in the battery. If found anything wrong, remove the cause or replace the battery.

• Check that the battery has been firmly secured by the mounting hardware. If found loose, re-tighten the nuts on the mounting hardware until the battery is firmly fastened.

• If poor connection of the terminal of the cable to the machine with the battery terminal is found, re-tighten the nut on the cable terminal until it is firmly fastened.

3-39

Maintenance

Battery

How to read hydrometer

Cleaning Battery Terminal ● Clean the battery with a piece of rug wetted with

1. Since this is a battery (which equiped at the new machine) of sealed type that will not need to supply water until the last of its service life, no liquid inlet plug is provided.

Check the battery for charged condition by the color on the hydrometer.

Color of hydrometer

Charged condition

clogging, and if it is blocked with mud and the like, wash it with water to remove the clogging.

Use of the battery with the exhaust hole clogged up allows the inside pressure to be increased by the gas generated from battery which may cause damage to it. ● If the terminal is dirty, clean it. If it is corroded and generates white powder, wash the terminal with hot water.

It is considerably corroded, clean it with a wire brush or sand paper. ● After cleaning, apply a thin coat of grease on the terminal.

Measures to be taken

Green

Good

Use as it is.

Black

Discharged (specific gravity of electrolyte is dropped).

Charge battery until color of hydrometer turns green.

Electrolyte level is low.

If engine fails to be started, it means last of battery life.

Replace battery as soon as possible.

Transparent (white)

water and do not use a dry rug for this purpose.

● Check the exhaust hole of liquid inlet plug for

2. Look at the hydrometer from right above it.

3. When the hydrometer indicates in transparent (white) or in light green, tap it to check that no bubbles are stuck on, and then observe the hydrometer again.

3-0035

Replacing Battery When replacing a battery, do not mix using old and new batteries together. (The service life of the new battery will be shortened.)

Specific Gravity of Electrolyte (The battery which requires added solutions)

Storing battery

Measure the charge rate of the battery with a battery tester or specific gravity gauge. Specific gravity varies with the temperature.

Referring to the table below, check the charge rate.

Measure the specific gravity of the battery with a specific gravity gauge.

Remove the battery out of the machine to store it at a place where well ventilated and no source of fire is expected.

Since battery discharges gradually, check the charge rate once a month to recharge it periodically (3 to 6 months).

Battery charge rate depending on the battery specific gravity Liquid Temperature 68゜ F 32゜ F 14゜ F F -4゜ (20℃) (0℃) (-10℃) (-20℃) Charge Rate 100% Satisfactory

1.28

1.29

1.30

1.31

90% Satisfactory

1.26

1.27

1.28

1.29

80% Charge

1.24

1.25

1.26

1.27

75% Charge

1.23

1.24

1.25

1.26

Replace the battery when still 75% even after charging.

3-40

E1622

Maintenance

Upper Frame Greasing Swing Ring Gear • Maintenance: every 500 hours

WARNING Before inspecting and greasing the turntable bearing and swing ring gear, low the bucket to the ground and stop the engine.

Inspection method 1. Remove the inspection port cover 1 and visually check for damage and the greasing condition of the gear surface.

Turntable Bearing Greasing • Maintenance: every 500 hours

2. If the gear surface is not well greased, add extreme pressure grease #2. (about 0.2 kg).

3. If the grease is white due to moisture or other substance it is necessary to replace it with new grease. ● Contact our office or Service Shop for ring gear repairs and grease replacement.

Greasing Supply extreme pressure grease #2 to the grease fittings (2 places) of the turntable bearing.

(Grease amount: Pump the grease gun 5-10 times at each grease fitting.)

4. If water has accumulated, remove the grease discharge port cover on the inside and discharge the water. a) Remove the guard cover of the lower center part. (If equipped) b) Remove the grease discharge port plug 2 on the lower inside. c) Discharge water or cloudy grease. d) Install the discharge port plug. e) Insert new extreme pressure grease #2 through the inspection port 3.

Refer to the page of the "Grease/oil and elements" for greasing amounts.

3-0283E

3-0284E

3-41

Maintenance

Travel Unit Oil Replacement for Travel Reduction Gear • After first 250 hours • Maintenance: every 1,000 hours

Travel Reduction Gear WARNING ● The motor, shoe and oil are hot just after stopping the machine to travel. Wait until all the parts have cooled down before beginning work. ● Slowly loosen the plug to release the pressure, otherwise, the oil or plug may fly out if a certain pressure remains in the case.

1. Remove the oil filler plug 1 and drain plug 2, and drain the oil.

Check the drained oil for foreign matter such as metallic chips or powder.

2. After the oil is completely drained, wrap seal tape on the drain plug 3 and install it. Refill the specified mount of gear oil through the oil filler port.

Recommended Lubricants Gear Oil: API rating GL-4 class SAE90

3. After refilling the oil, remove the level plug 2, and check the oil level.

Oil Level Inspection and Refilling of Travel Reduction Gear • Maintenance: every 250 hours

4. Wrap seal tape on the filler plug 1 and level plug 2 and install them.

5. Slowly travel the machine and check for oil leakage.

1. Stop the travel motor in the position as shown in the below figure.

2. Slowly loosen the filler plug 1 to release the pressure. Otherwise, the oil or plug may fly out if a certain pressure remains in the case.

3. Remove the level plug 2 and check if the oil flows out.

4. If no oil flows out, remove the oil filter plug 1 and add oil up to the level plug 2 throgh the oil filler port.

5. Wrap seal tape on the filler plug 1 and level plug 2 and install them.

6. Slowly travel the machine and check for oil leakage.

Motor stop position during inspection and refilling

3-0264E

1 Oil filler plug 2 Level plug 3 Drain plug

3-42

Maintenance

Travel Unit

Inspecting Upper/Lower Take-up Roller (Idler Wheel) • As necessary

Inspection and Tightening of Shoe Plate • As necessary

Recommended Lubricants Engine Oil: API rating CD class SAE30 (Take-up Roller /Upper Roller)

If the machine is operated with loose track shoe bolts, the bolts can break and cause additional damage. Immediately tighten the shoe bolts whenever the looseness is found.

Gear Oil:Mobile Gear Oil SHC320 (Lower Roller)

Tightening Sequence The upper and lower rollers 1,2 use a floating seal type sealing mechanism. The service life lasts until overhaul, but check visually everyday before work for oil leakage.

If oil leakage is found, contact our Service Shop since the roller is required to be overhauled.

Tighten the bolts in the sequence shown in the below figure and check that the nuts and shoe are closely fitted to the link joining surface.

3-0063 3-0265E

IMPORTANT

1 Lower roller 2 Upper roller

Wide shoes are designed for use in work on the soft ground or flat places.

If a wide shoe is used in the rocky place, the shoe will be deformed or damaged. Do not use wide shoes for work in the rocky or rough surface ground.

Cleaning Crawler • As necessary ● After finishing work on wet surface ground, remove the earth and mud attached between shoe and travel unit (sprocket). If left with earth attached, the earth gets solid and may cause damage to shoe and the travel performance will be affected. ● After finishing work on the beach or other salt covered places, wash off all salt completely. If washing off is not enough, the crawler will get rusty and cause early wearing and operational faults.

3-43

Maintenance

Travel Unit

Inspection and Adjustment of Track Shoe Tension • As necessary Tension adjustment

It is very important to adjust the track shoe tension to the proper level in order to extend the service life of the track and travel unit.

WARNING Slowly loosen the check valve. When the grease begins to flow out, do not loosen it any further. (Since the pressure inside the cylinder is very high, the grease will spout out or the plug will fly out if the valve is loosened too much.)

Tension inspection Swing the upper structure, press the bucket against the ground and use the boom cylinder to raise one side of the main body. Measure the clearance between the lower surface of the track frame and the upper surface of the shoe at the center of the crawler.

Depending on the conditions of the working area, slightly tighten for hard ground and slightly loosen for soft or sandy ground.

To tighten the tension of the track shoe, add grease through the grease nipple. To loosen the tension, loosen the check valve little by little to release the grease.

3-0285E

Proper clearance between the lower surface of the track frame and upper surface of the shoe: Iron Shoe ---- 7.1 - 8.1 in (180 - 205 mm) 3-0066

If any space 1 exists between the take-up roller shaft and the track frame, you may use pressure to apply the grease. If the shoe tension is still loose, repair is necessary. Contact our approved Service Shop for the service.

3-0065

Link chain Shoe ---- 6.3 - 7.3 in (160 - 185 mm)

Ԙ

3-0168E

3-0067

1 It’s OK, if there is any allowance!!

3-44

Maintenance

Bucket

Replacing Bucket Teeth: Standard type (Length Pin Type) • As necessary 2. Inspect the removed lock pin 2 and rubber lock pin 3.

Replace any damaged pins (short lock pin A or faulty rubber lock pin B, C). It is recommended that the rubber lock pin should be replaced with a new one each time a tooth is replaced.

WARNING ● When installing and removing the bucket teeth and side cutters, place the bucket on the block, to secure it. ● Wear protective equipment (safety goggles, gloves and others) during work.

Ԙ

Removing Bucket Teeth Inspect the bucket teeth for wear and if there are any holes or cracks, replace them.

Replace the teeth before they begin to wear down to the adapter.

A

B

C 3-0070

A Mutch the surface. Lock pin is too short.

B The rubber is cut and the steel projection is

ԙ

about to fall out.

C When pushed by hand, the steel projection sinks in.

Ԛ 3. Clean and remove the soil from the adapter 4.

Ԙ

ԛ

3-0068

1. Use a hammer A and punch B. Remove the lock pin 2 attached to the bucket to remove the tooth 1.

A

B

E1690

3-0069

3-45

Maintenance

Bucket

Installing Bucket Teeth

CAUTION

1. Insert the new rubber lock pin 3 into the hole of the adapter 4 by hand or with a hammer. Insert rubber lock pin 3 so that it does not protrude beyond the adapter surface.

When there is backlash on teeth, teeth might come off while working.

Check that the tooth is securely fastened.

ԛ

A

Ԛ

3-0071

A Make the surfaces even.

2. Attach the tooth 1 to the adapter 4. Check that the hole of the tooth 1 and the hole of the adapter 4 match.

B

Ԙ

ԛ

3-0072

3. Using the hammer, push the lock pin 2 so that it is even with the surface of the tooth 1.

A Ԙ

ԙ

3-0073

A Make the surfaces even.

4. Check that the tooth is securely fastened.

3-46

E1700

Maintenance

Bucket

Adjustment of Bucket Backlash • As necessary 6. Adjusting Method a) Loosen the hexagonal socket head bolt 1 to remove the plate 2. b) Remove the shim plates 3 (as required) the amount corresponding to the backlash amount of the joining area (wear amount). c) Install the plate 2 and tighten the hexagonal head socket bolt 1. d) As the hexagonal socket bolt 1 is tightened, the plate 2 will be pressed against the steel bushing to reduce the clearance.

Clearance amount of about 0.05 in (1.2 mm) is preferable.

7. Apply grease as necessary.

WARNING Stop the engine before adjusting the bucket backlash.

Bucket Backlash Adjustment The machine is provided with a bucket adjustment mechanism which eliminates the backlash of the bucket-to-arm joining area caused by wear.

Due to this mechanism, the sealing condition of the O-rings is kept stable and the wear is delayed. The service life of the bushings and pins thereby increases.

IMPORTANT Too small amount of clearance may cause scuffing or seizure. Always check the clearance.

D

3-0286E

IMPORTANT

C

If the bucket backlash adjustment is not carried out properly, scuffing, unusual noise and backlash will occur, which causes damage to the Orings.

G

G

Ԙ F ԙ Ԛ

Adjustment

E

A

1. Set the hydraulic bucket as shown in the above figure and have it lightly touch the ground.

B 3-0080

1Hexagonal socket head bolt 2Plate 3Shim plate ADust seal BO-ring CArm DClearance ESteel bushing FAttachment pin GBucket

2. Turn it slightly to the left and position it so the arm end is pressed to the side which is not to be adjusted. (When the bucket is turned over, turn it to the right.)

3. Stop the engine.

4. Measure the clearance between the bucket and the arm joining portion.

5. If the clearance is more than 0.08 in (2 mm), remove the shim plate and adjust as follows.

3-47

Maintenance

Air Conditioner

Inspection and Care of Air Conditioner (If Equipped) Inspecting air conditioner

4. Inspecting connecting lines and hoses Visually inspect the connecting parts of the air conditioner lines and hoses for oil, dirt and dust.

For continuous and comfortable use of the air conditioner, inspect it per the procedures below before beginning work.

1. Cleanliness of the condenser When the condenser is dirty, the heat dissipation ability is adversely affected. Wash with water to clean it.

IMPORTANT ● Do not wash the condenser with highly pressurized water. ● When the condenser installed in front of the radiator is very dirty, wash it with water.

3-0082

2. Inspecting fan V-belt tension When the tension of the V-belt is loose, it may slip or vibrate which causes shortened service life. Press down with your hand and check for deflection; tighten as required.

A

C

B

3-0081

A With a force of about 100 N (10 kgf), a deflection of 0.31 - 0.39 in (8 - 10 mm) should be kept.

3. Adjusting the tension of V-belt a) Loosen the nut B. b) Adjust the tension to tight tension bolt C. c) After adjusting, tight the nut B and fix.

3-48

Maintenance

Air Conditioner

Handling Air Conditioner

Maintenance of Air Conditioner

1. Before using the air conditioner in the summer, which has not been used for a long time.

WARNING

a) Refer to the "Inspecting the air conditioner" section and carry out the whole inspection. b) When operating the air conditioner, do not suddenly increase the compressor revolutions.

When using compressed air, wear protective goggles.

Cleaning fresh air intake filter Cleaning interval: every 50 hrs.

IMPORTANT

1. Remove the fresh air intake filter 1 to clean it.

2. After cleaning, attach the filter 1 and close the filter cover.

Inspecting the air conditioner before use will lengthen its service life and function.

2. Handling during off-season Whether it is summer or winter, leave the air conditioner installed because it has refrigerant inside it.

Cleaning inside air filter Cleaning interval: every 50 hrs.

1. The filter is located under the operator’s seat.

IMPORTANT

2. Remove the inside air filter 2 to clean it.

3. After cleaning, attach the filter.

Leave the compressor drive belt as it is regardless of the season.

3. When not using for a long time Operate the air conditioner 1-2 times every 2-3 weeks.

This care prevents oil loss in the components and helps improve the compressor's service life and performance.

3-0170E

3-49

Maintenance

Air Conditioner

Routine Inspection Chart To enjoy lasting and comfortable use of the air conditioner, it is necessary to inspect it routinely. It leads to unnecessarily expensive repair costs to repair the air conditioner after problems occur.

It is highly recommended that preventive maintenance is carried out according to the chart below.

If the air conditioner should break down, turn the switch to OFF and ask for necessary repair.

WARNING ● The air conditioner circuit is filled with high pressure gas and if the lines or compressor parts are loosened, gas will spray out, which is very dangerous. ● Special tools and gauges are needed for the refilling or refrigerant and other maintenance. Always have the air conditioner serviced at a properly equipped service shop. Use R134a as a refrigerant (gas).

Inspection Intervals (Every)

Item Inspection Item

Components Compressor

Operating condition

Condenser

Cleanliness,clogging

12 months

6 months Evaporator

Cleanliness,clogging

Switch motors

Operating condition

12 months

Refrigerant

Filling amount

6 months

Receiver dryer

Damage, aging

12 months

V-belt

Damage, aging

6 months

Hoses

Damage, aging

12 months

Hose connection

Refrigerant leakage

6 months

Air conditioner main body

Lines

Mounting part

Refrigerant leakage, 6 months looseness, contact, damage

Filter

Cleanliness

Every week

3-50

E1760

Maintenance

Air Conditioner

Inspecting Refrigerant Amount

Inspections and refilling should be conducted in our Service Shop. (Inspection method) Operate the air conditioner, increase the engine speed slightly (1,400-1,600 rpm) and compared with bubbles observed through the sight glass with the chart.

WARNING ● With excess refrigerant, overcharge occurs and cooling is deficient. Also, the pressure inside the circuit becomes abnormally high and is dangerous. Operate the system with proper level of refrigerant. ● Operating the air conditioner with no refrigerant (gas) adversely affects the compressor. ● The indication of the sight glass is a guide.

Depending on the outside air conditions, it is difficult to determine situations based on the sight glass indication. Check highpressure changes while carrying out inspection (a sudden pressure increase occurs when being overcharged).

Refrigerant Amount

◯ Sufficient

×

Sight glass of receiver dryer

3-0171E

Sight Glass Condition (1 minute after starting the air conditioner) Just after turning the air conditioner ON, few bubbles are visible, then they become transparent and turn into light milk-white color (transparent milk-White color) Bubbles flow is visible.

Insufficient

×

No bubbles are visible at all immediately after turning the air conditioner ON.

Overcharge

3-51

Check the fittings and refill refrigerant.

Maintenance

Routine Replacement Safety Parts Inspection Classification

WARNING Routinely replace important safety parts listed in the chart below, which specially are related to safety and fire prevention.

It is difficult to determine the service life of these parts by visual inspection or from operations, so routinely replace them early one either every 2 years or every 4000 hours.

Important Safety Parts Chart

Inspection Item

Start-Up Inspection

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts

Special Independent Inspection (Monthly Inspection)

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.

Fuel, Hydraulic hose damage (cracks, wear, gouge)

Special Independent Inspection (Yearly Inspection)

Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.

Fuel, Hydraulic hose interference, squeezing, aging, twisting, damage (cracks, wear, gouge).

● Fuel System Routine Replacement Safety Parts Fuel Hose (Fuel Tank to Engine) Fuel Hose (Fuel Filter to Injection Pump)

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

● Hydraulic System Routine Replacement Safety Parts

Pump Exit Hose (Pump to Operation Valve)

Routine Replacement Safety Parts Boom Cylinder Line Hose Arm Cylinder Line Hose Bucket Cylinder Line Hose

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

Replacement Interval Every 2 years or every 4,000 hours, whichever comes first.

If any problem is found with any of these parts before the replacement interval, repair or replace as required.

Regarding the hoses, if any deformation, cracks, deterioration, etc. is found with the hose clamps, replace the clamps at the same time as the hoses.

Regarding hydraulic hoses not included in the routine replacement safety parts, carry out the inspection described below. If any problem is found, retighten, replace them or take necessary measures.

● Replace O-rings and gaskets at the same time as hose.

● Contact our office or Service Shop for replacement of safety parts. ● Carry out inspection of the hydraulic hoses and fuel hoses at the routine inspection listed below.

3-52

E1780

Maintenance

Troubleshooting

To extend the machine service life and improve the rate of operation, daily inspection and lubrication are necessary as well as for isolating any problem found and dealing with it. If the machine is operated with the problem uncorrected, it may cause major problem and sometimes lead to a serious accident or injury.

If problem occurs, search for the cause in the items described below and make adjustments, repairs, or take measures as necessary. If the cause is not identified, contact our dealer or Service Shop.

Engine and Related Area Refer to "Operator's Manual for Engine".

Problem

Cause

Remedy

Possible seizure in engine Incomplete air bleeding of fuel system No fuel in fuel tank Poor Fuel Quality Fuel filter clogged Low compression Defective fuel injection pump

Connect, repair connection (improper connection on battery terminals) Discharged battery, starter problems, contaminated or loose wiring connectors Inspect and replace as necessary Preheat with air heater Warm up the coolant (add hot water) Repair* Bleed air completely Refill Inspect and replace as necessary Clean and replace as necessary Repair* Repair*

Engine stops during operation

No fuel in fuel tank Fuel filter clogged Air is mixed in the fuel system

Refill Clean or replace Retighten fuel line connection

Improper oil pressure (Engine oil pressure)

Improper oil Defective oil pressure switch Oil filter clogged Low oil viscosity

Refill Replace* Replace element Replace with oil of viscosity matching temperature Adjust, clean, or replace if necessary* Repair

Engine does not start

Defective starter switch (Starter does not run) Defective rotation of starter (Starter rotates slowly) Improper viscosity of engine oil Excessive cooling of engine (Cold weather)

Improper oil pumping Oil leakage

Improper fuel injection timing Low compression

Drain oil to proper level Replace with oil of viscosity matching temperature Cover over radiator or replace parts if necessary Adjust* Disassemble and repair, replace parts*

Engine exhaust shows black or dark gray hue

Improper fuel Improper valve clearance Improper injection pumping Low compression Insufficient air intake (air cleaner clogged)

Replace with correct fuel Adjust Adjust or replace if necessary* Disassemble and repair, replace parts* Clean or replace element

Excessive fuel consumption

Improper injection pumping Improper spray from fuel injection nozzle Improper fuel injection timing Improper fuel Low compression Insufficient air intake

Adjust or replace if necessary* Adjust or replace if necessary* Adjust or replace if necessary* Replace with correct fuel Disassemble and repair, replace parts* Clean or replace element.

Engine exhaust shows white or blue hue

Excessive oil level Low oil viscosity Excessive cooling on radiator

* For items marked with *, contact our Service Shop.

E1790

3-53

Maintenance Problem Excessive engine oil consumption

Troubleshooting Cause

Remedy

Excessive oil level Low oil viscosity Oil leakage Worn cylinder piston ring

Drain oil to proper level Replace with oil of viscosity matching temperature Retighten and replace parts if necessary Disassemble and repair, replace parts*

Unusual noise (Fuel or mechanical)

Poor fuel quality Damage inside muffler

Replace Replace

Engine overheat (Water temperature is too high)

Low coolant Water leakage from each part Over stretch of belt or oil stain on belt Defective radiator Broken fan Excessive amount of antifreeze in the mixture Defective thermostat Defective water pump Defective water temperature gauge

Refill Repair Clean or replace Clean or replace* Replace* Replace Replace* Replace* Replace*

Defective battery charge

Improper belt tension Electrical wiring problems Defective battery Defective regulator Defective alternator

Adjust Repair Replace Replace* Repair or replace*

Clogged on air cleaner

Clogged on air filter element Clogged in air intake system, or foreign substance exists

Clean or replace Clean

* For items marked with *, contact our Service Shop.

Display Monitor Contact a service shop for repair of electronic parts (for controller, etc.).

Problem

Cause

Remedy

OVER HEAT

Water leakage from each part Over stretch of belt or oil stain on belt Defective radiator Many relieving work Broken fan Excessive amount of antifreeze on the mixture Defective thermostat Defective water pump Dirty oil cooler (clogged) Dirty radiator (clogged) Defective dust-protective net (clogged) Defective monitor

Repair Clean or replace Repair or replace* Operate without relieving Replace* Replace Replace* Replace* Clean Clean Clean Replace*

LOW OIL PRESS

Low engine oil Oil leakage on connection Defective engine oil pressure switch Low engine oil viscosity Improper engine oil pumping function Defective monitor Clogged on engine oil filter Defective sensor

Refill Repair Replace* Replace with oil of viscosity matching temperature Adjust, clean or replace if necessary* Replace* Change oil and replace oil filter if necessary Replace*

Low fuel Defective sensor

Refill Replace*

LOW FUEL

* For items marked with *, contact our Service Shop.

3-54

E1800

Maintenance Problem

Troubleshooting Cause

Remedy

ALTERNATOR

Belt tension Electrical wiring problem Defective battery Defective regulator Defective alternator

Adjust Repair Replace Replace* Repair or replace if necessary*

CHECK ENGINE

Breakdown of electric system of the engine failure Fault of sensor

Inspect and replace* Replace*

* For items marked with *, contact our Service Shop.

Operation Problem Heavy operation motion

Cause

Remedy

Contaminants caught on control valve spool Valve sticking Insufficient lubrication on lever linkage Lever linkage sized

Wash control valve* Repair or replace valve assembly* Reapply grease / oil Reapply grease / oil

* For items marked with *, contact our Service Shop.

Hydraulic pump Problem

Cause

Remedy

No oil from hydraulic pump

Insufficient hydraulic oil Clogged on suction filter

Refill Replace filter, or change hydraulic oil if dirty

Hydraulic pump does not build pressure

Oil leakage inside hydraulic pump Air inside the hydraulic pump Main relief valve pressure is set too low

Replace hydraulic pump* Refill oil or check hose on suction side Adjust pressure*

Abnormal sound from hydraulic pump

Cavitation resulting from damaged hose on the suction side or suction filter is clogged Joint of the suction side is loose or hydraulic oil is low and air is entering.

Cavitation resulting from excessively high viscosity of hydraulic oil

Replace filter and/or replace hydraulic oil if dirty Retighten or grease the joints Check that oil is filled to proper level inside casing Replace with oil of correct viscosity

Oil leakage from hydraulic pump

Defective seal on hydraulic pump

Replace oil seal or hydraulic pump*

* For items marked with *, contact our Service Shop.

3-55

Maintenance

Troubleshooting

Working Attachments Problem

Cause

Remedy

Insufficient engine output Decreased performance due to wear of hydraulic pump Defective main relief valve Low hydraulic oil Incorrect viscosity of hydraulic oil Clogged on suction filter

Refer to ""Operator's manual for engine" Repair / replace hydraulic pump*

Defective operations

Damaged hydraulic pump Insufficient hydraulic oil level

Replace with hydraulic oil* Refill

Insufficient work power

Setting pressure for main or port relief valve is low or incorrect Damaged hydraulic cylinder packing Damage hydraulic cylinder piston

Adjust pressure or replace relieve valve*

Attachment lowers

Damaged hydraulic cylinder packing Damaged hydraulic cylinder piston / cylinder Oil leakage inside control valve Oil leakage inside holding valve

Replace hydraulic cylinder packing* Replace hydraulic cylinder piston or assembly* Repair valve assembly or replace if necessary* Repair valve assembly or replace if necessary*

Unusual noise from joints of the attachment

Insufficient grease Connecting pin seizure

Grease Replace the bushing and / or pin

Overall low power

Adjust the pressure or replace* Refill Replace with hydraulic oil of proper viscosity Replace suction filter

Replace hydraulic cylinder packing* Replace hydraulic cylinder piston or assembly*

* For items marked with *, contact our Service Shop.

Travel Problem

Cause

Remedy

Insufficient travel power

Pressure setting for main relief valve is too low Defective counterbalance valve Low performance of travel motor Swivel joint packing damaged Low performance of hydraulic pump

Adjust the pressure* Replace the counter balance valve* Replace travel motor* Replace swivel joint packing* Replace hydraulic pump*

Rough travel

Track too tight Stone or other object caught in track Defective valve Low performance of travel motor Air in travel motor

Adjust to proper tension Remove stone or foreign matter Repair / replace valve* Replace travel motor* Refill with oil

Crooked travel

Left and right tracks are not tensioned equally

Bleed air on right and left and adjust tracks to equal tension Replace hydraulic pump* Replace Hydraulic motor* Replace valve housing assembly* Replace swivel joint packing* Adjust

Low performance of hydraulic pump Low performance of travel motor Oil leakage inside control valve Damage swivel joint packing Lever linkage is loose * For items marked with *, contact our Service Shop.

3-56

E1820

Maintenance

Troubleshooting

Swing Problem

Cause

Remedy

Insufficient swing force

Low performance of swing motor Thermal seizure of swing shaft

Replace swing motor* Supply grease or replace the swing shaft*

During braking, swing does not stop

Low setting of brake valve Clogged valve Low performance of swing motor Internal oil leakage of control valve

Adjust pressure* Clean valve* Replace swing motor* Repair or replace valve assembly*

During stopping, swing slips

Low setting of port relief valve or break valve pressure Clogged valve Low performance of swing motor Internal oil leakage of control valve

Adjust the pressure*

Air in swing motor Insufficient lubrication of swing bearing

Grease Grease

Unusual noise during swing

Clean the valve* Replace swing motor* Repair or replace valve assembly*

* For items marked with *, contact our Service Shop.

Hydraulic Cylinder Problem

Cause

Remedy

Insufficient hydraulic cylinder power

Low setting of relief valve pressure Oil leakage inside hydraulic cylinder Damaged hydraulic cylinder piston or rod Oil leakage inside control valve

Adjust pressure* Replace cylinder packing* Replace hydraulic cylinder piston or rod* Repair or replace valve assembly*

Oil leakage outside hydraulic cylinders

Damaged hydraulic cylinder packing Damaged cylinder rod

Replace hydraulic cylinder packing* Replace cylinder rod*

* For items marked with *, contact our Service Shop.

E1830

3-57

Maintenance

Contacting Us

When ordering parts or asking questions about problems, give us the following information:

● Machine Serial Number & Engine Serial Number ● Service Meter Hours The Machine Serial Number and Engine Serial Number are on the warranty certificate as well as on the nameplate.

Machine Serial Number

Engine Serial Number

3-0287E

Machine Serial Number Stamped

Engine Model 4LE2X -

Number 000000

3-0268E

Service Meter Hour Meter

CNH America LLC Racine, WI 53404 U.S.A

● The engine running time is recorded on this meter.

The last digit indicates 1/10 of an hour (6 minutes). ● This is used as a standard for inspection and maintenance intervals of the machine.

Made in Japan Type

KHP10690-00

3-0016E

3-0173E

3-58

Specifications Contents • Conversion Factors • Specifications

Notice Please note that the specification of a vehicle delivered to you may be different from a model described in this manual because of continuing product improvement.

SPECIFICATIONS

4-0

Specifications

Conversion Factors

CONVERSION FACTORS Metric to U.S. MULTIPLY

BY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C + 32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969

cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (imperial) gallon (US liquid) gallon (imperial)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

gallon/min. (US liquid) gallon/min. (Imperial)

4-1

Specifications

Specifications DRAWN

CHK'D

APPR.

DATE

'07.October.4

BKAU7019-A

SPECIFICATIONS OF CX80 HYDRAULIC EXCAVATOR (TIER 3 EMISSION ENGINE) FOR CASE CORPORATION (NORTH AMERICA)

4-2

Specifications

Specifications

1. ENGINE Type

: Water-cooled, 4-cycle diesel, 4-cylinder in line, direct injection, Turbocharger with air cooled intercooler

Model

: ISUZU AU-4LE2X

Rated flywheel horse power (80/1269/EEC)

: 40.0 kW at 2000 min-1

Piston displacement

: 2179 cc

Maximum torque (80/1269/EEC)

: 210 N-m at 1500 min-1

Bore and stroke

: 85.0 mm × 96 mm

Voltage

: 24 V

Alternator

: 50 Amp

Starter

: 24 V 3.2 kW

Emergency stop

: Mechanical system

2. HYDRAULIC SYSTEM (a) Main pumps (1) Max. oil flow

: 2 variable displacement axial piston pumps : 2 × 68.0 l/min at 2000 min-1

(2) Working circuit pressure Boom/Arm/Bucket/Boom swing : 29.4 Mpa (300 kgf/cm2) Swing circuit

: 22.6 MPa (230 kgf/cm2)

Travel circuit

: 29.4 MPa (300 kgf/cm2)

(b) Pilot pump

: 1 gear pump

(1) Max. oil flow

: 21.4 l/min

(2) Working circuit pressure

: 4.2 MPa (42.8 kgf/cm2)

(c) Blade pump

: 1 gear pump

(1) Max. oil flow

: 24.2 l/min

(2) Working circuit pressure

: 22.6 MPa (230 kgf/cm2)

(d) Control valves

: With Boom holding valve : One 4-spool valve for Right track travel, Boom and Bucket and Arm acceleration : One 5-spool valve for Left track travel, Arm Swing and Boom acceleration and Auxiliary : One 2-spool valve for Boom swing and Blade

(e) Swing device (1) Motor

: Fixed displacement axial piston motor

(2) Brake

: Mechanical disc brake

(3) Final drive

: Planetary gear reduction

(4) Turn table bearing

: Ball bearing type with internal gear

(5) Maximum swing speed

: 9.5 min-1

BKAU7019

4-3

Specifications (f) Cylinders

Specifications NO.of cylinders - bore × Rod diameter × Stroke

Boom

: 1 - φ 110 mm

× φ 70 mm

Arm

: 1 - φ 95 mm

× φ 60 mm

× 797 mm

Bucket

: 1 - φ 85 mm

× φ 55 mm

× 665 mm

Blade

: 1 - φ 100 mm

Boom swing

: 1 - φ 95 mm

× φ 60 mm × φ 55 mm

× 911 mm

× 180 mm × 640 mm

(g) Cooling system Fan

: φ 475 mm (18.7 in) with 7-blades

Radiator capacity

: 32.2 kW (27690 kcal/h)

fin type fin space Oil cooler capacity fin type fin space

: Corrugated fin (wavy type) : 1.75 mm : 17.9 kW (15390 kcal/h) : Corrugated fin (wavy type) : 1.75 mm

Long life coolant

: Coolant 55 % , Water 45 %

Inter cooler capacity

: 4.2 kW (3611 kcal/h)

fin type fin space

: Corrugated fin (wavy type) : 2.0 mm

(h) Filters Suction filter

: 150 mesh

Return filter

:6μm

Pilot line filter

:8μm

3. HYDRAULIC CONTROLS (a) Boom/Arm/Bucket/Swing.................... Pilot pressure control system (ISO control pattern) (b) Travel.................................................. Pilot pressure control system (c) Blade................................................... Pilot pressure control system (d) Boom swing ........................................ Pilot pressure control system (e) Travel mode select (2-speed travel) (f) Attachment cushion control (g) Hydraulic lock (Gate lock)

4-4

BKAU7019

Specifications

Specifications

4. ELECTRICAL SYSTEM (a) Engine control (1) Dial type fuel control (2) One touch idle (b) Monitor system (1) Machine condition (Travel mode , etc) (2) Membrane switch (Wiper , light , etc) (3) Alarm display and buzzer (4) Water temperature (5) Fuel level (c) Wire harness Waterproof type connector (d) Safety Single horn (e) Battery

: 12 V 64Ah / 5HR × 2

(f) Lights (1) Working light Boom

: 24 V 70 W × 1

Cab

: 24 V 55 W × 1

House

: 24 V 55 W × 1

(2) Room Cab

: 24 V 6 W × 1

5. OPERATOR ENVIRONMENT (a) Operator's cab (1) Smooth and round shape design cab, fabricated by press work (2) Safety glass for all windows (3) Shock-less cab suspension by 4-point fluid mounting (4) Sliding front window with auto lock (5) Windshield wiper & washer (6) Heater 3.8 kW (3250 kcal/h) (7) AM/FM Radio with auto-tuner (8) Floor mat (9) Skylight (10) Optional air conditioner

BKAU7019

4-5

Specifications

Specifications

(b) Operator's seat KAB 515

: Low frequency mechanical suspension with helical springs and double acting hydraulic damper.

With following features Manual weight adjustment

Backrest angle adjustment

Seat height and tilt adjustment Adjustable pivoting armrests Adjustable headrest

Seat belt

(c) Others (1) Rear view mirror (Right and rear side)

6. UNDERCARRIAGE (a) Travel motor

: Variable displacement axial piston motor

(b) Brake

: Mechanical disc brake

(c) Hydraulic service brake

: Brake valve

(d) Final drive

: Planetary gear reduction

(e) Travel speeds

:Ⅱ

5.1 km/h

Ⅰ

3.3 km/h

(f) Drawbar pull

: 59.5 kN

(g) Number of carrier rollers (each side)

:1

(h) Number of track rollers (each side)

:5

(i) Number of shoes (each side)

: 39

(j) Type of shoe

: Triple grouser shoe

(k) Link pitch

: 154.0 mm

(l) Width of shoe

: 450 mm (S.T.D)

(m) Grade-ability

: 70 % (35°)

7. DOZER BLADE (a) Width of blade

: 2320 mm

(b) Height of blade

: 450 mm

(c) Max. lift above ground

: 415 mm

(d) Max. drop below ground

: 205 mm

4-6

BKAU7019

Specifications

Specifications

8. Mass (a) Operating mass with 1.71 m Arm , 0.28 m3 Sumitomo Bucket , 450 mm grouser shoe operator, lubricant, coolant and full fuel tank

8430 kg (b) Shipping mass 8070 kg (c) Ground pressure

Operating mass - (operator mass (75kg) + 90 % of fuel mass + bucket mass (210kg)) : 0.038 MPa

(450 mm grouser shoe , with 1.71 m Arm,0.28 m3 Sumitomo Bucket)

9. Digging force (with 1.71 m Arm, 0.28 m3 Sumitomo Bucket) (SAE J1179) Arm digging force

:

38.3 kN

Bucket digging force

:

56.9 kN

10.DIMENSIONS (1.71 m Arm)

(2.21 m Arm)

Overall length (without attachment)

3510 mm

3510 mm

Overall length (with attachment)

6655 mm

6740 mm

Overall height (with attachment)

2700 mm

2950 mm

Cab height

2700 mm

2700 mm

Upper structure overall width

2225 mm

2225 mm

Swing (rear end) radius

1655 mm

1655 mm

Clearance height under upper structure

745 mm

745 mm

Minimum ground clearance

360 mm

360 mm

Wheel base (Center to center of wheels)

2210 mm

2210 mm

Crawler overall length

2845 mm

2845 mm

Track gauge

1870 mm

1870 mm

Undercarriage overall width (with 450 mm shoes) 2320 mm

2320 mm

Crawler tracks height

675 mm

BKAU7019

675 mm

4-7

Specifications

Specifications

11. WORKING RANGES (1.71 m Arm)

(2.12 m Arm)

Boom length

3500 mm

3500 mm

Bucket radius

1050 mm

1050 mm

177°

177°

Maximum reach at GRP

6890 mm

7270 mm

Maximum reach

7030 mm

7400 mm

Max. digging depth

4180 mm

4590 mm

Max. digging height

6390 mm

6600 mm

Max. dumping height

4930 mm

4600 mm

Boom swing left

80 deg.

80 deg.

Boom swing right

50 deg.

50 deg.

Bucket wrist action

12. SYSTEM FLUID CAPACITIES AND SPECIFICATIONS Capacities

Specifications

Hydraulic system

97.3 liter

ISO VG 46

Hydraulic sump tank

50 liter

ISO VG 46

Fuel tank

100 liter

Light oil (Diesel)

Cooling system

10.2 liter

Coolant 55 %, Water 45 %

Final drive case (per side)

1.1 liter

API GL-4 90

Engine crank case

9.0 liter

API CD SAE 15W-40

13. PAINTING (a) Design and color Per the separate agreement reached between CASE Corp. and Sumitomo.

However, paint color of the inside of the machine house shall be made per Sumitomo's design. (b) Paint Cab .....................Melamine resin coating for baking finish Others .................Att & Upper Structure: Urethane resin coating Undercarriage

: Special modified acrylic resin coating

(c) Paint specification Method of application and type of paint shall be per Sumitomo standard.

NOTE ; (1) Sumitomo is constantly improving its products and therefore reserves the right to change design and specification at any time.

(2) Illustrations may include optional equipment and may not include all standard equipment.

(3) This specifications is made referring to ISO 7135 (Earth-moving machinery -Hydraulic excavators Terminology and commercial specifications) first edition dated 1993-08-15.

4-8

BKAU7019

Specifications

BKAU7019

Specifications

4-9

Specifications

Specifications

4-10

BKAU7019

Specifications

BKAU7019

Specifications

4-11

Specifications

Specifications

4-12

BKAU7019

Optional Components Contens • Breakers • Crusher • Load Lifting Operation

OPTION

5-0

E3510

Optional Components Handling the Breaker (Attachment)

Breakers Do not operate the hydraulic cylinder at stroke end !!

Otherwise, it may cause the cylinder and/or the shovel body to be damaged.

Do not operate the machine at the stroke end of the cylinder but operate it by taking a margin to some extent.

In case where the arm is brought down with the cylinder put at its stroke end in addition, the arm cylinder may be damaged by the shock.

Operate it so that each cylinder will not come at its stroke end.

CAUTION 1. When attaching hydraulic breaker It is necessary to choose a breaker suitable for the shovel body.

Contact your nearest distributor, when selecting a hydraulic breaker.

2. When using hydraulic breaker Read the instruction manual thoroughly for the breaker. Take care not to damage either the breaker or the machine and carry out operations safely.

Use for other purposes prohibited The breaker is intended to used for crushing stones, building wrecking, cracking quarried rocks, etc.

5-0008

Using the chisel for gouging work is prohibited

Don't use as a hammer!

Gouging work can cause damage to the breaker main body and shovel main body.

0-0002E

5-0009

E1870

5-1

Optional Components

Breakers

Stop work if the hydraulic hoses vibrate abnormally

Be careful that the chisel does not interfere with the boom

If used in such a condition, the shocks become stronger and lead to an accident.

Be especially careful when transporting the machine with the chisel in the folded position.

Stop work!

5-0003E 5-0012

When Using a Hydraulic Breaker

Underwater work

Finish continuous stroking within one minute!

Underwater work with a standard type hydraulic breaker can lead damage to hydraulic devices of the machine. Do not do such work.

If one place cannot be fragmented within one minute of continuous stroking, change the stroking surface.

Care should be taken to avoid injury by flying fragments during breaker operations. Attach guards as necessary.

One minute

5-0013

5-0004E

5-2

E1880

Optional Components Do not carry out work using the force of the swing It can cause damage to the swinging unit, breaker, arm or boom.

5-0014

Do not use the breaker for lifting work It can cause damage to the breaker. It is dangerous to use the breaker for other purpose.

5-0015

Use the breaker in front or in back of the machine Use of the breaker at the side leads to a decrease in the life of the crawler.

Use range

Use range

5-0005E

E1890

5-3

Breakers

Optional Components

Breakers

Operating the breaker Operating the breaker 1. Adjust the relief valve to the set pressure of the breaker to be used. (Adjustment should be done at approved Service Shop.)

2. Change the valves (stop valve, three way valve) to those for breaker use.

3. Adjust the throttle position to meet the oil flow to the attached breaker specification.

4. Operate with the operation pedals (front, right side of operator seat).

When the pedal is pressed: operates.

When the pedal is released: operation stops.

Operation pedals

CAUTION When not operating the breaker, do not put your foot on the operation pedal.

Operation

5-0019E

Inspection and maintenance when using the breaker: we recommend having the hydraulic oil checked by specialists (sampling) Contamination and deterioration of the hydraulic oil tends to be progress quickly since breaker work is extremely harder for the hydraulic shovel compared with excavation work.

If the machine is continuously used with contaminated or deteriorated hydraulic oil, it can cause malfunction of the control valves, earlier wear of the hydraulic pump and damage to the hydraulic oil circuit as a hole. Carry out inspection and maintenance of hydraulic oil periodically as outlined below: Inspection and Maintenance of hydraulic Oil and Filters Based on Frequency of Breaker Use Recommended Hydraulic Oil Servicing intervals Inspection/Maintenance Location

Time

Hydraulic Oil

Use frequency 100%

Use frequency 40%

Use frequency 20%

Use frequency 10%

10

600

10

10

10

◎

○

100

○

300 1500 ◎

600 3000

○

◎

800 4000

○

◎

Return Filter

◎

Suction Filter

◇

Pilot Filter

◎

◎

◎

◎

Every 200H

Every 300H

Every 600H

Every 800H

Measure hydraulic oil contamination ○ Inspect, add

◎ Change

◎ ◎

◇ Clean or change

CAUTION When the hour meter exceeds 100 hours and breaker operations are done continuously for short periods, change the element each time.

5-4

◇

◎ ◎

◇

◎ ◎

◇

◎

Optional Components

Breakers

Importance of Hydraulic oil Control Construction machinery uses a large volume of oil in the hydraulic system for power transmission, equipment lubrication, rust prevention, and sealing.

According to a survey conducted by a pump manufacturer, seventy percent of the cause for the problems in hydraulic equipment was attributable to inadequate hydraulic oil control.

Therefore, proper control of hydraulic oil helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore, it extends the life of hydraulic oil if it is maintained properly.

Inadequate maintenance 10% Mechanical problems 10%

Other 5% Inadequate hydraulic oil control (Incorrect application of hydraulic oil) 70%

Overload operation exceeding ratings 5%

Causes of Problems in Hydraulic Equipment

(1) Effects of contamination Once inside the hydraulic circuits, contaminants greatly affect the performance and life of hydraulic equipment.

For example, contaminants in a hydraulic pump develop internal wear to cause increased internal leakage and lower discharge.

Table 1. Routes of Infiltration of Contaminants Classification Particle con- Solid taminant particle

Contaminants Sand dust & fiber particles

Infiltration route During assembly and operation

During manuWelding scales, chips burr, molding facture sands, sealing materials, fibers rubber powder

Furthermore, wear particles generated will circulate in hydraulic oil to deteriorate the performance of others equipment.

Contaminants also enter principal sliding sections of the equipment and cause temporary malfunction, scuffing, and sticking, which can lead to major problems.

Nonparticle contaminants

(2) Causes of contamination Contaminants that deteriorate hydraulic oil quality are mainly classified as follows and by the route of contamination as outlined in Table 1.

Tables 2 and 3 outline the size of contaminants and the contaminants in atmosphere.

Wear particles, sludges

During operation

Liquid

Water content, treated oil, incompatvible oil, and grease

During manuacture and operation

Gas

Air. sulphur dioxide, During operaand other gases tion

Table 2. Size of Contaminants Size

Visbility

Other comparable particle

10 μ

Invisible with naked Face powder eyes

65 μ

Barely visible from a Human hair distance of about 1 inch (2.5cm)

100 μ

100Visible with ease Particle of table salt

Note:μ ; micron(1/1,000mm)

Table 3. Contaminants in Atmosphere Amount of contaminants Composition Size

E1910

5-5

Industrial cities 0.62--- 0.73kg/m2/year Clean cities 0.23kg/m2/year Sand and dust 40--- 43% Coal dust 45--- 47% Larger than 10 μ 15% 10 μ or smaller 85%

Optional Components

Breakers

(3) Contamination control standard indicated by the weight or size and number of solid particle contaminant (hereinafter called “particles”) contained in 100 ml. For construction machinery, National Aerospace Standard (NAS) (counting method) is popularly applied.

Particle contamination of new hydraulic oil is normally approximately NAS, Class 7. As its operating time becomes longer, oil is contaminated by contaminates or contaminants are generated within, to degrade its class.

NOTE: NAS 1638 for particle contamination (counting method) counts the number of particles in 100 ml of sample fluid according to the size and classify them in twelve classes as outlined in Table 4.

Control Standard........ Within NAS Class 10 It is desirable that the class of hydraulic oil be maintained within the above mentioned standard. Oil beyond Class 12 must be replaced.

Particle contamination of hydraulic fluid is normally

Table 4. Degree of Contamination Indicated According to NAS 1638 (within 100 ml.)

Contamination Class Size (micron) of particles and the Number of particle

Class 00

Class 0

Class 1

Class 2

Class 3

Class 4

Class 5

Class 6

Class 7

5-15 μ

125

250

500

1,000

2,000

4,000

15-25 μ

22

44

89

178

356

712

1,425

2,850

25-50 μ

4

8

16

32

63

126

253

506

1,102

50-100 μ

1

2

3

6

11

22

45

90

Over 100 μ

0

0

1

1

2

4

8

16

Class 8

Class 9

Class 10

Class 11

Class 12

8,000 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000 5,700 11,400

22,800

45,600

91,200

182,400

2,025

4,050

8,100

16,200

32,400

180

360

720

1,440

2,880

5,700

32

64

128

256

512

1024

Cleaning Operation The purpose of cleaning oil is to remove the contaminants and sludge by filtering hydraulic oil through a cleaning device.

Normally, the hydraulic system of a construction machine is installed with various filters, and if they are maintained properly, most of the contaminants and sludge is exhausted out of the circuits. However, fine particles (approximately 10 micron or smaller) that cannot be collected by the filters continues to circulate through the circuits.

An oil cleaning device is extremely effective for extending the life of hydraulic oil since it can collect fine particles (approx. 5 micron) that passes freely through the filters installed inside the hydraulic system.

5-6

E1920

Optional Components

Crusher

Using the Crusher (Attachment) Do not operate the hydraulic cylinder at stroke end!!

CAUTION 1. When attaching the crusher It is necessary to choose a crusher suitable for the shovel body. The crusher is heavier than the bucket; in order to prevent tipping over, use extreme care while operating it.

2. When using the crusher Read the instruction manual thoroughly for the crusher. Use extreme care and operate the machine safely by avoiding damage to the machine and tipping over.

Otherwise, it may cause the cylinder and/or the shovel body to be damaged.

Do not operate the machine at the stroke end of the cylinder but operate it by taking a margin to some extent.

In case where the arm is brought down with the cylinder put at its stroke end in addition, the arm cylinder may be damaged by the shock.

Operate it so that each cylinder will not come at its stroke end.

Do not use it for anything but its specified purpose Work suitable for the crusher is wrecking work and cracking rocks and boulders.

Do not use crusher to move or load the broken pieces.

5-0018

Work in front or in back of the track shoes Before starting work, make sure the main body is level and the footing is stable.

Work at the side of the shoe is not safe and can cause tipping over.

5-0017

5-0019

E1930

5-7

Optional Components

Crusher

Operation at the stroke end of the cylinder is prohibited

Prying operation with crusher is prohibited

When breaking a steel frame with the crusher pulling the steel frame to this side using the bucket cylinder may allow the frame to be broken suddenly, by which the cylinder may come to its stroke end.

In this case also, an excessive shock is to be applied.

Check the cylinder stroke while operating the machine so that it will not be brought to its stroke end even if the load is set free.

If prying operation using the crusher is carried out, an excessive force is applied to the crusher itself and to the arm/boom/cylinder by which may invite an accident and may cause damage to the crusher.

Therefore, prying operation with crusher is strictly prohibited.

5-0022 5-0020

Cautions when using super-long arm hydraulic shovel

When the arm is brought down, the arm cylinder may be damaged by the shock at its stroke end.

In addition, since an excessive force is to be applied to the arm cylinder when carrying out jacking-up with the cylinder put at its stroke end, do not operate the machine with the arm at its stroke end.

When operating the super-long arm hydraulic shovel with the crusher being installed, there is a risk causing the crawler of hydraulic shovel to be raised or the hydraulic shovel itself to be overturned when the boom is lowered or the arm is extended horizontally because it becomes unstable as a heavier load is shifted toward the top part.

Observe the restriction to the safe working radius for the hydraulic shovel and the allowable weight of load to operate it within a sufficiently safe working radius.

5-0021

5-0023

5-8

E1940

Optional Components No jacking up is allowed

Crusher Change each valve (stop valve, three way valve) tovalves for use with the crusher

If jacking up or turning of the hydraulic shovel with the crusher pushed against the ground is carrying out, not only an excessive force is applied to the crusher, but also unreasonable twist is applied to the arm and to the boom of the hydraulic shovel which in turn may invite a breakdown or an accident.

Therefore, jacking up of the hydraulic shovel is strictly prohibited.

• When transporting the hydraulic shovel (main body), remove the crusher.

• The crusher is heavier than the bucket. To prevent damage to the attachment due to the impacts while transporting, the crusher must be removed.

• When changing the attachments very often, hydraulic oil contamination tends to progress quickly. Carry out regular sampling of the hydraulic oil contamination.

• Be careful of falling objects when working at high places. Attach guards as necessary.

• When carrying out building wreckage work inside the building, check the strength of the floor before starting the operation.

If the machine is equipped with the shuttle plus compatible circuits, change the switches according to the machine operations.

5-0024

5-0029E

5-9

Optional Components

Load Lifting Operation Take measures to carry out safe operations

CAUTION

1. Decide on the signals to be used during lifting operations and the signalman who is to give the signals.

Hold a meeting to make plans for the work.

Precautions for lifting loads with the hydraulic shovel.

1. Only carry out such operations when it is unavoidable and when such work is necessary for safety reasons.

2. The operator and other workers must have special training for slinging work.

3. The sling fitting must be of sufficient strength and have a slip prevention device so that there is no danger of the load falling off.

4. Carry out crane work, at lower engine rotations, and low speeds.

5. Operate the machine slowly, especially when performing swing operations.

6. Do not leave the operator’s seat while lifting a load.

7. Do not attempt to travel while lifting a load.

8. Maintain a lifting position which does not allow the wire ropes and lifting rings out of hooks.

9. When bucket hooks or slings are damaged during the operation, stop work and repair them immediately.

5-0021E

2. Carry out the work on level ground. (There is danger of turning over if done on a slope.)

On the level

5-0022E

3. Level the footing on a slope before beginning work.

5-0020E

5-0023E

5-10

Optional Components 4. Do not allow anyone under the load or other dangerous places.

5-0024E

5. Do not lift a load which exceeds the rated capacity. (It can cause the machine to overturn or put the workers at the risk of their life.)

5-0025E

6. Use wire ropes and slings which are of sufficient strength and which are not deformed or corroded.

Safety factor of the wire rope should be greater than 6 Safety factor of the slings should be greater than 5

5-0026E

5-11

Load Lifting Operation