Fiat Kobelco E235SR Evolution Operation & Maintenance Manual PDF

E235SR Evolution Operation and Maintenance Instruction Manual Print No 604.21.091.00 English - Printed in Italy

E235SR Evolution Operation and Maintenance Instruction Manual

OPERATOR'S MANUAL ENGLISH Print n. 604.21.091.00

Edition: 05/2003 English - Printed in Italy Printed by Studio ti

WARNING

READ THIS MANUAL CAREFULLY BEFORE STARTING, OPERATING, SERVICING. REFUELLING OR CARRYING OUT ANY OTHER WORK ON THE MACHINE.

WARNING

This symbol is your alert sign and is specifically intended for safety purposes. It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Read and comply with all precautionary statements following the key-words DANGER, WARNING and CAUTION.

WARNING

Machine-mounted safety signs are colour coded yellow with black borders and lettering when they refer to points where special ATTENTION must be paid as an ACCIDENT may occur. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

IMPORTANT: Data contained in this manual was current at the time of publication. It is the Manufacturer’s policy to constantly improve its products and such changes may affect information herein. If variances are observed, contact your Dealer and After-Sales Service.

WARNING

Read this manual before operating the machine Most accidents occurring during work are due to non-observance of simple safety norms and elementary precautions.

Many accidents can be avoided if the causes are known and opportune cautions taken beforehand.

There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents as a careful and attentive behaviour.

WARNING

Ensure that the attachment is safely resting onto the ground before repairing, adjusting or servicing machines fitted with hydraulically, mechanically or cable controlled attachments (such as, excavators, loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, mechanically or cable controlled attachment to gain access to certain items, make sure the attachment is adequately retained in the raised position by means other than the hydraulic lift cylinders, cables and/or mechanical devices used for controlling it.

MACHINE SERIAL NO.

ENGINE TYPE

MITSUBISHI 6D34-TLU2D

ENGINE SERIAL NO.

NOTES

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Section I – SAFETY PRECAUTIONS

Table of Contents GENERAL SAFETY INFORMATION ........................................................................................................... 1-1 SAFETY PRECAUTIONS ............................................................................................................................. 1-1 ~ 1-3 PRE-START SAFETY ................................................................................................................................... 1-4 ~ 1-6 SAFETY DURING OPERATION ................................................................................................................... 1-6 ~ 1-9 INSPECTION & MAINTENANCE SAFETY .................................................................................................. 1-9 ~ 1-11 BATTERY SAFETY ...................................................................................................................................... 1-12 WARNING LABELS & DECALS .................................................................................................................. 1-13 ~ 1-17 PROHIBITED MACHINE OPERATION ........................................................................................................ 1-18 ~ 1-19 END OF WORK SHIFT SAFETY .................................................................................................................. 1-19 USE FOPS AND FRONT GUARD ................................................................................................................ 1-20 USE SAFETY VALVE AND OVERLOAD ALARM ....................................................................................... 1-20

WARNING

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READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS. THE MANUFACTURER CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT ARE THEREFORE NOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECHNIQUE NOT SPECIFICALLY RECOMMENDED BY THE MANUFACTURER IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

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Section I – SAFETY PRECAUTIONS

1.1 GENERAL SAFETY INFORMATION CAUTION c. 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 possible damage to the machine and its components.

WARNING DO NOT OPERATE OR PERFORM ANY MAINTENANCE ON THIS MACHINE UNTIL ALL INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN THOROUGHLY READ AND UNDERSTOOD. IMPROPER OPERATION OR MAINTENANCE OF THIS MACHINE MAY CAUSE ACCIDENTS AND COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS KEEP THIS MANUAL IN THE OPERATOR’S SEAT POCKET. IF IT IS MISSING OR DAMAGED, PLACE AN ORDER WITH YOUR DEALER FOR A REPLACEMENT. IF YOU HAVE ANY QUESTIONS, PLEASE CONSULT AN AUTHORIZED DISTRIBUTOR.

4. It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by the Manufacturer.

5. While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

6. Continue studying this manual until all safety, operation and Maintenance procedures are completely understood by all persons working with the machine.

1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules.

Sufficient care should be taken to avoid these accidents.

Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

1.2 SAFETY PRECAUTIONS WARNING THE PROPER AND SAFE LUBRICATION AND MAINTENANCE FOR THIS MACHINE, RECOMMENDED

BY THE MANUFACTURER, IS OUTLINED IN THE OPERATOR’S MANUAL FOR THIS MACHINE.

2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks.

The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.

IMPROPER PERFORMANCE OF LUBRICATION OR MAINTENANCE PROCEDURES ARE DANGEROUS AND COULD RESULT IN INJURY OR DEATH. READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE PERFORMING ANY LUBRICATION OR MAINTENANCE.

3. Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words “DANGER”, “WARNING” and “CAUTION”.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work.

A knowledge of the system and or components is important before the removal or disassembly of any component.

DANGER a. DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in Page 6-3 of SECTION VI – SPECIFICATIONS.

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WARNING b. WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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Section I – SAFETY PRECAUTIONS dropping unexpectedly.

8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud grease, oil or debris from steps, walkways or work platforms before using. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

THE FOLLOWING IS A LIST OF BASIC PRECAUTIONS THAT MUST ALWAYS BE OBSERVED. 1. Read and understand all Warning plates and decals on the machine before operating, maintaining or repairing this machine.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing.

Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

9. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and have the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

3. Disconnect the battery and hang a “Do Not Operate” tag in the Operator’s compartment. Remove ignition keys.

11. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

4. If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a “Do Not Operate” tag in the Operator’s compartment.

12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

5. Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

WARNING

13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.

DO NOT OPERATE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS IN THE OPERATOR’S MANUAL. IMPROPER MACHINE OPERATION IS DANGEROUS AND COULD RESULT IN INJURY OR DEATH.

6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.

7. Lower the bucket, blade or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade or other attachment is blocked correctly to prevent it from 1— 2

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14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

Section I – SAFETY PRECAUTIONS 23. Caution should be used to avoid breathing dust that may be generated when handling components.

16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

IF DUST IS PRESENT, THERE ARE SEVERAL COMMON SENSE GUIDELINES THAT SHOULD BE FOLLOWED.

17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete.

a . Never use compressed air for cleaning. b . Avoid brushing or grinding. c . For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air filter. d . Use exhaust ventilation on permanent machining jobs.

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment.

Do not fail to lower the attachment and place the bucket to the ground before starting the work.

e . Wear an approved respirator if there is no other way to control the dust. f . Comply with applicable rules and regulations for the work place.

19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pin hole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard, wood or metal to locate pin hole leaks.

g . Follow environmental rules and regulations for disposal. h . Avoid areas where particles may be in the air.

20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation.

Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

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22. Be careful when servicing or separating the tracks.

Chips can fly when removing or installing a track pin.

Wear safety glasses and long sleeve protective clothing. Tracks can unroll very quickly when separated.

Keep away from front and rear of machine. The machine can move unexpectedly when both tracks are disengaged from the sprockets. Block the machine to prevent it from moving.

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Section I – SAFETY PRECAUTIONS GER DAN

1.3 PRE-START SAFETY Many failures that occur during machine operation or servicing result from neglecting fundamental safety precautions. The following safety precautions are given to prevent such failures, but they are only a part of what you must follow. Read, understand and follow all safety precautions found in this manual and on the machine thoroughly before operating the machine.

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CAUT

ION Bucke t can co d am ag nt e ca act and b w machi CAUTIO h en ne equi N pped FOR some with attach INTER FERE ments .

C h ec k cl ea ra betwee n ce n bu cket cab be and forre op Exerc ise ca eration. re w operat hen ingBATTERY a buck EXPLOSION PREVENT et near • Batteries give off hydrogen gasses that can

WARNING

explode and cause personal injury.

2432 380 • Keep sparks, openP3 flames and cigarettes away from batteries.

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Never check charge by placing metal articles across battery terminals.

• Leave battery box open to improve ventilation

OBSERVE ALL SAFETY PRECAUTIONS A. OBSERVE SAFETY PRECAUTIONS Follow all safety rules, precautions, and operating procedures. If there are other personnel and flagmen working in the area, have them observe the specified signs.

B. WEAR PROTECTIVE CLOTHING Wear well fitting safety shoes, hard hat, and working clothes, and put on protective glasses, face shield, ear protection and gloves. When necessary, wear reflective vest.

WEAR PROTECTIVE CLOTHING STORAGE AREA

C. READ AND UNDERSTAND THE OPERATOR’S MANUAL Before operating the machine, read and understand this operator’s manual thoroughly in order to use the machine effectively and safely.

READ MANUAL / KEEP IN MACHINE CAB

D. KEEP OPERATOR’S MANUAL IN MACHINE CAB Keep this manual in the specified storage area located behind the operator’s seat for quick reference.

Should the operator’s manual become lost or damaged, contact your dealer to order the operator’s manual.

E. HOW TO HANDLE LIFE HAMMER A life hammer is provided on the left side of cab.

In case of emergency, take the life hammer, break the cab glass, and escape from the cab.

In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.

F. PREPARE FOR EMERGENCIES Have a fire extinguisher and first aid kit ready for emergencies. Know how to operate the fire extinguisher and know where the first aid kit is located for easy access in case of emergency.

PREPARE FOR EMERGENCIES 1— 4

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HOW TO HANDLE LIFE HAMMER

Section I – SAFETY PRECAUTIONS G. ENSURE SAFETY AT THE WORK SITE Know the work area! Before operating the machine, carefully survey and record the land and worksite features to prevent the machine from falling or the soil from caving in.

H. PERFORM PRE-START INSPECTION Before starting the machine, perform a PRE-START inspection of the machine. If any problems are found, repair or replace defective components immediately.

DO NOT OPERATE THE MACHINE until all problem areas are properly repaired.

Always keep the windshield, working lamps, and mirrors clean for good visibility.

WORKSITE SAFETY – KNOW THE AREA

I . ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE Before leaving the operator’s seat, move the safety lock lever to the “LOCKED” (Up) position.

This will not allow operation of any hydraulic c o n trols should they be accidentally moved. If the lever is not set to the “LOCKED” position and hydraulic controls are touched accidentally, the machine may move suddenly resulting in serious injury.

Also before leaving the machine, lower the bucket to the ground, place the safety lock lever in the “LOCKED” (Up) position, stop the engine and remove the starter switch key.

PRE-START INSPECTION OF MACHINE LOCKED (UP) POSITION

UNLOCKED (DOWN) POSITION

SAFETY LOCK LEVER

J. SIGNS, SIGNALS & FLAGMEN Install signs on soft shoulders and ground areas, have a flagman direct the operation if necessary.

The operator should note marks and follow signals from the flagman. All personnel should know the meaning of the signs, marks, and signals. Only one flagman should give the signs and signals.

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K. KEEP FIRE AWAY FROM FUEL AND OIL Oil, antifreeze, and especially fuel are highly flammable. Never use fire near the machine.

Securely tighten all fuel and oil caps. Keep fuel and oil in the designated storage areas. Promptly clean up any all spills and dispose of waste properly.

KEEP FIRE AWAY FROM FUEL & OIL

L. USE CAUTION NEAR NOISE If noise is high during operation, hearing loss may result. Approved hearing protection should be used if personnel will be exposed to high noise levels for a long period of time.

USE CAUTION NEAR NOISE 1— 5

Section I – SAFETY PRECAUTIONS M. MOUNTING & DISMOUNTING MACHINE When getting on and off the machine, always maintain three point contact by using the handrails and step. Inspect and clean handrails, step, and mounting parts. Remove slippery materials, such as lubricants, and mud. Always place the cab door entrance parallel to the tracks before stopping the engine for dismounting.

N. AVOID HOT SURFACES & AREAS Immediately after the machine is operated, the temperature and pressure of the engine coolant, engine oil, and hydraulic oil are very high. Burns may result if caps are removed, or oil, water, or filters are changed under these conditions. Wait until the temperature goes down, before attempting to check fluids or change filters.

MOUNTING/DISMOUNTING MACHINE

O. USE THE PROPER OPTIONAL ATTACHMENT Use only optional attachments designed for and approved by the Manufacturer. Read, understand and follow all instructions in the manual accompanying the optional attachment.

Use of any optional attachment not approved by the Manufacturer in writing, can cause serious injury to personnel, damage to the machine and its components and shorten the life of the machine. Contact your Dealer for optional attachments available for the machine.

HOT SURFACES

P. PREVENT FIRES Leaking or spilled fuel, lubricants and hydraulic oil are fire hazards. Clean and properly dispose of spills as they occur. Repair or replace all leaking components to prevent fire. Also, clean the machine regularly removing all debris to help prevent fires, pay particular attention to removal of leaves, sticks, paper etc. Keep fire extinguisher in an accessible area and know how to use the fire extinguisher should a fire occur.

USE PROPER ATTACHMENT

PREVENT FIRES– CLEAN UP SPILLS

A. STARTING ENGINE Sit in the operator’s seat.

Sound the horn before starting the engine to alert people the machine is being started. Make sure no one is near the machine.

Do not short circuit the starter circuit or battery to start the machine. This may cause serious injury or cause damage the electrical system.

HORN SWITCH (GREY)

SOUND HORN BEFORE STARTING 1— 6

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1.4 SAFETY DURING OPERATION

Section I – SAFETY PRECAUTIONS B. PASSENGERS This equipment is not intended or designed for the transportation of persons. Never allow persons to ride on the machine. Serious injury or death can result from allowing passengers on or in the machine.

C. TRAVEL Make certain of the location of the travel motors before operating travel controls. Sound horn before moving the machine to inform persons that the machine is travelling. Position the attachment as shown in illustration before beginning travel.

Move the machine at slow speeds. Do not turn suddenly on rough terrain. Avoid travelling over obstacles. Should it become necessary to travel over an obstacle, keep the attachment low to the ground and travel at extremely slow speed.

NO PASSENGERS

D. SWING Make certain the swing area of machine is clear of all persons and obstacles before operating swing controls. Sound horn before swinging machine. If necessary, have a flagman signal operator during operation to help prevent injury to persons or damage to obstacles and equipment.

KNOW TRAVEL MOTOR POSITION

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E. BOOM, ARM & ATTACHMENTS Give the work you are doing your undivided attention. Make certain the attachment being used is suited for the job at hand. Make certain of obstacles in the work area and operate the machine within those limits. If necessary have a flagman signal the operator to prevent injury to persons or damage to the machine or obstacles in the work area.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

ZL11M04116

SWING SAFETY

F. OPERATING ON INCLINES OR SLOPES Operation of this machine on an incline or slope may cause the machine to become unstable or unbalanced. Work up and down inclines or slopes never across. Never swing or turn machine around on slopes. Build a level area for the machine to operate. Operate controls carefully to prevent sudden movements which may cause the machine to slide or tip over. Use a flagman to direct the operator.

BUILD BANKING FOR SLOPE OPERATION 1— 7

Section I – SAFETY PRECAUTIONS G. WORKING AROUND UTILITIES If it is suspected that utility lines such as gas, water, phone or electrical power are in the work area, contact the local utility authority for line location BEFORE beginning work in the area. Use extreme caution around electrical power lines.

Keep a sufficient distance away from electrical lines during operation. See chart below for minimum distances.

LINE VOLTAGE

Minimum Distance - M (FEET)

0 ~ 50,000

3.0M (10) OR MORE

50,000 ~ 200,000

4.5M (15) OR MORE

200,000 ~ 350,000

6.0M (20) OR MORE

350,000 ~ 500,000

7.5M (25) OR MORE

500,000 ~ 750,000

10.5M (35) OR MORE

750,000 ~ 1,000,000

13.5M (45) OR MORE

KEEP A SAFE DISTANCE FROM UTILITIES

H. LIFTING This machine is an excavator. Use extreme caution when lifting or moving heavy loads. Use proper lifting equipment rated at a capacity to handle the load.

NEVER USE BUCKET TEETH TO LIFT OR MOVE LOADS. USE PROPER LIFTING DEVICES I . FROZEN OR SNOW COVERED WORK SITES Use extreme caution when operating the machine on frozen or snow covered work sites. Operate all controls slowly and cautiously to prevent sudden movements that may cause the machine to unexpectedly shift, slide or move. Even on the slightest slope, when snow is present or work area is frozen can allow a machine to unexpectedly move.

Snow on shoulders or snow drifts can be much deeper than expected. The machine can easily become buried under such conditions. Use extreme caution while operating the machine around or in snow.

J. FILLED OR UNSTABLE GROUND Be certain the condition of the work site is stable and capable of supporting the machine during operation. Do not operate attachment too close to the machine. Operation of the machine on shoulders or filled areas could cause the machine to become unstable presenting a work hazard.

Position the travel motors to the rear of the machine, allowing for quick reversal, should the work area become unstable.

WORK ON STABLE GROUND 1— 8

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USE EXTREME CAUTION ON FROZEN OR SNOW

Section I – SAFETY PRECAUTIONS K. RESTRICTED WORK AREAS In work sites with limited height and swing areas such as tunnels, bridges, around electrical power lines, other utilities, or inside structures, use extreme caution in keeping the machine and its attachment a safe distance away to prevent personal injury and/ or equipment or structure damage. Use a flagman to direct the operator.

L. PARKING THE MACHINE Always park the machine on a firm, level surface.

If no firm level surface is available, block the tracks and lower attachment to the ground to help prevent machine movement.

Should the machine be parked on a roadway, move the machine to the shoulder to allow passing of traffic. Also post reflective warning signs and markers at a distance from the machine to safely warn motorists. Refer to local code and regulations regarding the posting of work area warnings and markers.

BE AWARE OF OBSTACLES

120°

CHOCK TRACKS

M. STABILIZE ATTACHMENTS Stabilize all attachments removed from the machine to prevent the attachment falling over.

PARKING SAFETY

1.5 INSPECTION & MAINTENANCE SAFETY A. “TAG-OUT” MACHINE Before performing any inspection or maintenance procedures to the machine, fill out and post to the operator’s controls a “DO NOT OPERATE” tag to warn persons not to start the machine. Also inform the supervisor and all operators that the machine is under inspection or maintenance and they will be informed when the machine is ready for normal operation.

STABILIZE ATTACHMENTS WHEN REMOVED

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B. TOOLS & EQUIPMENT Use the proper tools and equipment for the task at hand. Know the proper use of the tools and equipment before starting any inspection or maintenance procedures.

C. PERSONAL EQUIPMENT Wear well fitting work clothes, hard hat, safety shoes and gloves. Confine long hair, loose clothing and remove all jewelry before attempting any inspection or maintenance procedures to this machine or attachments.

USE PROPER TOOLS 1— 9

Section I – SAFETY PRECAUTIONS D. STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE “LOCKED” (UP) POSITION before attempting any inspection or maintenance procedures to the machine. Failure to stop engine could result in serious bodily injury or death.

LOCKED (UP) POSITION

E. SET THE ATTACHMENT Always set the machine in the hydraulic oil check position on firm level ground before attempting any inspection or maintenance procedures to the machine. If it is not possible to put the machine in this position, secure the boom, arm and attachment to help prevent sudden movement. ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

STOP ENGINE/ENGAGE SAFETY LOCK LEVER

HYDRAULIC OIL CHECK POSITION

F. CLEAN THE MACHINE Keep the machine clean and free of debris, excess or spilled lubricants, fuel and fluids. Use approved solvents, detergents and water to clean the machine and its components on a regular basis.

Be careful not to allow water to reach electrical components. Serious damage can occur to the electrical system by allowing water to reach the electrical components. Never clean inside of cab, or electrical components with pressurized water or steam.

KEEP MACHINE CLEAN G. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure from hydraulic reservoir, engine coolant, fuel system and all systems containing pressure before removing any caps or components. BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MACHINES THAT HAVE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

RELEASE HYDRAULIC TANK PRESSURE H. SUPPORT THE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, always support the machine by positioning the machine as shown in the illustration and use safety supports or blocks, with a sufficient capacity rating to support the machine, under the tracks. NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLY SUPPORTED.

90 ~ 110°

SUPPORT THE MACHINE 1— 10

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SUPPORT

Section I – SAFETY PRECAUTIONS I. REFUELING Move the machine to a well ventilated area for refueling. Use only specified fuel as described in the MAINTENANCE section of this operator’s manual.

Immediately clean up all spilled fuel and dispose of it properly. After refueling is complete, securely tighten fuel cap.

J. HYDRAULIC PRESSURE Under normal conditions, all circuits of the hydraulic system are under extreme pressure. When inspecting for leaks, use a small piece of cardboard, wood or metal to locate leaks. SMALL (PINHOLE) LEAKS CAN BE DANGEROUS IF CONTACT WITH SKIN OR EYES IS MADE. Wear approved safety glasses or face shield, gloves, hard hat, safety shoes and work clothes during all inspection and maintenance procedures.

REFUELING

K. TRACK SHOE TENSION The grease used to adjust the track shoe tension is under extreme pressure in the cylinder. Use extreme caution when adjusting track shoe tension. KEEP FACE, HANDS AND LEGS AWAY FROM THE GREASE NIPPLE AREA. Carefully and slowly loosen the grease nipple when lessening track shoe tension. Never loosen grease nipple more than one complete turn.

CHECKING FOR HIGH PRESSURE LEAKS

L. ELECTRICAL SYSTEM Before performing any inspection or maintenance to the electrical system, or performing any welding procedures, disconnect the negative (–) cables from the battery terminals. Not disconnecting the negative (–) cable could cause extensive damage to the electrical system.

USE CAUTION WHEN ADJUSTING TRACKS

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

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M. USE APPROVED WORK LIGHTS Use only approved work lights when performing inspection and maintenance procedures to prevent possible fire or explosion. Certain types of work lights should not be used due to the possibility of ignition of certain flammable gasses and fluids from the machine.

ELECTRICAL SYSTEM PRECAUTION

N. DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc. according to federal, state and local codes and regulations regarding hazardous waste disposal. Contact local authorities for proper disposal methods of such materials.

USE PROPER LIGHTING 1— 11

Section I – SAFETY PRECAUTIONS

1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wear long sleeve shirt, gloves and approved safety glasses or face shield when working with or around batteries. Battery electrolyte (acid) will cause severe burns if allowed to make contact with clothing, skin or eyes.

Should electrolyte (acid) come in contact with clothes, skin or eyes, immediately remove effected clothing, flush area with clean water for 15 minutes and get prompt medical attention.

WEAR PROTECTIVE CLOTHES

B. KEEP AWAY FROM FIRE OR FLAMES Never allow batteries in the vicinity of fire or flames and do not smoke when working with batteries.

Explosive hydrogen gas is produced by the electrolyte (acid) in the batteries. Always work with batteries in a well ventilated area.

KEEP AWAY FROM FIRE OR FLAMES POSITIVE (+) CABLE

C. CHARGING BATTERY Charge battery off of and away from machine in a well ventilated area. When charging battery, remove cell covers to allow gasses to escape.

Avoid breathing gasses from battery. Wear approved safety equipment when working with batteries.

NEGATIVE (-) CABLE

D. USING BOOSTER CABLES Wear proper safety equipment when working with batteries.

MAKE CERTAIN OF THE POSITIVE (+) AND NEGATIVE (-) TERMINALS

If using another machine or vehicle to boost batteries, make certain the machine or vehicle DOES NOT touch the disabled machine.

WARNING

Make certain of the positive (+) and negative (–) terminals on the booster battery and the disabled machine before connecting booster cables.

When disconnecting, disconnect the negative (–) cable first, then disconnect the positive (+) cable.

1. CONNECT BOOSTER CABLE TO POSITIVE (+) BATTERY TERMINAL OF DISCHARGED BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO POSITIVE BATTERY TERMINAL OF NORMAL BATTERY.

Refer to BASIC MACHINE OPERATION section of this manual for proper procedures for use of booster cables.

2. CONNECT OTHER BOOSTER CABLE TO NEGATIVE (–) BATTERY TERMINAL OF NORMAL BATTERY. CONNECT OTHER END OF BOOSTER CABLE TO UPPER FRAME OF TROUBLED MACHINE.

Connect the positive (+) cable first, then connect negative (–).

3. START ENGINE AND REMOVE BOOSTER CABLES IN REVERSE ORDER.

1— 12

31602 60421091

IMPROPER BOOSTER CABLE CONNECTIONS CAN CAUSE AN EXPLOSION RESULTING IN PERSONAL INJURY. CONNECT BOOSTER CABLES USING FOLLOWING PROCEDURE.

Section I – SAFETY PRECAUTIONS

1.7 WARNING LABELS & DECALS Warning labels and decals are affixed to the machine to remind operators and personnel specific safety precautions in certain areas of the machine. The following are illustrated examples of all warning labels and decals along with their locations.

SUPPLEMENTARY EXPLANATION The content of pictograph ISO warning label is explained at the foot of the label. So read and understand it thoroughly.

1. SWING-DANGER Located on each side of the rear counterweight.

2. PRESSURIZED HOT OIL-WARNING Located on each hydraulic tank cover.

Pressurized hot oil can cause burns.

Depress cap slowly with engine off to relieve hydraulic tank pressure.

4. DO NOT CLIMB-WARNING Located on engine bonnet.

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3. PRESSURIZED HOT OIL & COOLANT-WARNING Located on top of engine radiator.

1— 13

5. STOP ENGINE-WARNING Located on engine radiator.

Section I – SAFETY PRECAUTIONS

6. HANDLING BATTERY-DANGER AND WARNING Located on hydraulic tank.

Improper booster cable connections can cause an explosion resulting in personal injury.

Connect booster cables using following procedure.

1. Connect booster cable to positive (+) battery terminal of discharged battery.

Connect other end of booster cable to positive battery terminal of normal battery.

2. Connect other booster cable to negative(–) battery terminal of normal battery. Connect other end of booster cable to upper frame of troubled machine.

3. Start engine and remove booster cables in reverse order.

CONNECTING A BOOSTER CABLE (RED) NORMAL BATTERY

(BLACK)

AVOID ACID BURNS • Electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

• Wear eye protection and protective clothing when handling or servicing batteries.

• If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention.

DISCHARGED BATTERY TO THE UPPER FRAME OF A TROUBLED MACHINE

7. BOOSTER CABLE-WARNING Located on hydraulic tank.

DANGER EXPLOSIVE GASES Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and face from battery. Do not charge or use booster cables or adjust post connections without proper instruction and training.

KEEP VENT CAPS TIGHT AND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid. Avoid contact with skin, eyes or clothing. In event of accident flush with water and call a physician immediately.

KEEP OUT OF REACH OF CHILDREN

Electric hazard may cause injury when mishandling the cable.

Read operator manual for safe and proper handling.

31602 60421091

PREVENT BATTERY EXPLOSION • Batteries give off hydrogen gasses that can explode and cause personal injury.

• Keep sparks, open flames and cigarettes away from batteries.

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Never check charge by placing metal articles across battery terminals.

• Leave battery box open to improve ventilation when charging.

1— 14

Section I – SAFETY PRECAUTIONS 8. HOT PARTS-CAUTION Located on engine bonnet.

9. STOP ENGINE-WARNING Located on engine radiator.

10. AIR CLEANER-CAUTION Located on air cleaner.

13. ENGINE BONNET OPEN-CAUTION Located on engine bonnet.

11. BUCKET TO CAB CONTACT-CAUTION Located inside cab R.H.

12. SAFETY LOCK LEVER-WARNING Located on control stand.

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Bucket can contact and damage cab when CAUTION machine equipped with FOR INTERFERE some attachments.

Check clearance between bucket and cab before operation.

Exercise care when operating a bucket near cab.

1— 15

Machine may move suddenly and cause serious personal injury if a control lever is accidentally touched be sure the safety lock lever is disengaged and in the locked position before exiting the cab.

Section I – SAFETY PRECAUTIONS 14. LIFTING FRONT WINDOW-WARNING Located inside cab front window.

15. NIBBLER & BREAKER OPERATION-CAUTION Located on rear side cover.

Do not set this switch to nibbler combined flow operation position when using breaker.

16. READ OPERATOR'S MANUAL -WARNING Located inside cab R.H.

17. ADJUSTING TRACK TENSION-WARNING Located inside cab R.H.

19. KEEP CLEAR WORKING AREA-DANGER Located on arm.

18. ELECTRICAL POWER LINES -WARNING Located inside cab R.H.

20. OPERATION BY FOOT PEDAL-CAUTION Located inside cab R.H.

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Attachment operation by foot pedal.

Always check the foot pedal control pattern before operation.

Always read operators manual before operating machine.

1— 16

Section I – SAFETY PRECAUTIONS 21. SELECTOR VALVE-CAUTION Located inside cab R.H.

22. RECIRCULATE AIR FILTER-CAUTION Located inside cab R.H.

MAINTENANCE Procedure to change selector valve (When using nibbler, breaker or extra) SELECTION Mark Nibbler N Breaker B EXTRA E Please adjust suitable notch to capscrew. (some mark may not be indicated)

• Contamination and deterioration of hydraulic oil may develop malfunctioning of control valves, early wear and seizure of hydraulic pumps, and consequential damage of entire hydraulic circuit.

Replace filters and hydraulic oil, refering to the following table.

CAPSCREW Notch

(1) Hydraulic oil change : Every 600 HRS. (2) Hydraulic line filter change First : 50 HRS Regular : Every 250 HRS

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Marks

1— 17

Section I – SAFETY PRECAUTIONS

1.8 PROHIBITED MACHINE OPERATION The following examples of machine abuse and misuse should never be attempted by even the most experienced operator. Such abuse and misuse of this machine and its attachments can result in serious bodily injury, death, severe equipment damage and shortened service life of the machine. Under no circumstance should any of these operations be attempted. Use common sense and follow proper operation procedures found in this operator’s manual while operating this equipment.

DO NOT USE TRACTIVE FORCE

A. DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT Doing so will exert excessive force on the machine structure, front end attachments and could cause severe equipment damage. Use tracks for normal travel operations only.

B. DO NOT USE SLEWING FORCE OF THE MACHINE FOR OPERATIONS Doing so will exert excessive force to the machine structure, front end attachments and shorten life of the swinging system of the machine. Also, serious injury or death could result from such operations.

DO NOT USE SLEWING FORCE C. DO NOT PERFORM “HAMMERING” OPERATIONS WITH THE BUCKET. Performing operations such as hammering and piling will cause extensive damage to the machine and its components. These types of operations can also result in serious injury or death.

DO NOT HAMMER WITH ATTACHMENT

USE ONLY FOR INTENDED PURPOSE

1— 18

31602 60421091

D. DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE. This machine is designed and manufactured for digging and loading operations only. Any other use can exert excessive force to the machine, its components, its systems and result in serious bodily injury or death to the operators and other personnel working in the vicinity of or with the machine.

Section I – SAFETY PRECAUTIONS E. DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY Extending the bucket and arm cylinders to stroke end to clean debris from the bucket, will cause impact to the bucket cylinder causing cylinder damage. Use high pressure water or manually remove stubborn material from the bucket.

ALLOWANCES

F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Know the limitations of the machine and its attachments and operate the machine within those specifications. Do not exceed lift charts. Never tip or raise the machine to obtain power to move material. This could cause extensive damage to the machine and its components as well as result in serious bodily injury or death.

DO NOT OPERATE CYLINDER TO STROKE END

1.9 END OF WORK SHIFT SAFETY Perform all of the following procedures after each shift is complete to insure the machine it in optimal operating condition for the next shift or job site.

A. Move the machine to a firm, level surface.

B. Lower attachment to the ground.

DO NOT OVER EXERT THE MACHINE

C. Refill fuel tank to full mark to reduce air volume and condensation (moisture). This will decrease the possibility of freezing in the fuel tank, rusting due to moisture and other problems associated with start up and operation.

D. Close and secure all windows in place to prevent water or moisture reaching the electrical components of the machine.

E. Thoroughly clean and inspect the machine. Perform lubrication maintenance and repair or replace any problem areas found before restarting the machine.

END OF WORK SHIFT SAFETY F. If operating the machine in cold climates, it may be necessary to remove the batteries from the machine and store in a warm well ventilated area. Install the batteries in the machine before next start up. This will help prevent premature battery deterioration.

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G. Remove key from key switch and lock all doors and access panels.

1— 19

Section I – SAFETY PRECAUTIONS

1.10 USE FOPS AND FRONT GUARD For some jobs (e.g. demolition), a safety structure (e.g. FOPS, Front guard) is needed. When your machine does not have this safety structure, you are not allowed to use your machine for this kind of application.

Please check your local dealer in case of doubt.

FOPS

FRONT GUARD

FOPS : Falling Object Protective Structure

NOTE FOPS ······ Falling object protective structure.

USE FOPS AND FRONT GUARD

1.11 USE SAFETY VALVE AND OVERLOAD ALARM

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If your machine is used for lifting application and has a maximum rated lifting capacity bigger than 1 ton or an overturning moment bigger than 40,000 Nm your machine needs safety valves and an overload alarm according to the EN 474 standard.

Please check your local dealer in case of doubt.

1— 20

Section II – MACHINE FAMILIARIZATION

Table of Contents FOREWORD ................................................................................................................................................. 2-1 IDENTIFICATION DATA ............................................................................................................................... 2-2

BASIC COMPONENTS OF THE EXCAVATOR ........................................................................................... 2-4 OPERATOR CAB NOMENCLATURE .......................................................................................................... 2-5 COMPONENT & CONTROLS NOMENCLATURE ....................................................................................... 2-6 ~ 2-33 Right Hand Operator Console .............................................................................................................. 2-6 ~ 2-8 Switch Panel ........................................................................................................................................... 2-9 ~ 2-10 Left Hand Operator Console ................................................................................................................. 2-11 ~ 2-15 Rear Panel And Others .......................................................................................................................... 2-16 ~ 2-18 Operating Levers And Controls ............................................................................................................ 2-18 ~ 2-20 Gauge Cluster ........................................................................................................................................ 2-21 ~ 2-26 Operator Cab And Operator Seat ......................................................................................................... 2-27 ~ 2-31 Seat Belt .................................................................................................................................................. 2-32 Machine Access Panels And Doors ..................................................................................................... 2-32 ~ 2-33

WARNING

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READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

2— 0

Section II – MACHINE FAMILIARIZATION

2.1 FOREWORD This manual has been prepared to assist you in the correct safe procedures for driving, operating and servicing the machine.

Only continuous compliance with the norms herein detailed guarantees best performance, economic operation, and durability of your machine and prevents the commonest causes for accidents which might occur during operation or maintenance.

Particularly, as regards safety, we recommend to carefully read the general safety precautions.

Each machine is supplied complete with a copy of this Manual. Descriptions and illustrations herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer.

DANGER For clarity purposes, some figures in this Manual show the machine with protection panels or covers removed. Never operate the machine with any protection panels or covers removed.

DANGER It is absolutely forbidden to tamper and/or change the setting of any of the hydraulic system valves to avoid damaging machine components with consequent risks to personal safety.

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F18202

FIGURE 2.1

2—1

Section II – MACHINE FAMILIARIZATION

2.2 IDENTIFICATION DATA

3

1

4

2 5

6

NOTICE : The numbers in the illustrations are for explanation only and differ from actual numbers.

• ENGINE No.

7

F22250

FIGURE 2.1/A

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EXCAVATOR MARKING DECAL 1. Machine technical type.

2. Serial number.

3. Machine total mass.

4. Machine manufacturing year.

5. Engine power in kW. 6. Frame identification number.

7. Identification decal: diesel engine type and serial number.

2—2

Section II – MACHINE FAMILIARIZATION

2.3 NOISE LEVELS (2000/14/CE) Sound power level

LWA

Lwa = 102 dB (A) Sound power level guaranteed, determined in compliance with European standard 2000/14/CE.

102

Sound pressure level in the operator’s seat Lpa = 75 dB (A) Sound pressure level: continuous, equivalent and average (A) measured on an identical machine in compliance with ISO 6396:1992.

VIBRATION TO THE OPERATOR The vibration level to the operator depends mainly on the conditions of the ground where the machine is being operated and on the use conditions of the machine and its equipment.

The exposition to vibrations can be remarkably reduced if the recommendations herebelow are followed: - use equipment suitable for the machine and the type of work to be carried out; - adjust and lock the seat in the correct position; regularly check for the seat suspensions and carry out adjustments or maintenance as required; - operate the equipment evenly, avoiding sudden motion or extreme shocks, if possible; - adjust speed and transfer route. Avoid very irregular routes or the impact with possible obstacles, in order to minimize the vibration level.

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s2.

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s2.

F22251

FIGURE 2.1/B

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NOTE: this machine is equipped with an operator’s seat in compliance with standard ISO 7096:2000. This guarantees that the operator’s body exposures to vibrations respect the requirements for protection against vibrations when the machine is used according to its destination as explained in this manual.

2—3

Section II – MACHINE FAMILIARIZATION

2.4 BASIC COMPONENTS OF THE EXCAVATOR

ARM CYLINDER ARM

BOOM

BUCKET CYLINDER

BATTERIES HYDRAULIC OIL TANK HANDRAIL ENGINE AIR CLEANER

IDLER LINK

MAIN CONTROL VALVE BOOM CYLINDER

BUCKET LINK

SWING MOTOR

OPERATOR CAB PUMP ACCESS DOOR

BUCKET

REARVIEW MIRROR HYDRAULIC PUMP

TRACK IDLER (1 EACH SIDE)

FUEL TANK TRACK SPRING (1 EACH SIDE)

MITSUBISHI 6D34-TLE2A

LOWER ROLLER (7 EACH SIDE)

COUNTERWEIGHT

RADIATOR ACCESS DOOR

ENGINE RADIATOR

UPPER ROLLER (2 EACH SIDE)

SWIVEL JOINT TRACK SHOE ASSEMBLY TRAVEL MOTOR

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FIGURE 2.1/C

2—4

Section II – MACHINE FAMILIARIZATION

2.5 OPERATOR CAB NOMENCLATURE

components on the machine. Specific information regarding these components are explained on the following pages of this section.

The operator cab nomenclature, see Figure below, points out locations of operator controls of the Manufacturer hydraulic excavator operator cab (Typical). Study these areas and locate these

LEFT TRAVEL LEVER

RIGHT TRAVEL LEVER

RIGHT FOOT REST GAUGE CLUSTER

LEFT FOOT REST LEFT HAND OPERATOR CONTROL LEVER (HORN SWITCH)

LEFT TRAVEL PEDAL

RIGHT TRAVEL PEDAL

RIGHT HAND OPERATOR CONTROL LEVER (POWER BOOST SWITCH) 24V CIGARETTE LIGHTER

SAFETY LOCK LEVER (FOR HYDRAULICS)

HEAVY LIFT SWITCH ADDITIONAL WORKING LIGHT SWITCH

OPERATORS SEAT (3 WAY ADJUSTABLE)

AUTO ACCEL SWITCH

CAP (FOR OPT. SWITCH) AIR-CONDITIONER PANEL

ROTARY LIGHT SWITCH

ARM REST

THROTTLE POTENTIOMETER

TUNER (FM & AM) LOCALLY-PROCURED PARTS IN EU AREA

OVER LOAD ALARM SELECT SWITCH KEY SWITCH

12V POWER SUPPLY

BREAKER AND NIBBLER SELECTOR SWITCH (OPT.)

FUSE BOX

HEAD REST (ADJUSTABLE)

KPSS RELEASE SWITCH

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HOUR METER

SWING PARKING BRAKE RELEASE SWITCH

ENGINE EMERGENCY STOP CONTROL

FIGURE 2.2 2—5

Section II – MACHINE FAMILIARIZATION

2.6 COMPONENT & CONTROLS NOMENCLATURE

KEY SWITCH POSITIONS ACC

ON

HI

LO

HE AT

F OF

T AR ST

The following information provides a brief description and function of the components and controls of the hydraulic excavator. All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

A. RIGHT HAND OPERATOR CONSOLE 1. Key Switch – FIGURE 2.3 The key switch is located on the right hand operator console and has 5 operating functions.

ACC

ON T AR ST

HE AT

F OF

“HEAT” .... This position is used for starting the engine in cold climates. See section III. “OFF” ...... When key is turned to this position, the engine stops and electrical power to the machine's electrical systems is stopped after approximately 4 seconds.

FIGURE 2.3

“ACC” ...... With key in the “ACC” position only the cigarette lighter, DC to DC converter and horn will have power.

“ON” ........ When key is in the ON position, electrical power is supplied to all the machine’s electrical systems.

“START” ... When key is turned to this position electrical power is supplied to the starter solenoid causing the starter to start the engine. After engine starts key should be released to go back to the “ON” position.

2. Auto Accel Switch – FIGURE 2.4 Press the symbol mark of this switch to turn it “ON”, and the auto accel actuates and switches the speed to the deceleration condition reducing the fuel consumption and the noise, when the accel dial position is set to the decel speed or more, and consequently the remote control pressure of control lever in operation and operating pedal (option) does not operate for 4 seconds.

When the control lever and operating lever are manipulated, the engine revolution rises to the accel dial set position gradually according to the manipulated variable.

And, if the button on which symbol mark is not indicated is pressed during decel rotation, the engine revolution rises to the accel set position.

PRESS HERE FOR "ON"

LO

PRESS HERE FOR "OFF"

HI

WARNING FIGURE 2.4 13503 60421091

WHEN LOADING OR UNLOADING MACHINE ON TRAILER, TURN THE AUTO ACCEL SWITCH OFF. IF IT IS OPERATED KEEPING THE ACCEL SWITCH ON, THE ENGINE SPEED CHANGES ABRUPTLY. 2—6

Section II – MACHINE FAMILIARIZATION

HI

LO

LO

HI

3. Throttle Potentiometer – FIGURE 2.5 The throttle potentiometer is located on the right hand operator console and controls engine RPM. When the throttle potentiometer is rotated to any position it increases or decreases engine rpm and maintains engine at the programmed RPM for that particular position on the dial.

THROTTLE POTENTIOMETER (CONTROL)

ACC

ON

T AR ST

HE AT

F OF

FIGURE 2.5 4. Rotary Light Switch – FIGURE 2.6 This switch is located on the right hand control console. Its basic function is to turn the rotary light “ON” and “OFF”.

PRESS HERE FOR "ON" PRESS HERE FOR "OFF"

Depress this side to turn rotary light “ON”.

Depress back side of switch to turn rotary light “OFF”.

LO

HI

FIGURE 2.6 5. Over Load Alarm Select Switch – FIGURE 2.7 The over load alarm select switch is located on the right hand control console. The over load alarm switch is a 2 position rocker switch and used for lifting operations.

PRESS HERE FOR "ON" LO

HI

“ON” ........ Push the symbol side of switch down to turn over load alarm ON when performing lifting operations.

“OFF” ...... Push the empty side of switch down to turn over load alarm OFF when performing other operations.

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ACC

ON T AR ST

HE AT

F OF

PRESS HERE FOR "OFF"

(FOR EU SPEC.) FIGURE 2.7 2—7

Section II – MACHINE FAMILIARIZATION 6. 24 Volt Cigarette Lighter – FIGURE 2.8 The cigarette lighter is located on the right wall of cab. To use the cigarette lighter the key switch must be in the ON position. Push the lighter in and wait approximately 30 seconds for it to “POP” out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

CAUTION Do not use the cigarette lighter as a power source for 12 Volt accessories. It is 24 Volt outlet.

FIGURE 2.8 7. Heavy Lift Switch – FIGURE 2.9 This switch is located under cigarette lighter and has 2 operating functions. The heavy lift function is used when precision control of heavy lifting operations is required.

PRESS HERE FOR "ON" PRESS HERE FOR "OFF"

“ON” ........ Push the symbol side of switch down to turn heavy lift function ON. “OFF” ...... Push back of switch down to turn heavy lift function OFF.

WARNING NEVER TURN OFF HEAVY LIFT SWITCH DURING ANY OPERATION. SUDDEN OR UNEXPECTED MOVEMENT COULD RESULT IN SERIOUS INJURY OR DEATH.

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FIGURE 2.9

2—8

Section II – MACHINE FAMILIARIZATION B. SWITCH PANEL The push type switch protected from dust and humidity is attached.

This switch panel is equipped with screen change switch, buzzer stop switch, work mode select switch, wiper switch and working light switch.

1. Screen Change Switch (1) – FIGURE 2.10 Start the engine, and OK is appeared on the multidisplay. And then press the screen change switch once and is indicated, and press it one more time and (E/G oil change cumulative time) is indicated.

(6)

2. Buzzer Stop Switch (2) – FIGURE 2.10 When the engine coolant temperature is too high, or various sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently. To stop sounding, press the buzzer stop button.

(1)

(4)

(2)

NOTE

(3) FIGURE 2.10

• Buzzer sounding due to engine cooling water temperature rise cannot be stopped.

• To stop buzzer sounding due to failures of the preheating, failure of engine oil pressure and the release of hydraulic pressure, turn the key switch off.

3. Working Lights Select Switch (3) – FIGURE 2.10 Press this switch, and working lights installed on boom and front right side go on.

Press it again, and working lights on boom and front right side go out.

4. Wiper Switch (4) – FIGURE 2.10 Press this switch, and the front window wiper starts moving. a . Press it once ........... Wiper moves intermittently. b . Press it again .......... Wiper moves continuously. c . Press it once more .... Wiper stops moving.

5. Washer Switch (5) – FIGURE 2.10 Press this switch, and washer fluid is sprayed while it is pushed.

Also, washer tank is installed in the front of radiator on the rear left side.

CAUTION 13503 60421091

(5)

Make certain the washer reservoir has washer fluid before operating washer.

2—9

LED LAMP

Section II – MACHINE FAMILIARIZATION 6. KPSS (KOBELCO Power Sensing System) Work Mode Switch (6) – FIGURE 2.11 The mode is set to mode after the engine stops. Select one effective mode from 3 modes depending on the work condition and the aim of work.

The mode is switched in turn every time when the switch is pressed, and the selected work mode indicator lamp lights on.

(7) KPSS WORK MODE FUNCTIONS

a . Is the machine capable of performing the particular job? b . What attachment (bucket) is best suited for the job?

(6) (1)

c . What type of material will the machine be excavating?

(5)

d . What operating mode is best suited for the job?

(4)

7. KPSS Work Mode Functions – FIGURE 2.11 The KPSS work mode switch allows the operation select and control the operation of the machine and the attachment effectively for a particular job by selecting one of three positions.

(2)

(3)

LED LAMP

FIGURE 2.11

a . “H” mode : Provides maximum speed and power for digging operations. b . “S” mode : Provides standard power and best fuel consumption. c . “FC” mode : Allows fine control of hydraulic functions for attachment.

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Select the KPSS work mode best suited for the particular job at hand.

2 — 10

Section II – MACHINE FAMILIARIZATION C. LEFT HAND OPERATOR CONSOLE 1. 12 Volt Power Supply – FIGURE 2.12 The 12 Volt power supply is located beside the left hand operator console.

For use of common auto accessories such as a fan or other accessories requiring 12 Volt (DC) power, pull cover away from 12 Volt power supply and insert 12 Volt male socket into power supply. Replace cover after use.

CAUTION Do not use the cigarette lighter as a power source for 12 Volt accessories. It is 24 Volt outlet. Plugging a 12 Volt accessory into a 24 Volt connector may result in shorting and/or fire.

MAXIMUM CONTINUOUS OUTPUT - 2.5 Amps

FIGURE 2.12

2. Air Conditioner – FIGURE 2.13 and 2.14 The climate control-AC provides a comfortable indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reducing window glass fogging.

The climate control-AC is installed behind operator’s seat and sends cold air or hot air into cab.

(A)

Air outlet selector Select a preferable air blowout direction moving grille by hand.

(A)

(A), (B), (C) .......... Air outlet

(B)

(C)

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FIGURE 2.13

2 — 11

Section II – MACHINE FAMILIARIZATION I . Control Panel Description AIR OUTLET MODE SELECTOR SWITCH

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

DEFROSTER SWITCH

LCD DISPLAY

COMPRESSOR SWITCH

TEMPERATURE FAN SPEED SELECTOR SWITCH SETTING SWITCH (°C °F SELECTOR SWITCH)

AUTO CONTROL SWITCH

MAIN POWER SWITCH

FIGURE 2.14

SUPPLEMENTARY EXPLANATION The LCD display indicates temperature, air outlet mode, compressor ON - OFF, AUTO, recirculate and fresh air and fan speed.

Each switch, FAN mark of blower, and TEMP mark are illuminated green at night.

II. Fundamental use – FIGURE 2.15 Before turning air-conditioner on, close doors of cab and windows to achieve the best performance.

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

1. Press control switch “AUTO” to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (65.3°F) to 31.5°C (88.7°F).

The outlet temperature, outlet opening and fan speed are adjusted automatically so that indoor temperature of cab comes closer to the set temperature.

COMPRESSOR AUTO SWITCH CONTROL SWITCH

FAN SPEED SELECTOR SWITCH

FIGURE 2.15

2. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF.

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3. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control, is not preferable.

The indicator lamp of “AUTO” in LCD display goes out. Press “AUTO” switch to return to automatic climate control.

2 — 12

Section II – MACHINE FAMILIARIZATION III. Control Panel Functions LCD DISPLAY

1. Main power switch and display – FIGURE 2.16 a. LCD display is illuminated when the climate control-AC is operating.

When the climate control-AC is stopped, LCD will be turned off. b. Press main power switch, and all functions for the climate control-AC switch ON or OFF. Each time when this switch is pressed, the function switches ON and OFF. When switched ON, the climate control-AC starts operating at the point set before switching OFF (when it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

MAIN POWER SWITCH

FIGURE 2.16

NOTE The key switch will switch air-conditioner OFF, but the operating condition just before switching off may not be restored when the key switch is turned ON again.

2. Auto Control Switch and Display - FIGURE 2.17 LCD DISPLAY

a. Press the main power switch to activate the climate control-AC and the LCD display will illuminate.

AUTO CONTROL SWITCH

b. Press control switch AUTO, and fan speed and air outlet are automatically controlled, and “AUTO” indicator lamp on LCD display is illuminated.

MAIN POWER SWITCH

c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power switch is pressed again, the climate control AC will come on in the auto control mode. In the auto mode, the fan speed and air outlet openings are operated automatically.

FIGURE 2.17

3. Temperature Setting Switch and Display - FIGURE 2.18

LCD DISPLAY

a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from Centigrade (°C) to Fahrenheit (°F) or viceversa in the LCD display

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(Eg.) 25°C

77°F or 77°F

TEMPERATURE SETTING SWITCH (°C °F SELECTOR SWITCH)

25°C

c. Press temperature set switch DOWN or UP to change the set temperature.

The temperature goes up or down by 0.5°C (0.9°F) in graduation.

The set temperature may be raised or lowered by continued pressing of the switch.

FIGURE 2.18

2 — 13

Section II – MACHINE FAMILIARIZATION d. The set temperature 18.5°C (65.3°F) is the lowest cooling temperature, and 31.5°C (88.7°F) is the highest heating temperature.

Control beyond either of these limits is not possible.

4. Air outlet mode selector switch and display – FIGURE 2.19 AIR OUTLET MODE SELECTOR SWITCH

a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet mode switch in the condition where auto display light is on, and the display mode is fixed., “AUTO” indicator lamp on LCD display goes out, and “AUTO” control of air outlet opening is released.

Press it again, and the level is changed to BI-LEVEL FOOT. VENT

FIGURE 2.19

LCD DISPLAY AIR OUTLET OPENING AIR OUTLET DIRECTION

VENT

BI-LEVEL

FOOT

UPPER HALF OF BODY UPPER HALF OF BODY, FOOT

5. Defroster switch and display – FIGURE 2.20

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

a. Press defroster switch, defroster indicator lamp will be displayed.

FOOT, FRONT GLASS

LCD DISPLAY

b. Press air outlet mode selector switch, and it returns to air outlet mode just before pressing defroster switch. c. Press defroster switch in the condition where AUTO display is lighting up, “AUTO” indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

DEFROSTER SWITCH

AIR OUTLET MODE SELECTOR SWITCH

FIGURE 2.20 6. Recirculate and fresh air selector switch and display – FIGURE 2.20 a. Suction (fresh air intake) mode is indicated on LCD display

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b. Each time recirculate and fresh air capacity selector switch is pressed, the mode is switched to air recirculate or fresh air intake.

2 — 14

Section II – MACHINE FAMILIARIZATION 7. Compressor switch and display – FIGURE 2.21 Press compressor switch in the condition where mark on LCD display is unlit, compressor starts operating and indicator lamp of mark on LCD display goes on.

Press it again, and compressor turns off, and indicator lamp of mark on LCD display goes out.

LCD DISPLAY

FAN COMPRESSOR SPEED SWITCH DISPLAY

FAN SPEED SELECTOR SWITCH

FIGURE 2.21

8. Fan speed selector switch and display – FIGURE 2.22 When it is set to MANUAL mode, fan speed on LCD display is as follows.

DISPLAY

FAN SPEED

LCD 1 LAMP IS LIT UP

LOW

LCD 2 LAMPS ARE LIT UP

MEDIUM

LCD 3 LAMPS ARE LIT UP

HIGH

LCD 4 LAMPS ARE LIT UP

MAX

LCD DISPLAY FAN SPEED

LOW

MEDIUM

FIGURE 2.22

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Press UP or DOWN of fan speed selector switch, and auto control of fan speed is released, and “AUTO” indicator lamp on LCD display goes out.

2 — 15

HIGH

MAX.

Section II – MACHINE FAMILIARIZATION D. REAR PANEL AND OTHERS 1. Swing Parking Brake Release Switch – FIGURE 2.23 Swing parking brake is usually locked. The swing parking brake is released in swing and arm-in operation. When the swing function becomes inoperable due to a malfunction, turn toggle switch to “RELEASE LOCK” position, and the parking brake is released. Move machine to a safe area immediately and contact your Dealer for assistance.

Return the toggle switch to “NORMAL” position after repairs are completed.

RELEASE LOCK

NORMAL

FIGURE 2.23

2. KPSS Release Switch – FIGURE 2.24 The KPSS release switch is located behind a rubber grommet in the panel behind operator seat. It is used when CPU trouble is displayed on the gauge cluster display. Its purpose is to allow operation of the machine if CPU FAIL is displayed and throttle control is still possible. If throttle control is lost, contact your Dealer for service assistance and temporary CPU bypass procedures.

RELEASE

KPSS

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FIGURE 2.24

2 — 16

Section II – MACHINE FAMILIARIZATION 4. Fuse Box – FIGURE 2.25 The fuse box is located behind the right side of the operator’s seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by gently pulling each end away from the box. Should a fuse require replacement, use a replacement fuse of the same type and amperage. Turn key switch to “OFF” and wait approximately 4 seconds for all electrical power to stop before removing or replacing a bad or blown fuse.

The fuse cover incorporates a fuse puller to remove fuses. Refer to the maintenance section of this manual for a detailed diagram and description of fuse box.

COVER

FUSE BOX

FIGURE 2.25

5. Hour Meter – FIGURE 2.26 This indicates the total time the engine has run. Even if the excavator is not moving, the meter continues to count as long as the engine is running.

HOUR METER

FIGURE 2.26

6. Holder – FIGURE 2.27 This cup holder is located the right front of operator.

Place a canned or a bottled drink.

LOCK BUTTON

Press lock button .......... cover open

COVER

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FIGURE 2.27

2 — 17

Section II – MACHINE FAMILIARIZATION 7. Travel Speed Select Switch – FIGURE 2.28 Select high speed (2nd speed) or low speed (1st speed) with this switch located on the right-hand travel lever. When the starter switch is turned from OFF to ON, the speed is automatically set to LOW. After starting the engine, select the desired speed.

PRESS HERE FOR "FAST" & "SLOW" TRAVEL SPEED SELECT SWITCH

WARNING DO NOT USE

SPEED WHEN PERFORMING DELI-

CATE OPERATIONS SUCH AS PIPE LAYING, FINE GRADING OR LOADING MACHINE ONTO A TRAILER. DO NOT CHANGE TRAVEL SPEED WHILE LOADING MACHINE COULD BECOME UNSTABLE AND CAUSE SERIOUS INJURY, EQUIPMENT DAMAGE AND/OR DEATH. FIGURE 2.28

.............. Set to LOW when moving the maLOW (1st) speed chine on a rough or soft road, slope, or in a narrow place, or when powerful tractive force is required. ............... Set to HIGH when moving the maHIGH (2nd) speed chine on flat, hard ground.

E. OPERATING LEVERS & CONTROLS ENGINE EMERGENCY STOP CONTROL

1. Engine Emergency Stop Control – FIGURE 2.29 The engine emergency stop control cable is located at the lower right hand side of operator’s seat. It is used only in an emergency situation to stop the engine quickly. It has 2 operating positions. a . “IN” ....... Releases the fuel stop lever on the governor to allow normal starting of the engine. b . “OUT” ... Activates the fuel stop lever on the engine governor to immediately stop the engine.

FIGURE 2.29

CAUTION

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Do not suddenly stop the engine when operating at high RPM. Doing so may damage engine.

2 — 18

Section II – MACHINE FAMILIARIZATION 2. Safety Lock Lever – FIGURE 2.30 The safety lock lever is located on the front outside of the left hand operator console and is red in color.

The safety lock lever is used to lock out the hydraulic controls disallowing the use of any hydraulic function. The safety lock lever has 2 operating positions.

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

a . “UP” ....... When placed in the up position the safety lock lever stops all hydraulic controls from functioning and allows the operator to enter and exit the operator seat. b . “DOWN”.. When placed in the down position, the safety lock lever allows all operating functions of the hydraulic controls to resume and also locks the left hand operating console in operating position.

WARNING SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

ALWAYS PLACE THE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR CAB. NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR LEVER IN THE DOWN POSITION.

FIGURE 2.30

3. Left Hand Operator Control Lever – FIGURE 2.31

L.H. CONTROL LEVER (ISO PATTERN)

ARM OUT

CAUTION Hydraulic controls are designed for and set to ISO operating pattern for optimum machine performance and safety.

Changing the control pattern will effect the performance of the machine.

SWING LEFT SWING RIGHT

The left hand operator control lever is located at the top front of the L.H. operator console. Its purpose is to allow the operator to control operations of the swing and arm. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has 4 basic operational functions.

ARM IN

a . “FORWARD” .... Variable speed arm out.

FIGURE 2.31

b . “BACKWARD” . Variable speed arm in.

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c . “LEFT” ............. Variable speed left swing. d . “RIGHT” ........... Variable speed right swing. e . “CENTER” ....... Neutral position.

2 — 19

Section II – MACHINE FAMILIARIZATION 4. Right Hand Operator Control Lever – FIGURE 2.32 The right hand operator control lever is located at the top front of the R.H. operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has 4 basic operational functions.

BOOM DOWN

R.H. CONTROL LEVER (ISO PATTERN)

BUCKET OUT BUCKET IN

a . “FORWARD” .... Variable speed boom down. b . “BACKWARD” .. Variable speed boom up. c . “LEFT” ............. Variable speed bucket in (Digging).

BOOM UP

d . “RIGHT” ........... Variable speed bucket out (Dump). e . “CENTER” ....... Neutral position.

FIGURE 2.32

5. Left and Right Travel Lever & Pedal – FIGURE 2.33 The travel lever & pedal are located in front of operator seat. They are used to move the left or right track of the machine either forward or reverse.

These controls have 2 basic operational functions.

LEFT HAND TRAVEL LEVER LEFT HAND TRAVEL PEDAL

RIGHT HAND TRAVEL LEVER RIGHT HAND TRAVEL PEDAL

a . “FORWARD” .... Variable speed forward track movement. b . “BACKWARD” .. Variable speed reverse track movement

FOOT REST

FOOT REST

c . “CENTER” ....... Neutral position.

These operations are with travel motors at the rear of the machine. If travel motors are positioned in front of the machine the functions of the travel levers will be opposite.

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FIGURE 2.33

2 — 20

Section II – MACHINE FAMILIARIZATION E. GAUGE CLUSTER The monitor displays information sent from sensors positioned at various places on the excavator, making it possible to monitor the excavator's operating working conditions.

KPSS WORK MODE LAMP WATER TEMPERATURE GAUGE

FUEL LEVEL GAUGE

LCD DISPLAY LCD DISPLAY KPSS WORK MODE SWITCH WASHER SWITCH SCREEN CHANGE SWITCH WIPER SWITCH BUZZER STOP SWITCH

WORKING LIGHTS SELECT SWITCH

LED LAMP

FIGURE 2.34 1. Fuel Level Gauge This indicates the amount of remaining fuel.

SUPPLEMENTARY EXPLANATION • For guideline of work mode selector switch, see pages

F : Full tank is about 290 Liter (77 gal).

2-7 and 3-8.

E: The remaining fuel oil is about 50 Liter (13 gal).

4.Screen Change Switch

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2. Water Temperature Gauge This indicates the temperature of the engine coolant, and operates when the starter switch is turned to the “ON” position.

The temperature is normal in the white range. If the needle enters the red range, let the engine idle until the water cools down and the needle moves back into the white range.

START THE ENGINE

OK

PRESS THE SCREEN CHANGE BUTTON

2250RPM

ENGINE RPM

256Hr AFT E/G OIL CH

ACCUMULATED HRS SINCE LAST ENGINE SERVICE

PRESS THE SCREEN CHANGE BUTTON

3. KPSS Work Mode Lamp Press KPSS work mode selec, , on tor switches switch panel, and the selected work mode indicator is displayed in green.

Machine is usually in S mode after starting engine.

PRESS THE SCREEN CHANGE BUTTON

OK 2 — 21

Section II – MACHINE FAMILIARIZATION 5. How To Correct The Engine Oil Supply Cumulative Time KPSS WORK MODE LAMP

WATER TEMPERATURE GAUGE

FUEL LEVEL GAUGE

LCD DISPLAY LCD DISPLAY

KPSS WORK MODE SWITCH WASHER SWITCH SCREEN CHANGE SWITCH

WIPER SWITCH

BUZZER STOP SWITCH

WORKING LIGHTS LED LAMP SELECT SWITCH

FIGURE 2.35

Procedure

Operating procedure

Display on multidisplay (Normal)

A

Turn the starter switch on.

B

Press the gauge cluster screen change switch once, and the E/G speed (rpm) is displayed.

C

Press once more, and the engine oil supply cumulative time screen is displayed.

D

Press the screen change switch for 5 to 10 seconds and release the hand, it returns to the correction mode.

Note) The hourmeter does not flicker.

E

Press the work mode selector switch and the cumulative time increases. (once 1 Hr)

Cumulative time increases

F

Press the buzzer stop switch, the cumulative time decreases. (once 1 Hr)

The cumulative time decreases

G

Press the gauge cluster screen change switch once the correcting time is stored, and exits from the correction mode and OK symbol is displayed to complete the correction.

is displayed.

(Normal)

E/G speed is displayed Press once

E/G speed is displayed Press once more

(Normal)

NOTE : 1. Press the screen change switch once after the procedure D, and the condition is stored and the correction is completed.

2. Even reaching procedure D, the hourmeter does not flicker, and even reaching procedure G, it still does not go on.

2 — 22

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Complete the correction

Section II – MACHINE FAMILIARIZATION

6. LCD Display – FIGURE 2.36 The LCD display is illustrated below and will display the icons listed on this page. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

b. WARNING DISPLAYS WARNING DISPLAYS The Buzzer will sound the instant #2, #3, #5, #6, #7, #9, #16 and #17 warning icons are displayed.

1. I.T.C.S. CONTROLLER – CPU ICON This icon will display when a problem exists in the I.T.C.S. (Intelligent Total Control System). Turn Key switch “OFF” and back to “ON” to try and reset CPU programming.

Should this icon remain on display, stopoperation,stopenginecallyourdealer for temporary CPU bypass procedures or refer to page 2-13.

LCD DISPLAY

2. SWING PARKING BRAKE RELEASE ICON Turn the “swing parking brake release switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed. While this warning is displayed, the swing parking brake does not actuates. So this switch should be used only in the event of emergency.

Call your dealer.

FIGURE 2.36

a. NORMAL DISPLAYS 1. SYSTEM STATUS ICON This icon will display after key switch is turned “ON” and all machine systems and components are checked by CPU and found to be in good working order.

3. KPSS RELEASE ICON Turn the “KPSS work mode release switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed. While this warning is displayed, the normal electric and hydraulic controls are impossible.

So this switch should be used only in the event of emergency.

Call your dealer.

2. ENGINE R.P.M. ICON The engine speed (output) corresponding to the throttle (accel) dial position is displayed.

3. ENGINE LUBRICATION CUMULATIVE TIME 256 hours has elapsed since the change of engine oil.

This mark shows the total cumulative time on and after the time when the engine oil has been changed.

4. ENGINE PRE-HEATING ICON This symbol is displayed when key switch is turned to heat position and the engine preheat circuit is activated.

This display goes out at completion of pre-heating, at which time GLOW is displayed.

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SUPPLEMENTARY EXPLANATION The word in display on gauge cluster is expressed by mother tongue of the country the machine will be shipped to.

Remove the back cover, and select desired language turning the dip switch.

2 — 23

Section II – MACHINE FAMILIARIZATION 5. ENGINE PRE-HEAT COMPLETE ICON This icon is displayed when the PREHEAT is completed.

If the buzzer sounds and can’t be stopped, turn key switch to the OFF position and wait for 4 sec’s until the electrical system is turned off. Then start engine. Continuous preheat after this icon is displayed could cause damage to the engine.

8. ENGINE AIR CLEANER ICON This icon will display should the engine air cleaner element(s) (FILTERS) become too dirty to allow proper air flow to the engine.

Should this icon display stop engine immediately and clean or replace engine air cleaner element(s) as required.

This icon will display only if alternator is charging.

NOTE Do not operate the preheat position of the key switch for more than 20 seconds at one time.

9. OVER LOAD ALARM ICON This icon will display and the buzzer will sound should the boom cylinder circuit pressure exceed the set, specified pressure.

Should this icon display and the buzzer sound, immediately stop all operation, stop engine and contact your dealer.

6. ENGINE OIL PRESSURE ICON This icon will display and the buzzer will sound should the engine oil pressure drop below a safe operating pressure. If this icon is on the display and buzzer is sounding, stop the engine immediately and check engine oil level. Fill engine to proper level with approved motor oil. If engine has LOW OIL PRESSURE, it will automatically go to “LO” idle, and immediately shut down.

This icon will display only if alternator is charging.

10. BATTERY CHARGING SYSTEM ICON This icon will display the electrical charging system not function properly. Should this icon display has electrical charging system repaired immediately. Icon displays only when engine is running with normal oil pressure and a problem occurs in the charging system.

7. ENGINE COOLANT TEMPERATURE ICON This icon will display and the buzzer will sound should the engine coolant temperature rise above safe operating temperature.

Should this icon display and buzzer sound, reduce engine RPM to idle and stop operation until engine coolant temperature reaches a safe operating temperature range.

11. FUEL LEVEL ICON This icon will display should the fuel level in fuel tank reaches 50 liters (13 Gal.) or less. Should this icon display refill fuel tank immediately using approved fuel oil.

13. ATTACHMENT BOOST PRESSURE ICON This icon will display when the power boost switch is depressed.

This icon is displayed only when this system is activated during operation.

2 — 24

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12. ENGINE OIL LEVEL ICON This icon is displayed when the engine oil level of the engine oil pan is low. Check the engine oil level immediately and make up the shortage of the engine oil.

Section II – MACHINE FAMILIARIZATION 14. HEAVY LIFT PRESSURE ICON This icon will display when the heavy lift switch is in the “ON” position. This icon is displayed only when this system is activated during operation.

17. PRESSURE RELEASE FAIL ICON When the pressure release fails, this “FAIL DRAIN HYD. PRESS” is displayed. Perform the pressure release procedure again.

WARNING

15. REPLACE ENGINE OIL ICON This icon will display at every 500 hours of machine operation to remind operator of scheduled engine oil change. The recommended oil change interval for MITSUBISHI engine is every 500 hours of operation.

When this icon is displayed and the buzzer sounds, press the buzzer stop switch once to stop the buzzer sound, and a second time to reset the oil change interval to zero.

Make sure to recalibrate the engine oil change interval as indicated in page 2-22.

WHEN THE PRESSURE RELEASE FAILS, DON’T DISCONNECT THE HIGH PRESSURE LINE.

SUPPLEMENTARY EXPLANATION For the correcting procedure of the accumulated time of engine oil changing, see page 2-22.

16. PRESSURE RELEASE ICON When the internal pressure of the hydraulic pressure system is required to be released, start the engine and keep the screen change switch ( ) and the buzzer stop ) on the switch panel switch ( pressed for 5 seconds simultaneously, and the “DRAINING HYD. PRESS” is displayed and the buzzer sounds intermittently, consequently the engine speed lowers to the low idling or less.

In this condition, operate the lever for attachment required to be released the pressure, and the internal pressure of the hydraulic pressure system is released.

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SUPPLEMENTARY EXPLANATION For the pressure releasing procedure, see Page 4-4.

2 — 25

Section II – MACHINE FAMILIARIZATION The following chart is aimed at familiarizing personnel with the priority of the gauge cluster display icons. Pay close attention to these icons as they can aid in avoiding unnecessary repairs and expense.

The icon in the chart below are listed in priority from the most serious to least serious.

EXAMPLE : If the engine oil pressure is abnormal and fuel level is low, the engine oil pressure icon will display and buzzer will sound. After the oil pressure is back to safe operating pressure, the low fuel icon will display.

LCD DISPLAY

SERVICE FUNCTION ICON SEQUENCE

BUZZER SOUNDING

Press it once after E/G starts.

Press once.

Press once more time.

NORMAL DISPLAY

No sounding

SUPPLEMENTARY EXPLANATION : The screen can be switched into three images by pressing the screen change switch.

• #2, #3, #5, #6, #7, #10, #32, #33 buzzer sounds.

SUPPLEMENTARY EXPLANATION : Icon #5, #6, #32 and #33 are displayed and buzzers do not stop sounding even if the buzzer stop switch is pressed.

When icon #6 is displayed, the engine RPM will idle immediately and the engine will shut down after 15 seconds.

WARNING

Icon #7 is displayed and buzzer stops sounding when the buzzer stop switch is pressed.

SUPPLEMENTARY EXPLANATION The LCD of gauge cluster on the machine for the EU displays only the icons (ISO STD) of the normal display code and warning displays item No. 1 to 29.

2 — 26

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Icons #2, #3 and #10 are displayed and buzzers sound intermittently and stop sounding after 5 seconds.

Section II – MACHINE FAMILIARIZATION G. OPERATOR CAB AND OPERATOR SEAT 1. Locking/Unlocking Cab Door Use the key switch key to lock or unlock cab door.

Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door. See Figure 2.37.

USE KEY SWITCH KEY TO LOCK & UNLOCK CAB DOOR

FIGURE 2.37

2. Cab Door Latch CAB DOOR LATCH

a . The cab door can be latched in an open position by opening door until it is locked open by the door latch located on the cab. See Figure 2.38.

CAB DOOR LATCH

FIGURE 2.38

b . Release door latch by pushing release lever down to release door from latch. See Figure 2.39.

PUSHING LEVER DOWN TO RELEASE DOOR

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FIGURE 2.39

2 — 27

Section II – MACHINE FAMILIARIZATION c . Pull release lever near side, and door opens from the inside of cab. See Figure 2.40.

PULL BACK RELEASE LEVER

FIGURE 2.40

3. Opening & Closing Windshield Front window (upper) can be stored in ceiling.

LEVER (1 EACH SIDE)

CAUTION Make sure to properly lock the window frame in place, or the wiper lock does not function, and consequently the wiper may be damaged because the wiper moves at the time when the wiper motor switch is turned on.

HANDLE

a . Pull levers on the right and left sides of front window upper section and levers are unlocked. See Figure 2.41.

FRONT INSIDE OF CAB

FIGURE 2.41

b . Hold handles on upper central and lower left sides of front window (upper), remove them up and move front window. Lift the front window up and slide overhead all the way to the back end.

Pull down on handles to lock the window in place.

See Figure 2.42.

CAUTION LEVER

Special attention must be paid not to injure hands and others when the front window is closed.

Always, make sure to properly lock the front window in place to avoid injury.

REAR INSIDE OF CAB

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FIGURE 2.42

2 — 28

Section II – MACHINE FAMILIARIZATION 4. Removing & Storing Lower Front Window HOLDER

a . After placing upper front window in ceiling and locking it in place, remove lower front window by hand from window frame.

HOLDER

b . Store the removed lower front window in holder in the rear of cab, behind the operator’s seat. c . To store it, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame. See Figure 2.43.

HOLDER

FIGURE 2.43

5. Opening and closing door glass a . Open cab door glass (upper) sliding it to front side after unlocking it.

LOCK

b . Close the door glass sliding it to LOCK position, then lock it. See Figure 2.44.

FIGURE 2.44

6. Opening and Closing Cab Guard

NUT

GUARD

a . When opening the cab guard, loosen the four nuts and open the guard, then support it with the stay. b . When closing the cab guard, remove the stay and close the guard, then tighten the nut. See Figure 2.45.

WARNING AFTER BOOM RAISE AND ARM IN OPERATION FOR DIGGING, BE CAREFUL OF THINGS IN THE BUCKET WHICH MAY BE DROPPED ON THE CAB.

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FIGURE 2.45

2 — 29

NUT

Section II – MACHINE FAMILIARIZATION 7. Cab Dome Light a . Turn cab dome light “ON” by pushing the dome light switch rightward. b . Turn “OFF” by pushing switch leftward. See Figure 2.46. c . Place dome light switch in the “CENTER” position and the light will be operated by the door switch. When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

USE THIS SWITCH TO TURN DOME LIGHT "ON" AND "OFF"

FIGURE 2.46 8. Storage Compartment The operator and parts manual storage compartment is a pouch located on the back of the operators seat. Keep the operator manual for this machine in this location at all times for quick, easy reference. See Figure 2.47.

MANUAL STORAGE

FIGURE 2.47 9. Operator Seat Adjustments The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety. The adjustment areas are as follows:

ROTATE TO SET OPERATOR WEIGHT

a . Operator weight adjustment – FIGURE 2.48 1. Rotate the adjustment knob until weight close to the operators weight is at the top end of the dial.

FIGURE 2.48 b . Seat height adjustment – FIGURE 2.49 1. Pull height adjustment lever up to raise or lower rear of seat.

PULL UP TO ADJUST REAR OF SEAT PUSH DOWN TO ADJUST FRONT OF SEAT

FIGURE 2.49 2 — 30

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2. Push height adjustment lever down to raise or lower front of seat.

Section II – MACHINE FAMILIARIZATION c . Seat reclining adjustment – FIGURE 2.50 1. Pull reclining adjustment lever up to set desired reclining angle.

2. Release reclining adjustment lever to lock seat in position.

PULL UP TO ADJUST SET RECLINING POSITION

FIGURE 2.50 d . Seat front to back adjustment – FIGURE 2.51

USE BOTTOM BAIL TO ADJUST CONTROL STAND

1. Pull up on seat adjustment bail and move seat forward or backward to desired position.

USE TOP BAIL TO ADJUST OPERATOR SEAT ONLY

FIGURE 2.51 e . Arm rest adjustment – FIGURE 2.52 1. Lower arm rest and with finger, turn adjustment wheel until arm rest is in desired position.

TURN WHEEL TO ADJUST ARM REST (1 EACH ARM REST)

FIGURE 2.52 f . Head rest adjustment – FIGURE 2.53

MANUALLY ADJUST HEAD REST HEIGHT AND RECLINING TO DESIRED POSITION

1. Move head rest forward or backward to desired reclining angle.

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2. Raise or lower head rest to desired height.

FIGURE 2.53 2 — 31

Section II – MACHINE FAMILIARIZATION H. SEAT BELT – FIGURE 2.54 ATTACH BELT ENDS AROUND WAIST

1. Sitting in operator seat, bring ends of seat belt around waist and insert L.H. end into latch (R.H. end). See Figure 2.54.

2. Adjust seat belt until snug around waist by pulling loose end of belt on R.H. side. See Figure 2.54.

TIGHTEN BY PULLING LOOSE END

FIGURE 2.54 3. Remove seat belt by pushing red release button on latch end. See Figure 2.55.

RELEASE BY DEPRESSING RED BUTTON

WARNING ALWAYS WEAR SEAT BELT WHILE SITTING IN OPERATOR SEAT. ALWAYS CHECK CONDITION OF SEAT BELT AND SEAT BELT MOUNTING HARDWARE TO MAKE CERTAIN SEAT BELT IS IN GOOD CONDITION AND PROPERLY SECURE. FIGURE 2.55 I . MACHINE ACCESS PANELS AND DOORS 1. Engine Coolant Tank – FIGURE 2.56 Located on the L.H. side of the machine the engine coolant tank access door allows access to the engine coolant tank. It also holds the engine air cleaner access door closed.

Use the key switch key to lock and unlock the engine coolant access door.

FIGURE 2.56

FIGURE 2.57 2 — 32

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2. Main Pump Access Door – FIGURE 2.57 Locate on the R.H. side of the machine this door allows access to the main pump.

Section II – MACHINE FAMILIARIZATION 3. Battery Box Access Cover – FIGURE 2.58 Located on the R.H. front of the upper frame this cover allows access to the batteries and battery relay. This access cover is also locked and unlocked by key switch key.

Use stay to leave the cover open.

BATTERY ACCESS COVER

FIGURE 2.58

4. Fuel Cap – FIGURE 2.59 Stop engine and remove cap on fuel tank. Fill to desired level or to full up. See page 4-7 for proper tank capacity.

FUEL CAP

FLOAT (RED)

FIGURE 2.59

5. Engine Cover – FIGURE 2.60 Open engine cover with key switch after stopping engine.

Use stay to support it.

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FIGURE 2.60

2 — 33

Section II – MACHINE FAMILIARIZATION

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NOTES:

2 — 34

Section III – BASIC MACHINE OPERATION

Table of Contents PRE-START CHECK .................................................................................................................................... 3-1 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) ....................... 3-1 Starting Engine ...................................................................................................................................... 3-1 Stopping Engine .................................................................................................................................... 3-1 Emergency Engine Shut Down ............................................................................................................. 3-1 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F) ...................... 3-2 Starting Engine ...................................................................................................................................... 3-2 Stopping Engine .................................................................................................................................... 3-2 Emergency Engine Shut Down ............................................................................................................. 3-2 STARTING MACHINE ENGINE WITH BOOSTER CABLES ....................................................................... 3-3 ~ 3-4 Connecting Booster Cables .................................................................................................................. 3-3 Starting Boosting Machine Engine ...................................................................................................... 3-4 Starting Disabled Machine Engine ....................................................................................................... 3-4 Disconnecting Booster Cables ............................................................................................................. 3-4 MACHINE WARM-UP ................................................................................................................................... 3-5 Engine ..................................................................................................................................................... 3-5 Hydraulic Oil ........................................................................................................................................... 3-5 Hydraulic Oil in Frigid Temperatures ................................................................................................... 3-5 CONTROLS DECAL ..................................................................................................................................... 3-6 Operating Pattern ................................................................................................................................... 3-6 Operating Pattern Decal ........................................................................................................................ 3-6 BASIC OPERATION OF HYDRAULIC CONTROLS ................................................................................... 3-7 ~ 3-14 Safety Lock Lever .................................................................................................................................. 3-7 KPSS (Power Sensing System) Work Mode Switch ........................................................................... 3-8 Machine Travel Controls ....................................................................................................................... 3-9 ~ 3-11 Machine Attachment & Swing Controls ............................................................................................... 3-12 ~ 3-13 Using Auto-accelerator .......................................................................................................................... 3-14 Towing the Machine ............................................................................................................................... 3-15 PRACTICES TO IMPROVE EFFICIENCY ................................................................................................... 3-16 ~ 3-17 OPERATING THE SHOVEL ......................................................................................................................... 3-17 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS .............................................................. 3-18 FLAGMAN HAND SIGNALS ........................................................................................................................ 3-19 ~ 3-24

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WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

3— 0

Section III – BASIC MACHINE OPERATION

3.1 PRE-START CHECK HI

Perform pre-start inspection and maintenance procedures before starting the machine. Refer to the maintenance section of this manual for specific instructions.

F OF

ACC

ON

T AR ST

HE AT

LO

3.2 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) A. STARTING ENGINE

THROTTLE IN "LO" POSITION

KEY SWITCH IN "ON" POSITION

1. Move throttle control to “LO” position. See Figure 3.1.

FIGURE 3.1

2. Insert key into key switch and turn to the “ON” position. See Figure 3.1.

3. Sound horn to warn personnel that the machine is being started. See Figure 3.2.

4. Turn key to the “START” position and release as soon as engine starts. Key will automatically return to the “ON” position.

CAUTION Release key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

FIGURE 3.2

NOTE If engine fails to start after 3 attempts, inspect fuel system and correct any problems found.

When cranking engine, the absence of “Blue” or “White” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

MACHINE ON FIRM, LEVEL SURFACE

B. STOPPING ENGINE – NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position. See Figure 3.3.

FIGURE 3.3

2. Move throttle control to “LO” position. See Figure 3.1. Allow engine to idle for 5 minutes.

USE ONLY IN EMERGENCY

3. Turn key switch to “OFF”.

EMERGENCY ENGINE STOP CONTROL

C. EMERGENCY ENGINE SHUT DOWN In only cases of emergency should this method be used.

1. Turn key switch to the “OFF” position.

2. Pull out the engine emergency stop control located on the lower right side of control stand until engine stop. See Figure 3.4.

FIGURE 3.4

3. Before restarting engine, push emergency engine stop control in.

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Section III – BASIC MACHINE OPERATION

HI

3.3 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F)

ACC

ON

T AR ST

F OF

A. STARTING ENGINE

HE AT

LO

1. Move throttle control to “LO” position. See Figure 3.5.

2. Turn the key switch to “HEAT” and preheat for 20 seconds to make start-up easier. See Figure 3.6.

THROTTLE IN "LO" POSITION

3. Turn key switch “ON” and sound horn to warn personnel that the machine is being started. See Figure 3.7.

KEY SWITCH IN "ON" POSITION

FIGURE 3.5 KEY IN "HEAT" POSITION FOR 20 SECONDS

4. Turn key to the “START” position and release as soon as engine starts. Key will automatically return to the “ON” position.

CAUTION Release key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

FIGURE 3.6 SOUND HORN

NOTE If engine fails to start after 3 attempts, inspect fuel system and correct any problems found.

When cranking engine, the absence of “Blue” or “White” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

FIGURE 3.7 ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

MACHINE ON FIRM, LEVEL SURFACE

B. STOPPING ENGINE – NORMAL CONDITIONS 1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position. See Figure 3.8.

2. Move throttle control to “LO” position. See Figure 3.5. Allow engine to idle for 5 minutes.

3. Turn key switch to “OFF”.

FIGURE 3.8

C. EMERGENCY ENGINE SHUT DOWN In only cases of emergency should this method be used.

USE ONLY IN EMERGENCY

1. Turn key switch to the “OFF” position.

3. Before attempting to restart the engine, push emergency engine stop control in.

FIGURE 3.9 3— 2

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EMERGENCY ENGINE STOP CONTROL

2. Pull out the engine emergency stop control located on the lower R.H. side of control stand until engine stop. See Figure 3.9.

Section III – BASIC MACHINE OPERATION

3.4 STARTING MACHINE ENGINE WITH BOOSTER CABLES

KEY SWITCH POSITIONS

A. CONNECTING BOOSTER CABLES

ACC

F

ON

RT

HEA

1. Move vehicle or machine to be used for boosting as close to the battery box of the disabled machine as possible.

STA

T

OF

HI

WARNING T AR ST

F OF

ACC

ON

DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLED MACHINE. THIS COULD SHORT CIRCUIT ELECTRICAL SYSTEMS AND CAUSE EXTENSIVE DAMAGE TO THE CPU AND OTHER COMPONENTS.

HE AT

LO

CAUTION

FIGURE 3.10

Use only vehicles or machines with 24 V DC electrical system for boost starting this machine.

2. Make certain key switch of disabled machine is in the “OFF” position before proceeding with booster cable connection. See Figure 3.10.

POSITIVE (+) CABLE

WARNING WEAR HARD HAT, APPROVED SAFETY GLASSES OR FACE SHIELD, GLOVES AND OTHER SAFETY EQUIPMENT WHEN WORKING WITH BATTERIES.

NEGATIVE (-) CABLE

3. Locate and connect one end of the booster cable to the positive (+) terminal on the battery of the disabled machine. See Figure 3.11.

FIGURE 3.11

4. Connect other end of positive booster cable to positive (+) terminal of battery being used for boosting.

5. Locate and connect second cable to the negative (–) terminal of the battery being used for boosting.

CABLE CONNECTING ORDER

6. Connect other end of negative (–) cable to the upper frame of disabled machine as far away from battery as possible. See Figure 3.12.

(3)

WARNING

12V

THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC CAUSING SPARKS. SPARKS COMING IN CONTACT WITH BATTERIES, COULD TRIGGER AN EXPLOSION. NEVER CONNECT NEGATIVE CABLE TO NEGATIVE (-) TERMINAL OF DISABLED BATTERY.

(1)

(2)

12V

NORMAL BATTERIES

12V

12V

DISCHARGED BATTERIES

(4) UPPER FRAME OF DISABLED MACHINE

FIGURE 3.12 3— 3

Section III – BASIC MACHINE OPERATION B. STARTING BOOSTING MACHINE ENGINE

CABLE DISCONNECTING ORDER

1. Start engine of boosting machine in normal manner according to climate conditions. Refer to pages 3-1 & 3-2 for specific starting instructions.

(3)

(1)

(2)

2. Allow five minutes or more to provide partial charge to the discharged batteries.

12V

C. STARTING DISABLED MACHINE ENGINE

12V

NORMAL BATTERIES

1. Start engine of disabled machine in normal manner according to climate conditions. Refer to pages 3-1 & 3-2 for specific starting instructions.

12V

12V

DISCHARGED BATTERIES

(4) UPPER FRAME OF DISABLED MACHINE

FIGURE 3.13

D. DISCONNECTING BOOSTER CABLES After disabled machine engine is running, first disconnect the negative (-) cable from disabled machine upper frame. See Figure 3.14.

1. Disconnect negative (-) cable from battery used for boosting.

2. Disconnect positive (+) cable from battery used for boosting.

DISCONNECT NEGATIVE (-) CABLE FROM DISABLED MACHINE

3. Disconnect positive (+) cable from terminal of disabled machine. See Figure 3.14.

FIGURE 3.14 CAUTION When using booster cables remember; 1. Connect positive (+) cable first.

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2. Disconnect negative (–) cable first from frame of disabled machine.

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Section III – BASIC MACHINE OPERATION

3.5 MACHINE WARM UP RUN ENGINE 5 MINUTES WITH THROTTLE IN "LO" IDLE POSITION

A. ENGINE 1. Allow the engine to run for 5 minutes under no load conditions with throttle control at “LO” idle position.

See Figure 3.15.

HI

LO

2. During warm up, visually and audibly inspect engine for abnormal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises.

ACC

ON

HE AT

F OF

T AR ST

3. Should problem areas be noticed, stop engine, locate and repair problem areas before restarting or operating the machine.

FIGURE 3.15

B. HYDRAULIC OIL

R.H. CONTROL LEVER (ISO PATTERN)

1. Move throttle control to “HI” idle position.

2. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket out and hold over relief for 10 to 15 seconds. Repeat this operation for 5 to 10 minutes to help oil to reach operating temperature. See Figure 3.16.

BOOM DOWN

BUCKET OUT

BUCKET IN

3. Move throttle control to mid position and operate the boom, arm and swing controls for 5 to 10 minutes each. See Figure 3.17.

BOOM UP

FIGURE 3.16

4. Push and pull the dozer blade control lever on the side of right control stand 4 or 5 times.

C. HYDRAULIC OIL IN FRIGID TEMPERATURES

L.H. CONTROL LEVER (ISO PATTERN)

1. Perform normal hydraulic oil warm-up procedures.

NOTE If machine is operated in frigid temperatures daily, it may be necessary to change the hydraulic oil to an oil designed for operation in frigid climates. Refer to maintenance section for hydraulic oil specifications.

ARM OUT

SWING LEFT SWING RIGHT

CAUTION ARM IN

In operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions.

Damage to hydraulic components may result due to the cold oil not providing adequate lubrication.

FIGURE 3.17 3— 5

Section III – BASIC MACHINE OPERATION

3.6 CONTROLS DECAL A. OPERATING PATTERN The operating and travel controls of this machine are factory set to ISO standard operating patterns for optimum performance of the machine and its systems.

B. OPERATING PATTERN DECAL Figure 3.18 is a representation of the “CONTROLS” decal located on the R.H. side window inside the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement of particular control.

Detailed instructions for each control and its functions are explained on the following pages of this section.

WARNING CHECK AND MAKE SURE THAT OPERATION’S PATTERN CONTROL MATCHES THE DECAL PROVIDED INSIDE THE RIGHT SIDE WINDOW.

HYDRAULIC CONTROL LEVERS

LEFT TRAVEL LEVER AND PEDAL

RIGHT TRAVEL LEVER AND PEDAL

RIGHT CONTROL LEVER

NOTE Travel motors are positioned behind the operator's cab.

(A) LOWER BLADE DOZER BLADE CONTROL LEVER (OPT.)

(B) LIFT BLADE

FIGURE 3.18 3— 6

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LEFT CONTROL LEVER

Section III – BASIC MACHINE OPERATION

3.7 BASIC OPERATION OF HYDRAULIC CONTROLS The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of these instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment.

Each operator must read, understand and follow these basic instructions along with all safety precautions found in this manual and on the machine before operating this equipment.

TRAVEL MOTORS AT REAR OF MACHINE

FIGURE 3.19 WARNING NORMAL POSITIONING OF THE MACHINE FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. SEE FIGURE 3.19.

ALWAYS KNOW THE LOCATION OF TRAVEL MOTORS BEFORE OPERATING ANY HYDRAULIC CONTROLS.

A. SAFETY LOCK LEVER– FIGURE 3.20 1. Unlocked Position Before any hydraulic operation is possible the safety lock lever must be placed in the “UNLOCKED” (DOWN) position. Placing the safety lock lever in the UNLOCKED (DOWN) position also positions the L.H. operator’s console in its operating and locked position.

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

2. Locked Position Before leaving the operator cab, place the safety lock lever in the “LOCKED” position by pulling lever up. With safety lock lever in the “LOCKED” (UP) position, no hydraulic operation is possible and allows easy access in and out of the operator seat.

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

WARNING ALWAYS PLACE THE SAFETY LOCK LEVER IN THE “LOCKED” (UP) POSITION BEFORE LEAVING CAB TO PREVENT ANY OPERATION OF HYDRAULIC CONTROLS. FAILURE TO PLACE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION COULD RESULT IN SERIOUS INJURY OR DEATH AS WELL AS SERIOUS DAMAGE TO THE MACHINE AND ITS COMPONENTS.

FIGURE 3.20

3— 7

Section III – BASIC MACHINE OPERATION B. KPSS (POWER SENSING SYSTEM) WORK MODE SWITCH The mode is switched in turn every time when the switch is pressed, and the selected work mode indicator lamp lights on.

Before selecting a machine work mode, the operator should always study each job site to answer some basic questions.

1. Is the machine capable of performing the particular job?

2. What attachment (bucket) is best suited for the job?

FIGURE 3.21

3. What type of material will the machine be excavating?

4. What operating mode is best suited for the job?

1. KPSS WORK MODE FUNCTIONS - FIGURE 3.21 The KPSS work mode switch allows the operation select and control the operation of the machine and the attachment effectively for a particular job by selecting one of three positions. a. “H” Mode .... Provides maximum speed and power for digging operations. b. “S” Mode ..... Provides standard power and best fuel consumption. c. “FC” Mode .. Allows fine control of hydraulic functions for attachment.

Select the KPSS work mode best suited for the particular job at hand.

2. KPSS WORK MODE SELECTION TABLE The KPSS work mode selection table gives examples of work types, work requirements and materials being excavated. Use this table when deciding the KPSS work mode best suited for the specific job at hand.

KPSS WORK MODE SELECTION TABLE DIGGING

LOADING CORRECTION

REFILLING & CRUSHING CORRECTION

TRANSFER

1

2

1

1

1

SOFT VISCOUS SOIL

H

S FC H

S FC FC FC FC H

S FC

Flat Land "S"

LOOSE SANDY SOIL

H

S FC H

S FC FC FC FC H

S FC

TIGHT SANDY SOIL

H

S FC H

S FC S FC FC

GRAVEL & STONE

H

H

S

H

H

S

S

S FC

Slope & Long Distance Travel "H"

TIGHT GRAVEL/MIXED SOIL

H

H

S

H

H

S

H

H

S

SOFT STONE

H

H

H

H

H

H

H

H

H

WORK REQUIREMENTS MATERIAL

3

2

3

1

2

3

2

3

1

2

H

3

2

3

Loading & Unloading etc. "FC"

Work Requirements – 1=large volumes at fast speed • 2=normal work, less fuel • 3=fine control of attachment

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WORK TYPE

Section III – BASIC MACHINE OPERATION C. MACHINE TRAVEL CONTROLS This machine incorporates several travel controls for the convenience of the operator. Each track can be operated independently to turn the machine or simultaneously to counter rotate the machine or to travel straight.

FORWARD TRAVEL

1. Operating Both Travel Levers Together a. Push both travel levers or press the pedals toward front of machine and machine will travel “FORWARD”. See Figure 3.22. b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”. See Figure 3.23.

FIGURE 3.22

c. Return both travel levers to “NEUTRAL” (center) position and machine will stop. Parking brakes are automatically applied when travel levers are in neutral position.

REVERSE TRAVEL

NOTE The distance travel levers are pushed or pulled determines travel speed of the machine.

EXAMPLE: Travel levers are pulled or pushed to full stroke - machine will travel at top speed.

Travel levers are pulled or pushed to mid position - machine will travel at 1/2 speed.

FIGURE 3.23

2. Use of Travel Speed Select Switch PRESS HERE FOR "FAST" & "SLOW"

a. For fast travel speed, depress and release the travel speed select switch once before operating the travel controls. See Figure 3.24.

This puts the travel motors in “FAST”( ) travel speed and the lamp for “FAST”( ), on the gauge cluster display, will come on.

TRAVEL SPEED SELECT SWITCH

b. To return to “SLOW” travel speed, depress and release travel speed select switch once. See Figure 3.24.

CAUTION Use “FAST” ( ) travel speed on firm, level surfaces only.

Do not travel continuously for more than two hours. Stop for a period of 10 min at low idle speed before resuming travel.

FIGURE 3.24

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Section III – BASIC MACHINE OPERATION 3. Turning Machine

LEFT FORWARD TRAVEL

a. Push the L.H. travel lever toward front of machine to turn machine RIGHT in forward motion. See Figure 3.25. b. Pull the L.H. travel lever back toward operator seat to turn machine to the LEFT in reverse motion. c. Push the R.H. travel lever toward front of machine to turn machine to the LEFT in forward motion. See Figure 3.26.

FIGURE 3.25

d. Pull R.H. travel lever toward operator seat to turn machine to the RIGHT in reverse motion.

RIGHT FORWARD TRAVEL

4. Counter Rotating Machine a. Pull L.H. travel lever BACK and push R.H. travel lever FORWARD to counter rotate machine to the LEFT. See Figure 3.27. b. Pull R.H. travel lever BACK and push L.H. travel lever FORWARD to counter rotate machine to the RIGHT. See Figure 3.28.

NOTE All the functions explained with use of travel levers can also be performed using the travel pedals.

FIGURE 3.26 COUNTER ROTATING TO THE LEFT

CAUTION 1.Depending on shoe type and ground conditions this machine has a maximum climbing ability of 35˚ (70%) maximum, limited by engine lubrication.

2. When approaching or descending a slope, operate the travel slowly.

3. For braking, slowly return travel levers or pedals to the neutral (center) position. Brakes are engaged automatically.

FIGURE 3.27

4. The travel operation for 2 hours or more may cause the failure of travel motor due to the rise of operating temperature. Don’t travel countinuously for more than 2 hours. Stop for 10 min at low idle before resuming travel.

COUNTER ROTATING TO THE RIGHT

FIGURE 3.28 3— 10

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5. In extremely cold conditions, below -20˚C (-4˚F), the travel lever or pedal action may be “heavier” than normal.

This is normal due to the viscosity of the hydraulic oil in frigid climates.

Section III – BASIC MACHINE OPERATION 5. Travel Safety a. Make certain travel motor location is known before performing any travel operation. b. Travel on firm, level surfaces as much as possible.

WATER DEPTH WATER MUST NOT BE OVER

c. When traveling on rough terrain, travel in SLOW ) speed with engine at a low idle. ( d. Travel with the travel motors in back of the machine for long distance travel. e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging. This will help keep the machine from sliding unexpectedly.

BED MUST BE FIRM & STABLE

MODEL E235SR E235SRLC E235SRNLC

f . Keep a safe distance from stationary objects and electrical power lines. g. Be aware of load capacities of bridges and road shoulders. Reinforce if necessary.

MAXIMUM WATER DEPTH 750 mm (2'-6")

FIGURE 3.29

h. Use decking or plating to protect road surfaces as much as possible. Be careful when turning or spinning machine on asphalt pavement. i . Do not allow large or heavy objects to strike travel motors. j . Do not travel over large objects such as boulders rocks etc. k. If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the chart in Figure 3.29.

NOTE If the machine is operated while the slewing bearing is submerged in water, then the slewing bearing, slewing pinion, and the swivel joint may wear out prematurely. Immediate replacement of grease in grease bath and overhaul of the slewing bearing is required. See maintenance section. l . On soft ground or mud the machine can sink.

Stay constantly aware of undercarriage position.

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Section III – BASIC MACHINE OPERATION D. MACHINE ATTACHMENT & SWING CONTROLS The following operation instructions are to be used with hoe bucket attachment only. If other attachments are being used, consult the operator’s manual for the particular attachment.

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS DURING ALL OPERATIONS OF THIS MACHINE AND ITS ATTACHMENT(S).

PULL BACKBOOM UP

1. Boom Operation – FIGURE 3.30 Operation of the boom is performed by pushing and pulling the R.H. control lever forward and backward.

Boom speed is determined by how far the lever is activated.

PUSH FORWARDBOOM DOWN

a. Pulling R.H. control lever BACK raises boom. b. Pushing R.H. control lever FORWARD lowers boom. c. Returning R.H. control lever to the neutral (center) position stops operation of the boom.

FIGURE 3.30

2. Arm Operation - FIGURE 3.31 Operation of the arm is performed by pushing or pulling the L.H. control lever forward and backward.

Arm speed is determined by how far the lever is activated.

PULL BACKARM IN

PUSH FORWARDARM OUT

a. Pushing the L.H. control lever FORWARD moves the arm out. b. Pulling the L.H. control lever BACK moves the arm in. c. Returning the L.H. control lever to the neutral (center) position, stops operation of the arm.

FIGURE 3.31

3. Bucket Operation - FIGURE 3.32 Operation of the bucket is performed by moving the R.H. control lever to the right or left.

PULL LEFTPUSH RIGHTBUCKET IN (DIGGING) BUCKET OUT (DUMPING)

a. Moving the R.H. control lever to the LEFT operates the bucket in (digging). b. Moving the R.H. control lever to the RIGHT operates the bucket out (dumping).

WARNING BE CAREFUL WHEN OPERATING CERTAIN ATTACHMENTS CLOSE TO THE CAB. CERTAIN ATTACHMENTS CAN HIT AND DAMAGE CAB. STOP ATTACHMENT A SAFE DISTANCE AWAY FROM CAB TO AVOID DAMAGE OR INJURY.

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FIGURE 3.32

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Section III – BASIC MACHINE OPERATION PUSH LEFT SWING LEFT

4. Swing Operation - FIGURE 3.33

PUSH RIGHT SWING RIGHT

NOTE Use rotary light during swing operations.

Swing operation is performed by moving the L.H. control lever to the right and left. Swing speed is determined by the amount the lever is moved. a. Moving the L.H. control lever to the LEFT swings the machine to the left.

FIGURE 3.33

b. Moving the L.H. control lever to the RIGHT swings the machine to the right. c. Returning control to the neutral (center) position stops swing.

WARNING MAKE CERTAIN AREA IS CLEAR OF OBSTACLES AND PERSONS BEFORE BEGINNING SWING OPERATION OF THE MACHINE. SOUND HORN BEFORE BEGINNING SWING OPERATIONS

E . USING POWER BOOST The power boost switch is located on top of the R.H. operator control. It is a momentary switch which is activated by depressing with the thumb. This system is designed for use during bucket digging operations when extra “Break-Out” power is required to allow the bucket to break through a dig.

DEPRESS WITH THUMB TO TURN "ON"

1. Operate the bucket in (digging) control. While bucket is digging, depress the power boost switch with right thumb. See Figure 3.34. This will increase bucket digging power by approximately 15%.

NOTE If the power boost switch is left depressed while performing other hydraulic operations the operator will experience slower operation of the hydraulic functions. While power boost switch is depressed the power boost icon ( ) will be displayed on the gauge cluster display.

FIGURE 3.34

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Section III – BASIC MACHINE OPERATION F. USING AUTO-ACCELERATOR 1. Auto Accel Switch – Figure 3.35 The auto accel switch is located to the right hand operator console.

The auto accel switch is a 2 position rocker switch and when “ON” will automatically decrease engine RPM approximately 4 seconds after all hydraulic controls have been placed in their neutral positions then, upon operation of any hydraulic control, will automatically increase engine RPM to match throttle control setting.

PRESS HERE FOR "ON"

LO

PRESS HERE FOR "OFF"

HI

Depress this side of switch to turn auto accel “ON”.

Depress back side of switch to turn auto accel “OFF”.

THROTTLE POTENTIO METER

FIGURE 3.35 WARNING PLEASE PUSH A SIDE WITHOUT THE MARK OF AN AUTO ACCEL SWITCH, AND CHANGE INTO THE CONDITION OF RELEASE. IF THE MACHINE IS OPERATED WITH AN AUTO ACCEL SWITCH NOT CANCELED, ENGINE SPEED MAY CHANGE SUDDENLY.

WARNING

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AUTOMATIC TWO SPEED TRAVEL SYSTEM CHANGES TRAVEL SPEED AUTOMATICALLY AND CAN ADVERSELY AFFECT MACHINE CONTROL WHEN DESCENDING A SLOPE AND LOADING OR UNLOADING ON A TRAILER. PERSONAL INJURY CAN OCCUR FROM SUDDEN CHANGE IN MACHINE CONTROL. PUT TRAVEL SPEED SELECT SWITCH IN LOW SPEED POSITION WHEN DESCENDING A SLOPE AND LOADING OR UNLOADING ON A TRAILER.

3— 14

Section III – BASIC MACHINE OPERATION G. TOWING THE MACHINE – FIGURE 3.36 & 3.37 Where you cannot get the machine out of soft soil, place wire slings as shown on the left and pull it by an other machine. Always place wire slings around the frame section and put pads on each corner to prevent the wire slings from being damaged.

NOTE Do not pull the machine utilizing the holes provided for pulling lightweight objects.

Otherwise the holes may break.

FIGURE 3.36

FIGURE 3.37

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Section III – BASIC MACHINE OPERATION

3.8 PRACTICES TO IMPROVE EFFICIENCY USE ARM IN ACTION AS MUCH AS POSSIBLE

A. USE ARM IN ACTION – FIGURE 3.38 Operate the bucket at shallow depths and use the Arm in Action to fill the bucket. Setting the bucket too deep will decrease the machine’s efficiency.

FIGURE 3.38 B. OPERATE BOOM SMOOTHLY – FIGURE 3.39 Always begin and end Boom Operation slowly with smooth, careful movement of the control lever. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

OPERATE BOOM SMOOTHLY DURING ALL BOOM OPERATIONS

FIGURE 3.39 C. BUCKET TEETH DIRECTION – FIGURE 3.40 Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and the possibility of bucket teeth damage.

ALWAYS POINT BUCKET TEETH IN DIRECTION OF DIGGING

FIGURE 3.40 D. MAXIMUM DIGGING FORCE POSITION –FIGURE 3.41 The attachment will provide maximum digging force when the Arm and Boom are at 90° ~ 110° of each other.

MAXIMUM DIGGING FORCE IS OBTAINED WITH BOOM AND ARM AT 90°~110° EACH OTHER

FIGURE 3.41 3— 16

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90~110°

Section III – BASIC MACHINE OPERATION E. CLEANING SAND & SOIL FROM BUCKET – FIGURE 3.42 Operate Arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

OPERATE BUCKET IN & OUT WITH ARM OUT TO DISLODGE MATERIAL FROM BUCKET

CAUTION Avoid shaking out soil using shocks at the end of the bucket cylinder stroke.

F. STOP SWING MOTION EARLY – FIGURE 3.43 To stop swing action, release the swing lever before you get to your final point of digging or dumping.

FIGURE 3.42

G. BACK FILLING & LEVELING – FIGURE 3.44 For back filling and leveling work after digging, move the bucket back and forth horizontally.

RELEASE SWING BEFORE REACHING DESIRED DIGGING POSITION

NOTE Do not push or pull material with the bucket like a bulldozer when using the machine to level material.

1. In leveling ground toward machine, pull the arm gently, lift the boom a little and when the arm has passed the vertical point, lower the boom gently and manipulate the machine so the bucket moves horizontally.

FIGURE 3.43

2. For leveling ground away from machine, reverse operation in step 1 above.

USE ARM TO MOVE BUCKET HORIZONTALLY FOR LEVELING

3. ln the above operation, bucket motion may be used together with the boom. By controlling the action of the boom work lever, you can dig a slope- like, slope facing operation.

4. Never travel with attachment touching the ground.

Severe structural damage could occur.

H. OPERATING THE SHOVEL – FIGURE 3.45 Digging with the shovel differs slightly from digging with backhoe.

FIGURE 3.44

1. Using the arm cylinder, scrape the ground.

GRADE AT 2~3° SLOPE FOR DRAINAGE

2. Scrape the ground at 2°-3° to improve draining in areas near the groundwater level.

3. Be careful not to bump the reversed bucket into the cab.

4. The excavating power during shovel operations is less than that during backhoe operations.

2~3°

5. If machine bucket is equipped with a lifting eye, check to make sure that the eye will clear arm with bucket cylinder in full extended (full dump) position.

FIGURE 3.45 3— 17

Section III – BASIC MACHINE OPERATION I . MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS

CAUTION

1. Operation in Extreme Cold

Do not allow dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen.

a. Follow procedures on page 3-2 as starting engine may be difficult due to extremely cold temperatures.

c. Keep all belts properly tensioned. d. Make certain that the engine coolant mixture is sufficient to keep the machine safe.

b. Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates. See maintenance section, page 4-8 for reference. Also, keep battery fully charged.

e. If the machine becomes overheated, idle the machine to help cool the engine, turn engine “OFF” and check coolant level. After filling to proper level the machine continues to over heat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

c. Make certain to perform machine warm-up procedures as described on page 3-5 to prevent premature wear or damage to pumps, motors and other components.

NOTE In extremely frigid climates, covering the radiator is a method to aid the machine warm-up. IF NECESSARY TO MAINTAIN OPERATING TEMPERATURES, COVER THE OUTER EDGES OF THE RADIATOR, LEAVING AN OPENING IN THE CENTER PART OF THE COVER THUS AVOIDING FAN OVERLOADING. Keep a close watch on the gauge cluster for warning icons during operation. It may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting.

f . Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. g. Keep a close watch on the gauge cluster for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

During slow, or no work periods, place throttle (accel) dial in “LO” idle position.

3. Operation in High Altitudes a. Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced.

Be aware of this fact when placing machine under heavy load in high altitude climates.

d. Make certain that the engine coolant mixture is sufficient to keep the machine safe. Take into consideration wind chill factors when mixing coolant ratios.

b. Keep close watch on the engine temperature gauge to avoid overheating of the engine.

4. Operation in Sandy and Dusty Areas

NOTE Mix coolant to a protection temperature of 5˚C (9˚F) lower than the machine will experience during operation, storage or transport.

a. Check the engine air cleaner elements frequently in sandy or dusty conditions. b. When air cleaner restriction lamp is lit, change filters immediately regardless of time intervals.

e. Keep battery terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine systems. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, it is recommended to remove the batteries and store in a warm area.

c. Service fuel filter, water separator, and all hydraulic filters frequently.

5. Operation at Seashore or Salty Climate a. Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods. b. Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

2. Operation in Extreme Heat a. Use an engine oil, hydraulic oil and fuel oil designed for use in hot climates. See maintenance section, page 4-8 for reference. Also, keep battery fully charged.

a. In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

b. Clean radiator, oil cooler and debris screen often to prevent damage or overheating of the machine.

3— 18

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6. Operation in Humid Climate

Section III – BASIC MACHINE OPERATION

3.9 FLAGMAN HAND SIGNALS The following is a compilation of the hand signals to be used when a flagman is required for excavator operation. All personnel associated with the operation of the excavator should know these signals and their meaning before attempting to operate this machine.

A. RAISE LOAD VERTICALLY Face machine operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion. See Figure 3.46.

FIGURE 3.46

B. LOWER LOAD VERTICALLY Face machine operator, extend right arm down, point index finger down and move hand in a small circular motion. See Figure 3.47.

FIGURE 3.47 C. MOVE LOAD IN HORIZONTALLY Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required. See Figure 3.48.

FIGURE 3.48 D. MOVE LOAD OUT HORIZONTALLY Face machine operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required. See Figure 3.49.

FIGURE 3.49 3— 19

Section III – BASIC MACHINE OPERATION E. RAISE BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb up. See Figure 3.50.

FIGURE 3.50 F. LOWER BOOM Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb down. See Figure 3.51.

FIGURE 3.51 G. SWING LEFT Face machine operator, extend right arm out horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 3.52.

FIGURE 3.52

FIGURE 3.53 3— 20

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H. SWING RIGHT Face machine operator, extend left arm out horizontally from shoulder, make a fist with index finger pointing in swing direction. See Figure 3.53.

Section III – BASIC MACHINE OPERATION I . ARM IN Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other. See Figure 3.54.

FIGURE 3.54 J. ARM OUT Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other. See Figure 3.55.

FIGURE 3.55 K. MOVE THIS MUCH Face machine operator, raise both forearms up, hands open and facing each other , move hands in laterally indicating how far to go. See Figure 3.64.

FIGURE 3.56

L. EMERGENCY STOP Face machine operator, raise both arms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth. See Figure 3.67.

FIGURE 3.57 3— 21

Section III – BASIC MACHINE OPERATION

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NOTES:

3— 22

Section IV – MAINTENANCE

Table of Contents GENERAL INFORMATION .......................................................................................................................... 4-1 GENERAL SAFETY ..................................................................................................................................... 4-1 ~ 4-4 INSPECTION AND MAINTENANCE CHART .............................................................................................. 4-5 ~ 4-6 FLUIDS AND FILTERS ................................................................................................................................. 4-7 ~ 4-8 Required Fluids And Quantities ........................................................................................................... 4-7 Required Filters ...................................................................................................................................... 4-7 Fluids And Lubricants ........................................................................................................................... 4-7 Lubricant Specifications ....................................................................................................................... 4-8 PRE-START (DAILY) INSPECTION & MAINTENANCE .............................................................................. 4-9 ~ 4-21 Engine Oil Level ..................................................................................................................................... 4-9 Engine Coolant Level ............................................................................................................................ 4-9 Engine Fluid Leaks ................................................................................................................................ 4-10 Fan Belt Wear And Tension ................................................................................................................... 4-10 Fuel Level ............................................................................................................................................... 4-11 Air Cleaner .............................................................................................................................................. 4-12 ~ 13 Engine Electrical .................................................................................................................................... 4-14 Hydraulic Oil Level ................................................................................................................................. 4-14 ~ 15 Hydraulic Functions .............................................................................................................................. 4-15 Hydraulic Oil Leaks ................................................................................................................................ 4-15 Machine Electrical .................................................................................................................................. 4-16 Step And Handrails ................................................................................................................................ 4-17 Frame Structure ..................................................................................................................................... 4-17 Tracks And Components ....................................................................................................................... 4-17 ~ 4-18 Track Tension ......................................................................................................................................... 4-19 Boom And Arm ....................................................................................................................................... 4-20 Bucket Teeth And Side Cutters ............................................................................................................. 4-20 Attachment Lubrication ......................................................................................................................... 4-21 50 HOUR & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE ................................................... 4-22 ~ 4-28 Engine Oil And Filter Element ............................................................................................................... 4-22 Engine Oil ............................................................................................................................................... 4-23 Fuel Tank Drain ...................................................................................................................................... 4-24 Water Separator ..................................................................................................................................... 4-24 Air Intake System ................................................................................................................................... 4-24 Radiator, Oil Cooler And Debris Screen .............................................................................................. 4-25 Hydraulic Return Filters ........................................................................................................................ 4-26 Batteries .................................................................................................................................................. 4-27 ~ 4-28 100 HOUR INSPECTION & MAINTENANCE .................................................................................................. 4-29 ~ 4-30 13503 60421091

Swing Motor Reduction Oil ................................................................................................................... 4-29 Travel Motors Reduction Oil ................................................................................................................. 4-30

4— 0-1

Section IV – MAINTENANCE

250 HOUR INSPECTION & MAINTENANCE .............................................................................................. 4-31 ~ 4-34 Attachment Lubrication ......................................................................................................................... 4-31 ~ 4-32 Fan and A/C Belt Wear and Tension ..................................................................................................... 4-3 3

Air Conditioner filters ............................................................................................................................ 4-34 Inspecting Counterweight Attaching Bolts for Loosening ................................................................ 4-34 500 HOUR INSPECTION & MAINTENANCE .............................................................................................. 4-35 ~ 4-38 Fuel Filter ................................................................................................................................................ 4-35 Bleeding Air from the Fuel System ...................................................................................................... 4-36 Greasing the Slewing Ring ................................................................................................................... 4-37 Checking Slewing Ring Fitting Bolts for Loosening .......................................................................... 4-37 Water Pump Bearing Lubrication ......................................................................................................... 4-37 Checking the Air Conditioner Refrigerant ........................................................................................... 4-38 Fuel System Injection Pressure and Nozzle Condition ...................................................................... 4-38 1000 HOUR INSPECTION & MAINTENANCE ............................................................................................ 4-39 Engine Valve Clearance ......................................................................................................................... 4-39 Engine Compression Pressure ............................................................................................................. 4-39 Inspection of Starter and Alternator ..................................................................................................... 4-39 Engine Fuel Injection Timing ................................................................................................................ 4-39 2000 HOUR INSPECTION & MAINTENANCE ............................................................................................ 4-40 ~ 4-51 Change Engine Coolant ........................................................................................................................ 4-40 ~ 4-41 Change Hydraulic Oil ............................................................................................................................. 4-42 ~ 4-44 Hydraulic Tank Breather ........................................................................................................................ 4-45 Change Oil in Travel Motor Reduction Units ....................................................................................... 4-46 Change Oil in Swing Reduction Unit .................................................................................................... 4-47 Change Grease in Slewing Ring Grease Bath ..................................................................................... 4-47 Pilot Line Filter ....................................................................................................................................... 4-48 Attachment & Dust Seals ...................................................................................................................... 4-49 ~ 4-51 Windshields Washer Reservoir ............................................................................................................ 4-51 MISCELLANEOUS ....................................................................................................................................... 4-52 ~ 4-56 Fuses ....................................................................................................................................................... 4-52 Towing the Machine ............................................................................................................................... 4-53 Periodical Inspection Items .................................................................................................................. 4-53 ~ 4-55 Machine Storage .................................................................................................................................... 4-56 Care During Storage .............................................................................................................................. 4-56

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Removing Machine From Storage ........................................................................................................ 4-56

4— 0-2

Section IV – MAINTENANCE

4.1 GENERAL INFORMATION WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES TO THIS MACHINE, ITS SYSTEMS OR COMPONENTS. A. It is recommended by the Manufacturer. that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine.

Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition. See Figure 4.1.

FIGURE 4.1

B. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance as they will guide the technician step by step for each procedure. Also, refer to the inspection and maintenance charts for general service interval recommendations.

FIGURE 4.2

NOTE The inspection and maintenance charts provided give only general time intervals. It may be necessary to develop a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

C. Use only the Manufacturer’s oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. See Figure 4.2.

4.2 GENERAL SAFETY A. DISPOSAL OF HAZARDOUS WASTE – FIGURE 4.3 Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

FIGURE 4.3

CAUTION

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Dispose of all hazardous waste in accordance with government environmental regulations, laws and codes.

B. KEEP MACHINE CLEAN – FIGURE 4.4 Thoroughly clean machine before performing inspection and maintenance procedures. It is easier and safer locate problems, perform maintenance and also reduces the risk of hydraulic system contamination when machine is clean.

FIGURE 4.4 4— 1

Section IV – MAINTENANCE C. HOT SURFACES & FLUIDS – FIGURE 4.5 Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool before performing maintenance procedures.

D. WARM ENGINE OIL Engine oil should have a temperature of between 20°C ~ 40°C (68°F ~ 104°F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature.

FIGURE 4.5

E. “TAG-OUT” MACHINE – FIGURE 4.6 Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operator’s console to inform the operator that the machine will be inoperable for inspection and maintenance.

This tag will help prevent accidental starting of the machine.

F. INSPECT WASTE OILS AND FILTERS – FIGURE 4.7 Before disposal, inspect all waste oils, fluids and filters for debris and foreign material.

It is recommended to cut open the oil filters to determine any abnormal wear.

FIGURE 4.6

CHECK FOR DEBRIS

G. PREVENT CONTAMINATION – FIGURE 4.8 Always cap or plug lines when hydraulic components are removed to help prevent hydraulic system contamination that can be caused by dirt, dust and debris entering a line or port.

FIGURE 4.7

CAUTION

H. SEALS AND “O”-RINGS Always replace seals and “O”-rings with new parts.

Never reuse a seal or “O”-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

FIGURE 4.8 4— 2

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Never allow a hydraulic line or component to become contaminated. This could cause severe system damage.

Contact your dealer to obtain the proper caps and plugs to be used on this machine.

Section IV – MAINTENANCE I . STOP ENGINE Never attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool.

J. WEAR SAFETY EQUIPMENT – FIGURE 4.9 Wear hard hat, safety goggles or face shield, work gloves, safety shoes and well fitting work clothes when performing inspection and maintenance procedures on this machine.

K. CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

FIGURE 4.9

DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA.

L. HYDRAULIC TANK PRESSURE Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

HYDRAULIC TANK

FIGURE 4.10

1. Push rubber cap “DOWN” to release air pressure in the reservoir. See Figure 4.10.

LO

HI

CAUTION Gasses from hydraulic tank may be hot.

Wear safety equipment.

KEY SWITCH IN "OFF" POSITION

M. WELDING SAFETY 1. Turn key switch to “OFF” position. Wait 4 seconds for electrical power to disconnect. See Figure 4.11.

FIGURE 4.11

2. Remove negative (-) cable from battery terminal.

See Figure 4.12.

3. Attach welder ground cable with 1 m (3´-3˝) away from component being welded.

4. Make certain welder ground is not located at a seal or bearing.

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5. Make certain that no bearings nor seals separates the welder ground and the weld area.

FIGURE 4.12 4— 3

ACC

ON T AR ST

HE AT

F OF

Section IV – MAINTENANCE N. RELEASING INNER PRESSURE IN HYDRAULIC SYSTEM WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

FIGURE 4.13

1. Select the hard and flat area and place the machine in the position shown in Figure 4.13.

2. Start the engine.

3. Keep the screen change switch and buzzer stop switch on the switch panel pressed for 5 seconds simultaneously, and the “DRAINING HYD. PRESS” is displayed on the multidisplay and the buzzer sounds intermittently.

4. In this condition, operate the lever for attachment required to be released the pressure, and the internal pressure of the hydraulic pressure system is released. Special attention must be given to operate because the attachment moves a little by its own weight.

FIGURE 4.14

5. After releasing the pressure, if the pressure release fails, the symbol “FAIL DRAIN HYD. PRESS” is displayed on the multidisplay.

6. At the same time, buzzer sounds continuously. Turn the starter key “OFF”, and the buzzer stops sounding.

7. Release the pressure again.

8. Stop the dozer operating at the position where the blade reaches close to the ground, and after the engine stops, move the dozer lever forward and rearward several times, and the blade contacts the ground, consequently the inner pressure is released.

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9. Stop the engine. Pressure release available.

4— 4

Section IV – MAINTENANCE

4.3 INSPECTION AND MAINTENANCE CHART Follow the chart below for recommended intervals of regular inspection and maintenance procedures.

SYSTEM

ENGINE

MAINTENANCE TO PERFORM

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE

COMPONENT LOCATION

CHECK OIL LEVEL

SIDE OF ENGINE

CHECK COOLANT LEVEL

RESERVOIR

CHECK FOR FLUID LEAKS

COMPLETE ENGINE

CHECK BELT TENSION

FRONT OF ENGINE

CHECK FUEL LEVEL

GAUGE CLUSTER

CHECK AIR CLEANER

AIR CLEANER

CHECK ENGINE ELECTRICAL

COMPLETE ENGINE

DRAIN WATER FROM FUEL

FUEL TANK BOTTOM

CHANGE ENGINE OIL

OIL PAN

CHANGE OIL FILTER

L.H. SIDE OF ENGINE

CHANGE FUEL FILTER

L.H. SIDE OF ENGINE

DRAIN WATER SEPARATOR

R.H. SIDE OF ENGINE

CHECK AIR INTAKE SYSTEM

HOSES & CLAMPS

CHECK FAN ASSEMBLY

FRONT OF ENGINE

CHECK BELT TENSIONER

FRONT OF ENGINE

CLEAN RADIATOR

RADIATOR BETWEEN RADIATOR AND OIL COOLER RADIATOR & ENGINE

CLEAN DEBRIS SCREEN CHANGE ENGINE COOLANT CHANGE AIR CLEANER ELEMENTS ADJUST VALVE CLEARANCE

INTERVAL (HOURS ON HOURMETER) Daily

AIR CLEANER ENGINE TOP

CHECK ENGINE COMPRESSION ENGINE CHECK INJECTION PRESSURE ENGINE CHECK INJECTION TIMING

ENGINE

LUBRICATE WATER PUMP

ENGINE

CHECK STARTER AND ALTERNATOR ENGINE HYDRAULIC OIL LEVEL

SIDE OF HYD TANK

CHECK HYD FUNCTIONS

CAB

CHECK FOR OIL LEAKS

HYDRAULIC SYSTEM

CHECK HOSES / LINES

HYDRAULIC SYSTEM

CLEAN SUCTION SCREEN

HYDRAULIC TANK

HYDRAULIC CHANGE RETURN FILTERS

HYDRAULIC TANK

CHANGE HYDRAULIC TANK BREATHER CHANGE HYDRAULIC OIL

HYDRAULIC TANK

PILOT LINE FILTER

HYDRAULIC TANK

INSPECT ALL WIRING

COMPLETE MACHINE

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BATTERY SERVICE

•••

HYDRAULIC TANK

CLEAN HYDRAULIC TANK

ELECTRICAL BATTERY ELECTROLYTE

•••

HYDRAULIC TANK

BATTERIES BATTERIES

Regular inspection & maintenance required.

Break-in (after first 50 hours) inspection & maintenance required.

4— 5

50

100

250

500 1,000 2,000

Section IV – MAINTENANCE

SYSTEM

UPPER FRAME

MAINTENANCE TO PERFORM

COMPONENT LOCATION

HYD. FUNCTION OPERATION

OPERATOR'S CONTROLS

CHECK SWITCHES

CONTROL PANELS

CHECK WARNING LIGHTS

CAB / FRAME / BOOM

CHECK BUZZER

CAB

CHECK GAUGES

GAUGE CLUSTER

CHECK HORN

HORN SWITCH

CHECK GAUGE CLUSTER CHECK SWING REDUCTION OIL LEVEL & FILL CHECK BOLTS / TORQUE CHECK SLEWING RING & PINION GEAR CHECK SLEWING RING SEAL

GAUGE CLUSTER

INTERVAL (HOURS ON HOURMETER) Daily

50

100

250

500 1,000 2,000

UPPER FRAME SLEWING RING SIGHT WINDOW IN CENTER SECTION SLEWING RING

SWIVEL JOINT CHECK SWIVEL JOINT SEALS DRAIN WATER FROM SLEWING LOWER FRAME RING GREASE BATH CAVITY DRAIN PORT SLEWING RING GREASE SLEWING RING REMOVE UPPER CHANGE GREASE IN SLEWING RING GREASE BATH FRAME CHANGE SWING SWING MOTOR REDUCTION UNIT OIL CHECK BOLTS / TORQUE COUNTERWEIGHT

LOWER FRAME

ATTACHMENT

CHECK FOR OIL LEAKS

COMPLETE SYSTEM

CHECK LINES FOR DAMAGE

FRAME CAVITY

CHECK STEPS & HANDRAILS

FRAME RAILS

CHECK FRAME STRUCTURE

ENTIRE FRAME

CHECK TRACKS & LINKS

TRACKS

CHECK SPROCKET WEAR

REAR OF TRACKS

CHECK IDLER WEAR

FRONT OF TRACKS

CHECK ROLLER WEAR

TRACKS

CHECK TRACK TENSION

RAISE TRACKS

ADJUST TRACK TENSION CHECK TRAVEL REDUCTION UNIT OIL LEVEL & FILL CHANGE TRAVEL REDUCTION UNIT OIL CHECK BOLTS / HARDWARE CHECK BOOM & ARM STRUCTURE CHECK BUCKET TEETH & SIDE CUTTERS

FRAME RAILS

GREASE BOOM PINS

BOOM

GREASE ARM PINS

ARM

GREASE BUCKET PINS

ARM & BUCKET LINK

TRAVEL MOTORS TRAVEL MOTORS ENTIRE MACHINE BOOM & ARM BUCKET & BLADE

Regular inspection & maintenance required.

Break-in (after first 50 hours) inspection & maintenance required.

• • • All attachment has to be lubricated every 10 hours for the first 50 hours of operation. Then the attachment should lubricated every 250 hours of operation. Next should be lubricated every 500 hours of operation, but the lubrication around bucket has to be applied every 250 hours.

• • •

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• • •

4— 6

Section IV – MAINTENANCE

4.4 FLUIDS AND FILTERS The following charts list all the necessary lubricants, oils, greases, fuels, coolants and filters required for the hydraulic excavator. Also a chart is provided giving specific information for the proper lubricants, oils, greases, fuels and coolants to be used in certain climates. Contact your dealer distributor to order the required filters, fluids and lubricants.

A. REQUIRED FLUIDS AND QUANTITIES TYPE OF FLUID

HYDRAULIC OIL

B. REQUIRED FILTERS

LOCATION OF USE

QUANTITIES REQUIRED

HYDRAULIC TANK

125 Liters (33 GAL)

RETURN FILTER ELEMENT KIT (BREAKER)

HYDRAULIC SYSTEM

230 Liters (61 GAL)

RETURN FILTER ELEMENT (BREAKER)

ENGINE OIL PAN (H LEVEL)

18 Liters (4.8 GAL)

ENGINE OIL PAN (L LEVEL)

15.5 Liters (4.1 GAL)

TANK BREATHER FILTER ELEMENT

UPPER ROLLER

30cm3 X 4 (1.8cu.in X 4)

ENGINE OIL FILTER CARTRIDGE (BYPASS)*

LOWER ROLLER

160cm3 X 16 (10cu.in X 16) 160cm3 X 18 (10cu.in X 18)-(N)LC

ENGINE OIL

IDLER

HYDRAULIC

TRAVEL MOTOR REDUCTION UNIT

4.7Liter X 2 (1.2GAL X 2)

OPERATING LEVER JOINT

"U" JOINT EACH SIDE

ATTACHMENT PINS

16 PLACES

SLEWING RING GEAR

1 PLACE 90° X 4

TRACK TENSION ADJUSTMENT

2 PLACES AS REQ'D

WITH LITHIUM SLEWING GEAR BASE MoS2 SUMP (BATH) GREASE

15.7 kg (34.6 lb)

ENGINE COOLANT

9.5 Liters (2.5 GAL)

COOLING SYSTEM TOTAL VOLUME

19 Liters (5 GAL)

FUEL TANK

290 Liters (77 GAL)

FUEL

TANK SUCTION STRAINER

AIR CLEANER INNER ELEMENT

ENGINE FUEL FILTER CARTRIDGE* ENGINE FEED PUMP GAUZE FILTER

AIR-CON FILTER OPERATOR (OUTER) CAB AIR-CON FILTER (INNER) *AVAILABLE FROM MITSUBISHI DEALER ONLY.

C. FLUIDS AND LUBRICANTS DESCRIPTION ENGINE OIL-SAE 15W/40 (1 GALLON) ENGINE OIL-SAE 15W/40 (5 GALLON) ENGINE OIL-SAE 15W/40 (55 GALLON) HYDRAULIC OIL-AW 46 (5 GALLON) HYDRAULIC OIL-AW 46 (55 GALLON) GREASE EP/2-14 OUNCE GREASE EP/2-35 POUNDS GREASE EP/2-120 POUNDS GEAR OIL 80W90-5 GALLONS

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FUEL

RADIATOR

LOCATION OF FILTER USE

AIR CLEANER OUTER ELEMENT

(12.2cu.in X 2) 15.3 Liter (4.0 GAL)

EXTREME PRESSURE GREASE

ENGINE

200cm3 X 2

SWING MOTOR REDUCTION UNIT GEAR OIL

SYSTEM

4— 7

Section IV – MAINTENANCE D. LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climates and certain working conditions.

LUBRICANT HYDRAULIC OIL (ANTI-WEAR, ANTIOXIDANT AND NON-FOAMING)

CLIMATE ZONE FRIGID -30¡C ~ 15¡C (-22¡F ~ 59¡F)

FRIGID -20¡C ~ 30¡C (-4¡F ~ 86¡F)

ISO VG22

ISO VG32

LUBRICANT ENGINE OIL* A.P.I. CLASSIFICATION FOR "SERVICE CD" *ALL ENGINES SHIPPED FROM FACTORY WITH SAE30 OR SAE15W40 OIL ACCORDING TO AMBIENT TEMPERATURE IN ENGINE OIL PAN.

LUBRICANT ENGINE OIL (FOR GENERAL PURPOSE LUBRICATION)

LUBRICANT GEAR OIL

ISO VG32S*

ISO VG46

VERY HOT 5¡C ~ 55¡C (41¡F ~ 131¡F) ISO VG68

CLIMATE ZONE FRIGID -30¡C ~ 30¡C (-22¡F ~ 86¡F)

WARM -5¡C ~ 40¡C (23¡F ~ 104¡F)

VERY HOT 30¡C and Above (86¡F and Above)

SAE10W30

SAE15W40

SAE15W50

LUBRICANT

FUEL

FRIGID ~ WARM WARM -5¡C ~ 40¡C -25¡C ~ 40¡C (-13¡F ~ 104¡F) (23¡F ~ 104¡F)

CLIMATE ZONE FRIGID -15¡F ~ -25¡C (5¡F ~ -13¡F) WINTERIZED ASTM D975 No.1

WARM -5¡C ~ -15¡C (23¡F ~ 5¡F)

VERY HOT -5¡C and Above (23¡F and Above)

ASTM D975 No.2

ASTM D975 No.2

FOR ROLLERS AND IDLERS ON ALL MODELS. A.P.I. Classification for "Service CD"-SAE30

FOR SWING MOTOR REDUCTION UNIT AND TRAVEL MOTOR REDUCTION UNITS ON THE FOLLOWING MODELS : E235SR(LC) & E235SRNLC EXTREME PRESSURE GEAR OIL #90 GRADE GL-4 BY A.P.I. CLASSIFICATION

LUBRICANT

GENERAL LUBRICATION

SLEWING GEAR SUMP (BATH)

GREASE

EXTREME PRESSURE MULTIPURPOSE GREASE No.2 EP TYPE GREASE

N.L.G.I. No.2 LITHIUM BASE WITH MoS2 GREASE

LUBRICANT ENGINE COOLANT (50% MIXTURE)

ANTIFREEZE (LLC) -34¡C (-29.2¡F) MIXTURE RATIO SHOULD PROSPECT TO 5¡C (9¡F) LOWER THAN THE COLDEST TEMPERATURE THE MACHINE WILL EXPERIENCE. TAKE INTO CONSIDERATION WIND CHILL FACTORS.

NOTE: USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information.

1. There are two types of BIO OIL available; vegetable-based and synthetic-based. You are recommended to use the synthetic-based type, because the vegetable-based oil has a maximum usage temperature of 80˚C (176˚F). Because of this, the degradation of vegetable-based oil occurs more rapidly, and caused reduced service life.

3. If you use BIO OIL, slewing and propel parking brake performance will be reduced, because of the lower friction factor of BIO OIL compared to that of mineral oil.

4. For further information about recommended Bio-degradable oil, please contact your Dealer.

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2. Do not mix either type of BIO OIL with the original factory-filled mineral oil. The hydraulic system has to be flushed three times if you want to use BIO OIL instead of the factory-filled mineral oil.

Section IV – MAINTENANCE

4.5 PRE-START(DAILY) INSPECTION & MAINTENANCE

ENGINE OIL DIPSTICK ON SIDE OF ENGINE

The following procedures are to be performed every 10 hours or daily, before the machine is started.

WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

ENGINE OIL FILLER CAP

H

A. ENGINE OIL LEVEL L

1. Stop engine and raise engine bonnet.

BETWEEN LOW & HIGH IS 2.5 LITER

2. Locate and pull engine dipstick. Clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again and visually inspect the engine oil level on dipstick.

See Figure 4.15.

FIGURE 4.15

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level. See Figure 4.15 and refer to page 4-8 for oil specifications.

NOTE After adding oil, check oil level again, replace oil filler cap, replace dipstick and close engine cover.

ENGINE COOLANT RESERVOIR

B. ENGINE COOLANT LEVEL FU LL

1. Open radiator access cover and inspect coolant level in engine coolant reservoir. See Figure 4.16.

LOW

PROPER LEVEL

2. Proper coolant level is between “FULL” and “LOW” marks. See Figure 4.16.

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

See Figure 4.16 and refer to page 4-8 for proper coolant specifications.

FIGURE 4.16

4. If no coolant is in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. See Figure 4.17. Then fill reservoir to proper level.

RADIATOR CAP

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WARNING NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. ALLOW ENGINE TO COOL BEFORE REMOVING RADIATOR CAP.

DO NOT REMOVE WHEN ENGINE IS HOT

FIGURE 4.17 4— 9

Section IV – MAINTENANCE C. ENGINE FLUID LEAKS USE CARDBORD TO CHECK FOR PRESSURE LEAKS

1. Inspect complete engine for signs of fluid leaks.

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard. See Figure 4.18.

CAUTION Never use hands to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

FIGURE 4.18 D. FAN BELT WEAR AND TENSION Inspect belt tensioner assembly on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

ALTERNATOR

COMPRESSOR

1. Measure belt tension on longest span of belt.

Belt deflection should be 7 mm ~ 15 mm.

BELT Fan belt Air conditioner

DEFLECTION 10 mm ~ 15 mm (0.4˝ ~ 0.6˝) 7 mm ~ 10 mm (0.3˝ ~ 0.4˝)

2. Loosen mounting nut and adjusting nut, and adjust tension of belt. See Figure 4.20.

FAN PULLY

3. Loosen adjusting bolt, adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut. See Figure 4.20.

CRANK PULLEY Force : Approx.

98 N (22 lbf, 10 kgf)

4. After adjustment, rotate engine at low idling for about 5 minutes, then check the tension of belt.

FIGURE 4.19

5. Adjust the tension of belt of air conditioner turning adjusting bolt of idle pulley. See Figure 4.20.

ADJUSTING BOLT ADJUSTING NUT 8.4 ± 1.0 kgf·m (61 ± 7 lbf·ft)

NOTE When moving the alternator, try not to damage the stater coil section between the front and rear brackets or the bolts.

Force : Approx.

98 N (22 lb, 10 kgf)

ADJUSTING NUT 7.7 ± 1.5 kgf·m (56 ± 11 lbf·ft)

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FIGURE 4.20

4— 10

Section IV – MAINTENANCE E. FUEL LEVEL 1. Turn key switch to “ON” position.

2. Visually watch fuel level gauge on gauge cluster panel. See Figure 4.21.

3. The fuel tank can be filled through the fuel filler cap located on top of the fuel tank or by using the auxiliary fuel pump located the cab left side. a . Filling tank through fuel filler cap 1. Open fuel filler cap with key switch key and fill tank to proper level with diesel fuel.

Refer to page 4-8 for fuel specifications.

FIGURE 4.21 USE KEY SWITCH KEY TO UNLOCK & LOCK

b . Filling tank using auxiliary fuel pump The fuel pump and suction hose are located in the front of radiator.

Use it in the following procedure.

1. Put the bucket on the ground, and stop the engine.

2. Open the fuel pump access cover with the key switch.(See Figure 4.23.)

3. Place the suction hose in the drum and turn the switch ON, and the fuel pump actuates regardless of the key switch and starts fueling.

After filling up the fuel tank, turn the switch OFF. Make certain the fuel level with a level gauge installed on the side of fuel tank.

FIGURE 4.22

NOTE • Do not use in volatile liquid, e.g. gasoline, etc.

• Do not operate more than 60 minutes continuously, and more 5 minutes in the dry operation.

• After the switch is turned ON, if the fuel pump does not actuate, check the fuse in the switch box for possible damage. The fuse is 10 A (tubular fuse).

FIGURE 4.23

4. After removing fuel delivery hose from fuel supply reservoir, coil hose and place filter into its storage housing. Replace fuel strainer and fuel filler cap.

FUEL PUMP SWITCH

FIGURE 4.24 4— 11

Section IV – MAINTENANCE F. AIR CLEANER CAUTION Wear protective glasses or goggles when using compressed air.

NOTE • The air restriction indicator will not signal if the element is torn or if the air cleaner compartment is not sealed properly. If “REST’D AIR CLEANER” icon is displayed, as indicated in Figure 4.25, inspect, clean, and/or replace the air cleaner elements.

FIGURE 4.25 ENGINE AIR CLEANER ACCESS COVER

• The removal and cleaning of inner element are not allowed. It may cause engine trouble due to the entry of dust.

• When replacing element, cover the engine intake port to prevent it from the entry of dust.

SUPPLEMENTARY EXPLANATION Cleaning and replacement of outer element.

WING BOLTS

Cleaning .......... When warning is indicated on multidisplay.

FIGURE 4.26

Replacement ... After cleaning of 6th time or an elapse of 1 year.

1. Cleaning or Replacement of Outer Element a. Loosen two wing bolts and remove air cleaner access cover. See Figure 4.26. b. Release clamp from the air cleaner cover. See Figure 4.27. c. Remove the air cleaner outer element from the housing. See Figure 4.28.

RELEASE CLAMP AND COVER

d. Clean the inside of air cleaner housing. e. To clean the outer element, blow compressed air {less than 7 bar (100 psi)} up and down along the folds of the filter element interior to remove clogged dust or other contaminants. See Figure 4.29.

FIGURE 4.27

f . After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing damage. Replace with a new element if necessary.

CAUTION Carefully hold the o-ring. Water inside cause engine failure.

REMOVE AIR CLEANER OUTER ELEMENT

FIGURE 4.28 4— 12

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g. Set outer element, and install cover.

Section IV – MAINTENANCE h. If the restricted icon appears on the multidisplay within the 6 times cleaning of outer element, replace the element with new one.

FIGURE 4.29

2. Replacement of Inner Element a. Remove the inner element. See Figure 4.30. b. Set new inner and outer elements, and install the cover.

CAUTION Carefully hold the o-ring.Water inside cause engine failure.

REMOVE AIR CLEANER INNER ELEMENT

FIGURE 4.30 NOTE For machines equipped with W (double) element and the inner element must be replaced together with the outer element. Don’t fail to replace the inner element with new one. See Figure 4.30.

4— 13

Section IV – MAINTENANCE G. ENGINE ELECTRICAL

POSITIVE (+) CABLE

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction. See Figure 4.31.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

NEGATIVE (-) CABLE

WARNING OPERATING THE MACHINE WITH DAMAGED OR MALFUNCTIONING ELECTRICAL COMPONENTS CAN CAUSE SERIOUS DAMAGE TO THE MACHINE AND SERIOUS INJURY TO PERSONNEL. REPAIR OR REPLACE FAULTY COMPONENTS IMMEDIATELY.

FIGURE 4.31

HYDRAULIC OIL CHECK POSITION

H. HYDRAULIC OIL LEVEL 1. Place the machine in the oil check position on a firm surface as shown in Figure 4.32.

FIGURE 4.32 2. Right hand hydraulic oil tank access cover and view the hydraulic oil level in the sight glass on side of hydraulic oil tank. See Figure 4.33.

WARNING FOR SAFE OPERATION ON INCLINES, THE HYDRAULIC OIL LEVEL MUST BE MAINTAINED BETWEEN “PROPER LEVEL” AND “UPPER LIMIT” MARK.

UPPER LIMIT PROPER LEVEL LOW (ADD OIL)

FIGURE 4.33 3. Use the following instructions to add hydraulic oil : DEPRESS RUBBER CAP TO RELEASE PRESSURE

a. Release hydraulic tank pressure. See Figure 4.34.

CAUTION

HYDRAULIC TANK

FIGURE 4.34 4— 14

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Gasses from hydraulic tank may be hot. Wear safety equipment.

Section IV – MAINTENANCE b. Remove the six mounting bolts from the hydraulic suction screen cover plate. See Figure 4.35.

STAY

SLOWLY REMOVE BOLTS & COVER

c. Add hydraulic oil through the suction screen, filling hydraulic tank to the proper level. See Figure 4.35. d. Before replacing filter cover, replace “O”-ring. See Figure 4.35. e. Place new “O”-ring in seat. Place cover over opening and install mounting bolts with lockwashers. f . Torque mounting bolts to proper value. Refer to torque specifications table.

ADD CLEAN OIL

FIGURE 4.35 WARNING CLEAN UP ALL SPILLED OIL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

I . HYDRAULIC FUNCTIONS

CHECK ALL CONTROLS FOR PROPER FUNCTION

1. Check all hydraulic controls for proper function before operating the machine. See Figure 4.36.

WARNING NEVER OPERATE THE MACHINE WITH A FAULTY CONTROL OR FUNCTION. MAKE ALL NECESSARY REPAIRS BEFORE ALLOWING ANY OPERATION.

J. HYDRAULIC OIL LEAKS

FIGURE 4.36

1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure. See Figure 4.37.

USE CARDBORD TO CHECK FOR PRESSURE LEAKS

CAUTION Never use hands to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

2. Check all hoses and lines for signs of damage.

3. Repair or replace damaged hoses and lines before allowing any operation.

FIGURE 4.37

WARNING CLEAN UP ALL SPILLED OIL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS. 4— 15

REPLACE "O"-RING

K. MACHINE ELECTRICAL

CHECK AND REPLACE ANY BROKEN WIRES

1. Check all switches for proper operation.

2. Visually check all wiring and connectors for signs of damage, corrosion etc..

3. Repair or replace all damaged or faulty electrical components before allowing any operation of the machine.

CHECK ALL GAUGES AND LCD DISPLAY

4. Check all gauges and LCD display on the gauge cluster panel for proper operation. See Figure 4.38.

WARNING DAMAGED OR FAULTY ELECTRICAL COMPONENTS CAN CAUSE SEVERE DAMAGE TO THE MACHINE AND CAUSE SERIOUS PERSONAL INJURY OR DEATH.

FIGURE 4.38

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S D

Section IV – MAINTENANCE

4— 16

Section IV – MAINTENANCE L. STEPS AND HANDRAILS 1. Inspect daily all mounting steps and handrails on the machine to make sure they are clean and in safe working condition. See Figure 4.39.

2. Repair or replace all areas before allowing any operation of the machine.

CAUTION Use steps, and handrails when mounting and dismounting the machine. Keep steps, handrails and step rails clean and in safe working condition.

FIGURE 4.39

M. FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds etc..

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding repair is required, consult the Manufacturer for proper procedures concerning weld repairs. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding.

FIGURE 4.40

CHECK FOR BEND

WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. SEE FIGURE 4.40. CONNECT WELDER GROUND CABLE 1M (3´-3˝) AWAY FROM AREA TO BE WELDED.

CHECK SHOE WEAR

FIGURE 4.41

N. TRACKS AND COMPONENTS 1. Track shoes

CHECK SHOES FOR WEAR & OR DAMAGE

a. Visually inspect track shoes for signs of excessive wear or damage. See Figure 4.41. b. Have all repair or replacement work done by the Dealer.

TORQUE BOLTS

c. Check tightness of shoe attaching bolts and nuts.

If loose, remove bolt, clean thread, apply engine oil and torque. See Figure 4.42.

E235SR E235SRLC E235SRNLC

85 ± 5 daN·m (627 ± 36 lbfáft) FIGURE 4.42 4— 17

Section IV – MAINTENANCE 2. Track Links a. Inspect links for signs of excessive wear or damage. See Figure 4.43. b. Have all repair or replacement work done by the dealer.

INSPECT TRACK LINK ASSEMBLIES

FIGURE 4.43

3. Sprockets

INSPECT THESE BOLTS

a. Inspect sprockets for excessive wear and damage.

See Figure 4.44. b. Should the sprockets require service, contact the Dealer. c. Check and make sure all sprocket bolts are properly tightened.

NOTE If any sprocket bolt is loose, proceed as follows: c.1 ... Remove bolt and clean threads. c.2 ... Apply loctite #262 to the bolt. c.3 ... Torque to 39,7daN·m (292 lbf·ft)

INSPECT THESE SURFACES

FIGURE 4.44

4. Idlers a. Inspect Idlers for excessive wear and damage. See Figure 4.45. b. Should the Idlers require service, contact the Dealer.

NOTE Every 10 hours of operation, make sure to check idlers and rollers for leakage and repair as needed. Contact the Dealer for any assistance.

Change oil in idlers and rollers every 2000 hours of operation. See 2000 hour maintenance in this section for specific details.

INSPECT THESE SURFACES

FIGURE 4.45

LOWER ROLLER

5. Rollers

UPPER ROLLER INSPECT THESE SURFACES

a. Inspect rollers for excessive wear and damage. See Figure 4.46.

INSPECT THESE SURFACES

FIGURE 4.46 4— 18

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b. Should the rollers require service, contact the Dealer.

Section IV – MAINTENANCE O. TRACK TENSION 1. Operate swing, arm, bucket and boom controls until machine is set up as shown in Figure 4.47.

WARNING SUPPORT LOWER FRAME WITH SUITABLE BLOCKS.

FIGURE 4.47

2. Measure the sag in the center of the track, between the bottom of the track frame and the track shoe surface. See Figure 4.48.

3. To increase track tension, set machine as shown in Figure 4.47 and with grease gun inject extreme pressure No.2 grease into idler adjustment grease fitting until proper tension is reached. See Figure 4.49. Perform this procedure on both tracks.

320~350 mm (12.6"~13.8")

4. To decrease track tension, carefully loosen grease nipple to allow grease to escape.

FIGURE 4.48

5. Tighten grease nipple as shown in Figure 4.49.

USE CAUTION WHEN ADJUSTING TRACKS

WARNING GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATE SKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE NIPPLE AREA. NEVER LOOSEN GREASE NIPPLE MORE THAN ONE COMPLETE TURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE NIPPLE, CALL A DEALER FOR ASSISTANCE.

GREASE FITTING

TORQUE GREASE NIPPLE TO 59 N·m (43 lbf·ft)

6. Start engine and operate the travel motor for the track being adjusted, back and forth. Recheck track tension and adjust if needed.

7. Perform steps 1 through 6 on the opposite track if needed.

FIGURE 4.49 4— 19

Section IV – MAINTENANCE P. BOOM AND ARM 1. Inspect boom and arm structures for signs of excessive wear and damage. See Figure 4.50.

2. Should repair or replacement be necessary, contact the Dealer.

INSPECT BOOM & ARM FOR DAMAGE

FIGURE 4.50 WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE. SEE FIGURE 4.56. CONNECT WELDER GROUND CABLE 1M (3´-3˝) AWAY FROM AREA TO BE WELDED. DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

FIGURE 4.51

Q. BUCKET TEETH AND SIDE CUTTERS 1. Inspect bucket teeth and side cutters for signs of excessive wear and damage. See Figure 4.52.

INSPECT TEETH AND SIDE CUTTERS FOR DAMAGE

2. Should repair or replacement be required, follow bucket manufacturers recommendations.

CAUTION Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

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FIGURE 4.52

4— 20

Section IV – MAINTENANCE R. ATTACHMENT LUBRICATION Lubricate attachment pins every 10 hours of engine operation. Use extreme pressure multi-purpose grease No. 2 EP type grease. Lubricate all points until grease oozes.

NOTE 1. All attachment has to be lubricated every 10 hours for the first 50 hours of operation.

BOOM CYLINDER HEAD PINS

2. Then the attachment should be lubricated every 250 hours of operation.

FIGURE 4.53

3. Next it should be lubricated every 500 hours of operation, but the lubrication around bucket has to be applied every 250 hours.

BOOM CYLINDER ROD ENDS ARM CYLINDER HEAD END

4. If attachment is sank in water, it is recommended to lubricate it every 10 hours.

BOOM FOOT PIN EACH END

BOOM FOOT PIN (CENTER)

1. Boom cylinder head pins. See Figure 4.53.

2. Boom foot pin. See Figure 4.54.

3. Boom cylinder rod pins. See Figure 4.54.

CENTRALIZED GREASE NIPPLES ON BOOM

4. Arm cylinder head pin. See Figure 4.54.

FIGURE 4.54 5. Arm cylinder rod pin. See Figure 4.54.

ARM TO BOOM PIN

6. Arm to boom pin. See Figure 4.55.

7. Bucket cylinder head pin. See Figure 4.55.

ARM CYLINDER ROD END

BUCKET CYLINDER HEAD PIN

FIGURE 4.55 8. Bucket link pins. See Figure 4.56.

IDLER LINK TO ARM PIN

9. Idler link to arm pin and arm to bucket pin. See Figure 4.56.

ARM TO BUCKET PIN BUCKET CYLINDER ROD END

10. Bucket cylinder rod pin. See Figure 4.56.

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TOP BUCKET LINK PIN

BOTTOM BUCKET LINK PIN

FIGURE 4.56 4— 21

Section IV – MAINTENANCE

4.6 50 HOUR & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES

REMOVE BOLTS AND LOWER COVER

Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

A. ENGINE OIL AND FILTER ELEMENT FIGURE 4.57

1. Move the machine to a firm, level surface and run engine for 5 minutes to warm the oil.

WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. NOTE

ENGINE OIL FILTER REMOVAL

• Check the waste oil. If there are metal chips or powder mixed in the oil, contact your Dealer.

• The oil filter can not be reused because it is cartridge

FILTER WRENCH

type.

EXTENSION BAR

2. Remove the six mounting bolts from the engine lower cover plates. See Figure 4.57.

RATCHET HANDLE

3. Place the oil container under the filter.

FIGURE 4.58

4. Remove the oil filter by turning counterclockwise.

See Figure 4.58.

5. To install the oil filter, apply a thin coat of engine oil to the gasket of the oil filter, and then secure the filter by tightening prescribed number of rotations after the gasket comes in contact with the oil filter head. See Figure 4.57.

APPLY CLEAN ENGINE OIL

6. When replacing the element only, and not the engine oil, the amount of oil to be added is shown below. Partially fill filter with oil before installing.

Oil volume ...... Approx. 1.1 L (0.29 GAL) 7. Start engine, operate it at idling operation for several minutes. Then check filter fitting section for oil leakage.

FIGURE 4.59

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8. Install cover just below the engine to the regular position.

4— 22

Section IV – MAINTENANCE B. ENGINE OIL Change the engine oil on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

REMOVE BOLTS AND LOWER COVER

1. Move the machine to a firm, level surface and run engine for 5 minutes to warm the oil.

WARNING

FIGURE 4.60

DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING.

ENGINE OIL DIPSTICK ON SIDE OF ENGINE

2. Remove the six retaining bolts from the oil pan access cover on the bottom, rear center of machine.

See Figure 4.60.

3. Raise engine bonnet and remove oil filler cap. See Figure 4.61.

ENGINE OIL FILLER CAP

4. Remove cap from engine oil drain by hand. See Figure 4.62. Place a 20 liter (5.3 Gal) capacity container under oil pan.

FIGURE 4.61

5. Install engine oil drain plug.

6. Refer to page 4-8 for the proper oil to use and fill engine oil to proper level.

• Total oil volume to be replaced: 18 liters (4.8 Gal) 7. Install oil filler cap. Clean up all spilled oil.

8. Start engine, run for 5 minutes. While running, check for oil leaks.

ENGINE OIL DRAIN PLUG

9. Should any oil leaks be found, repair immediately and refill with proper oil.

FIGURE 4.62

10. Check oil level and close cover.

CAUTION

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Dispose of all hazardous waste in accordance with government environmental regulation.

4— 23

Section IV – MAINTENANCE C. FUEL TANK DRAIN Drain the fuel tank every 50 hours or weekly. See Figure 4.63.

1. Place an empty container below the fuel tank drain valve.

2. Locate and open fuel tank drain valve on bottom of fuel tank. See Figure 4.63.

3. Allow all water and sediment to drain from fuel tank into a waste container, then close the drain valve.

FUEL TANK DRAIN VALVE

FIGURE 4.63

D. WATER SEPARATOR The water separator isolates water that mixes in with the fuel. The case is equipped with a float. When water accumulates, the float rises. When the float rises to the level line, drain the water. See Figure 4.64.

AIR PLUG

WATER SEPARATOR

1. Loosen the drain plug to drain the water.

2. When the float comes down to the bottom, close the drain plug.

LEVEL LINE (RED)

FLOAT (RED)

3. Tightening the drain plug and air plug.

4. Check that fuel is not leaking.

Drain water whenever the float rises to the level line, regardless of inspection time.

DRAIN PLUG

FIGURE 4.64

CAUTION Clean up all spilled fuel to avoid a fire.

Dispose of all hazardous waste in accordance with government environmental regulation, laws and codes.

E. AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system on a new machine after the first 50 hours of operation.

Then at every 500 hours of engine operation.

1. Inspect all hoses for damage and tighten all hose clamps. See Figure 4.65.

HOSE & CLAMPS FROM AIR CLEANER

2. Replace any hose found to be damaged before allowing any operation of the machine.

FIGURE 4.65 4— 24

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HOSE & CLAMPS

Section IV – MAINTENANCE F. RADIATOR, OIL COOLER AND DEBRIS SCREEN 1. Clean radiator after every 50 hours of operation using pressurized water.

CAUTION Do not use high pressure water as it will bend the radiator fins. Use standard water pressure.

2. Open engine air cleaner access door and engine bonnet for cleaning the radiator and oil cooler. See Figure 4.66.

FIGURE 4.66

3. Open engine bonnet and remove the wing bolts retaining the debris screen. See Figure 4.67. Carefully remove debris screen and clean with pressurized water.

WING BOLTS

SCREEN (REAR)

SCREEN (FRONT)

FIGURE 4.67

4. Remove wash out access cover from bottom of machine. See Figure 4.68.

DEBRIS SCREEN WASH OUT COVER

5. Rinse all dirt and debris from engine compartment.

Reinstall debris screen and wash out access cover.

CAUTION

REMOVE BOLTS

Be careful not to bend or damage cooling fins of the radiator or oil cooler. Replace debris screen if damage is found.

Repair damaged cooling fins of radiator and oil cooler.

FIGURE 4.68

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NOTE To remove or install the screen, remove three wing bolts on the upper section of radiator, and pull out the screen on the front side then pull the rear screen frontward and remove. After cleaning it, install it by the reverse procedure.

4— 25

Section IV – MAINTENANCE G. HYDRAULIC RETURN FILTERS Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 500 hours.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

1. Release hydraulic tank pressure. See Figure 4.69.

HYDRAULIC TANK

WARNING FIGURE 4.69

NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

SLOWLY REMOVE BOLTS & COVER

2. Remove the six mounting bolts from the hydraulic return cover plate. See Figure 4.70.

CAUTION

FIGURE 4.70

Slowly remove the mounting bolts. The filter cover plate is under spring tension.

BOLT COVER

SPRING WASHER

3. Remove “O”-rings, filter springs and bypass valves.

See Figure 4.71.

O-RING

4. Remove the filter from the housing. See Figure 4.71.

SPRING

5. Install new filter, bypass valve and spring into housing.

BYPASS VALVE

6. Install new “O”-ring,.

7. Install cover plates and torque attaching bolts to proper value. Refer to specifications section for torque value.

FIGURE 4.71

4— 26

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FILTER

Section IV – MAINTENANCE H. BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation.

Then, check electrolyte (acid) every 50 hours.

WARNING 1. WEAR SAFETY CLOTHES, GOGGLES OR FACE SHIELD, GLOVES AND SAFETY SHOES WHEN WORKING WITH BATTERIES. 2. WORK IN A WELL VENTILATED AREA. 3. BATTERY ELECTROLYTE (ACID) IS CORROSIVE. IF IT COMES IN CONTACT WITH SKIN, EYES OR CLOTHING, FLUSH WITH LARGE AMOUNTS OF WATER AND SEEK IMMEDIATE MEDICAL ATTENTION. SEE FIGURE 4.72.

FIGURE 4.72

4. BATTERY ELECTROLYTE (ACID) PRODUCES HYDROGEN GAS THAT IS HIGHLY EXPLOSIVE. DO NOT ALLOW NEAR SPARKS, FIRE OR FLAMES AND DO NOT SMOKE WHEN WORKING WITH BATTERIES. SEE FIGURE 4.72.

1. Open battery box access cover. See Figure 4.73.

BATTERY ACCESS DOOR

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10~15 mm (0.4˝ ~ 0.6˝) above cell plates. See Figure 4.74.

3. If necessary, fill each cell to proper level with distilled water only.

4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

FIGURE 4.73 5. If cables are found to be in poor condition, replace with new parts immediately.

ELECTROLYTE LEVEL

WARNING PREVENT BATTERY EXPLOSION

10 ~ 15 mm (0.4" ~ 0.6")

• Batteries give off hydrogen gasses that can explode and cause personal injury.

CELL PLATES

• Keep sparks, open flames and cigarettes away from batteries.

• Keep metallic articles away from batteries.

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• Keep all ventilation caps tightly secured.

• Never check charge by placing metal articles across battery terminals.

REMOVE CELL CAPS

• Leave battery box open to improve ventilation when charging.

FIGURE 4.74

4— 27

Section IV – MAINTENANCE 6. Use a densimeter to check the specific gravity of each cell. Compare readings to the chart below.

NOTE Use densimeter according to its manufacturer’s instructions. .

CHARGE % 100 % 90 % 80 % 75 %

DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

AMBIENT TEMPERATURE 20°C 0°C -10°C ° ° (68 F) (32 F) (14°F) 1.27 1.25 1.23 1.22

1.26 1.24 1.22 1.21

FIGURE 4.75

1.28 1.26 1.24 1.23

7. When disconnecting batteries, remove the negative (–) cable first. When connecting batteries, connect the negative (–) cable last. See Figure 4.75.

8. When the battery requires charging; a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

CAUTION Make certain not to cross positive and negative terminals when connecting charger. e. Stop charge if battery overheats. f . Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

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NOTE Battery life can be shortened by overcharging and over discharging of the battery. Replace any battery that will not hold charge or is difficult to charge.

4— 28

Section IV – MAINTENANCE

4.8 100 HOUR INSPECTION & MAINTENANCE PROCEDURE FILL PLUG

A. SWING MOTOR REDUCTION OIL Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation. Then check every 100 hours.

1. Locate the dipstick on the side of the swing motor.

See Figure 4.76. Pull dipstick, wipe clean and reinsert all the way in.

DIPSTICK

2. Pull dipstick and read oil level.

FIGURE 4.76 3. If necessary to add oil, remove plug from oil fill port and fill to full level with proper oil. See Figure 4.76 and refer to page 4-8 for oil specifications.

CAUTION DRAIN PORT

Reduction unit may be under pressure.

Remove plug slowly.

4. To drain oil from swing motor reduction unit; a. Locate drain port under rear of machine. See Figure 4.77. b. Place a 20 liter (5.3 gallon) container under drain port and remove plug allowing oil to drain into container.

FIGURE 4.77

c. Replace plug and tighten securely after all oil is drained. d. Fill through fill port using proper oil. See Figure 4.76 and refer to page 4-8 for oil specifications.

WARNING

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NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

4— 29

Section IV – MAINTENANCE B. TRAVEL MOTORS REDUCTION OIL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation.

Then check every 100 hours.

FILL PLUG

LEVEL PLUG

1. Move machine to a firm, level surface. Operate travel until “FILL / LEVEL” plugs on travel motors are at top . See Figure 4.78.

2. Stop engine and remove the travel motor reduction unit oil level plug. See Figure 4.78. If oil just seeps from the port, oil level is correct.

DRAIN PLUG

FIGURE 4.78 WARNING TRAVEL REDUCTION UNIT COULD BE UNDER PRESSURE. CAREFULLY LOOSEN PLUG AND REMOVE SLOWLY FILL AIR PRESSURE IS RELEASED.

3. To add oil, remove the oil fill plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from check plug.

4. Use teflon tape on the plug for better sealing. Install plug and tighten securely.

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NOTE Capacity of each travel motor reduction unit is 4.7 liters (1.2 Gallons).

4— 30

Section IV – MAINTENANCE

4.9 250 HOUR INSPECTION & MAINTENANCE PROCEDURE

ATTACHMENT LUBRICATION POSITION

NOTE Perform all pre-start (Every 10 hour and 50 hour) inspec2.

Water Temperature Gaugetion & maintenance procedures along with the following 250 hour inspection and maintenance procedures.

A. ATTACHMENT LUBRICATION Lubricate attachment pins every 250 hours of engine operation. Use extreme pressure multi-purpose No. 2 EP type grease. Lubricate all points until grease oozes.

See Figure 4.79.

FIGURE 4.79

1. Boom cylinder head and rod pins. See Figure 4.80.

BOOM CYLINDER HEAD PINS

FIGURE 4.80 2. Boom foot pin. See Figure 4.81.

BOOM CYLINDER ROD ENDS

3. Boom cylinder rod pins. See Figure 4.81.

ARM CYLINDER HEAD END

4. Arm cylinder head pin. See Figure 4.81.

BOOM FOOT PIN EACH END

BOOM FOOT PIN (CENTER)

CENTRALIZED GREASE NIPPLES ON BOOM

FIGURE 4.81 5. Arm cylinder rod end. See Figure 4.82.

ARM TO BOOM PIN

6. Arm to boom pin. See Figure 4.82.

7. Bucket cylinder head end. See Figure 4.82.

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ARM CYLINDER ROD END

BUCKET CYLINDER HEAD PIN

FIGURE 4.82 4— 31

Section IV – MAINTENANCE 8. Bucket link pins. See Figure 4.82A.

IDLER LINK TO ARM PIN

9. Idler link to arm pin and arm to bucket pin. See Figure 4.82A.

ARM TO BUCKET PIN BUCKET CYLINDER ROD END

10. Bucket cylinder rod pin. See Figure 4.82A.

TOP BUCKET LINK PIN

BOTTOM BUCKET LINK PIN

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FIGURE 4.82A

4— 32

Section IV – MAINTENANCE B. FAN AND A/C BELT WEAR AND TENSION Inspect belts and tensioner assembly on a new machine after the first 50 hours of operation. Then at every 250 hours of engine operation.

Measure belt tension on longest span of belt. Apply a 98 N(22 lbf) on the belts as indicated in Figure 4.83 and measure the belt deflection. Compare to the following table: BELT

ALTERNATOR

COMPRESSOR

DEFLECTION

Fan Belt

8 mm to 12 mm (0.3˝ to 0.5˝)

Air Conditioner

10 mm to 12 mm (0.4˝ to 0.5˝)

FAN PULLY CRANK PULLEY Force : Approx.

98 N (22 lbf)

FIGURE 4.83 1. Fan Belts Check fan belts for excessive wear and cracks and replace them if needed. When replacing a twin type V-belt, replace them both. If only one belt is replaced, it may fail due to the excessive loading. To adjust the fan belts, proceed as follows:

ADJUSTING BOLT

ATTACHING NUT 8.4 ± 1.0 kgf·m (61 ± 7 lbf·ft)

a. Loosen mounting capscrew and adjusting nut on the alternator. See Figure 4.84. b. Loosen or tighten adjusting bolt to adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut properly. See Figure 4.84.

ATTACHING NUT

TIGHTENING TORQUES Mounting capscrew .... 82.4 ± 9.8 N·m (60.5 ± 7.2 lbf·ft) Adjusting nut .............. 75.3 ± 14.7 N·m (55.3± 10.8 lbf·ft)

FIGURE 4.84

ALTERNATOR

COMPRESSOR

c. After adjustment, start engine and run it at low idle for about 5 minutes. Then recheck belt tension.

2. Air Conditioning Compressor Belt Check belt for excessive wear and cracks and replace if needed. To adjust the A/C compressor belt, proceed as follows: a. Loosen the idler pulley nut. See Figure 4.85. b. Loosen or tighten adjusting bolt.

FAN PULLY

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c. Tighten idler pulley nut to 39 ~ 54 N·m (29 ~ 40 lbf·ft).

ADJUSTING BOLT

d. After adjustment, start engine and run it at low idle for about 5 minutes with A/C turned on. Then recheck belt tension.

CRANK PULLEY

FIGURE 4.85 4— 33

Force : Approx.

98 N (22 lbf)

Section IV – MAINTENANCE C. AIR CONDITIONER FILTERS COVER

Cleaning recirculate and fresh air filters.

Recirculate air filter ........ Every 500 hours Fresh air filter ................. Every 250 hours 1. Cleaning fresh air filter a. Loosen 3 bolts under operator’s seat, and remove cover. See Figure 4.86. b. Remove cover, and take fresh air filter out. c. Blow compressed air to clean fresh air filter.

FIGURE 4.86 NOTE Water washing is not allowed to clean air filter because it is paper filter.

RECIRCULATE AIR FILTER

d. Cleaning about 10 times is allowed, or replace it with new one every two years.

FRESH AIR FILTER

2. Cleaning recirculate air filter COVER

a. Raise recirculate air filter slightly, and pull it out. b. Clean it with water or compressed air blow.

NOTE Washing with organic solvent (gasoline, trichlene, thinner, etc.) is strictly prohibited.

MACHINE FRONT

c. When frequently clogged, or damage is serious, replace it with new one.

FIGURE 4.87

d. After drying, set outside and recirculate air filters and install cover.

D. INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR LOOSENING – FIGURE 4.88 Check bolts and nuts for loosening.

CAUTION Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after 50 hours the first time, and every 250 hours after that.

Unit : N·m (lbf·ft)

E235SR(LC) E235SRNLC

TORQUE SPECIFICATION (Apply Loctite #262)

FIGURE 4.88

2943 ± 294 {2163 ± 216} 13503 60421091

MODEL

4— 34

Section IV – MAINTENANCE

4.9 500 HOUR INSPECTION & MAINTENANCE PROCEDURES NOTE Perform all pre-start (every 10 hour and 50 hour) inspection & maintenance procedures along with the following 250 hour inspection and maintenance procedures.

APPLY CLEAN FUEL REMOVAL

A. FUEL FILTER FILTER WRENCH

1. Raise engine cover and locate the fuel filter on the R.H. side of engine. See Figure 4.89.

2. Using appropriate filter wrench, turn counterclockwise to remove fuel filter.

EXTENSION BAR

3. Empty contents of fuel filter into a waste container.

4. With a clean, dry cloth, clean filter head mounting surface for the filter.

RATCHET HANDLE

FIGURE 4.89

5. Coat the gasket of new filter with a thin layer of fresh, clean engine oil and install onto filter head.

6. Fill fuel filter with fresh, clean fuel and install onto filter head. See Figure 4.89.

7. Install the filter by hand (do not use wrench), and tighten 2/3 turn after the gasket of filter has made contact with the filter head. See Figure 4.89.

8. Loosen the priming pump knob.

9. Loosen the air plug located on top of the fuel filter support mount.

10. Pump by hand to supply fuel until air bubbles stop coming out the air plug.

11. Tighten the air plug when no more air bubbles are present.

12. Continue pumping, even after tightening the air plug.

Stop pumping with the handle in the lower position and tighten the knob completely.

13. Run engine at low idle for 5 minutes to check and make sure there isn’t any fuel leakage. Repair if needed.

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WARNING CLEAN UP ALL SPILLED FUEL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS.

4— 35

Section IV – MAINTENANCE B. BLEEDING AIR FROM THE FUEL SYSTEM

AIR PLUG

WARNING FUEL FILTER

CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. If air contaminates the fuel system, the engine may become hard to start or it malfunction. Bleed the air whenever the fuel tank is empty, the water separator is drained, or the fuel filter element is replaced. See Figure 4.90.

PRIMING PUMP

KNOB

AIR PLUG

1. Loosen the knob of the priming pump.

2. Loosen the air plug of the fuel filter.

3. Moving the knob up and down by hand, supply fuel until air bubbles stop issuing from the air plug.

NOTE Cover the air plug with a cloth before performing this operation.

AIR PLUG

4. Tighten the air plug when the air bubbles stop issuing from it.

5. Move the knob up and down a few times, then set it in the down position and screw it in to secure it.

NOTE Wipe away all spilled fuel before starting up the engine.

After engine has started, check for fuel leaks.

6. The air in the injection pump will automatically be forced out when the engine starts.

TO UPPER RIGHT

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FIGURE 4.90

4— 36

Section IV – MAINTENANCE C. GREASING THE SLEWING RING

GREASING SWING BEARING 1. EXTREME-PRESSURE. MULTIPURPOSE GREASE. N.L.G. I No.2 LITHIUM BASE GREASE EP TYPE. 2. ADD GREASE EVERY 500 HOURS. 3. ROTATE UPPER FRAME ADDING GREASE EVERY 90° (TOTAL 4X)

1. Locate the grease nipple at the front of the slewing ring. See Figure 4.91.

2432P2689

2. Using grease gun filled with general purpose EP grease (refer to page 4-8), lubricate slewing ring with several shots from grease gun.

3. Swing machine 90° right, and repeat step 2. See label on frame.

4. Continue to swing machine at 90° increments and lubricating slewing ring until ring has been completely greased.

SLEWING RING GREASE NIPPLE

FIGURE 4.91

D. CHECKING SLEWING RING FITTING BOLTS FOR LOOSENING Check that bolts securing slewing ring are not loosened.

If loosened, remove bolts once, apply Loctite #262 or equivalent, and tighten them again.

BALL

SLEWING RING

BOLTS

Unit : N·m (lbf·ft) Model

Location

Torque Specification

E235SR(LC) E235SRNLC

Inner Race

564 ± 56 (414 ± 41)

Outer Race

400 ± 49 (360 ± 36)

LOWER FRAME

FIGURE 4.92

Alternately tighten bolts facing each other in order. See Figure 4.92.

NOTE Since the tightening of slewing ring requires special tools, contact your Dealer for assistance.

E . WATER PUMP BEARING LUBRICATION Lubricate the water pump bearing on a new machine after the first 50 hours of engine operation. Then check and lubricate every 500 hours.

1. Open the engine bonnet, lock it open, and locate grease nipple for the water pump bearing, in front of the engine. See Figure 4.93.

2. Wipe all dust and mud off the grease nipple.

3. Use N.L.G.I. No. 2 (Lithium soap) wheel bearing grease to lubricate the bearing.

4. Close engine bonnet.

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FIGURE 4.93 NOTE Do not over grease the water pump bearing. It only requires about one shot of a manual grease gun, which is equivalent to aprox. 6.1 cc. NEVER USE A PNEUMATIC GREASE GUN. 4— 37

Section IV – MAINTENANCE F. CHECKING THE AIR CONDITIONER REFRIGERANT

AIR CAPACITY SELECTOR SWITCH

1. Start the engine. Set the engine speed to the middle speed position.

COMPRESSOR SWITCH

2. Set the machine to the conditions shown below when checking the refrigerant. See Figure 4.94.

• Air conditioner switch . ON • Fan switch ...................... HI position (Maximum

) TEMPERATURE MAIN POWER SETTING SWITCH SWITCH (˚C ˚F SELECTOR SWITCH)

• Temp. adjustment switch ... Lower temp position ( ) • Door / Window ............... Close • Compressor switch ........ ON (The

FIGURE 4.94

lamp lit up)

3. Follow the procedure below and check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver dryer. See right table for better reference.

Refrigerant volume

Description

(A) Proper

a. Figure (A) shows that the refrigerant volume is proper. See Figure 4.95.

After the air conditioner is turned ON, little bubbles appear. The refrigerant becomes transparent, then turns a light milky white.

b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system. See Figure 4.95.

(B) Overcharged

After the air conditioner is turned ON, no bubbles appear.

(C) Insufficient

c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your dealer. See Figure 4.95.

After the air conditioner is turned ON, bubbles appear continuously.

FIGURE 4.95

NOTE • New refrigerant (HFC-R134a), whose characteristics are different from conventional CFC-12, is used in this machine. Do not mix HFC-134a with CFC-12.

Bubbles

• Keep the air conditioner ready for use all year round.

Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

: Refrigerant gas is mixed with refrigerant fluid.

No Bubbles : Whole refrigerant becomes fluid and transparent.

Cloudy

: Refrigerant is separated from oil.

The fluid becomes a light milky white.

G. FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (ATOMIZATION) Perform this inspection and adjustment every 500 hours of engine operation. Contact your Dealer for assistance.

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Initial injection pressure : 220 kgf/cm2 (3,128 psi)

4— 38

Section IV – MAINTENANCE

4.10 1000 HOUR INSPECTION MAINTENANCE PROCEDURES

&

A. ENGINE VALVE CLEARANCE Check and adjust the engine valve clearance every 1000 hours of engine operation. Contact your Dealer for assistance.

Adjust exhaust and intake valves at 0.4 mm (0.016˝) (With cold engine)

B. ENGINE COMPRESSION PRESSURE Check engine compression every 1000 hours of engine operation. Contact your Dealer for assistance.

Compression pressure : 2.6 MPa (377 psi) at 200 rpm at engine temperature between 75 ~ 85°C (167 ~ 185°F)

C. INSPECTION OF STARTER AND ALTERNATOR Check starter and alternator every 1000 hours of engine operation. Contact your Dealer. It is necessary to disassemble these components for proper cleaning and inspection.

D. ENGINE FUEL INJECTION TIMING Check engine fuel injection timing every 1000 hours of engine operation. Contact your Dealer for assistance.

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Injection timing : 14° BTDC (before Top Dead Center)

4— 39

Section IV – MAINTENANCE

4.11 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES Perform all other inspection & maintenance procedures as previously described in this section.

A. CHANGE ENGINE COOLANT - 2000 HOURS

REMOVE CAP SLOWLY

WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW ENGINE TO COOL BEFORE CHANGING FLUIDS.

ALLOW ENGINE TO COOL BEFORE OPENING

FIGURE 4.96

DEBRIS SCREEN WASH OUT COVER

1. Raise engine bonnet and slowly remove radiator cap. See Figure 4.96.

2. Locate coolant drain access cover under L.H. rear of machine. See Figure 4.97. Remove the four retaining bolts.

REMOVE BOLTS

3. Locate radiator drain valve, place a 13 liter (3.4 Gal) capacity container under drain tube and turn drain valve counterclockwise to open. See Figure 4.98.

4. After drainage, close drain valve and drain plug, and feed water in it.

FIGURE 4.97

5. Open drain valve and drain plug. And clean it with flowing water for 10 minutes in low idling state.

Be careful that water hose is not disconnected from water feeding port of radiator while cleaning and flowing water.

6. After cleaning, stop engine, and also stop water feeding.

Then after draining water, close drain valve and drain plug.

7. After draining, clean it with radiator flush.

Clean it following instruction manual for flush in use.

ENGINE DRAIN PLUG

RADIATOR DRAIN VALVE

FIGURE 4.98 8. After cleaning, open drain valve and drain plug, then close them after completely draining water, and fill it with water and clean out radiator flush material completely.

NOTE

NOTE Never spill the coolant on the ground that can cause the environmental pollution.

Change contaminated and foamy coolant with new one as soon as possible.

Cooling water other than long life coolant should be changed two times a year, in spring and autumn.

4— 40

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Expected minimum temperature Long life coolant 30% mixed -14.5˚C (5.9˚F) 50% mixed -34˚C (-29.2˚F)

Section IV – MAINTENANCE 9. Fill radiator with water, open drain valve and drain plug, and clean it flowing water with engine in a low idling state until clean water is flowing out.

Adjust water feeding and draining so as to keep radiator in full condition.

10. After clean water has drained out, stop engine and close drain valve and drain plug. See Figure 4.99.

Fill with "long life coolant" in appropriate concentration.

Refer to pages 4-8.

11. Run engine at low idling for 5 minutes and high idling for 5 minutes to bleed air contaminated in coolant (with cap of radiator removed).

ENGINE DRAIN PLUG

RADIATOR DRAIN VALVE

FIGURE 4.99

ENGINE COOLANT RESERVOIR

12. Drain coolant in reservoir, clean inside of reservoir and fill it up with long life coolant in appropriate concentration to mid point of FULL and LOW. See Figure 4.100.

FU LL

13. Stop engine, fill it with water to the top of radiator about 3 minutes later, and tighten cap.

LOW

PROPER LEVEL

14. Return engine bonnet and access door to the closed position respectively.

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NOTE Total cooling system volume is approximately 19 liters (5.0 Gal).

4— 41

FIGURE 4.100

Section IV – MAINTENANCE B. CHANGE HYDRAULIC OIL HYDRAULIC OIL CHECK POSITION

NOTE The following procedures are to be used for normal changing of the hydraulic oil only.

If necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure or changing main pump, contact your Dealer for assistance.

FIGURE 4.101 DEPRESS RUBBER CAP TO RELEASE PRESSURE

WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW HYDRAULIC OIL TO COOL BEFORE CHANGING. HYDRAULIC TANK

FIGURE 4.102 1. Move the machine to a firm, level surface and place the attachment in the hydraulic oil check position.

See Figure 4.101.

SLOWLY REMOVE BOLTS & COVER

NOTE If machine is cold, warm the hydraulic oil by operating attachment controls before placing machine in the hydraulic oil check position. See Sec. III (page 3-5).

FIGURE 4.103 2. Release hydraulic tank pressure. See Figure 4.102.

Clean area around cover of dirt and debris.

BOLT SPRING WASHER

3. Slowly remove the six retaining bolts from the suction strainer cover plate. See Figure 4.103.

COVER O-RING

4. Remove “O”-ring, and suction strainer from hydraulic tank. See Figure 4.104.

SUCTION STRAINER

NOTE Never spill the hydraulic oil on the ground, that can cause the environmental pollution.

FIGURE 4.104 4— 42

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STAY

Section IV – MAINTENANCE 5. Install special suction stopper, over suction tube inside hydraulic tank. See Figure 4.105.

HYDRAULIC TANK

6. Slowly remove the six retaining bolts from the hydraulic return filter cover plates. See Figure 4.106.

7. Remove “O”-ring, bypass valve and filter from hydraulic tank. See Figure 4.107.

8. Locate the hydraulic drain plug on bottom of hydraulic tank. See Figure 4.108.

SUCTION STOPPER ASSEMBLY

SUCTION TUBE

FIGURE 4.105

9. Place a 125 liter (33 Gal) capacity container under drain plug. Remove plug and allow all oil from hydraulic tank to drain onto container.

SLOWLY REMOVE BOLTS & COVER

10. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank.

11. Replace drain plug and tighten securely.

12. Clean bypass valve, suction strainer and covers using approved solvent and dry thoroughly.

13. Inspect filters and old oil for signs of contamination for troubleshooting purposes.

14. Install new return filters, along with the cleaned bypass valves and springs.

FIGURE 4.106

REMOVE SPRING

NOTE Order element kit, which consists of one filter, and “O”ring seal.

15. Remove suction stopper and clean outside of suction tube with a clean, dry cloth.

REMOVE BYPASS VALVE

REMOVE O-RING

FIGURE 4.107

16. Carefully inspect suction strainer for damage.

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REMOVE HYDRAULIC TANK DRAIN PLUG

FIGURE 4.108 4— 43

Section IV – MAINTENANCE 17. Install strainer assembly onto suction tube.

18. Install new “O”-ring, in cover plate mounting surface groove and install suction strainer cover plate onto hydraulic tank. Make certain plate boss is inside suction strainer holder. See Figure 4.109.

19. Torque retaining bolts to proper value. Refer to specifications section.

9 80

20. Fill hydraulic tank to proper level with fresh, clean hydraulic oil through hydraulic return filter. See Figure 4.110.

m

m

1 (3

.8

˝)

FIGURE 4.109 CAUTION Use same viscosity oil in hydraulic tank as was drained.

Refer to page 4-8 for oil specifications.

BOLT SPRING WASHER

COVER O-RING

SUCTION STRAINER

STAY

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FIGURE 4.110

4— 44

Section IV – MAINTENANCE C. HYDRAULIC TANK BREATHER DEPRESS RUBBER CAP TO RELEASE PRESSURE

1. Release hydraulic tank pressure. See Figure 4.111.

WARNING THE TEMPERATURE OF HYDRAULIC OIL IS HIGH IMMEDIATELY AFTER STOPPING THE OPERATION. SPECIAL ATTENTION MUST BE PAID WHEN RELEASING THE PRESSURE BECAUSE HOT GASES MAY ERUPT.

HYDRAULIC TANK

FIGURE 4.111

2. Remove rubber cap and nut. See Figure 4.112.

RUBBER CAP

3. Remove breather housing. See Figure 4.112.

NUT

FILTER BREATHER HOUSING

FIGURE 4.112

4. Remove old filter, clean mounting surfaces and install new filter. See Figure 4.113.

REMOVE FILTER

5. Install breather housing.

6. Install retaining nut and tighten securely.

Torque : 7.8 ~ 9.8 N·m (5.7 ~ 7.2 lbf·ft) 7. Install rubber cap.

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FIGURE 4.113

4— 45

Section IV – MAINTENANCE D. CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS Change the travel reduction units oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

FILL PLUG

LEVEL PLUG

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

DRAIN PLUG

FIGURE 4.114

1. Move machine to a firm, level surface. Operate travel until “FILL” plugs on travel motors are at top. See Figure 4.114.

2. Stop engine and remove the travel motor reduction unit oil “LEVEL and DRAIN PLUG”. See Figure 4.114.

If oil just seeps from level port, oil level is correct.

CAUTION Travel reduction unit could be under pressure. Slowly remove plug to release any pressurized gas.

3. To add oil, remove the oil fill plug and add extreme pressure gear oil #90 grade GL-4 until oil just begins to flow from level plug.

4. To drain oil, remove “FILL” plug and drain plug. Allow oil to drain into a 4.7 liter (1.2 Gal) capacity container.

Replace drain plug, remove level plug and fill through fill port using extreme pressure gear oil #90 grade GL-4.

NOTE Capacity of each travel motor reduction unit is 4.7 liters (1.2 Gallons).

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5. Replace all plugs and tighten securely.

4— 46

Section IV – MAINTENANCE E. CHANGE OIL IN SWING REDUCTION UNIT Change the swing reduction unit oil on a new machine after the first 500 hours of engine operation then change every 2000 hours.

FILL PLUG

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

DIPSTICK

1. Remove the drain plug on the rear lower side of the swing reduction unit to drain oil to the container. See Figure 4.116.

FIGURE 4.115

2. Clean the drain plug seal it with teflon tape. Install plug and tighten securely.

DRAIN PORT

3. Remove the oil filler plug and fill with extreme pressure gear oil #90 grade GL-4.

4. Using the dipstick, confirm that the extreme pressure gear oil #90 grade GL-4 levels is within the designated range. See Figure 4.115.

5. Clean the fill plug and use teflon tape on plug and install. Tighten it securely.

FIGURE 4.116

NOTE Capacity of each swing reduction unit is 20 liters (5.3 Gallons).

F. CHANGE GREASE IN SLEWING RING GREASE BATH 1. Drain water by removing drain plate located in lower frame cavity. See Figure 4.117.

CAUTION

SUMP BATH DRAIN PLATE

If the slewing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

2. To replace the slewing bath grease it is necessary to remove the upper frame. Contact your Dealer do it. See Figure 4.118.

FIGURE 4.117 CLEAN & FILL WITH MoS2 GREASE

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SUMP BATH GREASE QUANTITIES CHART

GREASE TYPE

E235SR(LC) - E235SRNLC

N.L.G.I.LITHIUM BASE W/MoS2

15.7 kg (34.6 lb) FIGURE 4.118 4— 47

Section IV – MAINTENANCE F . PILOT LINE FILTER When cleaning or replacing the filter, move the control lever several times and release the internal pressure in the pilot line completely.

Prepare an oil pan.

REMOVE BOLTS AND LOWER COVER

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT.

FIGURE 4.119

1. Remove the eight mounting bolts from the control valve lower cover plates. See Figure 4.119.

2. Locate the pilot manifold mounted to the upper frame positioned lower of control valve.

3. Loosen the manifold block case with spanner 24 mm (0.94˝).

ELEMENT O-RING

4. Clean the removed parts and fit new element and O-ring in the case. See Figure 4.120.

CASE

5. After the case is installed on the filter base, tighten it with spanner 24 mm (0.94˝).

FIGURE 4.120

Tightening torque : 24 to 34 N·m (18 to 25 lbf·ft)

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6. Close lower cover.

4— 48

Section IV – MAINTENANCE G. ATTACHMENT & DUST SEALS 1. Bucket Clearance a. Inspect bucket clearance frequently for wear. If clearance between bucket and bucket link and/or between arm and bucket is greater than 1.2 mm (0.05˝) adjust clearance according to following instructions.

CAUTION Set the safety lock lever to the locked position and stop the engine when adjusting the clearance of the bucket.

BUCKET CLEARANCE ADJUSTING MECHANISM

STANDARD CLEARANCE OF THE BUCKET (A)

FIGURE 4.121

1.2 mm (0.05˝) or less

b. Lower the bucket onto the ground to stabilize, as shown in the right figure. See Figure 4.121. c. Move the o-ring (1) from its normal position to the bucket boss. See Figure 4.123. d. Slightly swing in the left direction to slightly push the arm end to the bucket left side (where no clearance adjusting mechanism is equipped).

FIGURE 4.122

e. Set the safety lock lever to the locked position; then stop the engine.

(1)

f . Measure the clearance (A) between the arm and bucket boss. If the measurement value is 1.2 mm (0.05˝) or more, adjust the clearance. g. Five shims (3) 1.0 mm (0.04˝) on the average are inserted in the three capscrews (2) at the clearance adjusting part. Loosen every capscrews (2) and remove shims (3) corresponding the clearance.

See Figure 4.124.

BUCKET BOSS

FIGURE 4.123

h. Tighten the capscrews equally to the specified tightening torque.

(3)

Tightening torque : 275 ± 28 N·m (202 ± 20 lbf·ft)

(1) (A)

i . Return the o-ring to the normal position.

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(2)

FIGURE 4.124 4— 49

Section IV – MAINTENANCE 2. Reversing Backhoe Bucket a. Move the machine to a firm, level surface and rest the bucket on the ground, making certain the bucket is stable. See Figure 4.124A.

FIGURE 4.124A b. Roll “O”-rings onto bucket boss. See Figure 4.124B. FLEXIBLE RING AND PINS

c. Remove flexible ring and pin, and also remove bucket pin and link pin. See Figure 4.124C.

NOTE You may have to start the engine and slightly operate the boom and arm to remove load from pins.

ROLL "O"-RINGS ONTO BUCKET BOSS

FIGURE 4.124B d. Clean pins and pin hole, and apply grease on it. e. Carefully remove main pins mounting arm and bucket link to bucket f . Rotate bucket 180° or move machine, install arm and bucket link in their respective positions. See Figure 4.124D.

FLEXIBLE RING AND PIN

NOTE Make certain “O”-rings are on bucket boss for reinstallation.

FIGURE 4.124C g. Roll “O”-rings into grooves between bucket/arm and bucket/bucket link.

BUCKET LINK HERE

h. Align each pin holes, insert bucket pin, and fit flexible ring and pin.

FIGURE 4.124D 4— 50

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ARM HERE

NOTE Inspect “O”-rings for damage or excessive wear. If worn or damaged replace with new parts to protect seals, pins and surfaces from dirt and debris which can cause premature failure.

Section IV – MAINTENANCE 3. Dust Seals LOCATION OF ATTACHMENT SEALS

a. The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear. See Figure 4.125. b. If excessive wear or damage is found remove seal and replace with new parts.

8

1

8

7 2

5

5

6

3 NOTE Order the following part numbers for replacement seals:

4

9

1. BOOM FOOT (2 Req’d) FIGURE 4.125

2. ARM to BOOM (2 Req’d) 3. ARM to IDLER LINK (2 Req’d) 4. BKT CYLINDER to BKT LINK (4 Req’d) 5. ARM to BUCKET (2 Req’d)

LIP OUT

6. BOOM CYLINDER HEAD (4 Req’d) 7. BOOM CYLINDER ROD (4 Req’d) 8. ARM CYLINDER HEAD AND ROD (4 Req’d)

BOSS

9. BKT CYLINDER HEAD AND ROD (4 Req’d) c. Install replacement seals as shown in Figure 4.126. d. Make certain pin surface and tapered end are smooth and free from all burrs or imperfections.

Rough pin surfaces can cause damage to the new seals.

BUSHING SEAL

FIGURE 4.126

H. WINDSHIELD WASHER RESERVOIR Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

OPEN ENGINE RADIATOR ACCESS DOOR

1. Open engine radiator access door to locate washer fluid reservoir. See Figure 4.127.

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2. Pull cap off and fill with proper windshield washing fluid.

WINDSHIELD WASHER RESERVOIR CAP

3. Replace cap and reposition engine radiator access door.

FIGURE 4.127 4— 51

Section IV – MAINTENANCE

4.12 MISCELLANEOUS A. FUSES Follow the procedures below to replace “blown” or faulty fuses.

1. Move seat and seat base completely forward.

2. Remove fuse box cover from fuse box. See Figure 4.128.

FUSE BOX

3. Locate and remove faulty fuse. Replace fuse with same amperage fuse as removed.

WARNING

FIGURE 4.128

NEVER REPLACE A FAULTY FUSE WITH A HIGHER AMP FUSE. NEVER USE A “JUMPER” IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS.

12

11 20 20 10 10

20 10 10

20

19 10

10

20

20

20

17

10

18

10

4. Refer to fuse box cover or Figure 4.129 for fuse amperage and their functions.

15

10

16

20

13 14

20

1

10

2

20

NOTE When ordering replacement fuses, order the following part numbers: 10 AMP 20 AMP

3 4 6

10

5

7 8 9 FIGURE 4.129

EU SPEC. FUNCTION Mechatro Controller (CPU) Wiper, washer Relay Cigarette Lighter 24V DC to DC Converter Horn None Controller (Back Up) Fuel Supply Pump DC to DC Converter, Dome Lamp Starter Switch Fuel Pump, Cab Working Light Swing Flasher Gauge Cluster Wiper, Washer Solenoid Valve (Lever Lock) Working Light Resistor Heater, Air Conditioner Air Conditioner Spare 24V

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No. AMPS 20 A 1 10 A 2 10 A 3 10 A 4 10 A 5 6 NONE 10 A 7 20 A 8 10 A 9 20 A 10 20 A 11 10 A 12 10 A 13 20 A 14 10 A 15 20 A 16 10 A 17 20 A 18 10 A 19 20 A 20

4— 52

Section IV – MAINTENANCE B. TOWING THE MACHINE Where you cannot get the machine out of soft soil, place with slings as shown on the right and pull it by an other machine. Always place wire slings around the frame section and put pads between the wire and the frame on each corner to prevent the wire slings from being damaged. See Figure 4.130.

NOTE Do not pull the machine utilizing the brackets welded on the lower plates of the car body. These brackets are provided for pulling lightweight objects.

C. PERIODICAL INSPECTION ITEMS Since there is no definite time table for the replacement of hydraulic lines, tubes and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes and hoses with new parts. Refer to the parts manual for correct part numbers when ordering.

FIGURE 4.130

WARNING DO NOT BEND, STRIKE OR DAMAGE HIGH PRESSURE LINES. DO NOT INSTALL BENT OR DAMAGED LINES, TUBES OR HOSES. REPLACE ALL DAMAGED LINES, TUBES AND HOSES IMMEDIATELY. TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONS TO THE PROPER TORQUE VALUE. CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELY TO HELP PREVENT FIRES. NEVER USE HANDS TO CHECK FOR LEAKS. CAREFULLY INSPECT ALL LINES, TUBES AND HOSES FOR: 1. FITTINGS & CONNECTIONS DAMAGED OR LEAKING. 2. OUTER COVERING OF HOSES WORN, CUT OR DAMAGED EXPOSING WIRE REINFORCEMENT. 3. HOSE SWELLING OR “BALLOONING”.

4. EVIDENCE OF HOSE BEING KINKED OR COLLAPSED. 5. STEEL PROTECTIVE COVERING WORN OR DAMAGED. 6. LOOSE FITTINGS AND CONNECTIONS. MAKE CERTAIN ALL CLAMPS, GUARDS AND HEAT SHIELDS ARE IN PLACE AND SECURE. THIS WILL HELP PREVENT VIBRATION, EXCESSIVE WEAR OF COMPONENTS AND EXCESSIVE HEAT DURING OPERATION.

HEATER HOSES

FIGURE 4.131

BOOM HOSES AND TUBES

FIGURE 4.132

1. Heater Hoses Inspect the heater hoses between heater and engine for signs of damage and wear. See Figure 4.131.

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2. Boom Hoses & Tubes Inspect boom head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.132.

3. Arm Hoses & Tubes Inspect arm head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.133.

FIGURE 4.133 4— 53

Section IV – MAINTENANCE 4. Bucket Hoses & Tubes Inspect bucket head and rod hoses and tubes for damage, wear and loose connections. See Figure 4.134.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

FIGURE 4.134 6. Hydraulic Suction Tubes & Hoses Inspect all hydraulic tubes and hoses for damage, wear and loose connections. See Figure 4.135.

USE CARDBOAD TO CHECK FOR PRESSURE LEAKS

FIGURE 4.135 7. Radiator Hoses & Cap Inspect the radiator hoses for signs of damage or deterioration. Replace hoses if found to be in bad condition. Inspect the radiator cap seal for signs of damage and deterioration and replace with new part if found to be in bad condition. See Figure 4.136.

FIGURE 4.136 8. Foam Seals Inspect the foam rubber seals around the radiator, oil cooler and on the engine cover. Make certain they are in place and secure to prevent overheating of the engine. See Figure 4.137.

FIGURE 4.137 4— 54

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FOAM SEALS

Section IV – MAINTENANCE 9. Fuel Filler Strainer (with float) Inspect the fuel filler strainer beneath fuel filler cap for damage, dirt and debris. Make certain the strainer is clean and in place before fueling the machine.

See Figure 4.138. If the strainer is damaged, replace with a new part.

FUEL FILLER STRAINER

NOTE Do not remove this strainer to refuel machine. To do so may allow dirt and debris to enter fuel tank.

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FIGURE 4.138

4— 55

Section IV – MAINTENANCE D. MACHINE STORAGE Perform the following procedure to prepare the machine for long term storage.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank.

1. Perform all inspection and maintenance procedures as previously described in this section.

4. Move machine to an indoor location for storage.

5. Operate bucket and arm completely “IN” extending cylinders. Then lower boom until attachment is resting on the floor. See Figure 4.139.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage.

CAUTION Protect CPU and all electrical components from water and steam when cleaning the machine.

7. Remove batteries and store in a well ventilated, warm area.

POSITION MACHINE AS SHOWN INSIDE A STORAGE BUILDING

HEAVILY GREASE ALL CYLINDER RODS TO PREVENT CORROSION

FIGURE 4.139

E. CARE DURING STORAGE

F. REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in this section before bringing machine out of storage for normal operation.

1. Every 30 days during storage, it will be necessary to start and run the machine to circulate the fluids through the systems. Before starting clean cylinder rods and after running re-grease cylinder rods.

NOTE Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

3. Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of deterioration. Replace all hoses showing these signs.

4— 56

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2. Remove drain èplugs from travel motor and slewing gear reduction units to drain off any moisture which may have accumulated during storage.

Section V – TRANSPORTATION

Table of Contents GROUND TRANSPORTATION .................................................................................................................... 5-1 ~ 5-3 Machine Preparation .............................................................................................................................. 5-1 Loading the Machine ............................................................................................................................. 5-2 Securing Machine to Trailer .................................................................................................................. 5-3 LIFTING MACHINE ...................................................................................................................................... 5-4 ~ 5-5 LIFTING MACHINE (WITHOUT ATTACHMENT) ......................................................................................... 5-6 ~ 5-7 OVERALL SPECIFICATIONS OF BOOM .................................................................................................... 5-8

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OVERALL SPECIFICATIONS OF ARM ........................................................................................................ 5-8

5— 0

Section V – TRANSPORTATION

5.1 GROUND TRANSPORTATION

3. Obtain any permits required from proper government agencies for transport of machine.

A. MACHINE PREPARATION

4. Use only a trailer with a rated capacity sufficient to transport the machine.

1. Know the total weight, length, width and height of the machine being transported. See Figure 5.1 & 5.2.

5. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

2. Know route to be traveled. Investigate bridges, overpasses, trusses and traffic flow on route.

700 mm (2'-4")

100 mm (3.9ý) (3.9")

Dimensions and weights are with 2.94 m (9'-8") arm, 0.80 m3 (1.05 cu yd) bucket and 5.65 m (18'-6") boom.

MACHINE MODEL E235SR E235SRLC E235SRNLC

3790mm (12'-5")

3390mm (11'-1")

3090mm (10'-2")

8300mm (27'-3")

WEIGHT 600 mm SHOE 23,500 kg (51,820 lb) 24,000 kg (52,920 lb) 23,900 kg (52,700 lb)

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FIGURE 5.1

5— 1

Section V – TRANSPORTATION B. LOADING THE MACHINE THROTTLE CONTROL

TRAVEL SPEED SELECT SWITCH

WARNING

LO

HI

NEVER ATTEMPT TO LOAD OR UNLOAD MACHINE WITHOUT RAMPS. NEVER USE ATTACHMENT AS AN AID IN LOADING OR UNLOADING THE MACHINE. FIGURE 5.2

1. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine.

2. Lower ramps of trailer.

3. Place travel speed select switch on travel lever in 1st ( ) speed position and move throttle control to the “LO” idle position. See Figure 5.2.

4. Slowly travel machine up trailer ramps and over rear axles of trailer.

WARNING TO PREVENT THE ARM AND BUCKET CYLINDER(S) FROM ANY DAMAGE, YOU ARE ADVISED TO FOLLOW THE FOLLOWING INSTRUCTIONS. DO NOT HAVE THE ARM AND/OR BUCKET CYLINDER FULLY EXTENDED TO A “RAMP OVER CENTER” SITUATION. THIS ALLOWS SUDDEN AND ABRUPT CONTACT OF THE ARM OR BUCKET TO A TRAILER DECK, RAMP OR THE GROUND. THIS CAN RESULT IN INTERNAL MECHANICAL CONTACT, WHICH CAN STRETCH THE CYLINDER ROD(S).

FIGURE 5.3

5. Slowly travel machine completely onto trailer until in proper transport position.

SAFETY LOCK LEVER IN LOCKED (UP) POSITION

6. Slowly swing machine 180° until attachment is toward rear of trailer.

7. Slowly lower boom until attachment rests on trailer bed.

8. Place safety lock lever in the up “LOCKED” position.

See Figure 5.4.

FIGURE 5.4

9. Turn machine “OFF”, remove key and lock all doors, filler caps and access panels.

CAUTION 13503 60421091

Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

5— 2

Section V – TRANSPORTATION C. SECURING MACHINE TO TRAILER

SECURE FRONT & REAR OF EACH TRACK

1. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. See Figure 5.5. Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer. Also, make sure to secure front and rear of each track.

2. Securely fasten all loose parts, as well as removed parts to trailer or transporting platform.

SECURE ATTACHMENT

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FIGURE 5.5

5— 3

Section V – TRANSPORTATION

5.2 LIFTING MACHINE

4. Slowly lift and move machine to desired location.

The following procedures are for lifting the machine.

These procedure do not take into account modifications made to the machine that affect machine weight or center of gravity.

WARNING ALWAYS USE PROPER LIFTING EQUIPMENT AND DEVICES. USE OF IMPROPER LIFTING EQUIPMENT COULD ALLOW THE LOAD TO SHIFT OR FALL CAUSING SEVERE DAMAGE, SERIOUS INJURY OR DEATH.

1. Locate lifting locations at the front and rear of each crawler frame. See Figure 5.6 to 5.8.

2. Attach cables or wire rope with a capacity rating sufficient to lift the machine, at lifting locations.

WARNING

CAUTION Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting. See Figure 5.6 to 5.8.

DO NOT USE COUNTERWEIGHT LIFTING EYES TO LIFT WHOLE MACHINE. LIFTING EYES CAN FALL UNDER THIS LOAD RESULTING IN PERSONAL INJURY.

3. Bring loose ends of cables together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine. See Figure 5.7 to 5.10.

REFER TO OPERATOR’S MANUAL FOR PROPER WAY OF LIFTING MACHINE.

TOOLS NOTE It may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting. See Figure 5.6 to 5.8.

ITEM

SIZE

Q'TY

CABLE (A)

Ø35.5 X 14.9 m

1

CABLE (B)

Ø35.5 X 15.0 m

1

3.84 m

2

(A)

(1 0˚ )

(B)

(14

˚)

(44˚)

(44˚)

3,840 mm (12'-7")

3,400 mm (11'-2")

CENTER OF GRAVITY

(C)

678 mm (26.7")

147 mm (5.8")

644 mm (25.4")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.6

5— 4

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WEIGHT: 23,500 kg (51,820 lb) ARM : 2.94 m (9'-8") SHOE : 600 mm (23.6") MODEL : E235SR

2,000 mm (6'-7")

SPREADER BARS (C)

Section V – TRANSPORTATION TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(A)

(B)

(1 1˚ )

2,500 mm (8'-2")

WEIGHT : 26,000 kg (57,330 lb) ARM : 2.94 m (9'-8") SHOE : 800 mm (31.5") MODEL : E235SRLC

˚)

(14

3,400 mm (11'-2")

CENTER OF GRAVITY

710 mm (27.9")

143 mm (5.7")

675 mm (26.6")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

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FIGURE 5.7

5— 5

Q'TY 1 1 2

SIZE Ø35.5 X 16.8 m Ø35.5 X 17.0 m 4.72 m

(C) (4 3˚)

(4 3˚)

4,720 mm (15'-6")

Section V – TRANSPORTATION

5.3 LIFTING MACHINE (WITHOUT ATTACHMENT)

TOOLS ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(A)

(B)

(1 6˚

)

(8˚

)

Q'TY 1 1 2

SIZE Ø35.5 X 15.1 m Ø35.5 X 14.8 m 3.84 m

(C) (44˚)

(44˚)

3,840 mm (12'-7")

3,400 mm (11'-2")

WEIGHT : 20,100 kg (44,320 lb) SHOE : 600 mm (23.6") MODEL : E235SR

2,000 mm (6'-7")

Lift up machine without attachment is the procedure described below. See Figure 5.8 to 5.9.

CENTER OF GRAVITY

678 mm (26.7")

644 mm (25.4")

400 mm (15.7")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.8 TOOLS

ITEM CABLE (A) CABLE (B) SPREADER BARS (C)

(16 ˚)

(A)

( 9˚ )

2,500 mm (8'-2")

WEIGHT : 22,700 kg (50,050 lb) SHOE : 800 mm (31.5") MODEL : E235SRLC

(B)

SIZE Ø35.5 X 17.2 m Ø35.5 X 16.7 m 4.72 m

Q'TY 1 1 2

(C) (4 3˚)

(4 3˚)

4,720 mm (15'-6")

3,400 mm (11'-2")

CENTER OF GRAVITY

381 mm (15")

675 mm (26.6")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.9 5— 6

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710 mm (27.9")

Section V – TRANSPORTATION

5.4 OVERALL SPECIFICATIONS OF BOOM 5.65 m (18'-6")

Total length X Total height X Total width L X H X W mm (ft-in)

5,850 X 1,560 X 680 (19'-2" X 5'-1" X 2'-3")

Weight w/Arm Cylinder kg (lb)

2,280 (5,030)

H

Boom

L

5.5 OVERALL SPECIFICATIONS OF ARM 2.4 m (7'-10")

2.94 m (9'-8")

3.33 m (10'-10")

Total length X Total height X Total width L X H X W mm (ft-in)

3,360 X 800 X 540 (11'-0" X 2'-7" X 1'-9")

3,900 X 800 X 540 (12'-10" X 2'-7" X 1'-9")

4,350 X 800 X 540 (14'-3" X 2'-7" X 1'-9")

Weight w/Bucket Cylinder kg (lb)

910 (2,010)

990 (2,180)

1,050 (2,315)

H

Arm

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L

5— 7

Section V – TRANSPORTATION

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NOTES:

5— 8

Section VI – SPECIFICATIONS

Table of Contents GENERAL SPECIFICATIONS ...................................................................................................................... 6-1 ~ 6-38 Machine Dimensions ............................................................................................................................. 6-1 Working Weighst .................................................................................................................................... 6-2 Working Ranges ..................................................................................................................................... 6-2 Boom ....................................................................................................................................................... 6-3 Arm .......................................................................................................................................................... 6-3 Bucket ..................................................................................................................................................... 6-3 Shoes ...................................................................................................................................................... 6-3 Performance Specifications .................................................................................................................. 6-4 Travel speed ...................................................................................................................................... 6-4 Swing speed ...................................................................................................................................... 6-4 Gradeability ....................................................................................................................................... 6-4 Swing torque ..................................................................................................................................... 6-4 Engine ................................................................................................................................................ 6-4 Hydraulic components ..................................................................................................................... 6-4 Digging forces ................................................................................................................................... 6-4 Machine and Components Weights ...................................................................................................... 6-4 Lifting Capacities ................................................................................................................................... 6-5 ~ 6-20 Lifting Capacities (Heavy Lift Versions) .............................................................................................. 6-21 ~ 6-36 OPTIONAL ATTACHMENTS SPECIFICATIONS ......................................................................................... 6-37 ~ 6-38 Working Ranges ..................................................................................................................................... 6-37 ~ 6-38 Bucket & Arm Combinations ................................................................................................................ 6-38 TORQUE SPECIFICATIONS ........................................................................................................................ 6-39 ~ 6-41 Capscrews & Nuts ................................................................................................................................. 6-40 Nuts & Sleeves ....................................................................................................................................... 6-40 Flare Type Fitting Joints ........................................................................................................................ 6-40 Nylon Tube Fitting Joints ...................................................................................................................... 6-40 ORS Joints .............................................................................................................................................. 6-40 Torque Values for Most Common Bolts ............................................................................................... 6-41 MISCELLANEOUS INFORMATION ............................................................................................................. 6-42 Temperature Table ................................................................................................................................. 6-42 Special Pipe Wrenches .......................................................................................................................... 6-42 Weight of Materials Table ...................................................................................................................... 6-42 Caps and Plugs for Tubes and Hose Fittings ...................................................................................... 6-42

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WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

6— 0

Section VI – SPECIFICATIONS

6.1 GENERAL SPECIFICATIONS

A. MACHINE DIMENSIONS – FIGURE 6.1 These dimensions consider the following:

The specifications found in this section are given on the standard E235SR(LC), E235SRNLC hydraulic excavator. No modifications or options are taken into consideration in regard to these specifications.

a. Standard boom ....... 5.65 meter (18´-6”) b. Standard arm .......... 2.94 meter (9´-8”) c. Bucket ..................... 0.80 m3 (1.05 cu yd) d. Standard shoe ......... 600 mm (23.6”)

4260mm (14')-STD 4655mm (15'-3")-LC,NLC 8695mm (28'-6")-STD / 8890mm (29'-2")-LC,NLC

* Marked dimensions are not included height of shoe lug.

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FIGURE 6.1

6— 1

*455 mm (18")

3090mm (10'-2")

3000mm (9'-10")

*1065mm (3'-6") 2300mm (7'-7")

2955mm (9'-8")

R1680mm (5'-6")

600mm (23.6") 2990mm (9'-10")-STD,NLC 3190mm (10'-6")-LC

Section VI – SPECIFICATIONS B. WORKING WEIGHTS

Standard E235SRLC 2.94 m (9'-8") Arm and 0.8 m3 (1.05 cu yd) Bucket TRIPLE GROUSER SHOES TRACK SHOE WIDTH

mm (in)

600 (23.6")

700 (27.6")

800 (31.5")

OVERALL WIDTH

m (ft-in)

3,190 (10'-6")

3,290 (10'-10")

3,390 (11'-1")

GROUND PRESSURE

kPa (kgf/cm2)

47.5 (0.48)

41.2 (0.42)

36.5 (0.37)

WORKING WEIGHT

kg (lb)

24,000 (52,920)

24,300 (53,580)

24,600 (54,240)

Bucket weight : 650 kg (1,430 lb) Standard E235SRNLC 2.94 m (9'-8") Arm and 0.8 m3 (1.05 cu yd) Bucket TRIPLE GROUSER SHOES TRACK SHOE WIDTH

mm (in)

600 (23.6")

700 (27.6")

800 (31.5")

OVERALL WIDTH

m (ft-in)

2990 mm(9'-10")

3,090 (10'-2")

3,190 (10'-6")

GROUND PRESSURE

kPa (kgf/cm2)

47.4 (0.48)

41.1 (0.42)

36.4 (0.37)

WORKING WEIGHT

kg (lb)

23,900 (52,700)

24,200 (53,360)

24,500 (54,020)

Bucket weight : 650 kg (1,430 lb)

C. WORKING RANGES – FIGURE 6.3 Standard attachment working ranges:

A B H

a. Boom ................................... 5.65 meter (18´-6˝) b. Arm ..................................... 2.94 meter (9´-8˝)

E

D

c. Bucket SAE heaped ........................ 0.8 m3 (1.05 cu yd) Struck .................................. 0.59 m3 (0.77 cu yd) Width with side cutters ........ 1,160 mm (3´-10˝) Width without side cutters ... 1,050 mm (3´-5˝) Weight ................................. 650 kg (1,430 lb) ft-in

A

Maximum digging reach

9,850 32´- 4˝

B

Maximum digging reach at ground

9,660 31´- 8˝

C

Maximum digging depth

6,700 22´- 0˝

D

Maximum digging height

11,290 37´- 0˝

E

Maximum dumping clearance

8,420 27´- 7˝

F

Minimum dumping clearance

3,220 10´- 7˝

G

Max. vertical wall digging depth

6,060 19´- 11˝

H

Minimum swing radius

1,900 6´- 3˝

FIGURE 6.3

6— 2

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mm

F

FUNCTION

C G

ITEM

Section VI – SPECIFICATIONS

C

D. BOOM – FIGURE 6.3 Standard boom is 5.65 m (18´-6˝) A - Length is 5.65 m (18´-6˝) Center line to center line of pins.

ARM CYLINDER BOSS

B

B - Height is 1,182 mm (46.5˝) From centerline of boom end to centerline of arm cylinder boss.

C - Width is 670 mm (26.4˝) From edge to edge of boom foot.

GROUND LEVEL A

Weight - Approximately 1,295 kg (2,850 lb) FIGURE 6.3 E. ARM – FIGURE 6.4 Standard arm is 2.94 m (9´-8˝) B

A - Length is 2.94 m (9´-8˝) Center line to center line of pins.

B - Width is 325 mm (12.8˝) From edge to edge of arm end.

Weight - Approximately 610 kg (1,340 lb)

A

FIGURE 6.4 F. BUCKET – FIGURE 6.5 Standard bucket is 0.8 m3 (1.05 cu yd)

B

A - Length is 1.37 m (4´-6˝) B - Height is 1.26 m (4´-2˝) C - Width without side cutters is 1,050 mm (3´-5˝) D - Width with side cutters is 1,160 mm (3´-10˝) E - Bucket weight is 650 kg (1,430 lb) A

C D FIGURE 6.5

G. SHOES – FIGURE 6.6 1. Standard shoes for the E235SR(LC) and E235SRNLC are 600 mm (23.6˝) triple grouser.

2. Quantity of shoes ; E235SR ..................... 47 per track E235SR(N)LC ................ 51 per track

13503 60421091

TRIPLE GROUSER SHOE

FIGURE 6.6 6— 3

Section VI – SPECIFICATIONS G. PERFORMANCE SPECIFICATIONS The following performance specifications are based on the standard machine with standard attachment.

H. MACHINE AND COMPONENT WEIGHTS The following weight specifications are based on the standard machine with standard attachment.

1. Travel speed, swing speed, gradeability & swing torque

1. Component weight

DESCRIPTION

SPECIFICATION 5.3 km per hr (3.3 mph) in mode.

TRAVEL SPEED 3.3 km per hr (2.1 mph) in mode.

SWING SPEED 11 RPM in M-Mode / "HI" idle.

GRADEABILITY 70 % (35°) SWING TORQUE 79 kN

E235SR

E235SR(N)LC

24,000 (52,920) COMPLETE MACHINE (STANDARD) 23,500 (51,820) 23,900 (52,700)-NLC UPPER FRAME ASSEMBLY 11,500 (25,360) 11,500 (25,360) Counterweight

5,900 (13,010)

Cab

2. Engine Major engine specifications

5,900 (13,010)

200 (441)

200 (441)

Boom Cylinder*

250 (551) X 2

250 (551) X 2

Engine*

480 (1,060)

480 (1,060)

Radiator & Oil Cooler

70 (154)

70 (154)

Mitsubishi

Pump Assembly

127 (280)

127 (280)

6D34-TLU2D

Control valve

165 (360)

165 (360)

4-cycle, water cooled, direct injection with intercooler turbocharger, diesel

Fuel Tank*

130 (287)

130 (287)

Hydraulic Tank*

135 (298)

135 (298)

Swing Motor & Reduction Unit

310 (684)

Model

Number of cylinders-Bore X Stroke 6-104 mm X 115 mm (4.09˝ X 4.53˝) Displacement

5.8 liter (358 cu in.)

Compression ratio

110 kW / 2,000 min-1

Maximum torque

580 N•m / 1,500 min-1

Slewing ring Travel Motor & Reductin Unit

300 (662) X 2

300 (662) X 2

Idler Assembly

106 (234) X 2

106 (234) X 2

LOWER FRAME ASSEMBLY

18.2

Output rating

310 (684) 8,700 (19,184) 8,200 (18,081) 8,600 (18,963)-NLC 370 (816) 370 (816)

Ignition order

1 - 5 - 3 - 6 - 2 - 4 clockwise rotation

Lower Roller Assembly

35 (77) X 16

35 (77) X 18

Injection timing

14° Before Top Dead Center

Upper Roller Assembly

22 (48) X 4

22 (48) X 4

Intake valve clearance cold

0.4 mm (0.0157˝)

Track Tension Assembly

150 (331) X 2

150 (331) X 2

Exhaust valve clearance cold

0.4 mm (0. 0157˝)

Sprocket

54 (120) X 2

54 (120) X 2

Electrical system

D.C. 24V

Swivel Joint

30 (66)

30 (66)

Starting motor

24 V – 5.0 kW

Alternator

24 V – 35 A

Batteries

Track Link w/600mm (23.6˝) Shoes 1,370 (3,021) X 2 1,490 (3,285) X 2

2 - 12 V (130E41R)

Engine dry weight*

480 kg (1,060 lb) Wax type thermostat (bottom by-pass type)

Thermostat Cooling fan drive method

Ø600 (Ø24˝) suction type, belt drive, pulley ratio : 1.00

Air cleaner

Dry type with safety elements

520 (1,147) X 2

570 (1,257) X 2

3,300 (7,280)

3,300 (7,280)

Bucket Assembly [0.80m3 (1.05cu yd)]

655 (1,444)

655 (1,444)

Arm Assembly [2.94m (9´-8˝)]

990 (2,180)

990 (2,180)

Arm [2.94m (9´-8˝)]

610 (1,340)

610 (1,340)

Bucket cylinder*

148 (326)

148 (326)

Idler link

21 (46) X 2

21 (46) X 2

Bucket link

90 (198)

90 (190)

Pin (2pcs for mtg bucket cyl. & bucket)

97 (214)

97 (214)

1,700 (3,749)

1,700 (3,749)

1,400 (3,087)

1,400 (3,087)

250 (550)

250 (550)

Track Link ATTACHMENT (STANDARD)

*Less flywheel and electrics.

Boom Assembly

3. Hydraulic components COMPONENT

Boom

TYPE

Arm cylinder*

Parallel, variable displacement, axial piston with pilot gear pump

40 (88)

40 (88)

FLUIDS

490 (1,080)

490 (1,080)

Swing Motor

Axial piston

Hyd Oil

200 (441)

200 (441)

Travel Motor

Axial piston

Eng Oil

24 (53)

24 (53)

Control Valves

6 spool multiple control

Fuel

250 (551)

250 (551)

Cylinders (all)

Double acting

Water

20 (44)

20 (44)

Return Filter

Safety valve containing filter type

Oil Cooler

Air cooled

Hydraulic Pumps

Pin (mounting the arm)

*Dry weight.

WARNING

4. Digging forces COMPONENT Arm length

USE ONLY LIFTING DEVICES AND EQUIPMENT WITH RATED CAPACITIES SUFFICIENT TO LIFT THE SPECIFIC COMPONENT(S) BEING REMOVED OR INSTALLED.

TYPE 2.98 m (9´-9˝)

Bucket digging force

128 / *141 kN

Arm crowding force

93.9 / *103 kN *Power boost engaged.

6— 4

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Engine maker

Type

Unit : kg (lb)

COMPONENT

Section VI – SPECIFICATIONS

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I . LIFTING CAPACITIES

6— 5

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6— 6

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Section VI – SPECIFICATIONS

6.2 OPTIONAL ATTACHMENTS SPECIFICATIONS

A B H

A. WORKING RANGES – FIGURE 6.8 1. Attachment with: a. Boom ................................... 5.65 meter (18´-6˝) b. Arm ..................................... 3.33 meter (10´-11˝)

F

E

D

c. Bucket SAE heaped ........................ 0.68 m3 (0.89 cu yd) Struck .................................. 0.51 m3 (0.67 cu yd) Width with side cutters ........ 1,070 mm (3´-6˝) Width without side cutters ... 970 mm (3´-2˝) Weight ................................. 620 kg (1,370 lb) FUNCTION

A

Maximum digging reach

mm

ft-in SAE

10,210 33´-6˝

B

Maximum digging reach at ground 10,030 32´-11˝

C

Maximum digging depth

7,100 23´-4˝

D

Maximum digging height

11,590 38´-0˝

E

Maximum dumping clearance

8,690 28´-6˝

F

Minimum dumping clearance

2,980 9´-9˝

G

Max. vertical wall digging depth

6,480 21´-3˝

H

Minimum swing radius

2,450 8´-0˝

C G

ITEM

13503 60421091

FIGURE 6.8

6— 37

Section VI – SPECIFICATIONS B . WORKING RANGES - FIGURE 6.9

A B

2.Attachment with:

H

a. Boom ................................... 5.65 meter (18´-6˝) b. Arm ..................................... 2.4 meter (7´-10˝)

E

D

c. Bucket SAE heaped ........................ 0.93 m3 (1.22 cu yd) Struck .................................. 0.67 m3 (0.88 cu yd) Width with side cutters ........ 1,330 mm (4´-4˝) Width without side cutters ... 1,230 mm (4´-0˝) Weight ................................. 710 kg (1,570 lb) mm

ft-in SAE

A

Maximum digging reach

9,370 30´-9˝

B

Maximum digging reach at ground

9,170 30´-1˝

C

Maximum digging depth

6,160 20´-3˝

D

Maximum digging height

10,890 35´-9˝

E

Maximum dumping clearance

8,030 26´-4˝

F

Minimum dumping clearance

3,870 12´-8˝

G

Max. vertical wall digging depth

5,520 18´-1˝

H

Minimum swing radius

2,160 7´-1˝

F

FUNCTION

C G

ITEM

FIGURE 6.9

C. BUCKET AND ARM COMBINATIONS BUCKET m3 (cu yd)

ARM

SAE (JIS) (HEAPED)

SAE (JIS) (STRUCK)

2.94 m (9´-8˝)

3.33 m (10´-11˝)

0.51 (0.67)

0.39 (0.51)

·····

0.70 (0.92)

0.52 (0.68)

·····

0.80 (1.05)

0.59 (0.77)

HD 0.80 (1.05)

0.59 (0.77)

0.93 (1.22)

0.67 (0.88)

Normal working Standard · · · · · Light duty only · · · · · Do not use this combination

13503 60421091

2.4 m (7´-10˝)

6— 38

Section VI – SPECIFICATIONS

6.3 TORQUE SPECIFICATIONS The following torque specifications are provided for use when actual torque value of a fastener is not known.

A. CAPSCREWS AND NUTS 1. Metric coarse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values. a N · m(lbf·ft) Torque value unit - dkgf·m Classification

4.8 T

7T

10.9 T

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 1.77 ± 0.18 1.5 ± 0.15 0.98 ± 0.1 0.38 ± 0.04 0.83 ± 0.08 0.45 ± 0.05 M6 P=1 (12.8 ± 1.3) (10.8 ± 1.1) (7.1 ± 0.7) (2.7 ± 0.3) (6.0 ± 0.6) (3.2 ± 0.4) 4.3 ± 0.4 3.6 ± 0.4 2.4 ± 0.2 0.92 ± 0.09 2.0 ± 0.2 1.09 ± 0.11 M8 P=1.25 (31.0 ± 2.9) (26.0 ± 2.9) (17.3 ± 1.4) (6.6 ± 0.7) (14.4 ± 1.4) (7.9 ± 0.8) 8.5 ± 0.9 7.2 ± 0.7 4.7 ± 0.5 1.83 ± 0.18 4.0 ± 0.4 2.2 ± 0.2 M10 P=1.5 (61.3 ± 6.5) (52.0 ± 5.1) (33.9 ± 3.6) (13.2 ± 1.3) (28.9 ± 2.9) (15.9 ± 1.4) 14.6 ± 1.5 12.3 ± 1.2 8.1 ± 0.8 3.2 ± 0.3 6.8 ± 0.7 3.7 ± 0.4 M12 P=1.75 (105 ± 10.8) (88.8 ± 8.7) (58.5 ± 5.8) (23.1 ± 2.2) (49.1 ± 5.1) (26.7 ± 2.9) 23 ± 2 19.5 ± 1.9 12.8 ± 1.3 5.0 ± 0.5 10.8 ± 1.1 5.9 ± 0.6 M14 P=2 (166 ± 14) (140 ± 14) (92.5 ± 9.4) (36.1 ± 3.6) (78.0 ± 7.9) (42.6 ± 4.3) 35 ± 4 29 ± 3 19.5 ± 2.0 7.6 ± 0.7 16.4 ± 1.6 9.0 ± 0.9 M16 P=2 (252 ± 28.9) (209 ± 21.6) (140 ± 14.4) (54.8 ± 5.1) (118 ± 11.5) (64.9 ± 6.5) 49 ± 5 41 ± 4 27 ± 3 10.5 ± 1.0 23 ± 2 12.4 ± 1.2 M18 P=2.5 (354 ± 36) (296 ± 29) (195 ± 22) (75.8 ± 7.2) (166 ± 14) (89.6 ± 8.7) 68 ± 7 57 ± 6 38 ± 4 14.7 ± 1.4 32 ± 3 17.5 ± 1.7 M20 P=2.5 (491 ± 51) (412 ± 43) (274 ± 29) (106 ± 10.1) (231 ± 22) (126 ± 12.3) 92 ± 9 77 ± 7 51 ± 5 19.6 ± 2.0 43 ± 4 23 ± 2 M22 P=2.5 (663 ± 65) (555 ± 58) (368 ± 36) (142 ± 14) (310 ± 29) (166 ± 14) 118 ± 12 96 ± 10 65 ± 7 24 ± 3 53 ± 5 30 ± 3 M24 P=3 (852 ± 87) (693 ± 72) (469 ± 51) (173 ± 22) (383 ± 36) (217 ± 22) 173 ± 17 140 ± 14 96 ± 10 36 ± 3 78 ± 8 44 ± 4 M27 P=3 (1250 ± 120) (1010 ± 100) (693 ± 72) (260 ± 22) (563 ± 58) (318 ± 29) 235 ± 24 198 ± 20 131 ± 13 50 ± 5 110 ± 11 60 ± 6 M30 P=3.5 (1700 ± 170) (1430 ± 140) (946 ± 94) (361 ± 36) (794 ± 79) (433 ± 43) 317 ± 32 266 ± 27 176 ± 18 68 ± 7 148 ± 15 81 ± 8 M33 P=3.5 (2290 ± 200) (1920 ± 200) (1270 ± 130) (491 ± 51) (1070 ± 110) (585 ± 58) 409 ± 41 343 ± 34 227 ± 23 88 ± 9 190 ± 19 105 ± 10 M36 P=4 (2960 ± 300) (2480 ± 250) (1640 ± 170) (636 ± 65) (1370 ± 140) (758 ± 72)

2. Metric fine thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values. d a N · m(lbf·ft) Torque value unit - kgf·m Classification

4.8 T

7T

10.9 T

13503 60421091

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION 4.5 ± 0.4 3.8 ± 0.4 2.5 ± 0.2 0.97 ± 0.1 2.1 ± 0.2 1.15 ± 0.11 M8 P=1.0 (32.5 ± 2.9) (27.4 ± 2.9) (18.0 ± 1.4) (7.0 ± 0.7) (15.2 ± 1.4) (8.3 ± 0.8) 8.9 ± 0.9 7.5 ± 0.7 4.9 ± 0.5 1.91 ± 0.19 4.2 ± 0.4 2.3 ± 0.2 M10 P=1.25 (64.2 ± 6.5) (54.2 ± 5.1) (35.4 ± 3.6) (13.8 ± 1.4) (30.3 ± 2.9) (16.6 ± 1.4) 15.7 ± 1.6 13.2 ± 1.3 8.7 ± 0.9 3.4 ± 0.3 7.3 ± 0.7 4.0 ± 0.4 M12 P=1.25 (113 ± 13) (95.3 ± 9.4) (62.8 ± 6.5) (24.5 ± 2.2) (52.7 ± 5.1) (28.9 ± 2.9) 37 ± 4 31 ± 3 20 ± 2 7.9 ± 0.8 17.2 ± 1.7 9.4 ± 0.9 M16 P=1.5 (267 ± 29) (224 ± 22) (144 ± 14) (57.0 ± 5.8) (124 ± 12) (67.9 ± 6.5) 74 ± 7 62 ± 6 41 ± 4 15.8 ± 1.6 34 ± 3 19 ± 9 M20 P=1.5 (535 ± 51) (448 ± 43) (296 ± 29) (114 ± 14) (246 ± 22) (137 ± 14) 126 ± 12 105 ± 10 70 ± 7 27 ± 3 58 ± 6 32 ± 3 M24 P=2 (910 ± 87) (758 ± 72) (506 ± 51) (195 ± 22) (419 ± 43) (231 ± 22) 255 ± 26 212 ± 21 142 ± 14 54 ± 5 118 ± 12 65 ± 6 M30 P=2 (1840 ± 190) (1530 ± 150) (1030 ± 100) (390 ± 36) (852 ± 87) (469 ± 43) 428 ± 43 357 ± 36 238 ± 23 91 ± 9 198 ± 20 109 ± 11 M36 P=3 (3090 ± 310) (2580 ± 260) (1720 ± 170) (657 ± 65) (1430 ± 140) (787 ± 79)

6— 39

Section VI – SPECIFICATIONS B. NUTS AND SLEEVES SLEEVE

B

NUT

O.D. (Ø)

O.D. (¯)

MANUFACTURER'S WORKING PRESSURE kgf/cm2 (psi) NAME

NIPPON A.M.C

350 (4,980)

IHARA KOATSU

350 (4,980)

OPPOSING FLATS TUBE SIZE mm O.D. X THICKNESS Dimension B mm (in) 19 10 X 1.5 (0.394 X 0.059) 27 15 X 2.0 (0.591 X 0.079) 32 18 X 2.5 (0.709 X 0.098) 36 22 X 3.0 (0.866 X 0.118) 41 28 X 4.0 (1.10 X 0.157) 35 X 5.0 (1.38 X 0.20)

C. FLARE TYPE FITTING JOINTS Overtightening of flare type (union nut type) metal joints may cause damage to nuts, seat surfaces and prevent optimum sealing resulting in oil leaks.

1. Pipe threads

4.5 ± 0.5 (33 ± 4) 15 ± 2 (108 ± 14) 18 ± 2 (130 ± 14) 22 ± 2 (159 ± 14) 28 ± 3 (203 ± 22) 35 ± 4.5 (253 ± 33)

D. N2 (NYLON) TUBE FITTING JOINTS 1. Clean tube and make certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

Unit : daN·m (lbf·ft)

NOMINAL SIZE 1 / 4˝ 3 / 8˝ 1 / 2˝ 3 / 4˝ 1˝ 1-1 / 4˝ 1-1 / 2˝ 2˝

55

TORQUE VALUE daN·m (lbf·ft) kgf·m

3. Tighten the nut by hand.

TORQUE VALUE 2.5 ± 0.3 (18.1 ± 1.8) 5 ± 0.5 (36.2 ± 3.6) 6 ± 0.6 (43.4 ± 4.3) 12 ± 1.2 (86.8 ± 8.7) 14 ± 1.4 (101 ± 10) 17 ± 1.7 (123 ± 12) 21 ± 2.1 (152 ± 15) 42 ± 4.2 (304 ± 30)

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

PLASTIC SLEEVE

BODY

NUT

NYLON TUBE

E. ORS JOINT (O-RING SEALING TYPE) NOMINAL SIZE

CONNECTOR

O-RING

1-14 UNS 1-3/16 12 UN 1-7/16 12 UN NIPPLE

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Hose mouth ring and coupling

OPPOSING FLATS TORQUE VALUE WORKING PRESSURE daN·m(lbf·ft) mm kgf·m kgf/cm2 (psi) 30 • 32 14 ± 1.4 (101 ± 10) 350 (4,980) 36 • 41 18 ± 1.8 (130 ± 13) 385 (5,475) (Power boost) 41 • 46 21 ± 2.1 (152 ± 15)

NUT

6— 40

Section VI – SPECIFICATIONS F. TORQUE VALUES FOR MOST COMMON BOLTS Follow the table below and tighten or retighten every capscrew and nut. Check for any loose or missing capscrews or nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as required.

Size

Q'ty

Location

M5

5

• Sending unit mounting (fuel tank)

• 0.2 ± 0.02 (1.4 ± 0.1)

M6

6

• A/C Condenser mounting

• 0.45 ± 0.04 (3.2 ± 0.3)

M8

4 4 4

• Muffler mounting (Nut-Upper) • Muffler mounting (Nut-Lower) • A/C compressor mounting

• 1.1 ± 0.01 (8.0 ± 0.07) • 0.9 ± 0.08 (6.5 ± 0.6) • 2.75 ± 0.2 (20 ± 1.8)

M10

4 5 5 4 3 12 8 4 12

• Air cleaner mounting • Swivel joint dust cover mounting • Cab mounting • Muffler bracket mounting • Stepping motor mounting • Take-up bracket mounting • Floor plate rubber mounting • Travelling lever mounting • Hydraulic oil tank cover mounting

• 4.0 ± 0.4 (29 ± 2.9) Apply Loctite #262 • 1.5 ± 0.15 (10.8 ± 1.1) • 4.7 ± 0.5 (34 ± 3.7) • 4.0 ± 0.4 (29 ± 2.9) • 4.7 ± 0.5 (34 ± 3.4) • 6.6 ± 0.6 (48 ± 4.3) Apply Loctite #262 • 4.7 ± 0.5 (34 ± 3.6) • 4.3 ± 0.4 (31 ± 2.9) • 4.7 ± 0.5 (34 ± 3.6)

M12

12 8 3 4 4

• Step mounting • Travel motor cover mounting • Swivel joint mounting • Radiator stay mounting • Radiator mounting

• 11.7 ± 1.2 (85 ± 8.7) Apply Loctite #262 • 8.5 ± 0.9 (61.5 ± 6.2) • 11.0 ± 1.0 (79 ± 7.0) Apply Loctite #262 • 8.1 ± 0.8 (59 ± 5.8) • 12.3 ± 1.2 (89 ± 9.0) Apply Loctite #262

M16

4 4 4

• Idler and idler adjuster connection • Fuel tank mounting • Hyd. tank mounting

• 28.5 ± 3.0 (206 ± 21) Apply Loctite #262 • 22.0 ± 2.0 (159 ± 14) Apply Loctite #262 • 22.0 ± 2.0 (159 ± 14) Apply Loctite #262

daN·m •m (lbf·ft) Tightening torque kgf

52 • Sprocket mounting 64(72-LC) • Lower roller mounting M18 • Track guide mounting 8 • Engine mounting 4

• 40.5 ± 4.0 (293 ± 29) Apply Loctite #262 • 40.5 ± 4.0 (293 ± 29) Apply Loctite #262 • 40.5 ± 4.0 (293 ± 29) • 23.0 ± 2.0 (166 ± 14) Apply Loctite #271

33 • Slewing bearing outer race mounting 36 • Slewing bearing inner race mounting 4 • Hyd. pump mounting 40 • Travel motor mounting M20 188(204-LC) • Shoe bolt mounting • Swing reduction unit mounting 16 • Upper roller mounting 4

• 50.0 ± 5.0 (361 ± 36) • 57.5 ± 5.7 (416 ± 41) • 44.0 ± 4.0 (318 ± 29) • 55.0 ± 5.5 (398 ± 40) • 87.0 ± 5.0 (629 ± 36) • 55.0 ± 5.5 (398 ± 40) • 55.0 ± 5.5 (398 ± 40)

Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply Loctite #262 Apply SAE30 CD Apply Loctite #262 Apply Loctite #262

8

• Side cutter mounting

• 100 ± 5.0 (723 ± 36)

M36

4

• Counterweight mounting

• 300 ± 30 (2170 ± 217) Apply Loctite #262

5/8-18 UNF

2

• Idler adjuster grease nipple mounting

• 6.0 ± 1.0 (43 ± 7.3)

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M24

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Section VI – SPECIFICATIONS

6.7 MISCELLANEOUS INFORMATION

D. CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS C

A. TEMPERATURE TABLE ˚C ˚F -10 14 -5 23 0 32 5 41 10 50 15 59 20 68 25 77 30 86 35 95 40 104 45 113 50 122

˚C ˚F 55 131 60 140 65 149 70 158 75 167 80 176 85 185 90 194 95 203 100 212 105 221 110 230 115 239

˚C ˚F 120 248 125 257 130 266 135 275 140 284 145 293 150 302 155 311 160 320 165 329 170 338 175 347 180 356

˚C ˚F 185 365 190 374 195 383 200 392 205 401 210 410 215 419 220 428 225 437 230 446 235 455 240 464 245 473

˚C ˚F 250 482 255 491 260 500 265 509 270 518 275 527 280 536 285 245 290 554 295 563 300 572 305 581 310 590

Tube & Hose Plugs

˚C ˚F 315 599 320 608 325 617 330 626 335 635 340 644 345 653 350 662 355 671 360 680 365 689 370 698 375 707

B

A

TUBE DIA. 10 mm 15 mm

Example of how to convert 45˚C to ˚F: ˚F = 1.8 X ˚C + 32 ˚F = 1.8 X 45 + 32 = 81 + 32 = 113˚F Example of how to convert 122˚F to ˚C ˚C = 0.56 (˚F - 32) ˚C = 0.56 (122 - 32) = 0.56 X 90 = 50˚C

18 mm 22 mm 28 mm 35 mm

B. SPECIAL PIPE WRENCHES A

B

Male PF Plugs

C

G

"D"

"C" D

TUBE DIA. 15 (0.591) 18 (0.709) 22 (0.866) 28 (1.10) 35 (1.38)

E

A

Unit : mm (in) B

C

D

E

F

G "A" Dia. (ø)

27 70 22 12.7 8 40 16 (1.06) (2.76) (0.87) (0.50) (0.32) (1.57) (0.63) 32 70 22 12.7 11 42 19 (1.26) (2.76) (0.87) (0.50) (0.43) (1.65) (0.75) 36 70 22 12.7 11.5 48 23 (1.42) (2.76) (0.87) (0.50) (0.44) (1.89) (0.91) 41 109 22 12.7 14.5 60 29 (1.614) (4.29) (0.87) (0.50) (0.57) (2.36) (1.14) 55 90 45 20 20.5 81 41 (2.17) (3.54) (1.77) (0.79) (0.81) (3.19) (1.61)

60˚

Unit : mm

C. WEIGHT OF MATERIALS TABLE lb/yd3 700 750 950 1170 1600 1780 2100 2100 2250 2400 2500 2550 2600 2700 2800 2800 2850 2900 3100 3400

kg/m3 420 440 560 690 950 1050 1250 1250 1330 1420 1480 1510 1540 1600 1660 1660 1690 1720 1840 2020

Material (loose weight) Wood chips Peat, dry Cinders Peat, wet Topsoil Coal Caliches Earth, loam Shale Sand, dry Clay, dry Earth, dry Limestone, broken or crushed Earth, wet Clay, wet Rock, granite, blasted & broken Sand, moist Sand and gravel, dry Sand, wet Sand and gravel, wet

PLUG SIZE

"A" O.D. (Ø)

"B" "C" LENGTH LENGTH

"D" FLATS

PF 1/4

13.5

16.5

24.5

14

PF 3/8

16.6

17.5

25.5

17

PF 1/2

20.6

20.0

31.0

22

PF 3/4

26.2

21.5

34.0

27

PF 1

33.3

23.5

36.0

36

Female PF caps SIZE PF 1/4 PF 3/8

Thread Screw

PF 1/2 PF 3/4 PF 1 PF 1 1/4

6— 42

13503 60421091

F

"B"

Section VII – TROUBLESHOOTING

Table of Contents GENERAL TROUBLESHOOTING ............................................................................................................... 7-1 ~ 7-3

WARNING

13503 60421091

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

7— 0

Section VII – TROUBLESHOOTING

7.1 GENERAL TROUBLESHOOTING replacement of components or adjustment of valves be required, contact your Dealer for assistance.

This troubleshooting information covers the components and systems as described in this operator’s manual. Should in depth troubleshooting, repair or SYS

PROBLEM

PROBABLE CAUSE a. Low hydraulic oil level b. Air leaking into the suction pipe

1. All operating speeds are slow or power is lost

OPERATING

2. A specific cylinder functions improperly or loses power 3. The cylinder position will not hold with operating lever in neutral

4. Machine does not swing

5. Swing speed is slow 6. Abnormal sound occurs when swing 7. With swing stopped, the machine drifts and is hard to control

13503 60421091

TRAVEL

1. Machine does not travel smoothly

2. Traveling power is insufficient

3. Machine does not travel in a straight line

c. Hydraulic pump damaged d. Pilot gear pump damaged e. Main relief valve is not adjusted correctly f. Pilot relief valve is not adjusted correctly a. Cylinder seal is damaged b. Control valve or overload valve functions incorrectly or there are signs of air in the cylinder c. Pilot valve is damaged d. Pilot valve piping is loose a. Cylinder seal is scored b. Control valve or overload valve is damaged c. Overload valve is not operating d. Pilot valve is damaged a. Brake valve is not working b. Hydraulic motor (swing) is not working or swing gear is damaged c. Swing bearing is damaged d. Pilot valve is not working e. Swing reduction unit is damaged a. Brake valve is not working b. Control valve is not working c. Hydraulic motor (swing) is not working d. Hydraulic pump is not working a. Insufficient lubrication of swing gear and bearings b. Low oil level in the swing reduction unit a. Brake valve malfunctions b. Set pressure of brake valve is incorrect c. Brake lining is worn a. Too much track tension b. Dirty track links and shoes c. Brake valve is not working d. Travel reduction unit is damaged a. Hydraulic pump is damaged b. Poor engine performance c. Main relief valve pressure is set incorrectly d. Low hydraulic oil level e. Hydraulic motor (travel) is not working f. Brake valve is not working g. Seal in swivel joint is scored or oil is leaking a. Unequal tensions on tracks b. Set pressures of main relief valves unbalanced c. Performances of hydraulic travel motor has deteriorated 7— 1

POSSIBLE REMEDY Fill oil to specified level Tighten suction pipe hose clamp or replace hose Repair or replace Repair or replace Adjust or replace Adjust or replace Repair or replace Repair or replace/Bleed air from cylinder Repair or replace Retighten Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Grease Refill with proper oil Repair or replace Adjust or replace Repair or replace Adjust track tension Clean tracks Repair or replace Repair or replace Repair or replace Repair or replace Adjust or replace Fill to proper level Repair or replace Repair or replace Repair or replace Adjust tension Adjust Repair or replace

Section VII – TROUBLESHOOTING

PROBLEM

1. Temperature rise in the hydraulic oil tank.

1. Engine oil pressure is too low. (Buzzer sounds and icon displays)

2. Abnormal rise in the coolant temperature (Buzzer sounds and icon displays)

3. Air cleaner clogged 1. Starter does not turn or turns slowly which does not start the engine

ENGINE

2 . Starter turns but engine does not start

3. Engine tends to stop at low speed

4. No power

5. Engine overheats

6. Engine exhaust is black 7. Poor fuel consumption

PROBABLE CAUSE

POSSIBLE REMEDY

a. Oil cooler core clogged b. Engine fan belt slipping c. Low hydraulic oil level

Clean Adjust or replace Refill to specified level Replace with correct, new d. Wrong type hydraulic oil used oil Repair or replace e. Hydraulic pump is not working Fill to specified level a. Engine oil level low Repair & fill to proper level b. Oil leaking Replace with proper oil c. Wrong oil viscosity Fill to proper level a. Low coolant Repair & fill to proper level b. Coolant leaking Tighten c. Loose radiator cap Clean cooling system d. Radiator core clogged Tighten to proper tension e. V-belt loose or damaged Flush system / fill to level f . Rust or scale in coolant Replace g. Faulty thermostat Replace elements a. Clogged air cleaner Clean, repair or replace b. Hoses from air cleaner to turbo clogged.

Connect a. Battery disconnected Charge b. Battery discharged Clean and connect c. Battery terminals disconnected, loose, or corroded Connect d. Ground cable disconnected Change to proper oil e. Engine oil viscosity too thick (Cold weather) Refuel a. Insufficient fuel Refer to pages 3-1~3-2 b. Improper starting procedure Bleed (See page 4-36) c. Air in fuel line Replace element d. Clogged fuel filter Replace elements e. Clogged air cleaner Check circuit f . Air heater circuit malfunctioning Contact authorized Dealer a. Low idling RPM Replace element b. Fuel filter clogged Replace elements c. Air cleaner clogged Contact authorized Dealer d. Improper valve clearance Replace element a. Fuel filter clogged Replace elements b. Air cleaner clogged Contact authorized Dealer c. Improper valve clearance d. Loose clamps on the air inlet hose (with turbo charger) Tighten clamps Replace hose e. Cracked air inlet hose (with turbo charger) Refill coolant a. Insufficient coolant Clean cooling components b. Clogged radiator Adjust or replace belt c. V-belt loose or damaged Replace d. Faulty thermostat Replace elements a. Air cleaner clogged Contact authorized Dealer b. Improper valve clearance Contact authorized Dealer a. Fuel leak Replace elements b. Air cleaner clogged Tighten clamps c. Loose clamps on suction hose (with turbo charger) Replace w/new hose d. Cracked suction hose (with turbo charger) 7— 2

13503 60421091

GAUGE CLUSTER DISPLAY

HYDRAULIC

SYS

Section VII – TROUBLESHOOTING

SYS

PROBLEM

ENGINE

8. Excessive oil consumption

9. Engine oil pressure does not rise

POSSIBLE REMEDY

a. Improper oil b. Oil leak c. Improper oil replacement intervals d. Improper warming-up operation a. Low oil volume b. Oil leak c. Improper oil viscosity a. Battery terminals disconnected loose, or corroded b. Low battery electrolyte c. V-belt loose or damaged d. Defective battery

Replace with correct oil Contact authorized Dealer Change at correct interval Refer to page 3-5 Fill to specified level Contact authorized Dealer Replace with proper oil Clean & tighten terminals Fill cells w/distilled water Adjust or replace belt Replace battery

13503 60421091

10. Battery dies often

PROBABLE CAUSE

7— 3

Section VII – TROUBLESHOOTING

13503 60421091

NOTE:

7— 4

Section VIII – SCHEMATICS

Table of Contents ELECTRIC CIRCUIT DIAGRAM (A) ............................................................................................................. 8-1 ELECTRIC CIRCUIT DIAGRAM (B) ............................................................................................................. 8-2 ELECTRIC CIRCUIT DIAGRAM (C) ............................................................................................................. 8-3 ELECTRIC CIRCUIT DIAGRAM (D) ............................................................................................................. 8-4

WARNING

13503 60421091

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

8— 0

PUMP TUNER BACK UP, 9 ROOM LAMP DC-DC CONVERTER WV 1.25 10 KEY SW.

C-1 : MECHATRO CONTROLLER

SE-7 : BOOM LOWERING

EA

51B R EB

60B

W

903 503 953 904 504 954

SE-7 : ARM IN

60A

60A

B

902 502 952

905 505 955

BATTERY BATTERY 60B 60B SE-8 : ARM OUT

B

906 506 956

SHIELD

10 1.25WV

B ACC M G1 G2 ST

60

SE-9 : TRAVEL RIGHT

D-10

GrL

64 GW

D-1

D-2 61 62 63

909 509 959

SE-10 : TRAVEL LEFT R-3 : GLOW RELAY GLOW 66 5W

67 2OB

BrY GrB WY B

M-1 : STARTER MOTOR

M

M

D-4

E

S

R-2 : STARTER RELAY

69 WL

S

E

B

D-3

64 GW

OPTION

65 5L

10

908 508 958

R-1 : BATTERY RELAY

60B

SW-1 : KEY SW.

TERMINAL POSITION PREHEATING OFF ACC ON START

SE-5 : SWING

R P L

68 W 651 WR

SE-11 : OPT. 1

910 510 960

RL (5V) GO BL (GND)

SE-20 : OPT.2

912 512 962

RB(5V) LgR BO(GND)

914 514 964

YL (5V) 12-3 VY 12-2 BrB (GND) 12-1 YR(5V) 12-4 Sb 12-5 BrL (GND) 12-6 YG (5V) 12-10 VY 12-11 Br (GND) 12-12

PRESS. SENSOR (HIGH)

E-2 : ALTERNATOR 5B B E 65 L R P L

SE-22 : PUMP P1

915 515 965

SE-23 : PUMP P2

907 507 957

R-4 : SAFETY RELAY EU OPT

13

SE-14 : COOLANT THERMO SENSOR SE-15 : FUEL SENSOR

537 YR

21-2

ENG. WATER TEMP INDICATOR

21-1

FUEL METER

536 BrR

C-1:

15-21 15-23 15-6 15-7 15-8 15-9 15-4 15-5 15-10 15-11

651 WR

KEY ON

60 GrL

GLOW

61 BrY

BACK LIGHT SW-34 : POWER BOOST SW. B H

S

FC

SW-35 : HEAVY LIFT SW.

A M

B

M-2 : STEPPING MOTOR

SHIELD B

560 V

561 Lg 700 VR

3 2 1

703 P

B

B

559 PL

B

567 GR 540 GO

B

12-15

15-17

14-5

15-20 15-19

SV-2 : POWER BOOST SOL. PSV-B : P2 BY-PASS CUT PROPORIONAL SOL.

752 GrR 753 GB

PSV-C : TRAVEL PRIORITY PROPORTIONAL SOL.

754 GrB 755 BP

PSV-D : P1 BY-PASS CUT PROPORTIONAL SOL.

756 PW 757 BrG

PSV-A: ARM VALUABLE RECIRCULATION PROPOPTIONAL SOL.

758 YV

650 Sb

17 WL

759 GrG 760 VR

12-16 12-17

SV-3 : TWO-SPEED SELECT SOL.

751 BO

17

15-18

SV-1 : SWING PARKING BRAKE SOL.

B

701 PB

B

15-24 12-13

SW-4 : SWING PARKING RELEASE SW.

702 LgB

E-14 : RESISTOR

CHARGE

SW-3 : TWO-SPEED SELECT SW.

763 GY 764 VW

650 Sb

1 2 3 4 5 6 7 8 9 10 11 12

SW-5 : K.P.S.S MODE RELEASE SW. B 761 G

762 L

B

PSV-P1 : PUMP P1 PROPORTIONAL SOL.

765GB

766 LB

PSV-P2 : PUMP P2 PROPORTIONAL SOL.

16-15

21-7 534 B

SE-13 : ENG. REVOLUTION SENSOR

535 W

LCD

SHIELD 21-3

600 0.5R

21-4

601 0.5W

21-5

602 0.5B

SHIELD

DISPLAY BUZZER MODE WASHER SELECT STOP SW. LED 13503 60421091

15-22

12-19

805 WG

5 MECHATRO

CONTROLLER

12-18

851 GREEN 852 BLACK 853 RED 854 WHITE

HáM

21-6

553 BrB

B

12-9 12-8 12-7

E-3 : HOUR METER B 651 WR

C-2 : CLUSTER GAUGE W

13

SE-24 : EXTRA PRESS.

13-3 13-2 13-1

15-1 15-2 15-15 15-16 15-3 11-34

TERMINAL POSITION NORMAL RELEASE

20A WR

1.25

SE-3 : BOOM RAISING

51A G

901 501 951

SE-2 : BUCKET DUMP

RESERVE 20

AIR CON.

RL 19

WG AIR CON. HEATER 18 1.25

WL RESISTOR 17

10A

20A

20A

10A

RW

WORK LIGHT 16 1.25

WB

20A

10A

10A SOLENOID 15

3

10A

C-1

TRAVEL ALARM 12 RG SWING FLASHER CLUSTER W GAUGE 13 RB WIPER, WASHER 14 1.25

20A

53 5Y

WR(5V) 11-33 P 11-32 BW(GND) 11-31 RB (5V) 11-15 LgR 11-14 BrR (GND) 11-13 RL (5V) 11-16 LgW 11-17 BL (GND) 11-18 WV(5V) 11-3 LgY 11-2 BR(GND) 11-1 OB(5V) 11-4 LO 11-5 BrW(GND) 11-6 OL (5V) 11-9 PW 11-8 BrY (GND) 11-7 OW (5V) 11-10 PL 11-11 Gr (GND) 11-12 YB (5V) 11-21 V 11-20 GrL(GND) 11-19 YL (5V) 11-27 VY 11-26 BY (GND) 11-25 YR(5V) 11-28 Sb 11-29 BG(GND) 11-30

TERMINAL POSITION NORMAL RELEASE

900 500 950

52 5R

FUEL PUMP R CAB WORK LIGHT 11 1.25

4

PRESS. SENSOR(LOW) SE-1 : BUCKET DIGGING

50 1.25L

C-1 : MECHA TRO CONTROLLER

930 530 970

SE-16 : ACCEL POTENTIO E-1 : FUSE BOX

20A

WR 8 FUEL SUPPLY

YB

10A

MECHATRO CONTROLLER 7 BACK UP

YG 10A

WG 5 HORN

10A

10A

20A

RL 3 CIGARETTE LIGHTER OL 4 TUNER

2W

51

RELAY

WY 2 WIPER / WASHER 10A

10A

MECHATRO

RY 1B CONTROLLER

RY 1A

A. ELECTRIC CIRCUIT DIAGRAM (A)

20A

8.1 ELECTRICAL SCHEMATIC

DC-DC CONVERTER

Section VIII – SCHEMATICS

WORKING WAIPER LIGHT

RY

1A

1A

1B

1B RY

3

EA B

4

EB B

7

7

YG

12-20 12-21 12-22 14-25 14-26 14-27 14-28 15-12 15-13 15-25 15-26

TO 2/6

15-14

8— 1

Section VIII – SCHEMATICS B. ELECTRIC CIRCUIT DIAGRAM (B)

C-1 : MECHATRO CONTOLLER

FROM 1/6 550 O

SW-7 : ENG. OIL PRESS. SW. B

SW-8 : AIR FILTER RESTRICTION SW.

551 BrL 552 GB

SW-6 : ENG. WATER TEMP. SW. 1

E-1 : FUSE BOX

1

14-1 14

14

FUEL WARNING

553

SW-9 : ENG.OIL LEVEL SW. SW-17 : ENG.COOLANT LEVEL SW. SW-18 : HYD.FLUID LEVEL SW.

BrB

555 LB 543

BR

B

568

BrY

B

569

GB

17-8

SW-22 : DOUBLE SINGLE SELECT SW.

KCMA, EU OPTION

SW-38 : WARM-UP SW. SW-37 : HYD FLUID TEMP SW.

800

17-12

B

563 PL

B

586 VG

584 VY

583

VW

585 VR

R-6 : WINDOW WASHER MOTOR RELAY B 82 GO M-4 : WINDOW WASHER MOTOR M

14 RB 2

2

WY

14-11 14-4

14-15

17-9

GrL

801

16 1.25RW

16

R-8 : WORK LIGHT RELAY 85 1.25WB

16 1.25RW

85

16

85

14-6 14-16

B

SW-23 : WIPER INTERLOCK SW. GB 180 OL

17-10

KCMA, OPT

SW-39 : OVERLOAD SW.

802

BrY

B

85

WORKING LIGHT ON

E-10 : RECEIVER DRIER

E-15 : TRAVEL ALARM

WY B

814

E-11 : AIR COMMPRESSOR CLUTCH

1.25B

2

LgY

93 LW

19 RL

19

12

92 BP

18 1.25WG

18

RG

C-4 : AIR CONDITIONER AMP.

85 WB

R-18 : TRAVEL ALARM RELAY 206 PG

L-1 : BOOM WORKING LIGHT LEFT L-9 :BOOM WORKING LIGHT RIGHT EU STD L-2 : WORKING LIGHT RIGHT

12-14

SW-32 : OVERLOAD INDICATE SW.

EU STD

M-3 : WIPER MOTOR

14-19

558 YV

B

B

M

WY

GB

800

14

FLOW CONTROLLER CONECTOR

81 BrB

1.25RB

2

14-8

14-13

B

RB R-5 : WIPER MOTOR RELAY 80 LY

330Ω

B

SW-16 : AUTO ACCEL RELEASE SW.

14

14-3

2

5

SE-15 : FUEL SENSOR

RY

14-2

24V TXD RXD

17-6

KCMA·STD COOLING UNIT

181 R 608 G 609 W 184 B

24V

SW-13 : AIR CONDITIONER SW.

TXD GND

KCMA·OPT R-21 : BREAKER RELAY 14

D-9

SWING FLASHER UNIT

220 LW

15

R-22 : CLOCKWISE RELAY 16

R-19 : FLASHER RELAY

R-24 : NIBBLER OPEN RELAY

12

L-11 : SWING FLASHER RIGHT

RG

25W 209 LY

B

R-20 : TIMER RELAY 15

15 WB

87 WL

E

D

SW-11 : LEVER LOCK SW. A TIMER

86 OW

B

17-3

SV-4 : OPERATING LEVER LOCK SOL. B

17-4

865

GL

866

GrR

L-12 : SWING FLASHER LEFT 25W B 210 Lg B

17-11

KCMA·STD

TO 3/6

8— 2

557

Gr

B

SW-19 : SWING FLASHER SELECT SW. 13503 60421091

17-13

Section VIII – SCHEMATICS C. ELECTRIC CIRCUIT DIAGRAM (C)

C-1 : MECHATRO CONTOLLER

SCHEMATIC NOMENCLATURE Example of wire color : SYMBOL COLOR 15

R-21 : BREAKER RELAY WB 4

LW

262

223

LY

D-9

SV-5 : BREAKER SOL. YG B

B

Black

B

G

Green

L

Blue

R

Red

W

White

Y

Yellow

P

Pink

O

Orange

Br

Brown

Lg

Light Green

Gr

Gray

Sb

Sky Blue

V

Violet

SW-45 : BREAKER SW. KCMA·OPT D-6

214

15

YG

LW

216

D-9

217

O

607

LG

13-16

HAND CONTROL FOR BREAKER

SV-6 : CLOCKWISE SOL. B

B

LO

SW-46 : CLOCKWISE SW. R-22 : CLOCKWISE RELAY

D-7 610

215

GR

D-8 218

219

GrL

GY

P

14-7 SV-7 : COUNTERCLOKWISE SOL. B

Stripe color (Blue) Base color (White) Abreviations : BZ • • • • • Buzzer SV • • • • • Solenoid valve SW • • • • Switch SE • • • • • Sensor M • • • • • • Motor R • • • • • • • Relay L • • • • • • • Light PSV • • • Proportional solenoid valve D • • • • • • • Diode E • • • • • • • Electrical fitting

B KCMA·OPT

SW-47 : COUNTERCLOCKWISE SW. R-23 : COUNTERCLOCKWISE RELAY

HAND CONTROL EXTRA (ROTATION)

R-20 : TIMER RELAY OW 16

R-24 : NIBBLER OPEN RELAY 240 LW

B

WY SW-48 : NIBBLER OPEN SW. B

982

SV-9 : NIBBLER OPEN SOL.

2

BG

14-9 17-2

541

G

SW-49 : NIBBLER CLOSE SW. B

983

GW

241

14-10 17-1

570

LO

B

SV-10 : NIBBLER CLOSE SOL.

GL

R-25 : NIBBLER CLOSE RELAY

KCMA·OPT HAND CONTROL FOR NIBBLER OPEN/CLOSE

R-26 : EXTRA DISPRESS RELAY 15 2 590

V

270

GL

B

WY SV-11 : EXTRA DISPRESS SOL.

EU·OPT EXTRA

13503 60421091

14-17

WB

8— 3

Section VIII – SCHEMATICS D. ELECTRIC CIRCUIT DIAGRAM (D) C-1 : MECHATRO CONTOLLER

C-6 : IT CONTROLLER (ORBCOMM) E-16 : CONVERTER 9

YB DC IN 12-24V

ANTENNA

E-23 : ANTENNA

4

GPS

E-24 : ANTENNA

9

B

OL YB

IGN

12V

24V

MEM

E-7 : TUNER AM&FM

ANT.

207 PB

E-17 : SOCKET B

B

LR OB

E-9 : SPEAKER RIGHT

1(+) 5(-)

90 91

LW Br B

E-8 : SPEAKER LEFT

3

7 6

8

EU·STD

11 REMOTE POWER CONTROL

611 R 612 W 613 B

17-14 17-15 17-16

208 PW

INTERFACE

GND AT SLEEP RELEASE 811 V

88 89

FM/AM

208 PW

207 PB

17-5

2(+) 6(-)

2 1 7 3 4 5 6 8 9 10 12 13 14 15

BG BW BY Br BrW GL GY L LB RW V

300 301 302 303 304 305 306 307 308 309 310

(RXD1) (TXD1) (GND) DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL INPUT DIGITAL INPUT ANALOG INPUT ANALOG INPUT ANALOG INPUT ANALOG GND OUTPUT TRANSMITTING OUTPUT RECEIVING (GND)

ANT.

E-7 : TUNER AM&FM 2(+) 6(-)

OL

9

9

E-9 : SPEAKER RIGHT

90 LW 91 Br

E-8 : SPEAKER LEFT

FM/AM

4

4

88 LR 89 OB

1(+) 5(-)

3 YB : BACK UP

8

B

7 6

OPTION CONNECTOR

KCMA·STD ORBCOMM

L-3 : ROOM LIGHT KCMA·OPT

11

11 1.25R

11 11

R-10 : CAB WORK LIGHT RELAY 1 179 1.25L 185 LY

SW-21 : WORK LIGHT SW.

L-6 : CAB WORKING LIGHT (FRONT 3) 20

3

3 RL

11

11

L-4 : CAB WORKING LIGHT (FRONT 1) L-5 : CAB WORKING LIGHT (FRONT 2)

B

20 1.25WR

9

9 YB

178 WY

B

L-7 : CAB WORKING LIGHT(FRONT 4) L-10 : CAB WORKING LIGHT(BACK)

R-11 : CAB WORK LIGHT RELAY 2

B

R

E-6 : CIGARETTE LIGHTER

B

M M-9 : FUEL PUMP

B

176 LO

EU, KCMA OPTION

L-15 : ROTARY LIGHT

SW-30 : ROTARY LIGHT SW.

SW-42 : ENG.ROOM LIGHT SW. 9

YB

L-8 : ENG. ROOM LIGHT B 8

WR

1.25

M-11 : FUEL SUPPLY PUMP 15A M

B

EU·STD EU·STD KCMA·OPT

R-7 : HORN RELAY 5

WG

5

83 WL

5

84 WB

B

SW-10 : HORN SW.(LEFT) 84 WB

B

E-4 : HORN LOW

B

SW-20 : HORN SW.(RIGHT) OPTION

8— 4

E-5 : HORN HIGH

B

13503 60421091

5

Section IX – OPTIONAL EQUIPMENT

Table of Contents HYDRAULIC BREAKER ............................................................................................................................... 9-1 ~ 9-3 SAFETY PRECAUTIONS ............................................................................................................................. 9-4 ~ 9-5 MAINTENANCE FOR NIBBLER / BREAKER .............................................................................................. 9-6 REINFORCEMENT OF ATTACHMENT ........................................................................................................ 9-6 EXTRA (GRAPPLE, CLAMSHELL, ETC.) / EXTRA & BRAKER ................................................................. 9-7 ~ 9-8

WARNING

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READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

9— 0

Section IX – OPTIONAL EQUIPMENT

9.1 HYDRAULIC BREAKER A. SELECTION OF THE HYDRAULIC BREAKER When mounting the breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil level for each breaker. To select hydraulic breakers, contact your Dealer.

B. BEFORE OPERATING THE HYDRAULIC BREAKER Consult your Dealer distributor for the piping or enforcement of the arm when installing the hydraulic breaker.

REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE LISTED ON PAGE 9-6. Thoroughly read the hydraulic breaker operation manual and SAFETY PRECAUTIONS from this section, as well as the safety precaution’s section on this manual to avoid damaging the machine or hydraulic breaker during operation. SELECT THE APPROPRIATE HYDRAULIC FLOW FOR THE BREAKER BY FOLLOWING THE INSTRUCTIONS DETAILED IN PAGE 9-2.

C. HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm top end and the hose end on the hydraulic breaker side to prevent dust and water from entering into the piping.

Before starting operation, check the capscrews on the tube fixing clamps for looseness, and the connections of the tubes and hoses for oil leakage.

D. BASIC OPERATION WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. 1. Start machine and place the safety lock lever in the “UNLOCKED” (down) position. See Figure 9.1.

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

2. Move throttle control to the “HI” idle position.

FIGURE 9.1

3. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

PUSH LOCK ROD FORWARD TO RELEASE

4. Release control pedal lock rod. See Figure 9.2.

5. Make certain breaker or nibbler is in desired position and against material to be broken.

PULL LOCK ROD BACKWARD TO LOCK PEDAL

6. Place right foot on pedal and depress with toe to activate breaker. See Figure 9.2.

7. Operate breaker for one minute then release pedal.

DEPRESS PEDAL WITH TOE TO ACTIVATE

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WARNING FIGURE 9.2

OPERATION OF BREAKER OR NIBBLER LONGER THAN ONE MINUTE INTERVALS COULD CAUSE PREMATURE WEAR OR DAMAGE TO THE ATTACHMENT AND THE MACHINE. IF MATERIAL IS NOT BREAKING, REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATION IN ONE MINUTE INTERVALS.

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

9— 1

Section IX – OPTIONAL EQUIPMENT E. BREAKER AND NIBBLER SELECTOR SWITCH This machine is provided with breaker single circuit and nibbler and breaker Bi direction flow circuit. To use breaker or nibbler, select circuit appropriate to the specification through switch on the rear side of operator’s seat. See Figure 9.3.

1. Switch Position

Specification Switch Position

Circuit

Breaker

Single flow

Nibbler

Bi direction flow

CAUTION Never turn switch on (Bi direction flow) to operate breaker.

It may cause damage of machine.

FIGURE 9.3

F. CONTROL PEDAL 1. Hydraulic Breaker Single Circuit Release pedal lock on the right front side of operator’s seat to operate pedal. See Figure 9.4.

CAUTION Precaution for pedal operation.

The operation varies in the specifications, so before operating, read the operator’s manual carefully.

Foot Pedal Depressing Section

Operating Condition

Depress toe section

Breaker starts operation

Pedal in neutral position

Breaker stops operation

PUSH LOCK ROD FOWARD TO RELEASE

2. Nibbler and Breaker Combined (Conflux) Circuit Release pedal lock on the right front side of operator’s seat to operate pedal. See Figure 9.4.

PULL LOCK ROD BACKWARD TO LOCK PEDAL

Hydraulic breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operation

Depress heel section

Breaker starts operating

DEPRESS PEDAL WITH TOE /HEEL TO ACTIVATE

FIGURE 9.4

Nibbler Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

9— 2

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Foot Pedal Depressing Section

Section IX – OPTIONAL EQUIPMENT G. SETTING SELECTOR VALVE – FIGURE 9.5 For machines provided in nibbler and breaker specification, the selector valve installed on the main control valve is required to be switched to the position corresponding to the specification.

NOTE • Inappropriate switching of selector valve may cause decrease of work efficiency and operating speed due to inferior operation, and also cause damage of machine.

Securely switch selector valve.

(A)

TO HYD. TANK

• Be sure to switch selector valve 1 or 2 times a month periodically.

1. Tools Used SELECTOR VALVE

CIRCUIT

(A)

MAIN (Circuit)

TO HYD. TANK

TO ATT

TO ATT

TO C/V Ao2

TO C/V Ao2

TOOLS SOCKET BOLT

Spanner (24 mm) Allen Wrench (5 mm)

USE BREAKER

USE NIBBLER

FIGURE 9.5

2. Setting Procedure a. Use an allen wrench to loosen and remove the socket bolt. b. Use a spanner to turn the selector valve to the proper position. c. After the valve is in the proper position, tighten the socket bolt. d. Markings of the selector valve are shown below.

B : Breaker N : Bi direction flow of nibbler H. SETTING STOP VALVE – FIGURE 9.6 Stop valve on arm top end is used to stop hydraulic oil flowing.

Free : Hydraulic oil flows.

Stop : Hydraulic oil stops flowing.

Before removing attachment, set stop valve to “STOP” position.

(B)

1. Tools Used

CIRCUIT

(B)

MAIN (Arm)

TOOLS 24

mm

Spanner (24 mm)

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STOP VALVE

FREE

STOP

FIGURE 9.6 9— 3

Section IX – OPTIONAL EQUIPMENT

9.2 SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with all other safety precautions found in this manual.

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. FIGURE 9.7 A. USE FOR INTENDED PURPOSE – FIGURE 9.7 Use the attachment only for its intended purpose. If not used in accordance with the manufactures instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS Never allow passengers on the attachment or machine.

INSTALL GUARD AND CLOSE WINDOWS

C. PROTECTIVE EQUIPMENT – FIGURE 9.8 Install protective guards on the machine and close the all window to protect the operator from flying debris.

Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

FIGURE 9.8

D. CYLINDERS – FIGURE 9.9 Do not operate boom, am or bucket cylinders to stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

FIGURE 9.9 E. AVOID CONTINUOUS OPERATION – FIGURE 9.10 Operate the breaker or nibbler in one minute intervals.

Operation for longer than one minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

FIGURE 9.10 9— 4

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Within One Minute

Section IX – OPTIONAL EQUIPMENT F. HOSE SURGE – FIGURE 9.11 Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a breaker or nibbler, immediately stop operation and contact your Dealer for assistance. This problem often is a result in damaged accumulator and can also result in valve failure.

FIGURE 9.11 G. DO NOT USE DROPPING FORCE – FIGURE 9.12 Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

FIGURE 9.12 H. DO NOT USE SWING FORCE – FIGURE 9.13 Never use the swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

FIGURE 9.13 I . DO NOT LIFT– FIGURE 9.14 Never use an optional attachment to lift or transport objects or material. Doing so can cause extensive damage to the attachment, the machine structures and cause injury or death.

FIGURE 9.14 J. WORKING RANGES – FIGURE 9.15 Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

UNACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

ACCEPTABLE WORK RANGE

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UNACCEPTABLE WORK RANGE

FIGURE 9.15 9— 5

Section IX – OPTIONAL EQUIPMENT

9.3 MAINTENANCE FOR NIBBLER / BREAKER It is necessary to perform the following maintenance schedule in regard to hydraulic oil and filters along with normal inspection and maintenance as described in Section IV of this manual for the nibbler / breaker optional attachment.

DEPRESS RUBBER CAP TO RELEASE PRESSURE

HYDRAULIC TANK

FIGURE 9.16 REPLACEMENT SCHEDULE COMPONENT

LOCATION

1st MAINTENANCE

2nd MAINTENANCE

REGULAR MAINTENANCE

Change Hydraulic Oil

Hydraulic Tank

—

—

Every 600 hours

Return Filter

Hydraulic Tank

50 hours

250 hours

Every 250 hours

1. Move machine to firm level ground and place attachment in oil level check position.

BOLT COVER

SPRING WASHER

O-RING SPRING BYPASS VALVE

2. Release hydraulic tank pressure. See Figure 9.16.

3. Remove the six mounting bolts from the hydraulic return cover plate. See Figure 9.17.

FILTER

4. Remove “O”-rings, filter springs and bypass valves.

See Figure 9.17.

5. Remove the filter from the housing. See Figure 9.17.

6. Install new filter, bypass valve and spring into housing.

7. Install new “O”-ring, Lubricate “O”-ring before installing.

FIGURE 9.17

8. Install cover plates and torque mounting bolts to proper value. Refer to specifications section for torque value.

9.4 REINFORCEMENT OF ATTACHMENT 13503 60421091

The use of machine with breaker and nibbler may cause damage of attachment. So contact your Dealer to reinforce arm.

9— 6

Section IX – OPTIONAL EQUIPMENT

9.5 EXTRA (GRAPPLE, CLAMSHELL, ETC) AND EXTRA & BREAKER A. BASIC OPERATION WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

1. Start machine and place the safety lock lever in the “UNLOCKED” (Down) position. See Figure 9.18.

FIGURE 9.18

2. Move throttle control to the “HI” idle position.

PUSH LOCK ROD FORWARD TO RELEASE

3. Using boom, arm and bucket controls set the attachment to desired position.

DEPRESS PEDAL WITH TOE TO ACTIVATE

4. Use the boom, arm and bucket controls to position the attachment.

PULL LOCK ROD BACKWARD TO LOCK PEDAL

5. Place left foot on pedal and depress with toe to close attachment and depress back of pedal with heel to open attachment. See Figure 9.19.

EXTRA SPEC.

6. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, See Figure 9.19, position attachment in hydraulic oil check position, move throttle control to "LO" idle position.

THROTTLE CONTROL

SUPPLEMENTARY EXPLANATION For machine provided in extra & breaker specification, before starting operating, unlock left control pedal. See Figure 9.19.

PUSH LOCK ROD FORWARD TO RELEASE

WARNING NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

PULL LOCK ROD BACKWARD TO LOCK PEDAL

DEPRESS PEDAL WITH TOE TO ACTIVATE

BREAKER SPEC.

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FIGURE 9.19

9— 7

Section IX – OPTIONAL EQUIPMENT B. PRESSURE RELIEF OF EXTRA CIRCUIT (EU SPECIFICATION) The pressure relief of extra circuit is carried out by means of switch provided on the switch panel of gauge cluster.

1. Start machine and place the safety lock lever in the “UNLOCKED” (down) position. See Figure 9.20.

2. Throttle dial position is available at any angle.

SAFETY LOCK LEVER IN UNLOCKED (DOWN) POSITION

3. Using boom, arm and bucket controls set the attachment to desired position.

FIGURE 9.20 4. Hold screen change switch (1) and buzzer stop switch (2) pressed. Press the switch for 5 seconds or more continuously, and multidisplay displays “ ”, and consequently the engine speed reduces to idling speed or less.

5. Buzzer continues sounding intermittently. Operate control pedal for extra circuit in this condition.

6. After confirming the completion of pressure relief, turn engine key switch “OFF” to finish the work.

7. If multidisplay displays “ ”, during pressure relief operation, it shows the failure.

(1)

8. Simultaneously buzzer sounds continuously and the buzzer cannot be stopped sounding. It can be stopped only when starter key turns “OFF”.

(2)

9. Carry out the pressure relief again.

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FIGURE 9.21

9— 8

Section X – SPECIAL PROCEDURES

Table of Contents GENERAL ..................................................................................................................................................... 10-1 RELEASING TRAVEL MOTOR BRAKES .................................................................................................... 10-1 ~ 10-3 LOWERING ATTACHMENT WITH ENGINE FAILURE ................................................................................ 10-4 RELEASING SWING BRAKE ....................................................................................................................... 10-5 ~ 10-7

WARNING

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READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

10— 0

Section X – SPECIAL PROCEDURES

10.1 GENERAL ATTACHMENT ON GROUND

The machine incorporates automatically applied spring brake systems in the travel motors and swing motors.

These systems will automatically engage the brakes when engine is stopped making it impossible to move the machine.

This section contains the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachment to the ground should sudden engine failure be experienced.

CHOCK BLOCKS AT FRONT AND REAR OF EACH TRACK

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCE OR REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS.

WARNING MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES.

WARNING FIGURE 10.1

THROTTLE IN "LO" POSITION

HI

LO

THE PROCEDURES FOUND IN THIS SECTION SHOULD BE PERFORMED BY A WELL TRAINED EXPERIENCED SERVICE TECHNICIAN.

10.2 RELEASING TRAVEL MOTOR BRAKES A. TOOLS AND EQUIPMENT REQUIRED 1. Four chock blocks.

3. One 8 mm allen wrench.

OF HE AT

KEY SWITCH IN "OFF" POSITION

F

ACC

ON T AR ST

2. One 12 mm allen wrench.

4. Two 6 liter (1.6 Gal) capacity drain pans.

5. One M10-1.5 X 30 mm lifting eyes.

FIGURE 10.2

6. Overhead lifting device capable of lifting and holding 45 kg (100 lb).

7. Torque wrench 48 ~ 157 N·m (72 ~ 116 lbf·ft) capacity or better.

REMOVE CHECK / FILL PLUG WITH 12 mm ALLEN WRENCH

8. Thread sealant. (For drain and check/fill plugs) 9. Rubber or soft faced mallet.

B. PROCEDURES 1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released. See Figure 10.1.

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2. Lower attachment to ground. See “10.2 Lowering attachment” for proper procedures, page 10-5.

3. Turn key switch “OFF” and remove key. See Figure 10.2.

FIGURE 10.3

4. Remove check/fill plug from each travel motor using the 12 mm socket head wrench. See Figure 10.3.

10— 1

Section X – SPECIAL PROCEDURES 5. Place a clean 6 liter (1.6 gallon) capacity drain pan under each travel motor drain plug and remove drain plug using the 12 mm socket head wrench. See Figure 10.4.

REMOVE DRAIN PLUG WITH 12 mm SOCKET WRENCH

6. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine.

6 LITER (1.6 GAL) CAPACITY DRAIN PAN

7. Remove the sixteen plate mounting bolts from the travel motor reduction unit cover plates. See Figure 10.5.

FIGURE 10.4

8. Remove the two bolts from the bossed areas and install the two M10-1.5 X 30 mm lifting eyes into each of these holes. See Figure 10.6.

REMOVE 16 MOUNTING BOLTS WITH 8 mm SOCKET WRENCH

9. Attach the overhead lifting device to the lifting eyes and remove most of the slack from the chain or cable.

10. Using a rubber mallet, gently strike the edge of the cover plate to help release plate from housing.

CAUTION Be careful not to damage lip of cover plate. Any damage to the lip could result in a gear oil leak.

FIGURE 10.5

REMOVE BOLTS FROM BOSSES WITH 8 mm SOCKET WRENCH

11. After cover plate has release from housing, carefully move cover away from machine with lifting device.

INSTALL M10-1.5 X 30 mm LIFTING EYE INTO EACH BOSS

CAUTION When removing the following components it will be necessary to have a clean area free of dirt and grit to lay these components.

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FIGURE 10.6

10— 2

Section X – SPECIAL PROCEDURES 12. Remove the thrust plate and sun gear. See Figure 10.7.

REMOVE SUNGEAR REMOVE THRUST PLATE

13. Attach the overhead lifting device to the M10 lifting eye and remove most of the slack from the cable or chain. See Figure 10.8.

FIGURE 10.7

14. Carefully by hand work the planetary gear assembly free from the housing. See Figure 10.8.

INSTALL M10-1.5 X 20 mm LIFTING EYE INTO PINION GEAR SHAFT

CAUTION Be aware of and protect hands from pinch areas when removing and installing planetary gears or any other component which may cause personal injury.

15. Install cover plates onto housings and tighten all bolts securely.

WORK PLANETARY GEAR ASSEMBLY FREE FROM HOUSING WITH LIFTING DEVICE AND HANDS

16. Install fill and drain plugs into cover plates and replace gear oil into travel reduction units through fill/ check port to proper level.

FIGURE 10.8

17. After steps 4 through 16 have been performed on both travel reduction units, the machine may be towed to an area where repairs can be made.

18. After repairs are made reinstall the “drive gear” in reverse order. Use the following torque specifications for bolts and plugs.

TORQUE SPECIFICATIONS COVER BOLTS ........ 74 N·m (54 lbf·ft) PLUGS ..................... 157 N·m (115 lbf·ft)

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FIGURE 10.9 NOTE Refer to Section 4, page 4-8 and 4-9 for proper oils specification and capacity.

10— 3

Section X – SPECIAL PROCEDURES

10.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS A. HOW TO LOWER ATTACHMENT – FIGURE 10.10 The port relief valve is used to return the oil remaining in the cylinder to the hydraulic tank to protect the piping when the pressure inside of piping rises higher than the set pressure owing to the external load exerted on the cylinder, and also may be used as a measure to lower attachment when the engine stops owing to trouble, etc.

After loosening lock nut of port relief valve as adjuster screw is loosened the set pressure gradually falls. When the set pressure decreases lower than the hold pressure of cylinder currently holding attachment, the above

PISTON

POPPET

hold pressure opens the poppet, the plunger moves rightward and the continuity from P to R is made. And the oil remaining in the cylinder returns to the tank.

With this, attachment can be brought down to the ground while engine stops.

NOTE Before loosening adjuster screw, mark those positions, and after bringing down attachment to the ground, tighten adjuster screw to the marked positions.

LOCK NUT

P

P R

R

PLUNGER

SEAT

SPRING

TO TANK BOOM CONFLUENCE

BOOM SLEWING

CUT & ARM CONFLUENCE ARM

BUCKET TRAVEL LEFT TRAVEL RIGHT

BOOM SPOOL

ARM REGENERATION & CUT

TRAVEL STRAIGHT

PBb PLc1 Drc

R

R

H

H

(Ab)

Bb

FIGURE 10.10

10— 4

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BOOM CYLINDER

Section X – SPECIAL PROCEDURES B. HOW TO LOWER ATTACHMENT – FIGURE 10.11 When engine stops because of troubles, the relief valve incorporated in the holding valve mounted on the boom cylinder head side is available to lower attachment.

As shown in the figure, after loosening lock nut of stop valve as setscrew is loosened, the poppet is opened and then the oil remaining in the boom cylinder head side returns to the tank through T port enabling attachment to be lowered.

HOLDING VALVE

NOTE Before loosening adjuster screw, mark those positions, and after bringing down attachment to the ground, tighten adjuster screw to the marked positions.

CAUTION Be careful when lowering attachment. Do not stand under boom.

LOCK NUT

RELIEF VALVE

FIGURE 10.11

10.4 HYDRAULIC TANK PRESSURE – FIGURE 10.12

DEPRESS RUBBER CAP TO RELEASE PRESSURE

How to release air pressure remaining in the hydraulic tank.

After engine stops, the air pressure remaining in the hydraulic tank.

Can be released by pushing valve on the air breather rubber cap several times (5 ~ 7 times). Air breather mounted on the upper part of hydraulic tank.

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FIGURE 10.12

10— 5

Section X – SPECIAL PROCEDURES

10.5 RELEASING SWING BRAKE WARNING MAKE CERTAIN THAT THE ATTACHMENT IS ON THE GROUND TO HELP PREVENT SUDDEN ROTATION OF THE UPPER STRUCTURE BEFORE ATTEMPTING TO RELEASE THE SWING BRAKE. REFER TO PAGE 10-5 FOR ATTACHMENT LOWERING PROCEDURES.

REMOVE ALL HOSES, TUBES AND FITTINGS TO GAIN ACCESS

The Manufacturer highly recommends the use of a hydraulic hand pump to release the swing brake manually when the engines fails to start. Refer the Figure 10.14 to use the proper fitting connector on PG port. Remove the hose and install the proper connector on PG port. Install the hydraulic hand pump and apply hydraulic pressure as follows:

FIGURE 10.13

TOP VIEW

SWING MOTOR

E235SR(LC), E235SRNLC ... 29 kgf/cm2 (413 psi)

Dr Au

P

CAUTION

L

In highly contaminated environments it is recommended to remove the whole swing motor assembly, if a hydraulic hand pump is not available. Contact your Dealer for assistance. When the swing motor is removed, make sure to use caps and plugs on hoses, tubes and fittings to protect the hydraulic system from any contamination. Also, a cover must be used to protect the swing reduction unit. If this approach is taken, and the swing reduction unit becomes contaminated, make sure to flush and clean the swing reduction unit. Refer to page 4-8 and 4-9 for proper oil and component capacity.

IP

Mu B

A Mu

SIDE VIEW

2-M12 DEPTH 18 LIFTING CAPACITY 220kg/2 bolts

A,B

If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed to the next page for specific instructions on a different alternative to release the swing parking brake.

CAUTION Torque N·m (lbf·ft) 2-PF3/4 162±15 (119±11) A,B Main port PF1 255±10 (187±7) Mu Make-up port PF3/8 73.5±5 (54±4) Dr Drain port P Brake release port PF1/4 36.3±2 (27±1.5) L Gear oil level port PT1/2 65 (48) IP Gear oil filling port PT3/4 98 (72) PF1/4 Au Air bleed 29 (21)

Code

Name

Size

FIGURE 10.14 10— 6

Remarks

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Use safety protection such as: hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

Section X – SPECIAL PROCEDURES A. TOOLS & EQUIPMENT REQUIRED 1. Handtools required for removal of hydraulic tubes, hoses and fittings.

INSTALL PROPER CAPS AND PLUGS ON HOSES, TUBES AND FITTINGS TO HELP PREVENT CONTAMINATION ENTERING THE SYSTEM

2. Plugs and caps for tubes, hoses and fittings.

3. 10 mm allen wrench.

4. 5 mm allen wrench.

5. Two M12-1.75 X 26 mm lifting eye.

FIGURE 10.15

6. Overhead lifting device capable of lifting and holding 100 kg (220 lb).

7. Plenty of clean, dry shop rags and/or paper towels.

REMOVE THE TWO PLUGS AND INSTALL LIFTING EYES (M12-1.75 X 26 mm)

8. 14 mm allen wrench.

9. 441 N·m (325 lbf·ft) torque wrench.

B. PROCEDURES 1. Lower attachment to ground. Refer to previous page for proper procedures in lowering the attachment.

2. Remove all hoses and tubes from the swing motor top plate and swing valve to gain access to the top plate mounting bolts. See Figure 10.14.

TOP COVER

3. Install the proper plugs and caps onto hoses, tubes and fittings to avoid the possibility of contamination entering the hydraulic system. See Figure 10.15.

FIGURE 10.16

CAUTION Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

4. Remove two plugs, as indicated in Fig. 10.16, and install 2 X M12-1.75 X 26 mm eye bolts.

LOOSEN (4) COVER MOUNTING BOLTS

NOTE Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the top plate.

5. Loosen the four top plate mounting bolts with the 14 mm allen wrench. See Figure 10.17.

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FIGURE 10.17

10— 7

Section X – SPECIAL PROCEDURES 6. Remove two top plate mounting bolts from corners opposite of each other.

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

REMOVE ALL SPRINGS

8. Carefully remove the remaining two bolts from the top mounting plate.

NOTE The top plate will raise from spring pressure as the last two bolts are removed. Some movement of the upper frame may be experienced as the spring tension is released.

FIGURE 10.18

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shockless valve assembly and away from the swing motor.

CAUTION Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

ALIGN DISTRIBUTOR PLATE HOLES TOWARDS FRONT AND REAR OF HOUSING

10. Carefully remove all brake springs and place in a container filled with fresh, clean hydraulic oil. Then, seal the container to prevent contamination. See Figure 10.18.

FIGURE 10.19

11. Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing. See Figure 10.19.

DOWEL PINS

12. Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate. See Figure 10.20.

13. Carefully and slowly lower the top plate into position on the swing motor and install, by hand, the four top plate mounting bolts.

14. After the machine upper structure is positioned for towing, remove cover again and reinstall the swing brake springs. Repeat steps 11~13 to lock the upper frame into position for proper transportation.

FIGURE 10.20

CAUTION CAUTION Avoid oil spills. Use containers, rags, and / or paper towels to contain any oil leakage. Dispose all waste oils, fluids lubricants and other hazardous waste properly, according to government regulations.

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Make certain the top plate dowel pins and the distributor plate holes mesh together.

10— 8

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COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Print No. 604.21.091.00 - V - 2003

13503 60421091

Reproduction of text or illustrations, in whole or in part, is strictly prohibited

E235SR Evolution Operation and Maintenance Instruction Manual Print No 604.21.091.00 English - Printed in Italy

E235SR Evolution Operation and Maintenance Instruction Manual