Kobelco 17SR Acera Tier 4 Operator's Manual PDF

OPERATOR’S MANUAL COMPACT CRAWLER EXCAVATOR

17SR ACERA TIER 4

S2PU00013ZE01 Issued March, 2010 KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

English Part Number S2PU00013ZE01 Printed in U.S.A. • Rac

APPLICABLE: 17SR . . . . . . . . . . . . . . . . PU09-08001~

17SR ACERA TIER 4 COMPACT CRAWLER EXCAVATOR OPERATOR’S MANUAL

Part Number: S2PU00013ZE01

Applicable Pin Number: PU09-08001 and higher

KOBELCO CONSTRUCTION TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

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

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

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or

serious injury. The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or

serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as

and STOP if used, are RED.

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

machine on a job site.

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

WARNING_01_NA

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

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2009 Kobelco Construction, LLC All Rights Reserved Kobelco is a registered trademark of CNH America LLC

Rac S2PU00013ZE01NA Issued March 2010

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Starting and Stopping Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting and Stopping Machine Engine in Cold Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 50 hour maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 I

1500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER SK17SR COMPACT CRAWLER EXCAVATOR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. The risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

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

The standard attachments and tools of this machine are designed to carry out all kinds of earth moving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is equipped for this type of work. For these applications, the machine must be equipped with safety valves, a load handling chart corresponding to the type of machine and its attachment, and a load fixing point. All legal requirements must also be strictly observed.

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

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

The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your Kobelco Construction, LLC Dealer.

Before permitting a new operator on this machine, make certain: That the operator has received the necessary training on how to operate the machine correctly and safely.

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

Contact your dealer for operator manuals translated into Spanish or French Canadian.

Always keep this manual in the operator's compartment in its designated storage space. Make sure it is complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your Kobelco Construction, LLC Dealer.

Your Kobelco Construction, LLC Dealer is available for any further information. They will also provide any after-sales service you may need, and genuine Kobelco Construction LLC spare parts, your guarantee of quality and match.

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CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

5. TRAVEL REDUCTION GEARS (TRAVEL MOTORS) 6. IDLER WHEELS

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

1

2

3 4 5

8 9

7

6

10

29

11 28 27 12

26 25 24 23

13

22 21

20

14 19

16 15 18 17 Figure 2

RH09H184

MACHINE COMPONENTS

1. ARM 2. ARM CYLINDER 3. BUCKET CYLINDER 4. IDLER LINK 5. BUCKET LINK 6. BOOM 7. CANOPY 8. SWING CYLINDER 9. FUEL TANK 10. RADIATOR, OIL COOLER

11. AIR CLEANER 12. BATTERY 13. ENGINE 14. COUNTER WEIGHT 15. SLEWING MOTOR 16. HYDRAULIC PUMP 17. TRAVEL MOTOR 18. HYDRAULIC TANK 19. SLEWING BEARING 20. GUARD

21. CONTROL VALVE 22. LOWET ROLLER 23. IDLER ADJUST 24. FRONT IDLER 25. SHOE 26. DOZER 27. DOZER CYLINDER 28. BOOM CYLINDER 29. BUCKET

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CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

When ordering par ts, obtaining infor mation or a s s i s t a n c e , a l w a y s s u p p l y y o u r Ko b e l c o Construction, LLC Dealer with the type and serial number of your machine or accessories.

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

Figure 4

BS10B052

ENGINE ➤ Make and Model ➤ Serial Number Figure 3

BS07M602

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year

1-4

CHAPTER 1 - GENERAL INFORMATION FOPS ROPS CERTIFICATION

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump ➤ Swing Reduction Gear ➤ Travel Reduction Gears ➤ Travel Control Valve ➤ Attachment Control Valve ➤ Swing Control Valve

Figure 5

RH10B051

ROPS/FOPS SERIAL NUMBERS PRODUCT IDENTIFICATION PLATE ➤ FOPS Serial Number ➤ ROPS Certification

1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Decal locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Boom and Arm Movement - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hydraulic Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Safety Controls - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hot Surfaces - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Pressurized Fluids and Lubricants - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Counterweight Swing Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Engine Stop - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS track Tension Adjustment - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Keep Clear of Working Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 Battery - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Electrical Line Safety - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 Safety Lock Lever - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Foot pedal - caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Seat Belt - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19 Hydraulic Oil Check Position - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 track frame/dozer- notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 nibbler & breaker- Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 ROPS Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Confirm attachment movement (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21 Stop Engine - Danger (Option - Multicontrol lever‘) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 battery- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 Counter Weight Lifting Eyes - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22 use specified diesel oil for fuel according to epa regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Window Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Door Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-2

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES PERSONAL SAFETY

WARNING

If Safety Decals on this machine are ISO two panel pictorial, decals are defined as follows:

This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

• The first panel indicates the nature of the

M171C

hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW Most accidents involving machine operating and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety signs on the machine before you operate or service the machine. The Operator’s Manual is stored in the ceiling of the canopy. Always keep the manual with the machine.

Prohibition symbols such as used, are RED.

and STOP if

SAFETY AREA

1

2 Figure 2

BC02N198

1. WORKING AREA 2. SAFETY AREA UPU00100024ES1

Figure 1

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability, and load characteristics of this machine before you start to operate this machine.

The safety area is the space necessary for the machine to operate at the maximum range of the tool. The area is a full 360 ° swing plus 6 feet (2 meters).

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

The safety information given in this manual does not replace safety codes, insurance needs, federal, state, or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

Additional safety messages are used in the text of the manual to show specific safety hazards.

NOTICE: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS UTILITY SAFETY Safety precautions MUST be followed when working near buried and overhead utility lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• Electrical Power Line • Gas Line • Water Line • Communication Line - Telephone or Cable Television

• Telephone or Cable Television NOTICE: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

NOTICE: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

RH99G001

Figure 3

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a h o l e by h a n d a n d / o r w i t h a u t o m a t i c va c u u m equipment to the utility line to verify the location and depth of the line.`

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS PERSONAL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

aid kit and a working fire extinguisher with you and know how to use each.

points of support when getting on and off the machine. Keep steps and platform clean. Face the machine when climbing up and down.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of the type of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old or damaged hard hats may not provide the same level of protection as a new hard hat. Faded and soiled vests are no longer as highly visible as new vests.

See the manufacturer’s recommendation.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• DO NOT OPERATE this machine or perform

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machine’s tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s seat.

maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

• Do not bypass the machine’s neutral-start

• Wear the seat belt to maximize the protection

• Use booster cables only in the recommended

capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using booster cables. Make sure that using booster cables will not interfere or harm electronic processing or computer devices.

• Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• DO NOT use the bucket or attachment to lift persons or carry riders on the machine.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

system. The neutral-start repaired if it malfunctions.

system

must

be

• DO NOT OPERATE the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

• Before leaving the operator’s station, lower the equipment to the ground, shut off the engine and place the safety lock lever into the locked or up position.

2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Remove the starter key or disconnect switch

• When roading a machine, know and use the

when leaving the machine parked or unattended.

signaling devices required on the machine.

Provide an escort for roading where required.

OPERATING PRECAUTIONS

• Check brakes, steering and other machine control devices in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a DO NOT OPERATE tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a DO NOT OPERATE tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

• Understand the machine limitations and keep the machine under control.

• On machines with independently operated wheel brakes, lock the brake pedals together when roading to provide equalized brake application.

• Use the recommended transport devices when roading the machine.

• Use the approved drawbar and / or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Before you operate at night, check that all lamps illuminate.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers and washers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Operate and drive the machine with care and at

• Check all controls in a clear area and make sure

speeds compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Dust, fog, smoke, etc., can decrease your vision

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

2-6

the machine is operating correctly. and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

• If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS 3. If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

• DO NOT OPERATE the machine if you do not feel well. This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking brake, place the equipment in a safe position, securely block the tracks and use extreme caution.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a tow bar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake. Avoid towing over long distances.

DC04E084

Figure 4

• 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 prevent accidental starting of the machine.

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternate: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

• Wear gloves to protect hands when handling cable.

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• When the battery electrolyte is frozen, the

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to contaminate the environment.

• To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top.

Allow room for expansion.

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

• Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturers approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc. used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

• Before you service your machine, check the

BURN PREVENTION

MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

WARNING BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

M144B

WARNING

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Check with your local environmental or recycling center or your dealer for correct disposal information.

TRANSPORTING PRECAUTIONS K n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n t necessary for transporting this machine on a road or highway.

ROLL-OVER PROTECTIVE STRUCTURE (IF EQUIPPED)

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in death or serious injury.

M422A

2-8

battery can explode if you try to charge the battery or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured

D o N OT m o d i f y t h e R O P S i n a n y m a n n e r.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS EMERGENCY EXIT HAMMER

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. Contact your dealer for the type and location of a fire extinguisher for this machine.

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system

22

M422A

11

SEAT BELT PRECAUTIONS

1 UPW00100007E01

Figure 6

An emergency exit hammer is provided on the right s i d e o f c a b. I n c a s e o f e m e r g e n c y, t a ke t h e emergency hammer (1), break the cab glass, and escape from the cab. In addition, the emergency hammer is equipped with a cutter (2) on the lever side to cut seat belt, etc.

2

SPECIFIC PRECAUTIONS TO THIS MACHINE Figure 5

DC04D529.

• Keep the load or tool as low as possible while moving the machine around the job site.

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

• Always confirm travel direction before moving the

1. Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat.

• Never smoke while refueling.

• Do not use tractive force of the machine for

machine.

2. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

loading the bucket attachment nor to push or pull any objects.

• Do not use swinging force of the machine for operations.

WARNING Before starting the engine make certain seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

• Do not perform “hammering” operation with the bucket.

• Do not use this machine for anything other than its intended purpose.

• DO NOT OPERATE bucket and arm cylinders to stroke end repeatedly.

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS Safety decals are placed on your machine as a guide for your safety. Walk around the machine, and note the content and location of these decals before operating your machine.

WARNING An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply could result in death or serious injury.

CE-NA000

WARNING Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply could result in death or serious injury.

CE-NA000

NOTE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals for the machine, consult your authorized dealer.

384270A1A

Figure 7

This symbol instructs you to refer the Operator’s M a n u a l fo r f u r t h e r i n fo r m a t i o n r e g a r d i n g maintenance, operational guidelines, etc.

BC00G075

Figure 8

This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

NOTE: Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED.

• WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW • Prohibition symbols such as and STOP if used are RED.

2-10

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DECAL LOCATIONS

88 A

44

FUL L LOW

F F

DETAIL A

2

SECTION AA

B A

A

C C B

B

77 6

10

UPUX1201001E01

Figure 9

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

13 55

SECTION BB

SECTION CC

33

D

15 28 28 14 14 11

17 20 20 16 17

99 24 23 23 DETAIL D

18 18 27 27

E

22 19 21 22 19 12

10 UPUX1301001E01

2-12

VIEW E

11 11 Figure 10

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CAB

[ CAB ] 29 29

B A

30 30

29 SECTION AA

B A

23 23

18 18

21 21 SECTION BB

33

19 19

24 24

DETAIL B (CAB SPEC.)

28 14 14 11

17 20 16 17

9

DETAIL D

26

25 25

SECTION BB (CAB SPEC.)

UPUX1301003E01

31 (CAB SPEC.) 31 26 26

VIEW I

Figure 11

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOM AND ARM MOVEMENT - CAUTION Located on seat stand cover.

1

Part Number PU20T01020P1 Use caution when operating machine not to strike the cab or machine with bucket or attachment.

/RH09N018

HYDRAULIC OIL - WARNING Located on hydraulic tank.

Part Number PW20T01007P1

2

Always release pressure from the hydraulic system before performing any maintenance.

Pressurized hot oil can cause burns.

Depress stem or remove cap slowly with engine off to relieve Hydraulic Tank pressure.

PW20T01007P1

UPV00100002ES1

Figure 12

SAFETY CONTROLS - WARNING Located on seat stand cover.

Part Number YN20T01016P1 Lists machine operation war nings and safety precautions.

2-14

3 Read and understand the operators manual before operating or performing maintenance on this machine.

Failure to follow or pay attention to instructions in operators manual can result in injury or death.

It is your responsibility to be aware of and follow all local laws and regulations.

Before starting machine, make sure hydraulic control lever is in lockout position and all control levers are in neutral.

Sound horn to alert people.

Ensure bystanders and obstacles are clear of machine before moving machine or its attachments.

Do not carry riders on machine.

Before leaving operators compartment, park on level ground, lower attachments to ground, make sure hydraulic control lever is in lockout position and stop engine.

UPV00100003ES1 Figure 13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT SURFACES - CAUTION Located on radiator reservoir tank bracket.

4

Part Number YN20T01220P1 Engine coolant, oil, and hydraulic oil temperatures are very high after machine operation. Allow machine t o c o o l b e fo r e a t t e m p t i n g a ny m a i n t e n a n c e procedure.

Engine may be hot which could cause burns.

Do not touch engine until it cools down.

YN20T01220P1 UPUX1201006E01

Figure 14

PRESSURIZED FLUIDS AND LUBRICANTS - WARNING Located on the control box.

Part Number PE20T01013P1

5

Always release pressure from pressurized systems before performing any inspection or maintenance procedures. Always allow machine to cool prior to performing any procedure.

PW20T01094P1

Figure 15

ENGINE STOP - CAUTION Located on hood support.

Part Number YN20T01012P1

6

Always stop the engine before opening the hood.

Rotating parts such as fans and pulleys can cause serious injury or death.

BS07M648

Figure 16

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT SWING AREA - DANGER Located on right rear of machine.

7

Part Number PE20T01014P1 Warns of swing area danger. Make certain area is clear before moving machine.

PE20T01014P1

UPJ00010004E01

Figure 17

ENGINE STOP - WARNING Located on engine radiator.

Part Number YN20T01009P1

8

Keep away from rotating parts. Stop engine before servicing.

BS07M649

Figure 18

BOOSTER CABLE - WARNING Located on seat stand cover.

9

Part Number YN20T01338P1 Do not mishandle battery cables. Read operator manual for proper procedure.

BS07M650

2-16

Figure 19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS TRACK TENSION ADJUSTMENT - WARNING Located on crawler frame.

10

Part Number YN20T01813P1 Read the operator’s manual before making any track adjustments. System under pressure.

YN20T01813P1

UPUX1701011B01

Figure 20

KEEP CLEAR OF WORKING AREA - DANGER Located on both sides of arm.

Part Number PE20T01012P1

11

Make certain work area is clear. Sound horn before beginning any movement or swing operation.

PE20T01012P1

Figure 21

DOZER BLADE- CAUTION Located on canopy support.

Part Number PU20T01034P1

12

Check canopy bolts for proper torque.

UPUX1201014E01

Figure 22

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BATTERY - DANGER Located on the battery.

Part Number PY20T01069P1

13

PY20T01069P1

Figure 23

ELECTRICAL LINE SAFETY - DANGER Located on seat stand cover.

Part Number YN20T01006P1

14

Keep a safe distance from power lines when operating machine.

BS07M654

Figure 24

SELECTOR VALVE - CAUTION Located on left hand cover.

Part Number PU20T01023P2

15

RH09M017

2-18

Figure 25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SAFETY LOCK LEVER - WARNING Located on seat stand cover/ Part Number PY20T01073P1

16

Always engage safety lock lever before exiting cab to prevent unexpected machine movement.

Figure 26

UPX00100017E01

FOOT PEDAL - CAUTION Located on seat stand cover.

Part Number PY20T01062P1

17

Check foot pedal control pattern before operating.

Attachment operation by foot pedal.

Always check the foot pedal control pattern before operation.

Always read operators manual before operating machine.

PY20T01062P1

Figure 27

UPV00100018ES1

SEAT BELT - WARNING Located on ceiling (canopy and cab).

Part Number PE20T01027P1

18

Always wear the seat belt when operating machine.

AVOID CRUSHING . DO NOT JUMP IF MACHINE TIPS BUCKLE UP PE20T01027P1

UPX00100019E01

Figure 28

2-19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HYDRAULIC OIL CHECK POSITION - NOTICE Located on ceiling (canopy and cab).

Part Number 2432P3379

19

Check hydraulic oil to prevent machine damage.

/DFN RI K\GUDXOLF RLO ZLOO FDXVH GDPDJH WR PDLQ K\GUDXOLF SXPS %HIRUH VWDUWLQJ RSHUDWLRQ 3ODFH PDFKLQH RQ OHYHO JURXQG )XOO\ UHWUDFW DUP DQG EXFNHW F\LQGHUV DQG ORZHU ERRP WR JURXQG &KHFN K\GUDXOLF RLO OHYHO JDXJH IRU SURSHU OHYHO

3

UPX00100027E01

Figure 29

TRACK FRAME/DOZER- NOTICE Located on seat stand cover.

Part Number PU20T01018P1

20

Directions for expanding and contracting track frame.

UPU00100013ES1

2-20

Figure 30

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS NIBBLER & BREAKER- CAUTION Located on the ceiling (canopy and cab).

Part Number PE20T01020P1

21

Always make cer tain track frame is in the fully expanded position. Do not use attachment over the side of machine.

UPU00100015ES1

Figure 31

ROPS WARNING Located on the ceiling (canopy).

Part Number PE20T011028P1

22

Warns against operating the machine if ROPS is damaged. Wear seat belt and do not modify ROPS. Read the operator’s manual for more information.

UPUX1201024E01

Figure 32

CONFIRM ATTACHMENT MOVEMENT (OPTION) Located on seat stand cover and cab.

Part Number YN20T01039P1

23

Confirm the movement pattern of the attachment before operating the machine.

This machine equipped with a rotary multi-control valve which allows changing of operating lever control patterns.

Operating this machine before checking function of each control lever can cause unexpected machine movement, which can result in serious personal injur Make sure you check and know function of each control lever before operating.

YN20T01039 UPX00100032E01

Figure 33

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP ENGINE - DANGER (OPTION - MULTICONTROL LEVER‘) Located on inside of side cover.

Part Number YN20T01214P1

24

Always stop the engine when making a change with the lever on the multi-control valve.

UPX00100031E01

Figure 34

BATTERY- WARNING Located on counter weight.

Part Number YN20T01495P1

25

Battery posts and terminals may contain lead and other lead compounds.

UPU00100014ES1

Figure 35

COUNTER WEIGHT LIFTING EYES - DANGER Located on the counter weight.

Part Number YN20T01221P1

26

DC03H144

2-22

Figure 36

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS USE SPECIFIED DIESEL OIL FOR FUEL ACCORDING TO EPA REGULATIONS Located on right side of service door.

Part Number PV20T01068P1

27

Fuel advisory notice pertaining to EPA regulations.

Figure 37

PV20T01068P1

BATTERY Located on the seat stand.

Part Number YN20T01356P1

28

YN20T01356P1

Figure 38

UPUX1701014B01

WINDOW LOCK Located inside front window of cab.

Part Number ZL11M06008

29

ZL11M06008

ULC00010018E01

Figure 39

2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DOOR EDGE Located on inside right window.

Part Number PU20T01055P1

30

Rear edge of door extends beyond machine in the open/latched position. Do not strike objects with door protrusion.

Figure 40

UPU00100033ES1

FRONT WINDOW Located on inside cab front window Part Number YN20T01416P1

31

Lock front window securely in place on both sides.

Falling front window can cause injury.

Always lock securely in place with lock lever on both sides.

YN20T01416P1 UPX00100026E01

2-24

Figure 41

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS NOTICE: When operating the machine, never attempt to carry out tasks calling for the control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

MOVE LOAD IN HORIZONTALLY

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

RAISE LOAD VERTICALLY

DC04E040

Figure 44

Face Machine Operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 42

Face Machine Operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

LOWER LOAD VERTICALLY

DC04E041

Figure 45

Face Machine Operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

RAISE BOOM

DC04E039

Figure 43

Face Machine Operator, extend right arm down, point index finger down and move hand in small circular motion.

DC04E042

Figure 46

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb up.

2-25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LOWER BOOM

DC04E043

ARM IN

Figure 47

DC04E046

Figure 50

Face Machine Operator, extend r ight ar m out horizontally from shoulder, make a fist with thumb down.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

SWING LEFT

ARM OUT

DC04E044

Figure 48

DC04E047

Figure 51

Face Machine Operator, extend r ight ar m out horizontally from shoulder, make a fist with index finger pointing in swing direction.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other.

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 49 DC04E048

Fa c e M a c h i n e O p e ra t o r, ex t en d l e f t a r m o u t horizontally from shoulder, make a fist with index finger pointing in swing direction.

2-26

Figure 52

Face machine Operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CLOSE BUCKET (BUCKET IN OR DIG)

COUNTER ROTATE RIGHT

DC04E049

Figure 53

DC04E052

Figure 56

Face Machine Operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

Face Machine Operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

TRAVEL FORWARD

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 54

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion

DC04E053

Figure 57

Face Machine Operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion.

TRAVEL REVERSE TURN LEFT

DC04E051

Figure 55

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

DC04E054

Figure 58

Face Machine Operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small reverse circular motion.

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP

TURN RIGHT

DE04E055

Figure 59

DC04E058

Figure 62

Face Machine Operator, raise left forearm up, make fist with left hand and hold stationary, bend right hand arm in, make fist with right hand and rotate right fist in a small forward circular motion.

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

MOVE THIS MUCH

EMERGENCY STOP

DC04E056

Figure 60

Face Machine Operator, raise both forearms up, hands open and facing each other, move hands in laterally indicating how far to go.

DC04E059

Figure 63

Face Machine Operator, raise both ar ms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY STOP ENGINE

DC04E057

Figure 61

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

2-28

DC04E060

Figure 64

Face Machine Operator, right arm at side, draw left thumb or index finger across throat.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Storing Upper Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cab Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Opening Right Window Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Window Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Door Cover - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Door Cover - Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Right Hand Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Operating Control Levers (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Operating Control Levers (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Left and Right Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Throttle Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Dozer Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Adjustable Crawler Frame Width Control Lever/dozer Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Crawler Frame Width Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Nibbler and Breaker Pedal (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Swing Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

CAB DOOR LATCH

Figure 1

RH09M020

Use the ignition switch key to lock and unlock the cab door. Insert the key fully into the door lock, and turn to lock and unlock cab door. Use this key to open other machine locking compartments.

Figure 2

RH09M020

1. The cab door can be latched in an open position by opening door until it is locked in place by the door latch located on the cab.

WARNING WARNING Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab or making adjustments to the machine. Never leave the machine unattended with engine running, unexpected machine or attachment movement could occur. Failure to comply could result in death or serious injury.

To provide secure hand and foot mobility, preventing slipping and possible injury, always face the machine when mounting and dismounting.

Failure to comply could result in death or serious injury.

R131B

M1710

Figure 3

RH09M021

1. DOOR RELEASE LEVER

2. To release door from the open position, push down on the release lever.

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS STORING LOWER FRONT WINDOW

STORING UPPER FRONT WINDOW The upper front window can slide into the ceiling for storage.

WARNING A falling window can cause injury to you or others.

Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in death or serious injury.

M1709

RH09M023

2. Pull down the levers provided on the left and right sides of the upper portion to unlock the front windshield.

3. Grasp the handle on the windshield, hold it up and slide into backside ceiling.

4. Be sure to lock the front windshield housed into the ceiling by pushing up the lever.

5. Close the upper front windshield in the reverse order.

3-4

A falling window can cause injury to you or others.

Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in death or serious injury.

M1709

After storing the upper front windshield, the lower front windshield can be removed and stored.

Figure 4

1. Move the machine to level ground, set the safety lock lever to the locked position, then stop the engine.

RH09M024

WARNING

Figure 5

RH09M025

Figure 6

1. Hold up the lower front windshield to remove it from the window frame.

2. Insert the lower front windshield into the lower rail portion of the window frame to store.

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDOW WASHER TANK

CAB LAMP

The washer tank is installed on the right rear of the cab.

2

Figure 7

RH09M026

3

1

1. Operate the cab lamp switch as required.

Figure 9

RH09M022

OPENING RIGHT WINDOW GLASS

1. WASHER TANK 2. CAP 3. MOTOR

1

1. Check the washer tank (1) fluid level.

2. When the fluid level becomes low, remove the cap (2) and fill with washer fluid.

3. Do not operate the washer without fluid in the tank. This could damage the windshield washer motor.

Figure 8

RH09M027

1. LOCK

1. Open right window by releasing lock and sliding the window.

2. Close the glass sliding it to closed position, then lock it.

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOCUMENT POUCH

UPU00100024ES1

SEAT BELT

Figure 10

T h e O p e r a t o r a n d Pa r t s M a n u a l s t o r a g e compartment is located in the ceiling of the cab.

Keep the Operator and Parts Manual for this machine in this location at all times for quick, easy reference.

OPERATOR SEAT ADJUSTMENTS The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety.

Figure 12

RH09M028

1. Sit on the operator’s seat and adjust the seat position so that the operator’s back closely contacts with the seat back.

2. Verify that the seat belt is not twisted, then fully insert the belt end into the buckle.

3. Adjust the belt length until there is no slack.

SEAT FRONT AND REAR HEIGHT ADJUSTMENT

Figure 13

RH09M029

4. Push the button to release the seat belt.

Figure 11

BS07666

WARNING

SEAT FRONT AND REAR ADJUSTMENT LEVER

1. Move the seat adjustment lever to the right.

Adjust the seat forward or backward to the desired position.

2. Release lever to lock the seat in position.

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. Failure to comply could result in death or serious injury.

M422B

NOTE: Replace the seat belt every three years regardless of appearance. Note date of replacement on support mount for reference.

3-6

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS ENGINE DOOR COVER - LOCKING

ENGINE DOOR COVER - OPEN NOTICE: Stop the engine when the engine door or radiator cover is opened.

UPU00200013JS1

Figure 14

BS07M667

A lock is provided for the engine doors. Use the ignition key to open and lock the engine doors.

Figure 16

1. Return the strut to the storage position by placing it into the holder.

2. Close the cover.

3. Insert the key and turn it counter clockwise to lock the cover. Then remove the key.

3

NOTICE: Stop the engine when the engine door or radiator cover is opened.

WORK LAMP

1 2 Figure 15

RH09M030

1. KEY CYLINDER 2. ENGINE DOOR 3. FUEL DOOR

1. Insert the key.

2. After releasing the lock, remove the key and open the cover.

RH09M036

3. Secure the cover in the open position with the strut.

A work light is provided on the boom for work at night.

Figure 17

WARNING Secure the engine doors in open position with strut when servicing. Failure to comply could result in death or serious injury.

M1438

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

3

4

5

6

7

8

9

10

11

12 13

2 14 15 1 16 17

18

Figure 18

RH09H185

COMPONENTS 1. Crawler/dozer shifting lever 2. Safety lock lever 3. Left operating lever 4. Horn switch 5. Option Switch (Nibbler And Breaker) 6. Left travel pedal

3-8

7. Left travel pedal 8. Travel speed select switch 9. Right travel lever 10. Right travel pedal

13. Right operating lever 14. Dozer blade operating lever 15. Starter switch 16. Throttle lever

11. Slewing lock lever

17. Monitor panel (gauge cluster)

12. Boom swing operating pedal

18. Operator seat

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR CAB NOMENCLATURE

RIGHT HAND CONSOLE AND MONITOR

A brief description and function of the hydraulic excavator components and controls has been included in this section.

IGNITION KEY SWITCH

WARNING Improper service or repair can cause injury or death.

If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine. Failure to comply could result in death or serious injury.

M84-102

All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

Figure 19

BS07M672

KEY SWITCH

The ignition key switch is located on the right hand operator console and has three operating functions.

OFF - In this position, the electrical system is turned off and the engine is stopped.

ON (Heat) - In this position, the machine electrical system is energized. Maintain the key in this position while the machine is in operation.

When engine start-up is difficult due to cold temperatures, turn the key to the ON position to activate the pre-heat feature. Leave the key in this position for approximately 15 seconds and then turn the key to the START position to start the engine. Release the key after the engine starts.

START - Turn the key to the start position to start the engine. After the engine starts, release the key and it will return to the ON position.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL GAUGE

MONITOR PANEL

1 2 3 4 5 RH09M040

6

Figure 21

The fuel gauge needle indicates the amount of fuel in fuel tank. F: Indicates a full tank. Refuel when the indicator is approaching empty with diesel fuel only.

Do not allow the machine to run out of fuel. The needle takes time to move to the appropriate level after turning the key switch to the ON position.

HOUR METER

Figure 20

RH09M038

1. GLOW LAMP 2. BATTERY CHARGE LAMP 3. ENGINE OIL PRESSURE LAMP 4. COOLANT TEMPERATURE LAMP 5. HIGH TRAVEL SPEED LAMP 6. AIR CLEANER RESTRICTION LAMP

WARNING

RH09M039.

Do not perform any maintenance on a hot engine.

Allow the engine to cool before inspection or maintenance. Failure to comply could result in death or serious injury.

M1393

3-10

Figure 22

The hour meter indicates the total time the engine has been running, If the machine is not moving and is stopped, the hour meter continues to record time as long as the engine is running, regardless of engine speed. While the engine is running, the indicator flashes to show that the hour meter is active. Use the hour meter as a reference for maintenance.

CHAPTER 3 - INSTRUMENTS AND CONTROLS ENGINE OIL PRESSURE (Red)

INDICATOR LAMPS NOTICE: If warning lamps illuminate, change machine operating method immediately. If the lamp remains illuminated, stop the engine and determine the cause of the problem. See the Maintenance Section in this manual or contact your dealer.

GLOW LAMP (Yellow)

BS07M776

Figure 25

The engine oil pressure lamp will illuminate if the engine oil pressure drops abnormally while the engine is running. Stop the engine immediately and check engine oil.

See the Maintenance Section for checking oil level.

RH09M041

Figure 23

The lamp will illuminate when the preheat circuit is activated. When engine start-up is difficult due to cold temperatures, use the pre-heat feature to aid in starting.

BATTERY CHARGE LAMP (Red)

BS07M779

Figure 24

This indicator light will illuminate when there is a problem in the battery charging circuit. The indicator lamp will turn on briefly when the key switch is turned to the ON position and should turn off when the engine is started. Check the charging system if the indicator does not turn off after the engine is started.

See the Maintenance section for details.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS HIGH (2nd) TRAVEL SPEED LAMP (Yellow)

COOLANT TEMPERATURE (Red)

Figure 26

BS07M777

WARNING Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply could result in death or serious injury.

BS07M781

Figure 27

The indicator lamp will illuminate when the travel speed is switched to high (2nd) speed. The travel speed selector switch is located on the grip of the right travel lever. The speed automatically returns to low (1st) speed when the starter key switch is turned to OFF.

AIR FILTER RESTRCTION LAMP

M49-39

If the coolant temperature rises abnormally, the coolant temperature lamp (4) will illuminate. Run the machine at low idle until the coolant temperature drops to a normal range.

Reduce engine RPM to idle, and stop operation until engine coolant temperature reaches a safe operating temperature range.

See the Maintenance Section for checking coolant level.

RH09M042

Figure 28

The indicator lamp will illuminate if the air filter cleaner is restricted. If the lamp comes on, stop the engine and clean or replace the air filter element immediately.

See the Maintenance Section for checking air filter.

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS SWITCHES

3

2

1

4

Figure 29

RH09M042

1. Ignition switch 2. Travel speed select switch

66

3. Horn switch

5

4. Travel alarm select switch 5. Work lamp switch (Cab spec.)

77

6. Heater switch (Cab spec.)

7. Wiper and washer switch (Cab spec.)

UPU00200021ES1

Figure 30

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS HORN SWITCH

TRAVEL SPEED SELECT SWITCH Use the travel speed select switch (2) to change travel speeds. When the machine is turned off, the travel speed is automatically set to low (1st).

WARNING Use low speed when operating on a slope or loading/unloading from a truck or trailer. Sudden changes in ground level can cause accidents.

Failure to comply could result in death or serious injury.

SA130

Select low speed when travelling on rough or soft ground, slopes, in confined spaces, loading or unloading from a trailer, or when tractive force is required.

Select high when moving on flat, level ground.

BS07M783

3-14

Figure 31

BS07M784

Figure 32

The horn switch (3) is located on the top of the right control. Always sound the horn before star ting engine or moving the machine.

CHAPTER 3 - INSTRUMENTS AND CONTROLS TRAVEL ALARM SELECT SWITCH (OPTIONAL)

CAB SWITCHES

The travel alarm switch is located on the right side panel. When travel is engaged the alarm sounds automatically.

3

1 2

UPW00200010E01

Figure 33

The travel alarm function is optional. The travel alarm buzzer sounds automatically when operating the lever or pedal to travel.

Figure 34

RH09M044

1. WORK LAMP SWITCH 2. HEATER SWITCH 3. WIPER & WASHER SWITCH

WORK LAMP SWITCH

BS07M786

Figure 35

Use the work lamp switch (5) for turning the boom and machine work lights on and off.

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS HEATER SWITCH (OPTIONAL)

BS07M787

Figure 36

WIPER AND WASHER SWITCH Use the washer/wiper switch (7) to spray washer fluid or turn on the windshield wipers. The switch has four settings.

Wash: (left): Sprays washer fluid Off: Stop On: Operates wipers only Wash: (right) Operates washer fluid and wipers

BS07M788

Figure 37

NOTICE: Do not use the washer for more than 20 seconds continually or without washer fluid, as the washer tank motor may be damaged.

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEVERS AND PEDALS

2

8

3

9

7

2

1 6

4

5

Figure 38

RH09M045

1. Safety Lock Lever

6. Dozer Operating Lever

2. Right/Left Control Levers

7. Boom Swing Operating Lever

3. Travel Levers with Pedals

8. Nibbler and Breaker Pedal (optional)

4. Throttle Levers

9. Slewing Lock Lever

5. Crawler Width Lever

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS SAFETY LOCK LEVER .

1

2

Figure 39

BS06H080

1. SAFETY LOCK LEVER IN LOCKED (UP) POSITION 2. SAFETY LOCK LEVER IN UNLOCK (DOWN) POSITION

The safety lock lever is provided to prevent any unexpected operation due to accidental movement of the operator control lever.

WARNING Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab. Never leave the machine unattended with engine running.

Failure to comply could result in death or serious injury.

M1710

LOCKING THE HYDRAULIC SYSTEM When the safety lock lever is set in the LOCKED (UP) position the hydraulic system is shut down.

When the safety lock lever is set to the LOCKED (UP) position, each attachment and swing motor is locked simultaneously. However, the travel levers are locked separately.

UNLOCKING THE HYDRAULIC SYSTEM When the safety lock lever is set to the UNLOCKED (DOWN) position, all hydraulic functions are active.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATING CONTROL LEVERS (ISO/SAE PATTERN)

Figure 41

DC04D565

WARNING

Figure 40

BS07N561

LH CONTROL LEVER 2

4

E

Arm Out

F

Arm In

G

Swing Left

H

Swing Right

RH CONTROL LEVER 1

3

A

Boom Down

B

Boom Up

C

Bucket In

D

Bucket Out

If your machine is set to the operational BHL pattern control make sure to remove the ISO/SAE operation pattern control decal and use the decal supplied for the optional BHL pattern control. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Confirm that the operating pattern of the levers conforms to the machine lever decal.

Unexpected movement could result if decal and lever pattern do not match. Failure to comply could result in death or serious injury M1716

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATING CONTROL LEVERS (BHL PATTERN)

DC04D566

Figure 43

NOTICE: An optional Pattern control change valve is available. Contact your dealer for more information. If your excavator already has this valve installed use the following instructions (BHL Pattern) regarding its operation.

Figure 42

BS07N562

LH CONTROL LEVER 1

4

E

Boom Down

F

Boom Up

G

Swing Left

H

Swing Right

RH CONTROL LEVER 2

3

A

Arm Out

B

Arm In

C

Bucket In

D

Bucket Out

With the BHL multi control shifting the boom and arm functions are opposite the ISO system. Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT AND RIGHT TRAVEL LEVERS AND PEDALS

BS07N624

Figure 45

1. Push both levers forward (or press the front of the pedals) to travel forward.

2. Pull both levers towards you (or press the near side of pedals) to move in reverse.

3. Release both levers in the center position to stop movement and place the machine in neutral.

THROTTLE CONTROL LEVER

Figure 44

BS07N623

The travel levers and pedals are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward.

• FORWARD - Variable speed forward track movement.

• BACKWARD - Variable speed reverse track movement.

BS07N625

Figure 46

The throttle control lever is located to the right of the operator’s seat and is used to control engine speed.

• CENTER - Neutral position.

The travel functions described are with the travel motor located behind the cab.

(A) LOW (low idling) - Push the throttle fully forward to set the engine to low idle.

(B) HIGH (high idling) - Pull the throttle fully backward to set the engine to high idle.

WARNING Always know the position of excavator travel motors to prevent unexpected movement of the machine.

Normal positioning for determining front, rear, forward, and reverse is with the travel motors located behind the operator's cab. Failure to comply could result in death or serious injury.

M1726

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOZER CONTROL LEVER

ADJUSTABLE CRAWLER FRAME WIDTH CONTROL LEVER/DOZER SELECTOR LEVER

D

1

C

BS07N626

Figure 47

This lever is located on the right side of the operator’s right control panel. Use the dozer control lever to move the dozer up or down.

(C) Dozer Blade Up - Pull the lever back.

(D) Dozer Blade Down - Push the lever forward.

When traveling, raise the dozer blade to its maximum height.

UPU00200008JS1.

Figure 48

NOTICE: This lever is located on the front lower side of the operator’s seat. Use it to select the dozer operation or to adjust the crawler frame width. This lever would normally be placed in the (C) position (dozer). Use the (D) position to allow adjustment to the crawler frame width.

C: Dozer D. Crawler Width NOTICE: Operating the machine at maximum width is recommended. This will increase the stability of the machine. Use a narrower width only when he job site space is limited.

3-22

CHAPTER 3 - INSTRUMENTS AND CONTROLS CRAWLER FRAME WIDTH CONTROL LEVER

A

BOOM SWING OPERATING PEDAL

B

1

RH09N021

Figure 50

BC08J113

A B

Use this pedal to operate the swing motion of the boom.

Figure 49

(A) Push the lever forward to narrow the width of the crawler frame. Minimum width 990mm (39 in) (B) Pull the lever back to widen the width of the crawler frame.

Operating the machine at the maximum width is recommended. This will increase the stability of the machine. Use a narrower width only when the job site space is limited.

See Section 4 - Operating Instructions for further information on adjusting the dozer width and dozer blade width.

To use the pedal, lift the pedal locking cover (1) up.

Right swing: push down right side of pedal Left swing: push down left side of pedal.

WARNING Always lock the pedal if not using the boom swing operating function. Failure to comply could result in death or serious injury.

M1491

To lock the pedal, close cover (1).

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS NIBBLER AND BREAKER PEDAL (OPTIONAL)

SWING LOCK LEVER

1 A B A

1 UPU00200009JS1

Figure 51

The optional pedal (1) is used for nibbler and breaker attachments. When not using this type of attachment, close cover (A) to prevent accidental operation.

UPU00200010JS1

Figure 52

The swing lock lever is located on the front lower side of the operator’s seat. It is used to lock the machine’s upper structure for transpor tation. The upper structure can be locked in a forward or backward position.

A: LOCKED POSITION B: UNLOCKED POSITION NOTICE: DO NOT operate the swing function when the upper structure is in the locked position. Damage to the machine could result.

3-24

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 STARTING AND STOPPING MACHINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 STOPPING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Check Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Check Gauges and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Warming Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 ISO Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operating Control Levers (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 BASIC OPERATION OF HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 safety lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Turning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Boom Swing Operating Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Operating in a narrow space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Dozer Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Using the dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Changing Crawler Frame Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Changing Dozer Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Operating The Machine In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Operating Machine on a Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Offset Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Rubber Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Use of Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 HYDRAULIC BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Setting Machine Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in injury or death.

CE-NA000

Before operating this machine: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr ican ts ar e suita ble for p reva iling conditions. See Chapter 6 - Maintenance and Adjustments.

2. Carry out the daily maintenance operations.

3. Inspect the machine, look for any signs of possible leaks and check the hoses. Tighten or r e p l a c e a s n e c e s s a r y. S e e C h a p t e r 6 Maintenance and Adjustments.

4. See run-in period if the machine is new or if the engine has been reconditioned.

5. Check the track assemblies.

6. Clean the steps and access handles. Grease, oil, mud or ice on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

15. Work out a convenient means of escape from the machine (be proa ctive and deter mine an emergency exit) in the event of the cab door being jammed or the machine turning over. Cab models are equipped with an emergency hammer.

16. Before undertaking any travel or work operations during hours of darkness, make cer tain the lighting and signaling equipment is fully operative.

OPERATING THE MACHINE WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death.

CE-NA000

1. When starting the engine, use the correct procedure for the prevailing weather conditions.

See Starting The Engine in this chapter.

2. Regularly consult the hourmeter to ensure that all servicing operations are routinely carried out.

See Chapter 6 - Maintenance and Adjustments.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

3. If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the ser vicing inter vals should be reduced accordingly.

8. Make sure that the engine hood and the side doors are properly closed and latched.

4. Take note of the locations of hoses/cables before starting work.

9. Secure the cab door in either fully closed or fully opened position.

5. Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the safest distances: See the decal on this machine for safe working distances.

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

11. Check that no tools or other items have been left on the machine (the undercarr iage or the upperstructure) or in the operator's compartment.

12. Make sure no one is on or under the machine.

The operator must be alone on the machine.

13. Make sure nobody is standing in the machine working area.

14. Find out about current safety measures in use on the work site.

6. When working on a public highway, use standard traffic signals and take into consideration the working range of the upperstructure and its attachments. Local regulations stipulate the number, type and location of reflector strips.

7. Never operate the working or travel controls unless you are properly seated in the operator's seat with the seat belt correctly fastened.

8. Modify your driving to suit the type of work and working conditions.

9. Do not allow anyone within the machine's operating radius. Stop all operations until everyone has cleared the area.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 10. Operate all controls gradually to ensure smooth machine operation.

STARTING AND STOPPING MACHINE ENGINE

11. See Operating in Water if the machine will be standing in water during use.

STARTING ENGINE

12. See Transporting the Machine in this chapter when driving the machine onto a trailer.

1. Sit comfortably in the operator’s seat, making certain you can reach all the pedals and controls.

Fasten the seat belt.

13. See Lifting Procedures for the Machine in this chapter when it is necessary to lift the machine.

2. Move throttle control to LOW position.

14. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine.

15. Never use the attachment for sweeping the ground to level out rubble or push objects (this creates transversal stress on the attachment).

16. Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

17. Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete stop until visibility has improved.

18. In the event of an operation problem or failure, move the machine to a safe place, lower the attachment to the ground, shut down the engine and remove the key switch. Locate the problem, and take the necessary steps to warn others not to attempt to operate the machine.

3. Insert key into ignition switch and turn to the ON position.

4. Sound horn to warn personnel that the machine is being started.

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

NOTICE: 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.

NOTICE: If engine fails to start after 3 attempts, inspect fuel system and correct any problem found.

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

STOPPING THE MACHINE

19. Do not stop the engine without taking prevailing weather conditions into consideration. See Stopping the Engine.

20. See Parking the Machine when you park the machine.

21. Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See Load Handling.

22. When travelling with the hydraulic breaker (optional), make sure it is not too close to the ground or cab and not pointing in the direction of the cab.

BS07M794

Figure 1

1. Move machine to a firm, level area and place the attachment in the position illustrated.

2. Move throttle to LOW position. Allow engine to idle for 5 minutes.

3. Turn Key Switch to OFF position.

4. Set the safety lock lever in the LOCKED position.

4-4

CHAPTER 4 - OPERATING INSTRUCTIONS EMERGENCY ENGINE SHUT DOWN Use this emergency shut down measure ONLY when the key switch fails to shut down the engine.

STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES STARTING ENGINE 1. Move throttle control to LOW position.

2. Turn the key switch to ON and preheat for 20 seconds to make start-up easier. The Preheat Icon will display.

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

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

1 Figure 2

DC04C344

1. ENGINE EMERGENCY STOP CONTROL

1. Pull out the engine emergency stop control located at the lower right hand side of the operator’s seat until engine stops.

2. Before restarting engine, engine stop control in.

push

emergency

NOTICE: 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.

NOTICE:

• After starting the engine, use the auto warm up system described in Machine Warm Up in this chapter, and warm the engine and hydraulic oil.

• If engine fails to start after 3 attempts, inspect fuel system and correct any problem.

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

STOPPING THE MACHINE

1

BS07M861

2

Figure 3

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

2. Move throttle control to LOW position. Allow engine to idle for 5 minutes.

3. Turn key switch to OFF position.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS MANUAL WARM UP

CHECK GAUGES AND INDICATOR LAMPS

WARMING UP ENGINE

Before starting the engine, check the gauges and indicator lamps in accordance with the following procedures.

a. Allow the engine to run for 5 minutes under no load conditions with throttle control at LOW idle position.

1. Verify the safety lock lever is in the LOCKED (UP) position.

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

2. Verify all control levers are in the NEUTRAL position.

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

4 . D o n o t o p e r a t e t h e m a c h i n e u n d e r fa u l t y conditions. Consult with an authorized dealer if necessary. Repair any malfunctions before resuming operation.

3. Use the starter key to check all warning lamps and indicators for proper operation.

CHECK MONITOR PANEL

CAUTION Improper machine inspection and maintenance can cause accidents. Check all gauges, warning lamps and indicators frequently during machine operation.

Do not operate this machine if any gauge, warning lamp or indicator does not work or shows a problem with the machine. Failure to comply could result in death, serious injury or machine damage.

84-62

Figure 5

RH09N022 RH09M038

Figure 4 Key Operation

OFF - ON (Heat) Before Start

START-ON (Heat) Just After Start

1

Glow Lamp

ON

OFF

2

Battery Charge Lamp

ON

OFF

3

Engine Oil Pressure Lamp

ON

OFF

4

Engine Coolant Lamp

OFF

OFF

5

2nd Speed Travel Lamp

OFF

OFF

6

Air Filter Restriction

OFF

OFF

Lamp

4-6

CHAPTER 4 - OPERATING INSTRUCTIONS WARMING HYDRAULIC OIL CAUTION: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab. a. Move throttle control to HI idle position.

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions. Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

Auto warm up should be utilized when ever machine is started in temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in death or serious injury.

M1715

DC04D473

Figure 6

b. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket dump and hold over relief for 10 to 15 seconds. Repeat these procedures for 5 to 10 minutes. c. Move throttle control to mid position.

DC04D474

Figure 7

d. Operate the boom and arm controls for 5 to 10 minutes each.

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL DECAL OPERATING PATTERN The operating and travel controls of this machine are factory set at ISO/SAE standard operating patterns.

ISO OPERATING PATTERN DECAL The illustrations are a repres entation of the CONTROLS decal located inside the right side window of 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 chapter. Should this decal become damaged or missing, install a new decal.

BS07M796

Figure 8

BS07M797

Figure 9

WARNING Check and make sure that operations pattern control matches the decal provided inside the right side window. Failure to comply could result in death or serious injury.

M1713

WARNING If your machine is set to the operational BHL pattern control, change, make sure to remove the ISO/SAE operation pattern control decal inside the right side window and use the decal supplied for the optional BHL pattern control. This decal should be placed inside the door below the handle. See Pattern Control Change (BHL pattern) for detailed information on how to operate the pattern control changer. Failure to comply could result in death or serious injury.

M1716

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING CONTROL LEVERS (BHL PATTERN)

DC04D566

Figure 11

NOTICE: An optional Pattern control change valve is available. Contact your dealer for more information. If your excavator already has this valve installed use the following instructions (BHL Pattern) regarding its operation.

Figure 10

BS07N562

LH CONTROL LEVER 1

4

E

Boom Down

F

Boom Up

G

Swing Left

H

Swing Right

RH CONTROL LEVER 2

3

A

Arm Out

B

Arm In

C

Bucket In

D

Bucket Out

With the BHL multi control shifting the boom and arm functions are opposite the ISO system. Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS

BASIC OPERATION OF HYDRAULIC CONTROLS The following instructions explain the basic function of each hydraulic control. Use these instructions, and practice with a machine in a safe, clear area in order to operate the machine safely and efficiently.

WARNING Normal positioning of the machine for the purpose of determining front, rear, forward, reverse are with the travel motors located behind the operator’s cab.

Always have the travel motor positioned correctly.

Failure to comply could result in machine damage, injury or death.

M1726

Figure 13

BC08J114

WARNING

SAFETY LOCK LEVER FUNCTION MACHINES WITH BOOM SWING PEDAL CONTROL

Always know the location of travel motors before operating any hydraulic controls.Failure to comply could result in death or serious injury.

With engine running, set the safety control lever to the LOCKED (up) position.

M1727

Move the following controls: Left control lever

SAFETY LOCK LEVER

Right control lever Boom swing pedal - left and right

2

Travel control lever The functions should not actuate when the safety control lever is in the LOCKED (up) position. If any operation is functional, contact your authorized dealer for repairs to prevent unexpected machine movement.

1

WARNING

Figure 12

BS06H080

1. UNLOCKED POSITION 2. LOCKED POSITION

Dozer blade control function is live at all times. The hydraulic safety lock lever in the locked (UP) position does not affect the operation of the dozer blade. Use care when operating a machine with a dozer blade.

Failure to comply could result in death or serious injury.

M1710

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 left hand Operator’s Console in its operating and lock position.

1. Locked Position Before leaving the operator cab, place the Safety Lock Lever in the LOCKED (up) position by pulling lever up. With Safety Lock Lever in the LOCKED (up) position, hydraulic operation is not possible and this allows easy access in and out of the operator seat.

4-10

WARNING Always place the Safety Lock Lever in the Locked (up) position before leaving cab to prevent any operation of hydraulic controls. Failure to comply could result in death or serious injury.

CHAPTER 4 - OPERATING INSTRUCTIONS TRAVEL SPEED SELECT SWITCH

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 operated simultaneously to counter rotate the machine or to travel straight.

OPERATING BOTH TRAVEL LEVERS TOGETHER

1

BS07M800

Figure 16

For fast travel speed, press and release the travel speed select switch once before operating the travel controls. This puts the travel motors in FAST (1) travel speed and the lamp for FAST on the gauge cluster display will illuminate.

DC04D477

Figure 14

With the travel motors positioned behind the cab: a. Push both travel levers or press the pedals toward front of machine and machine will travel FORWARD.

DC04D478

To return to SLOW travel speed, stop travel and press and release travel speed select switch once.

NOTICE: Use FAST travel speed on firm, level surfaces only. Do not travel continuously for more than two hours. Stop for a period of 10 minutes at low idle speed before resuming travel.

Figure 15

b. Pull both travel levers or press the pedals toward operator seat and machine will travel in REVERSE. c. Return both travel levers to NEUTRAL (center) position and machine will stop travelling.

NOTE: The distance the 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.

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS TURNING THE MACHINE

DC04D482 DC04D479

Figure 17

a. Push the left travel lever toward front of machine to turn machine to the RIGHT in forward motion.

COUNTER ROTATING MACHINE

DC04D483 DC04D480

Figure 18

b. Pull the left travel lever back toward operator seat to turn machine to the LEFT in reverse motion.

Figure 19

c. Push the right travel lever toward front of machine to turn machine to the LEFT in forward motion.

Figure 21

a. Pull left travel lever BACK and push right travel lever FORWARD to counter rotate machine to the LEFT.

DC04D484 DC04D481

Figure 20

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

Figure 22

b. Pull right travel lever BACK and push left travel lever FORWARD to counter rotate machine to the RIGHT. NOTE: All functions explained with use of travel levers can also be performed using the travel pedals.

4-12

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE ATTACHMENT AND SWING - ISO/SAE PATTERN

WARNING Read, understand and follow all safety precautions during all operations of this machine and its attachment. Failure to comply could result in death or serious injury.

Left Control Lever Operation of the Arm is performed by pushing or pulling the Left Control Lever forward and backward.

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

Right Control lever Operation of the Boom is performed by pushing and p u l l i n g t h e R i g h t C o n t r o l L eve r fo r wa r d a n d backward. Boom speed is determined by how far the lever is activated.

DC04D487

Figure 25

a. Pushing the left control lever FORWARD moves the arm out.

DC04D485

Figure 23

a. Pulling right control lever BACK raises boom.

DC04D488

Figure 26

b. Pulling the left control lever BACK brings arm in. c. Moving the lever to the left swings arm left. d. Moving the lever to the right swings arm right.

A. Returning the left control lever to the Neutral (center) position, stops operation of the arm.

DC04D486

Figure 24

b. Pushing right control lever FORWARD lowers boom. c. Returning right control lever to the neutral (center) position stops operation of the boom. d. Pushing the lever to the left brings the bucket in. e. Pushing the lever to the right moves the bucket out.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS BOOM SWING OPERATING PEDAL The swing function can also be operated with the boom swing operating pedal. Practice with this pedal in an open area. If the pedal is not in use, close cover to prevent unintentional swing. Do not use this pedal as a foot rest.

1

Figure 27

BC08J113

Use this pedal to operate the swing motion of the boom.

To use the pedal, lift the pedal locking cover (1) up.

Right swing: push down right side of pedal - boom will swing right.

Left swing: push down left side of pedal - boom will swing left.

WARNING Always lock the pedal if not using the boom swing operating function. Failure to comply could result in death or serious injury.

M1918

4-14

CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET OPERATION

SWING OPERATION - LEVER

NOTICE: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

Swing operation is performed by moving the Left Control Lever to the right and left. Swing speed is determined by the amount the lever is moved.

Operation of the Bucket is performed by moving the Right Control Lever to the right or left.

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death.

M1088

NOTICE: Use operations.

DC04D489

swing

flashers

during

swing

Figure 28

a. Moving the right control lever to the LEFT operates the bucket in (digging).

DC04D491

Figure 30

a. Moving the left control lever to the LEFT swing machine to the left.

DC04D490

Figure 29

b. Moving the right control lever to the RIGHT operates the bucket out (dumping). c. Returning the right control lever to Neutral (center) position, stops operation of the bucket.

DC04D492

Figure 31

b. Moving the left control lever to the RIGHT swings the machine to the right. c. Returning control to the Neutral (center) position stops swing.

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS NOTICE:

OPERATING IN A NARROW SPACE

A. Climbing ability of a machine can change depending upon shoe type, engine lubrication, etc.

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

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

D. The travel operation for 2 hours or more may cause the failure of the travel motors due to the rise of the operating temperature. Don’t travel continuously for more than 2 hours.

S t o p fo r 1 0 m i nu t e s a t l ow i d l e b e fo r e resuming travel.

E. In extremely cold conditions, below -20°C (-4°F), the travel lever or pedal action may be “heavier” than normal. This is due to the viscosity of the hydraulic oil in frigid climates.

TRAVEL SAFETY a. Know the position of the travel motor before beginning travel. b. Travel on firm, level surfaces as much as possible.

Figure 32

BS07N682

BOOM IN FOLDED POSITION

T h e b oo m m ay b e fo l d e d i n a s s h ow n i n t he illustration. Folding the boom in will decrease the swing radius of the machine.

Canopy swing radius with folded boom: 1320 m (4 ft 4 in.)

Cab swing radius with folded boom: 1600 m (5 ft 3 in.)

c. When traveling on rough terrain, travel in SLOW speed with engine at a low idle. d. Travel with the travel motors in the 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. 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. h. Use decking or planks to protect road surfaces as much as possible. Be careful when turning or counter rotating machine on asphalt pavement.

Figure 33

XPX00300013E01

BOOM IN FORWARD POSITION

i. Do not allow large or heavy objects to strike travel motors.

Canopy swing radius with forward boom: 1560 m (5 ft 1 in.)

j. Do not travel over large objects such as boulders, rock, etc.

Cab swing radius with forward boom: 1890 m (6 ft 2 in.)

k. The machine can sink in soft ground or mud.

Avoid these areas.

4-16

CHAPTER 4 - OPERATING INSTRUCTIONS DOZER BLADE

E

USING THE DOZER

F

F

1

BS07M856

E UPUX1502003B01

Figure 34

The dozer control lever is located on the right side of the operator’s right control panel. Use it to select the dozer operation. It can also be used adjust the crawler frame width.

The dozer blade will move in an up and down pattern.

E: Dozer down - Push the lever forward F: Dozer up - Pull the lever back

Figure 35

For back filling and leveling work after digging, use the dozer to push the soil back into the ditch or to level ground.

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

1. Scrape the soil at its upper surface with the dozer.

2. Use the dozer to back fill a trench.

3. Adjust the height of dozer with the dozer control lever to avoid over loading the engine.

4. Never travel with front attachment touching the ground. Severe structural damage could occur.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS CHANGING CRAWLER FRAME WIDTH

Figure 39

UPU00300031ES1

Figure 36

UPU00300018JS1

1. Change the machine width on flat, level ground with a fir m surface. Keep all unauthorized personnel clear of the area. The machine should be lifte d u p to ch an ge th e crawle r wid th .

Attempting to change width without lifting the machine body can cause damage to the body and adjusting cylinder.

4. Move the adjustable crawler frame width/dozer lever to the (C) position for retracting the frame.

CHANGING DOZER WIDTH

11

2

A

UPUX1703006B01

Figure 40

1. The width of the dozer blade can be changed as required.

UPU00300019JS1

Figure 37S

2. Set the crawler dozer shifting lever to the (A) position (crawler frame width side).

2. Pull out the pin (1) and remove plate (2).

3. Reverse plate (2), and align plate holes with holes in blade.

4. Insert pin (1) into install plate (2) 5. When using the dozer, adjust the height of the dozer with the dozer control lever to avoid overloading the engine.

UPU00300030ES1

Figure 38

3. Move the adjustable crawler frame width/dozer lever to the (B) position to expand the machine width (crawler frame width).

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

3

OPERATING MACHINE ON A SLOPE

2

4

1 BS07M851

1. UPPER ROLLER 2. SWING BEARING

Figure 41 3. WATER SURFACE 4. RIVER BED

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 illustration (A).

NOTICE: If the machine is operated while the swing bearing is submerged in water, then the swing bearing, swing pinion, and the swivel joint may wear out prematurely. Immediate replacement of grease in grease bath and flushing of the swing bearing is required. See Maintenance Section.

UPW00300091J01

Figure 42

The maximum gradeability of the machine is 58% (30 degrees). When moving down a slop, operate the travel levers slowly. Travel in low speed (1st). Keep the bucket at a height of 30-40 cm (12-16 in) above the ground. Travel up and down the slope. Do not move the machine horizontally on a slope. It is possible to tip the machine if travelling horizontally on a hill side.

If the machine should stall on a slope, place the bucket/attachment on the ground and make certain each operating lever is in the neutral position. Restart the engine.

If it is necessar y to park on a slope, place all attachments on the ground, place each operating lever in the neutral position, place the safety lock lever in the locked (UP) position. Block the crawler tracks.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY CLEANING SAND & SOIL FROM BUCKET

USE ARM IN ACTION

BS07M852

Figure 43 BS07M854

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. Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and the possibility of bucket teeth damage.

OPERATE BOOM SMOOTHLY

BS07M853

NOTICE: Avoid shaking out soil using the stops at the end of the bucket cylinder stroke.

DITCH DIGGING

Figure 44 BS07M855

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.

The attachment will provide maximum digging force when the arm and boom are at 90° - 110° of each other.

4-20

Figure 45

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.

Figure 46

For efficient ditch digging, position the machine parallel to the ditch to be dug using smooth bucket and arm motions. For wide ditch digging, dig both sides first, then dig the center portion.

CHAPTER 4 - OPERATING INSTRUCTIONS OFFSET DIGGING

LOADING

BS07M857

Figure 47

1. Operating efficiency can be improved by positioning the dump truck so the swing distance is kept to a minimum. Always have a good field of view.

2. Start at the front side of the dump body and work toward the back.

Figure 48

BS07M858

To operate the boom swing function, press the button on the top of the left control lever. Operate the control lever to the left for left boom swing or right for right boom swing.

NOTICE: While the boom swing control function is engaged, the boom will continue to swing when the finger is removed from boom swing control button. To cancel the boom swing function, return the left control handle back to the neutral position.

WARNING Make certain area is clear of obstacles and persons before beginning swing operation of the machine.

Sound horn before beginning swing operation.

Failure to comply could result in death or serious injury.

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS RUBBER CRAWLER TRACK

OPERATING WITH RUBBER TRACK

Rubber track offers many benefits over metal track, but must be used in accordance to the m a nu fa c t u r e r ’s s p e c i fi c a t i o n s. T h e m a c h i n e guarantee does not cover improper operation at job sites. Do not operate the machine over objects such as steel plate, steel pipes, concrete rod, stones and r o ck s w i t h s h a r p e d g e s. O b s e r ve o p e r a t i n g conditions and characteristics of rubber track to gain optimum performance.

Track Comparison

BS07N286

Figure 50

DO NOT operate in gravel mixed land, rugged and solid rock bed, over iron scraps, or edges of iron plates such as concrete rebar.

BS07N292

Figure 49

BS07N287

Figure 51

DO NOT operate or travel over river beds with stones of different sizes. Rubber crawler belts may be damaged or come off the rollers. The service life of the rubber crawler belts will be reduced if the belt is not maintained with the correct tension.

BS07N288

Figure 52

DO NOT operate on oil contaminated surfaces. Oil will damage the rubber crawler belts.

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS

BS07N293

Figure 53

DO NOT operate near open fires, or on steel plates exposed to the sun or use in asphalt leveling. Heat will damage rubber crawler belts.

When storing the machine for long periods indoor storage is recommended. Rubber crawler belts can be damaged if exposed for long periods of time to harsh environments in a non-operational mode.

BS07N290

Figure 54

DO NOT operate the crawler belt on the ground if the other track has been lifted. The additional weight may damage the track or cause the track to come off.

BS07N291

BS07N294

Figure 56

Use care not to damage the track with the machine attachment.

Do not apply side load force or side impact on the bucket or attachment during operation.

If the machine is raised with the bucket, lower machine slowly.

BS07N295

Figure 57

I f m a c h i n e i s o p e ra t e d i n s a l t y o r c o r r o s i ve conditions, the bonding of the rubber to the metal core can be damaged. Clean the belts after use. The normal temperature operating range for rubber crawler belts is between -25° to 55° C (-13 to 131° F).

Figure 55

Use caution when operating on ice or snow. Rubber belts can easily slip. Avoid making sudden turns on concrete. Avoid sudden direction changes, as this may cause premature wear on the crawler belts.

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

BS07N296

Figure 58

Avoid changing direction of the machine on ground with a difference in level of 20 cm (8 in.) or more.

Travel at right angles over ground when there is a significant difference in level.

BS07N298

Do not travel on a slope with one side of the machine lifted. Always travel with both sides level to avoid damage to the track.

BS07N299 BS07N297

Figure 59

When moving up a slope, avoid changing direction of the machine when the machine is at a point between the level ground and the slope.

4-24

Figure 60

Figure 61

Do not change direction of the machine with the rubber crawler on high spots as illustrated. This can cause the rubber crawler belt to be damaged or come off.

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS OPERATION IN EXTREME COLD 1. Follow procedures at the beginning of this chapter as starting the engine may be difficult due to extremely cold temperature.

2. Use an engine oil, hydraulic oil, and diesel fuel d e s i g n e d fo r u s e i n c o l d c l i m a t e s . S e e Maintenance Section for reference. Keep batteries fully charged.

3. Make certain to perform machine warm-up procedures as described at the beginning of this chapter to prevent premature wear or damage to pumps, motors, and other components.

NOTICE: In extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain operating temperature, 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 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.

4. Make certain that the engine coolant mixture is sufficient to keep the machine safe.

NOTICE: Mix coolant to a protection temperature of 5°C (9°F) lower than the machine may experience during operation, storage or transport.

5. 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 system. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, removing the batteries and storing in a warm area is recommended.

OPERATION IN EXTREME HEAT 1. Use an engine oil, hydraulic oil and fuel designed for use in hot climates. See Maintenance Section for reference. Also keep batteries fully charged.

2. Clean radiator, oil cooler and debris screen often t o p r eve n t d a m a g e o r ove r h e a ti n g o f th e machine.

NOTICE: Do not allow dirt and debris to accumulate in the radiator fins, oil cooler fins or debris screen, as this may cause a fire.

5. If the machine becomes overheated, idle the machine to help cool the engine, turn engine OFF and check coolant level. If after filling to proper level the machine continues to overheat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

WARNING Do not drain the cooling system when the engine is hot. Allow time to cool all engine parts. Failure to comply could result in death or serious injury.

6. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water.

7. Keep a close watch on the gauges for warning icons during operation. Avoid unnecessary low speed running of the engine during operation.

OPERATION IN HIGH ALTITUDES 1. 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 altitudes climates.

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

OPERATION IN SANDY AND DUSTY AREAS 1. Check the engine air cleaner elements frequently in sandy or dusty conditions.

2. When air cleaner restriction lamp illuminates, change filters immediately regardless of time intervals.

3. Service fuel filter, water separator, engine oil and filters, and all hydraulic filters frequently.

4. Keep the radiator, oil cooler, inter-cooler, and air conditioning condenser clean.

OPERATION AT SEASHORE OR SALTY CLIMATE 1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electr ical components and cylinder rods.

2. Frequently check all mounting hardware for proper tightness. Torque to proper value to help prevent salt from entering the machine systems.

3. Keep all belts properly tensioned.

4. Make certain that the engine coolant mixture is sufficient to keep the machine safe.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION IN HUMID CLIMATE

BUCKET SELECTION GUIDE

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

Bucke t se lection is extremely impo r tant to a machine’s productivity, durability, and stability.

2. Operate the A/C with the cab doors and windows closed.

LONGER UNDERCARRIAGE LIFE

Choosing an excessively large bucket can reduce productivity due to slower than normal cycle times.

Using an oversized or overly wide bucket in severe conditions such as mining, will lead to durability problems for both the machine and bucket involved.

Undercarriage life varies upon the operation method.

Use the following guides to increase the life of the machine’s undercarriage.

Stability will be adversely affected using a bucket that is unnecessarily large.

1. Select the track shoe that best suits the machine’s application. If in doubt, consult with your dealer when selecting track shoes.

If the buckets used locally var y in weight from recommended buckets, it will be necessary to adjust the bucket capacity accordingly. A heavier bucket must correspond to a reduced capacity.

2. Do not allow the tracks to slip during operation. If this occurs, reduce load until slipping stops.

3. Avoid sudden starts, accelerations, abrupt speed changes, high speeds on rough terrains, sharp turns, and sudden stops.

4. Always operate machine in straight lines whenever possible. Avoid short radius when turning. Make turns with the largest possible radius.

5. Prior to operation, clear boulders and obstacles to prevent damage to track shoes.

6. Always operate machine parallel to the incline of the slope. Operating machine across the incline of the slope will not only shorten the machine’s undercarr iage life, but the machine could unexpectedly slide down hill, and/or roll over.

7. Do not force the machine to carry out work that exceeds its working capability.

8. It is very important that inspections and maintenance schedules be followed as indicated in the Maintenance Section. Work conditions may require these scheduled times to be significantly shorter.

9. DO NOT OPERATE machine with loose track shoes, and maintain proper track tension adjustment at all times during operation.

4-26

If the material density (weight) exceeds guideline specifications then the bucket capacity must be reduced.

If the machine is to continuously dig rock, wasted shale, river cobble or other severe applications the narrowest bucket possible should be utilized. This will allow the greatest possible penetration and minimal twisting of the attachment (boom and arm). Bucket capacity is not to be the prime consideration for severe applications.

If a machine is used in a spoil pile operation, which causes a large radius dump cycle, applicable loads may have to be adjusted down by 5% from the Lift Chart Values.

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION c. Obtain any permits required from proper gover nment agencies for machine transportation.

GROUND TRANSPORTATION Machine Preparation a. Know the total weight, length, width and height of the machine being transported.

d. Use only a trailer with a rated capacity sufficient to transport the machine.

b. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

e. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

)

0”

0

.

2’2

(

6 R6

55

MAX 1,320 (4’4.0”) / MIN 990 (3’3.0”) 540 (1’9.3”) 530 (1’8.9”) 70 (2.8”)

160 (6.3”)

CANOPY MACHINE

40 (1.6”)

65

990 (3’3.0”)

1200 (3’11.2”)

MIN. 990 (3’3.0”) MAX. 1320 (4’4.0”) UPUX1206001E01

250 (9.8”)

230 (9.1”)

175 (6.9”)

2410 (7’10.9”)

445 (1’5.5”)

640 (2’1.2”)

1150 (3’9.3”) 740 (2’5.1”) 1210 (3’11.6”) 1560 (5’1.4”) 3420 (11’2.6”)

Figure 62

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

R755

55

MAX 1,320 (4’4.0”) / MIN 990 (3’3.0”) 540 (1’9.3”) 530 (1’8.9”) 70 (2.8”)

160 (6.3”)

CAB MACHINE

”)

(2’5.7

40 (1.6”)

65

1320 (4’4.0”) 755 (2’5.7”)

230 (9.1”)

MIN. 990 (3’3.0”) MAX. 1320 (4’4.0”) UPUX1306003E01

4-28

250 (9.8”)

175 (6.9”)

445 (1’5.5”)

2350 (7’8.5”)

990 (3’3.0”)

1150 (3’9.3”) 740 (2’5.1”) 1210 (3’11.6”) 1560 (5’1.4”) 3440 (11’3.4”) PU15Z00044P1 Figure 63

CHAPTER 4 - OPERATING INSTRUCTIONS LOADING THE MACHINE

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury. .

1

CM113A

a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower trailer ramps. c. Start the machine. d. Set travel speed to LOW - 1st speed. e. Move throttle control to low idle position. f. Raise the attachment and slowly drive machine up trailer ramps and over rear axles of trailer.

Figure 64

BS06H080

1. SAFETY LOCK LEVER

k. Place Safety Lock Lever in the LOCKED (up) position. l. Turn machine OFF, remove key and lock all doors, filler caps and access panels.

NOTICE: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine.

g. Slowly move machine completely onto trailer until in proper transport position. h. Slowly swing machine 180° until attachment is toward rear of trailer. i. Slowly lower boom until attachment rests on trailer bed. j. Do not have bucket and arm cylinder at full stroke during transport as this may cause damage to cylinders.

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS Securing Machine to Trailer

DC04D581

Figure 65

a. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. 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. b. Securely fasten all loose parts, as well as removed parts from the machine to the trailer or transporting platform.

4-30

CHAPTER 4 - OPERATING INSTRUCTIONS CANOPY

LIFTING MACHINE The following procedures are for lifting the machine, as built by the manufacturer. These procedures do not take into account modifications made to the machine that affect machine weight or center of gravity.

Rubber shoe 1,650 kg (3,640 lbs) Iron shoe‫ ޓ‬1,710 kg (3,770 lbs) CABLE Φ14 X 2700mm (Φ0.55” X 8’10”) {X 1Q’ty}

LIFTING MACHINE WITH ATTACHMENT INSTALLED

WARNING

CABLE Φ14 X 4500mm (Φ0.55” X 14’9”) {X 2Q’ty}

Always inspect the lifting equipment, lifting points on the machine to insure they are in safe condition. If worn or damaged, DO NOT USE.

4600mm (15’1”)

10q 15q

(B)

M1147

a. Install lift eyes/shackles at holes provided at both ends of the dozer blade. Locate lift areas.

(A)

b. Attach cables or wire ropes with a capacity rating sufficient to lift the machine, at lifting locations.

50mm (2.0”)

Figure 67

UPUX1505001E01

CAB CAB Rubber shoe 1,730 kg (3,810 lbs) Iron shoe 1,790 kg (3,950 lbs)

14 2700mm 0.55 8 10

1

20 15

BAR 1300mm 4 3

Figure 66

DC04D582

14 4500mm 0.55 14 9

1. HARDWOOD OR STEEL BLOCK

(B)

c. Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting. d. Slowly raise the lift apparatus to check with contact with machine, security, and balance.

Do not lift the machine over any personnel.

(A)

e. Lift machine carefully, keeping sway to a minimum. Place machine in desired location.

50mm (2.0 )

UPUX1704027E01

Figure 68

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE

Figure 69

BS07M870

MACHINE IN STORAGE POSITION

PREPARE MACHINE

CARE DURING STORAGE

Perform the following procedures to prepare the machine for long term storage.

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.

1. Perform all inspection and maintenance proce dure s as de scr ibed in Mainte nance Section. Make certain fluid levels are correct.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

NOTICE: Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank. Make sure to use an anti-algae additive in the fuel tank.

4. Move machine to an indoor location for storage.

5. Park the machine with belts/tracks on top of wood if possible with the exposed piston rods of the cylinders retracted as much as possible.

NOTICE: Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in the Maintenance Section before bringing machine out of storage for normal operation.

2. Remove drain plugs from the travel motors and swing gear reduction units to drain off any moisture which may have accumulated during storage.

6. Rest the bucket on a stable wood block.

3. Carefully and closely inspect all hydraulic hoses after long per iods of stora ge for signs of deterioration. Replace all hoses showing signs of deterioration.

7. Coat cylinder rods with heavy coat of grease to prevent corrosion during storage.

4. Refill fluids to proper levels and lubricate as required.

8. Remove batteries and store in a well ventilated, warm area.

4-32

CHAPTER 4 - OPERATING INSTRUCTIONS

OPTIONAL EQUIPMENT USE OF OPTIONAL ATTACHMENTS If a machine is equipped with optional attachments, applicable bucket sizes and suspended loads must be reduced in direct proportion to the weight or combined weight of these attachments. Failure to consider the added weight of such attachments will cause stability problems. Additionally the weights of such attachments must be considered when the Lift Chart is referred to before lifting a load.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine.

HYDRAULIC BREAKER 3. HYDRAULIC OIL LEVEL CHECK CONTAMINATION PREVENTION

1. SELECTION OF THE HYDRAULIC BREAKER When mounting a breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each breaker. To select hydraulic breakers, contact your dealer.

2. BEFORE OPERATING BREAKER

THE

HYDRAULIC

Consult your dealer for the piping needed for the boom and arm when installing a hydraulic breaker.

Replace the hydraulic return filter according to the replacement schedule table listed on Maintenance Fo r N i bbl e r / b r e a ke r i n t h e M a i n t e n a n c e a n d Adjustment Section. Thoroughly read the Hydraulic B r e a ke r O p e r a t i o n M a n u a l a n d a l l S A F E T Y PRECAUTIONS from this manual to avoid damaging the machine or hydraulic breaker during operation.

Select the appropriate hydraulic flow for the breaker b y fo l l o w i n g t h e i n s t r u c t i o n d e t a i l e d i n t h e Nibbler/breaker Basic Machine Operation in this section.

AND

When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm-bucket end and the hose end on the on the hydraulic breaker side to prevent dust and water from entering into piping.

Before starting operation, check the cap screws on the tube securing clamps for looseness, and the connection of the tubes and hoses for oil leakage .

WARNING Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

4-33

CHAPTER 4 - OPERATING INSTRUCTIONS 4. BASIC OPERATION

1 B A

11 Figure 72

UPU00700005JS1

Figure 70

BS06H080

1. SAFETY LOCK LEVER

a. Start machine and place the safety lock lever in UNLOCKED (down) position.

c. Make certain breaker or nibbler is in desired position and against material to be broken. d. Place foot on pedal and depress with heel to activate. e. Operate for 30 seconds, then release pedal. f. Do not rest foot on pedal except during operation.

BREAKER

A

b. Release pedal control lock (1).

Operation

Left side (A)

Breaker stops operating

Right side (B)

Breaker starts operating

NIBBLER

11 UPUX1707001B01

Depress pedal

Figure 71

Depress pedal

Operation

Left side (A)

Nibbler closes

Right side (B)

Nibbler opens

NOTICE: Operation of a nibbler or breaker with the selector valve in the incorrect position may result in poor performance and/or damage to the machine.

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B

4-34

CHAPTER 4 - OPERATING INSTRUCTIONS SETTING MACHINE SELECTOR VALVE

Figure 74

RH09N023 RH09M024

Figure 73

a. Use a 19 mm Allen wrench to loosen bolt (3).

1. SELECTOR VALVE 2. COVER

b. Use wrench (4) to turn the selector valve (1) to the desired position.

Machines equipped with a nibbler breaker attachment must have the selector valve (1) set to the correct position for the breaker or nibbler operation.

c. After valve is in position, tighten socket bolt (3).

2

NOTICE: Make sure to relieve hydraulic system and tank pressure as instructed in Releasing Hydraulic System and Tank Pressure in Chapter 6.

Lower the attachment to the ground and stop the engine. Set the safety lock lever in the locked position.

1

2

BS07M865

Figure 75

1. EXCAVATOR ARM 2. PLUG ATTACHMENT HYDRAULIC OIL VALVE POSITIONS A. CLOSED B. OPEN

NOTICE: Make sure to switch the position of the stop valves to the CLOSED position before removing the attachment.

4-35

CHAPTER 4 - OPERATING INSTRUCTIONS PATTERN CONTROL CHANGE (BHL PATTERN)

3 2

To change the machine’s control pattern from ISO (SAE) to (BHL) pattern: 1. Place the attachment on the ground, throttle control in low idle, and turn the ignition switch off.

34

Figure 78

UPU00700008ES1

4. Loosen wing bolt (2), and change the lever position to the desired pattern.

5. Hand tighten the wing bolt (2) securely. Do not use tools to tighten.

6. Close compartment cover.

7. Carefully operate the control levers to verify functions match the pattern selected. Practice in an open area to become familiar with the new pattern.

Figure 76

UPU00700009ES1

2. Place the safety lock lever in the lock (UP) position before leaving the cab.

2

WARNING Check machine’s control pattern for conformance to pattern on decal-card in cab. If pattern does not match decal-card on cab door holder, flip decal-card on holder to match the machine’s control pattern before operating machine. Failure to comply could result in death or serious injury.

11

M1716

WARNING

Figure 77

UPU00700009ES1

Whenever a change is made to the machine’s control pattern, also change the pattern decal card in the cab to match the new pattern. Failure to comply could result in death or serious injury.

M956

1. PATTERN CHANGER VALVE

3. Open the right compartment door, locate the pattern changer lever (1).

4-36

In the BHL multi control shifting the boom and arm functions are opposite the ISO system. Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

CHAPTER 4 - OPERATING INSTRUCTIONS GETTING THE MOST OUT OF YOUR BREAKER

WARNING Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

A. BREAKER PROPER POSITIONING

DC03M065

When the excavator boom is lowered, it normally follows a curved path, which changes the original perpendicular position of the breaker. It is very important to keep adjusting the operator’s controls to maintain constant perpendicularity between the breaker and the surface of the material being broken.

In addition, the applied pressure should be sufficient to avoid the breaker tool from bouncing on the rock rather than transmitting the shock wave into it. The applied pressure should not lift the machine high off the ground, since the excavator can drop suddenly, as the breaker breaks through the material, and harmful shock loads will be transmitted through the entire machine.

Figure 79

Always position the breaker perpendicular to the material you intend to break. The breaker can be vertical, horizontal, or anywhere in between, as long as the tool is perpendicular to the surface and the pressure applied is in the same direction of the tool.

B. APPLIED PRESSURE ON BREAKER The breaker must have sufficient pressure between the tool and the surface of the material intended to break in order to allow the shock wave to flow through the tool and to the material being broken.

The applied pressure has to be constantly adjusted by combining the boom, arm, and bucket functions so that the breaker follows the tool at all times during breaker operation.

4-37

CHAPTER 4 - OPERATING INSTRUCTIONS E. EXCAVATING AND TRENCHING

C. BREAKING OVERSIZE ROCKS

DC03M066

Figure 80

Do not attempt breaking oversize boulders from the center. It is much more efficient to break these type of rocks from the edges. Also, do not break into smaller pieces than necessary. There is a direct relationship between the size of the boulders and the size of the breaker. It is inefficient to break large rocks with small breakers and vice versa.

DC03M068

Figure 82

Lay back side walls a bit at the time so that they do not interfere with the breaker housing. To lessen the opportunity for side loading, approach each wall from the opposite side by positioning the excavator perpendicular to the trench.

F. RULES TO REMEMBER Use the following rules for correct breaker operation:

D. SURFACE ROCK DEMOLITION

1. Make sure to adjust the proper hydraulic flow according to the breaker specifications.

2. Place tool against material to be broken at 90° angle to work surface.

3. Use the boom, arm, and bucket controls to press firmly against surface, keeping perpendicularity while operating the breaker.

4. As material breaks, stop breaker quickly to prevent idle strokes.

5. Reposition breaker if material does not break after 15 seconds of operation.

DC03M067

Figure 81

Use the breaker just as if it were a hand held breaker, or a plain hammer and chisel. Adjust the breaker’s position according to the work to be done, and take small bites at a time. The only difference between a hand held breaker and the hydraulic excavator breaker is the size of the rocks that can be broken.

Do not try to break too much at one time.

6. Do not bend or pry with the breaker tool while operating.

7. DO NOT OPERATE breaker with attachment cylinders at full extension.

8. DO NOT OPERATE breaker submerged in water.

9. DO NOT OPERATE breaker for more than a minute at a time.

10. Lubricate breaker every 30 minutes. Keep tool lubricated at all times.

4-38

CHAPTER 4 - OPERATING INSTRUCTIONS C. PASSENGERS

SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with other safety precautions found in this manual.

Never allow passengers on the attachment or machine.

D. CYLINDERS

WARNING Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

A. USE FOR INTENDED PURPOSE

DC04E063

Figure 85

DO NOT OPERATE boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

E. AVOID CONTINUOUS OPERATION

DC04E061

Figure 83

Use the attachment only for its intended purpose. If not used in accordance with the manufacturer’s instructions, the excessive pressure exerted on the boom, arm and frame structure of the machine will cause premature failure of the components.

B. PROTECTIVE EQUIPMENT

DC04E064

Figure 86

Operate the nibbler/breaker in one (1) minute intervals. Operation for longer than one (1) minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and/or pump damage.

DC04E062

Figure 84

When operating attachments that produce flying debris, installing protective guards on the machine is highly recommended. Close all windows 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.

4-39

CHAPTER 4 - OPERATING INSTRUCTIONS I. DO NOT LIFT

F. HOSE SURGE

DC04E065

Figure 87 DC04E068

Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an authorized dealer for assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

Figure 88

Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

H. DO NOT USE SWING FORCE

DC04E067

Figure 89

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.

4-40

Never use optional attachment to lift or transport objects or materials. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

J. WORKING RANGES

G. DO NOT USE DROPPING FORCE

DC04E066

Figure 90

DC04E069

Figure 91

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Transmission Component Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Use of Bio-degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Biodiesel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES

NOTICE: See ATTACHMENT LUBRICATION in Chapter 6 for proper lubrications.

ENGINE Type of Oil ------------------------ Engine Oil SAE 10W30

SWING BEARING

Capacity:

Type of Oil -------------------------------- EP Grease EP/2

Engine Oil (H Level) -----3.5 liters (0.9 gal) Engine Oil (L Level) -----2.2 liters (0.6 gal) NOTICE: See ENGINE OIL LEVEL in Chapter 6 for

Capacity --------- As required (1 place - swing 90° x 4) NOTICE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

proper oil filling and/or checking engine oil level.

HYDRAULIC

TRACK TENSION ADJUSTMENT

Type of Oil ---------------------------- Hydraulic Oil AW 46

Type of Oil -------------------------------- EP Grease EP/2

Capacity:

Capacity ---------------------------- As required (2 places)

Hydraulic Tank ---------------- 9 liters (2.4 gal) Hydraulic System ------------15 liters (4.0 gal)

NOTICE: See TRACK TENSION in Chapter 6 for proper procedures in injecting grease.

NOTICE: See HYDRAULIC OIL LEVEL in Chapter 6 for proper filling and/or checking hydraulic oil level.

RADIATOR

TRAVEL MOTOR REDUCTION UNIT

Coolant --------------- Ethylene-glycol Coolant Solution

Type of Oil ------------------------- SAE 90 GL4 Gear Oil ENGINE COOLANT MIXTURE

Capacity -----------------------330 cc (20.1 cu. in.) Each

Expected Minimum Temp.

Long Life Coolant

OIL in Chapter 6 for proper filling and/or checking oil level.

-14.5°C (5.9°F)

30% mixed

IDLERS

-34°C (-29.2°F)

50% mixed

NOTICE: See TRAVEL MOTORS REDUCTION UNIT

Type of Oil ------------------------- SAE 90 GL4 Gear Oil

Capacity:

Capacity ------------------ 30 cc (1.8 cu. in.) Each x 2

Radiator --------------------------1.8 liters (0.48 gal)

LOWER ROLLERS

Cooling System ------------------3.7 liters (1.0 gal)

Type of Oil ------------------------- SAE 30 Capacity ------------------ 60 cc (3.7 cu. in.) Each x 6

OPERATING LEVER JOINT Type of Oil -------------------------------- EP Grease EP/2 Capacity ------------------------- As required in each joint NOTICE: See CONTROL LEVER JOINT LUBRICATION in chapter 6 for proper lubrications.

NOTICE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

FUEL TANK Type of Fuel --------------------- Diesel Fuel grade No. 2 Capacity ---------------Fuel Tank - 22 liters (5.8 gal) NOTICE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

UPPER ATTACHMENT PINS Type of Oil -------------------------------- EP Grease EP/2 Capacity -------------------------- As required in each pin 5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REQUIRED FILTERS NOTICE: Refer to the Parts Manual for the correct part numbers.

HYDRAULIC

• Return Filter Element for Standard Machine • Return Filter Element for Breaker and N&B • Tank Suction Strainer • Tank Breather Filler Element • Pilot Line Filter

Engine

• Engine Oil Filter • Air Cleaner Inner Element • Air Cleaner Outer Element FUEL

• Engine Fuel Filter OPERATOR CAB

• A/C Fresh Air Filter • A/C Recirculate Air Filter NOTICE: Refer to MAINTENANCE Chapter 6 in this Manual for the Locations and proper procedures in replacing filters.

5-4

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climate and certain conditions.

CLIMATE ZONE

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

FRIGID -30°C~15°C (-22°F~59°F)

FRIGID -20°C~30°C (-4°F~86°F)

FRIGID-WARM -25°C~40°C (-13°F~104°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 5°C~55°C (41°F~131°F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT

ENGINE OIL A.P.I. CLASSIFICATION FOR SERVICE CD

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

*Notice: All engines shipped from factory with SAE10W30 engine oil.

CLIMATE ZONE

LUBRICANT

FUEL

LUBRICANT

FRIGID -15°C ~ -25°C (5°F ~ -13°F)

WARM -5°C ~ -15°C (23°F ~ 5°F)

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

WINTERIZED ASTM D975 No.1

ASTM D975 No.2

ASTM D975 No.2

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL A.P.I. Classification for Service CD - SAE15W40

(For General Purpose Lubrication) LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

Extreme Pressure Multi Purpose Grease No.2 EP Type Grease

N.L.G.I. No. 2 Lithium Base with MOS2 Grease

FLUID ENGINE COOLANT (50% MIXTURE)

ANTIFREEZE (LLC) -34°C (-29.2°F) Mixture ratio should protect to 5°C (9°F) lower than the coldest temperature the machine will experience.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

HYDRAULIC FLUID Use hydraulic fluid specifically designed for high pressure applications. Your dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions.

GREASE The type of grease to use depends on ambient temperature. Use a quality extreme pressure multipurpose No. 2 grease.

ENGINE OIL CI-4 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, flush the hydraulic system that was filled with mineral oil twice. This is a requirement before adding bio oil.

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

4. For further information about recommended Bio-degradable oil, please contact local dealer.

ENVIRONMENT Before you service this machine and dispose of oil, f l u i d s, a n d l u b r i c a n ts, a l way s re m e m b e r t he environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.

FUEL STORAGE

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out with approved lubricants.

Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

USE OF BIO-DEGRADABLE OILS

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

When using Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

5-6

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 DAILY INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Grease Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Check Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Inspect Alternator/Fan Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Attachment Lubrication (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 50 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Engine Oil and oil filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Inspect Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Engine Oil and oil filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Radiator and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Inspect Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Bolt and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Greasing the Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Dozer Pin Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Boom, Arm, and Attachment Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Boom Swing Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Cleaning and Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Hydraulic Return Filter (Breaker Use Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Clean and Drain Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Replacing Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Travel Reduction Gear (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Replacing Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Repairing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Check Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Check Starter and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Change Hydraulic Oil - Breaker/nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Hydraulic Suction Strainer Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Pilot Valve and Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Travel Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Lower Roller and Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Idler Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Change Swing Gear Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Fuel Injection Timing Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Intake and Exhaust Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Replacing the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Replacing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Rubber Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Rubber Track Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Rubber Track Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Releasing Lock on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Removing Gears from Travel Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Assembling the Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Lowering Bucket Attachment on a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

DC04B668

Figure 1

1. It is recommended that an inspection and maintenance schedule should 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.

2. 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 a guide. Also, refer to the inspection and maintenance charts for general service interval recommendations. If you doubt your ability to perform these tasks, contact your dealer for assistance.

3. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL SAFETY

WARM ENGINE OIL

DISPOSAL OF HAZARDOUS WASTE

The engine should have a temperature 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.

Dispose of waste oils, fluids, lubricants, filters, and other hazardous waste properly.

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

TAG-OUT MACHINE

KEEP MACHINE CLEAN

DC04B671

DC04B669

Figure 2

Thoroughly clean machine before perfor ming inspection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also r educe r isk of hydraulic sys tem contamination when the machine is clean.

Figure 4

Before beginning any inspection or maintenance procedures, secure a DO NOT OPERATE tag to the operator’s console to infor m the operator the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine.

INSPECT WASTE OILS AND FILTERS

HOT SURFACE & FLUIDS

DC04B672

DC04B670

Figure 3

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 any maintenance procedure.

6-4

Figure 5

Before disposal, inspect all waste oils, fluids, and filters for debris and foreign material. Cut the filters open to determine any abnormal wear.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY

PREVENT CONTAMINATION

1. Turn key switch to OFF position.

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

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

WARNING

Figure 6

DC04B673

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.

ALWAYS disconnect the battery (both terminals) before welding on any part of the machine. Always wash your hands after battery components. Failure to comply could damage sensitive electrical components, death or serious injury.

M866A

NOTICE: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

FRAME STRUCTURE

SEALS AND O-RINGS

NOTICE: Remove any excessive grease from the attachment pin connecting areas to inspect welds.

Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Lubricate all new seals with the appropriate oil before installation.

STOP ENGINE NEVER attempt any maintenance with engine running. Always stop the engine and allow machine to cool.

1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. Do not make repairs to the ROPS/FOPS. If any structural damage is apparent on the ROPS/FOPS, contact your authorized dealer.

Wear hard hat, safety goggles or face shield, work gloves, safety shoes, and well fitting work clothes when perfor ming inspection and maintenance procedures on this machine.

4. In cases where welding is required, consult your authorized Dealer for proper procedures. Use only certified welding personnel familiar with structural welding methods to perform welding repairs. Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

CLEANING PARTS

STEPS AND HAND HOLDS

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

1. Inspect daily all mounting steps and hand holds on the machine to make sure they are clean and in safe working condition.

WARNING

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

WEAR SAFETY EQUIPMENT

Improper use of solvents can result in fire or explosion. Do not use gasoline or low flash point solvents. Clean only in a well ventilated area away from sources of sparks or flame, including any appliances with a pilot light. Failure to comply could result in death or serious injury.

NOTICE: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition free of grease, oil, mud, ice, and snow.

M1629

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM NOTICE: Relieve all pressure in the hydraulic circuits before performing any work on the hydraulic system.

2

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

1

M1333

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

Figure 8

RH09N025

5. Verify the hydraulic oil temperature is below 40° C (104° F).

6. Open the door to the hydraulic tank (1) and secure in place with strut.

7. Slowly loosen the cap (2) about a half turn to release pressure inside.

WARNING

Figure 7

BS07M861

2. Turn the ignition switch key to the ON position.

Pilot control switch must be on.

3. Operate the control levers from right to left and front to rear approximately 12 times. Turn the ignition key to the OFF position.

4. Set the safety lock lever to LOCKED position.

Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, seek medical attention immediately. Failure to comply could result in death or serious injury.

M587A

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

6-6

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GUIDELINES TO REPLACE GROUND TOOLS

GUIDELINES FOR ATTACHMENT LUBRICATION

It is very important to keep bucket teeth and side cutters properly tightened. Loose or missing bolts will increase loads and eventually cause tool failure.

Extended operation with loose hardware can cause the bolts to stretch and wear on the support mounting holes. Heating of hardware and support mounting holes will cause the same effect. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters.

Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubrication inter vals are based on a standard excavator (see Specifications Section for the definition of Standard Excavator) working in an average duty cycle. Average duty cycle is defined as “Most typical digging application, road construction in natural bed clay, digging 50% ~ 60% of the daily work schedule”.

• When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld spatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

• Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT.

• When installing end bits, start at the center and work toward the outside edges.

• Always torque bolts according to specifications.

WARNING Avoid eye injury when using a drill, hammer, saw, or other tools that may cause chips to fly. Always wear safety glasses when working. Failure to comply could result in death or serious injury.

M428B

• When new parts are used, the mating surfaces will seat more uniformly and the bolt torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

• Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

• When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mount hole if needed. Torque bolts according to specifications.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points.

Because of these high spots, it is recommended that the front attachment or the repaired area be lubricated a minimum of once every eight (8) hours for the first one hundred (100) hours for a standard machine working in an average duty cycle. All other machines should be lubricated every 4 hours for the first twenty (20) hours and every eight (8) hours for the next eighty (80) hours of operation. This lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand operated grease dispenser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standard lubr ication procedure is modified. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. Therefore, to avoid this situation, the front attachment has to be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

Every 500 hours

Every 1000 hours

6-8

6-16

Fan and air conditioning drive belt

6-31

Air filter

6-11

Radiator cap and hoses

8-11

Bolt and nut torque

6-10

Rubber track (if equipped)

AR

6-11

Engine oil level

8

Coolant level

8

Radiator and oil cooler

8

6-12

Electrical connections

8

6-12

Fuel level

8

6-13

Water separator

8

6-14

Hydraulic reservoir level

8

Cylinders, hydraulic lines Fan/alternator belt tension

6-16

Grease bucket, boom, arm cylinder, dozer

6-17

Machine/Attachment

Drain

AR

6-11

6-16

Lubricate

AR AR

6-11

6-14

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

Run-in

8 50

6-17

Drain fuel tank sediment

6-18

Engine oil and filter

Run-in

50

6-19

Rubber track

Run-in

7-4

Battery check

6-24

Fan/alternator belt

Run in

6-25

Hydraulic return filter

Run-in

6-26

Engine oil and filter

6-27

Radiator hoses

250

6-28

Fan/alternator belt

250

6-29

Swing bearing

6-29

Boom, arm cylinder, dozer

6-31

Air Cleaner Element

50 50 50 50 50 250

250 250 250

6-32

Hydraulic return filter (Breaker attachment)

6-33

Fuel water separator

250

6-34

Fuel filter

500

6-35

Air cleaner elements

500

6-36

Travel reduction gear

6-37

Radiator coolant

1000

6-39

Hydraulic return filters

1000

6-49

Hydraulic oil (breaker/nibbler)

1000

RM

Valve clearances

1000

RM

Starter/generator

1000

RM

Injector Timing

1000

500

Run-in

500

Every 2000 hours

Every 5000 hours

6-40

Hydraulic suction strainer

2000

6-42

Pilot valve

2000

6-42

In-line filter

2000

Drain

Lubricate

Replace

Check

page

Service points

Intervals in hours

Clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-45

Travel reduction gears

2000

6-47

Idler oil change

2000

RM

Swing gear grease

RM

Intake and exhaust

6-49

Hydraulic oil

2000 2000 5000

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTE: RM = See Repair Manual or contact Authorized Dealer

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION AND MAINTENANCE DOZER PIN GREASE POINTS

WARNING

3

To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

1 2 3

M110B.

GREASE MACHINE AND ATTACHMENTS

Figure 11

BS07N035

1. DOZER CYLINDER ROD PIN 2. DOZER CYLINDER FOOT PIN 3. DOZER FOOT PINS (2 - ONE EACH SIDE)

B O O M , A R M , A N D AT TAC H M E N T G R E A S E POINTS

7

4

8 10

Figure 9

BS07M861

During the initial 50 hours of operation, during the run-in period, grease bucket, boom, arm cylinder and dozer every 8 hours. After the initial run-in period, grease every 50 hours.

11 6 5

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

9

Figure 12

BS07N033

5. BOOM FOOT PIN 6. BOOM CYLINDER FOOT PIN (3 PLACES) 7. BOOM CYLINDER ROD PIN 8. ARM CYLINDER FOOT PIN

3

4

9. ARM CYLINDER ROD PIN 10. BOOM/ARM CONNECTING PIN (2 PLACES)

1

11. BUCKET CYLINDER FOOT PIN

2

12. BUCKET CYLINDER ROD PIN

BS07N028

1. Bucket Cylinder Rod Pin 2. Idler Link Arm Connecting Pin

Figure 10 3. Bucket Link Pin 4. Arm Bucket Connecting Pin

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease the leaks out of the pin connection.

6-10

NOTE: Dispose of all waste in accordance with environmental regulations.

WARNING The machine and attachment should not be moved when greasing. Personal injury may result. Move attachment to a different position, stop the engine and lubricate the attachment again. Repeat this procedure until the front attachment is completely lubricated. Failure to comply could result in death or serious injury.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL LEVEL

ENGINE COOLANT LEVEL

2

1 1 Figure 14

RH09N026

1. ENGINE COOLANT RESERVOIR

1. Check coolant level every 8 hours. Coolant should be changed at 1000 hours. The coolant reservoir tank (1) is located on the right side of the engine compartment.

BS07N039

Figure 13

1. DIPSTICK 2. OIL FILL CAP

1. Check oil level every day or each 8 hour shift. Oil should be changed at 50 hour run-in period and at every 250 hours thereafter.

2. Raise the engine cover.

3. Pull engine dipstick out, and wipe clean with a clean, dry, lint free cloth. Reinsert into engine.

Pull out again to visually inspect the engine oil level on dipstick.

4. Oil should be between L and H marks on the dipstick.

5. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

2. Proper coolant level is between FULL and LOW marks.

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

4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then refill reservoir to proper level. Inspect hoses and connections for leaks.

WARNING Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

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

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL LEVEL

ENGINE ELECTRICAL

Figure 15

DC04C292

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

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

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Failure to comply could result in death or serious injury.

M1725

6-12

Figure 16

RH09M040

1. FUEL LEVEL GAUGE

1. Turn ON the key from key switch and the fuel gauge in the cluster will indicate the fuel tank level.

2. To refuel the machine, remove the fuel tank cap.

Do not remove the fuel screen for fueling. Refill fuel tank to full mark to reduce air volume (condensation). Failure to do so could create problems such as rusting and fuel freezing, as well as other associated problems.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DRAIN WATER SEPARATOR

1. Clean around the water separator.

2. Place a drip pan under the water separator.

3. Place the cock (1) in the upright, closed position.

4. Remove the ring nut (5) and remove the filter base(4).

5. Drain the filter base and clean the element with clean diesel fuel.

6. Verify that the O-ring (3) is not damaged and is in good condition.

7. Install the filter base and secure it with the ring nut (5).

8. Bleed the air from the water separator.

9. Place the cock (1) in the open position.

10. Check for fuel leaking from the system.

11. Repair or replace damaged hoses and lines.

RH09N027

1

Figure 17

2 3 4 5

RH09N028

Figure 18

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL

6. Add hydraulic oil, filling hydraulic tank to the proper level.

7. Install the cap and check all hydraulic controls for proper functionality before operating the machine NOTICE: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

WARNING

Figure 19

BS07M861

1. Place the machine in the hydraulic oil check position on a firm level surface.

The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

2. Check the sight glass located on the side of the hydraulic tank. The oil level should be between H and L. NOTICE: Oil level will depend on oil temperature.

Cold: L level (oil temperature 10-30° C [50-86° F]) Operating: H level (oil temperature 50-80° C [122-176° F]) 3. Refill if oil level is below L. 4. To add hydraulic oil, open the right side cover and support with strut.

WARNING When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury M1303A

2 WARNING For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. DO NOT OPERATE machines on inclined surfaces with a slope greater than 35°.

Failure to comply could result in death or serious injury.

1

M1718

Figure 20

RH09N025

1. COVER 2. HYDRAULIC TANK CAP

5.Slowly loosen the cap (2) about a half turn to release pressure inside 6-14

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK CRAWLER BELTS

HYDRAULIC OIL LEAKS

Keep crawler belts free of dirt and imbedded rock for maximum traction. Visually check for cracking, separating, exposed core or other damage. Check tension after the first 50 hours of initial operation.

Figure 21

DC04C287

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

BS07M874

Figure 22

M587

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

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

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

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECT ALTERNATOR/FAN BELT CONDITION

ATTACHMENT LUBRICATION (INITIAL)

Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time, and every 250 hours thereafter.

2

3

3

4

1

A

2 1 Figure 24

BS07N028

1. BUCKET CYLINDER ROD PIN Figure 23

UPU00300026JS1

2. IDLER LINK/ARM CONNECTING PIN

1. ATTACHING BOLT

3. BUCKET LINK PIN

2. ADJUSTING BOLT

4. ARM/BUCKET CONNECTING PIN

3. ADJUSTING BOLT

During the first 50 hours of operation, grease attachment every 8 hours. After the initial run-in period, grease every 50 hours.

WARNING Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

M124B

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fittings.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

6-16

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE: ATTACHMENT LUBRICATION

DRAIN FUEL TANK SEDIMENT

2

3

4

1 2

Figure 25

BS07N028

1

1. BUCKET CYLINDER ROD PIN 2. IDLER LINK/ARM CONNECTING PIN 3. BUCKET LINK PIN 4. ARM/BUCKET CONNECTING PIN

During the first 50 hours of operation, grease attachment every 8 hours. After the initial run-in period, grease every 50 hours.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fittings.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

Figure 26

RH09N029

1. FUEL TANK 2. DRAIN PLUG

WARNING Drain fuel, using a suitable container, in a well ventilated area away from any source of flame or sparks, including any appliances with a pilot light.

Failure to comply could result in death or serious injury.

M1398.

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

1. Draining water and sediment is most effectively perfor med in the mor ning. Tur n the upper structure of the machine so the drain plug (2) is midway between the crawler belts.

2. Place a suitable container under the drain plug (2) to catch the discharged fuel.

3. Slowly loosen the drain plug (2) to drain water and sediment. When clean fuel begins to flow, tighten the drain plug.

4. Check for fuel leakage after tightening drain plug.

If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

5. Dispose of drained water and sediment according to local environmental regulations.

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE OIL AND OIL FILTER (INITIAL)

3

11 Figure 28

BS07N032

3. FILTER WRENCH

22

6. Use the filter wrench (3) provided with the machine, and turn counter clockwise to remove the oil filter.

A UPU00400018JS1

Figure 27

1. FILTER CARTRIDGE 2. CARTRIDGE HEAD

Change oil and oil filter at 50 hour run-in period for a new machine, then at every 250 hours thereafter.

1. Keep all unauthorized personnel clear of the area. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off. Open the engine door. Remove the dipstick to allow oil to run more freely.

2. Remove bolts and engine belly pan covers 3. Locate the engine oil drain plug and place an empty oil container of sufficient capacity under the drain plug. Attach the quick drain hose, and drain the oil into the container.

4. Remove engine oil drain plug and let the engine oil drain out completely.

5. After draining oil, remove drain hose, and tighten drain cap securely. Remove any spilled oil.

BD07N040

Figure 29

7. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter. Turn the filter cartridge on by hand until it is snug, then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head. Do not over tighten.

NOTICE: Check the waste oil and used filter. If there are metal flakes in the oil, contact your authorized Dealer. Do not reuse the oil filter.

8. Clean oil drain plug and install it. Tighten securely.

9. Fill with the specified amount of oil through engine filler port and install oil filler cap.

10. Before starting the engine, check oil level using the dipstick. The level should be between the L and H limits. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

11. Install under cover to its original position.

6-18

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACKS AND COMPONENTS Check rubber track tension every 50 hours.

1

Figure 32

BS07N042

DC04C300

Figure 30

Abrasion on the rubber crawler belt varies depending on working conditions. Frequently check for wear and tension, particularly on a new crawler belt as there will be an initial stretch during the first 30 hours of operation.

3. Move the upper structure at 90° to the crawler frame. Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Support the lower travel structure with a safety support (1).

2

1

1. Visually inspect track shoes for signs of excessive wear or damage.

3

4

BS07N043

Figure 33

1. CRAWLER FRAME 2. LOWER ROLLER 3. RUBBER BELT BS07N041

Figure 31

2. Move the rubber crawler belt so the joining ends (M mark) comes to the upper center position.

4. IRON SHOE

4. Measure the clearance in the center of the track, between the bottom of the track frame and the track shoe surface.

Measure Clearance (A) Rubber belt 45- 50 mm (1.77 - 1.97in.)

Iron shoe 90-95 mm (3.54 - 3.74) If track tension is not within the specifications, make adjustment to the track.

NOTICE: If working on firm, hard ground, more track tension is recommended. If working on loose gravel or stone, lower track tension is recommended.

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

Figure 34

DC04C307-1

BS07N045

2

Figure 36

1. GREASE FITTING 2. GREASE CYLINDER

WARNING

A. GREASE FILL

Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

B. PRESSURE

M1720

BS07N046

6. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting with a grease gun until proper tension is reach.

1

BS07N044

NOTICE: If the adjustment to the track cannot be maintained, the grease cylinder may need repair.

Contact your authorized dealer.

Figure 35

5. Grease in the track tensioning mechanism is under extreme pressure and can penetrate the skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call an authorized service dealer for assistance.

6-20

Figure 37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Removing Rubber Crawler Belt

Adjusting for less tension

1 1

Figure 38

BS07N046

1. Gradually loosen the grease fitting to release grease under pressure. Do not loosen the grease fitting (1) more than one turn.

2. If the grease does not release adequately, move the machine forward and backward.

Figure 40

BS07N042

1. Park the machine on a hard, level surface. Move the upper structure at a 90° to the crawler frame.

Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Support the lower travel structure with a safety support (1).

1

1

BS07N047

Figure 39

3. After grease has been released, tighten the grease fitting.

Torque to: 49-68.6 Nm (36.2-50.6 lbf ft). Move the machine forward and backward to confirm the correct tension of th e crawle r be lt. If necessary, adjust again.

BS07N046

Figure 41

2. Gradually loosen the grease fitting to release grease under pressure. Loosen the grease fitting (1) less than one turn. Grease will flow from the fitting.

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

1 Figure 42

BS07N049

3. Insert three steel pipes into the bottom front rubber crawler belt, then slowly rotate the sprocket backward by moving the track.

4. Stop the rotation when the rubber crawler belt separates from the idler wheel. Shut off the engine.

5. Slide the crawler belt over the steel pipes to remove.

REPLACING THE RUBBER CRAWLER BELT

1

BS07N042

Figure 43

1. Park the machine on a hard, level surface. Move the upper structure at a 90° to the crawler frame.

Operate the attachment placing it on the ground as illustrated and gradually lower the boom to lift one side of the machine. Shut off the engine.Support the lower travel structure with a safety support (1).

6-22

BS07N049

Figure 44

2. Engage the rubber crawler belt with the sprocket and hang it on the idler.

3. Insert three steel pipes into the bottom front r ubber crawler belt then slowly rotate the sprocket backward. When the rubber crawler belt separates from the idler wheel, stop the rotation.

Shut of the engine.

4. Slide the rubber crawler belt over the steel pipes to install it.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

2

6

5 4

7 3

BS07N050

Figure 45

1. LOWER ROLLER 2. RUBBER CRAWLER BELT 3. SPROCKET 4. IDLER 5. LUG 6. METAL CORE 7. TRAVEL MOTOR

5. Stop the rotation of the sprocket to confirm the rubber crawler belt is securely engaged to the sprocket, idler, and lower rollers. See illustration.

6. Check the tension on the belt and make any necessary adjustments.

7. If tension is correct, lower the machine to the ground.

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECT BELT CONDITION Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time, and every 250 hours thereafter.

2. Apply a force of 98 N (22 lb) to the center of the belt between pulleys. Measure the deflection.

3. Belt deflection: 8-10 mm (.31-.39 in) 4. If the belt has a greater deflection, adjust the belt to tighten. If belt is cracked or frayed, replace belt.

3 ADJUSTING BELT 1. Slightly loosen attaching bolt (1) and adjusting bolt (2).

2

2. Loosen adjust bolt (3) adjust the fan belt to the correct tension, and tighten bolts (1) and (2).

1

3. After adjustment, run the engine at low idle for approximately 5 minutes, then recheck the tension of belt.

Figure 46

RH09N044

4. Belt deflection: 8-10 mm (0.31-0.39 in)

WARNING Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

M124B

22

3

A

11

UPU00300026JS1

Figure 47

1. MOUNTING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level area. Turn the engine off and allow the machine to cool.

6-24

NOTICE: A used belt refers to a belt that has been run 5 minutes or more.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

33

44

11 22 88

Figure 48

BS07M861

Replace the hydraulic return filter at 50 hour run-in period for a new machine. The hydraulic return filter should be replaced every 1000 hours thereafter.

55

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

66

77 UPUX1404023J01

Figure 49

5. Slowly loosen the cap (2) about a half turn to release tank pressure.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

6. Remove bolt (5) and cover (6) from the side surface of the tank.

7. Remove the element (7) from the tank.

8. Replace O-ring (8) fitted on the face of the cover (4).

9. Clean the parts removed with clean hydraulic oil.

10. Install the element in the reverse order.

3. Open the left cover (1) to the hydraulic tank and secure with the strut.

11. Install the cover (6) and element (7).

Tightening torque: 90-95 NM (18-25 lb ft).

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

12. Connect hoses (3) and (4) to original position.

13. Tightening torque: PF1/4 24-34 Nm (18-25 lb ft).

Tightening torque: PF3/4 108-128 Nm (80-94 lb ft).

14. Install cover bolts. Tightening torque 21-25 Nm (15-18 lb ft).

15. Verify the cap (2) is properly installed.

16. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in hydraulic oil level check position. Stop the engine and check the oil level. Add oil if needed.

17. Install the left cover (1).

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE ENGINE OIL AND OIL FILTER (INITIAL)

3

11 Figure 51

BS07N032

3. FILTER WRENCH

22

6. Use the filter wrench (3) provided with the machine, and turn counter clockwise to remove the oil filter.

A UPU00400018JS1

Figure 50

1. FILTER CARTRIDGE 2. CARTRIDGE HEAD

Change oil and oil filter at when the hourmeter registers 250 hours and every 250 hours thereafter.

1. Keep all unauthorized personnel clear of the area. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off. Open the engine door. Remove the dipstick to allow oil to run more freely.

2. Remove bolts and engine belly pan covers 3. Locate the engine oil drain plug and place an empty oil container of sufficient capacity under the drain plug. Attach the quick drain hose, and drain the oil into the container.

4. Remove engine oil drain plug and let the engine oil drain out completely.

5. After draining oil, remove drain hose, and tighten drain cap securely. Remove any spilled oil.

BD07N040

Figure 52

7. To install the oil filter, apply a thin coat of engine oil to the gasket (A) of the new oil filter. Turn the filter cartridge on by hand until it is snug, then secure the filter by tightening 2/3 of a complete turn by hand after the gasket comes in contact with the oil filter head. Do not over tighten.

NOTICE: Check the waste oil and used filter. If there are metal flakes in the oil, contact your authorized Dealer. Do not reuse the oil filter.

8. Clean oil drain plug and install it. Tighten securely.

9. Fill with the specified amount of oil through engine filler port and install oil filler cap.

10. Before starting the engine, check oil level using the dipstick. The level should be between the L and H limits. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

6-26

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 11. Install under cover to its original position.Before starting the engine, check oil level using the dipstick (1). The level should be between the L and H limits as shown. Start and run the engine for five minutes. Stop the engine and recheck the oil level after 30 minutes. Add oil if necessary.

RADIATOR AND HOSES

11

12. Install cover (2) to its original position.

33

L FUL W

LO

44

22 Figure 53

UPU00400019JS1

1. RADIATOR CAP 2. DRAIN HOSE 3. RADIATOR 4. RESERVOIR TANK

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Open the engine cover and secure it with strut.

3. Check the hoses for leakage due to loose clamps, or cracked and worn hoses.

4. Tighten any loose clamps.

5. Replace any hoses that are damaged. See replacing radiator hoses for further information.

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECT BELT CONDITION Visually check the belt every day. Belt tension should be checked after the first 50 hours of run in time, and every 250 hours thereafter.

2. Apply a force of 98 N (22 lb) to the center of the belt between pulleys. Measure the deflection.

3. Belt deflection: 8-10 mm (.31-.39 in) 4. If the belt has a greater deflection, adjust the belt to tighten. If belt is cracked or frayed, replace belt.

3 ADJUSTING BELT 1. Slightly loosen attaching bolt (1) and adjusting bolt (2).

2

2. Loosen adjust bolt (3) adjust the fan belt to the correct tension, and tighten bolts (1) and (2).

1

3. After adjustment, run the engine at low idle for approximately 5 minutes, then recheck the tension of belt.

Figure 54

RH09N044

WARNING

Adjusting Belt

Entanglement Hazard - Stay clear! Rotating machine parts. Keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing. Failure to comply could result in death or serious injury.

M124B

22

4. Belt deflection: 8-10 mm (0.31-0.39 in)

1. Slightly loosen attaching bolt (1) and adjusting bolt (2).

2. Loosen adjusting bolt (3) adjust the fan belt to the correct tension, and tighten bolts (1) and (2).

3. After adjustment, run the engine at low idle for approximately 5 minutes, then recheck the tension of belt.

3 New Belt Tension

Used Belt Tension

8 - 12 mm (8/16 - 7/16 inch)

10 - 14 mm (3/8- 1/2 inch)

A NOTICE: A used belt refers to a belt that has been run 5 minutes or more.

11

BOLT AND NUT TORQUE When the hour meter registers 250 hours, check all machine bolts and nuts for proper torque. See charts in Chapter 8 - Specifications.

UPU00300026JS1

Figure 55

1. MOUNTING BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

Check belt for insufficient tension, wear, and damage. A loose belt can cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be prematurely damaged.

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level area. Turn the engine off and allow the machine to cool.

6-28

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DOZER PIN GREASE POINTS

GREASING THE SWING BEARING

3 1 2 3

Figure 56

BS07N130

Grease the swing bearing by adding grease to each fitting (4 locations) until grease comes out fittings.

Figure 57

BS07N035

1. DOZER CYLINDER ROD PIN 2. DOZER CYLINDER FOOT PIN 3. DOZER FOOT PIN (2 PLACES)

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

When machine is new, during the first 50 hours of operation, grease attachment, boom, arm, and boom swing every 8 hours. After the initial run-in period, grease every 250 hours.

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any excess grease that may leak out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BOOM, ARM, AND ATTACHMENT GREASE POINTS

7

4

BOOM SWING GREASE POINTS

8 14

10 11 12 12

6 5 9

13 13 BS07N033

Figure 58 UPU00400017JS1

4. BOOM FOOT PIN 5. BOOM CYLINDER FOOT PIN (3 PLACES) 6. BOOM CYLINDER ROD PIN 7. ARM CYLINDER FOOT PIN 8. ARM CYLINDER ROD PIN 9. BOOM/ARM CONNECTING PIN (2 PLACES) 10. BUCKET CYLINDER FOOT PIN 11. BUCKET CYLINDER ROD PIN

Figure 59

12. SWING CYLINDER FOOT PIN 13. SWING CYLINDER ROD PIN 14. SWING BRACKET/FRAME CONNECTING PIN (2 PLACES)

1. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off.

2. Clean the grease fitting before greasing. Replace any damaged grease fitting.

3. Lubricate with a grease gun through the grease fittings shown. Wipe off any grease that leaks out of the pin connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

6-30

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING AND REPLACING ENGINE AIR FILTER Clean the air filter element every 250 hours. The air filter should be replaced after being cleaned six times or after 500 hours of operation. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance.

BS07N132

Figure 61

5. To clean the outer element, blow compressed air 0.3 MPa (43 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

RH09N032

Figure 60

NOTICE: When cleaning the outer element, do not remove the inner the element. This will prevent dust from entering the air intake.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Release the two clamps from the air cleaner cover.

3. Remove the air cleaner outer element from the housing.

6. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing d a m a g e . R e p l a c e w i t h a n ew e l e m e n t i f necessary.

7. Set outer element in the casing.

8. Install the cover on two clamp positions, directing the mark "TOP" on the cover to the inlet side 9. The TOP position mark should face up. Make certain to avoid interference with the intake hose.

Incline the air filter casing approximately 15° to the engine side.

NOTICE: For machines equipped with double element (optional), the inner element must be replaced together with the outer element. Do not clean inner element. It must be replaced with a new element.

4. Clean the inside of air cleaner casing.

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER (BREAKER USE ONLY)

33

44

11 22 88 Figure 62

BS07M861

66 55

When using a breaker attachment on the machine, replace the hydraulic return filter every 250 hours.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

77 UPUX1404023J01

Figure 63

5. Slowly loosen the cap (2) about a half turn to release tank pressure.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

6. Remove bolt (5) and cover (6) from the side surface of the tank.

7. Remove the element (7) from the tank.

8. Replace O-ring (8) fitted on the face of the cover (4).

9. Clean the parts removed with clean hydraulic oil.

10. Install the element in the reverse order.

3. Open the left cover (1) to the hydraulic tank and secure with the strut.

11. Install the cover (6) and element (7).

Tightening torque: 90-95 NM (18-25 lb ft).

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

12. Connect hoses (3) and (4) to original position.

13. Tightening torque: PF1/4 24-34 Nm (18-25 lb ft).

Tightening torque: PF3/4 108-128 Nm (80-94 lb ft).

14. Install cover bolts. Tightening torque 21-25 Nm (15-18 lb ft).

15. Verify the cap (2) is properly installed.

16. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in hydraulic oil level check position. Stop the engine and check the oil level. Add oil if needed.

17. Install the left cover (1).

18.

6-32

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE CLEAN AND DRAIN WATER SEPARATOR Check the water separator every 8 hours. Replace the engine water separator filter every 500 hours.

1 2 3 4 5

Figure 65

RH09N028

1. VALVE 2. CARTRIDGE ELEMENT 3. O-RING 4. BASE5 5. RING A. CLOSE / B OPEN

RH09N027

Figure 64

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Clean around the water separator. Place a drip pan under the water separator.

3. Place the valve (1) in the upright, closed position.

6

4. Remove the ring (5) and remove the filter base (4).

5. Drain the filter base and clean the element with clean diesel fuel.

6. Replace the element (2) and O-ring (3.

7. Install the filter base and secure it with the ring nut (5).

RH09N027

Figure 66

8. Bleed the air from the water separator.

9. Place the valve (1) in the open position. Loosen plug (6). When clean fuel free of air bubbles flows, tighten plug.

10. Check for fuel leaking from the system.

6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING FUEL FILTER The fuel filter should be replaced when the hourmeter registers 500 hours and every 500 hours thereafter. The fuel filter should not be reused. It must be replaced.

5. Remove ring (4). Remove filter body, O-ring (1) and O-ring (3).

6. Replace O-rings and cartridge element (2) with new components.

7. Reassemble fuel filter in reverse order, using care to make certain O-rings seat.

8. Secure filter body with ring (4).

A 11 22

B

33 44

51

Figure 68

UPU00400005JS1

9. Bleed air from the fuel system. Fuel is delivered by the solenoid pump (5).

Figure 67

UPU00400015JS1

WARNING

6

Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393 UPUX1704011B01A

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Allow the machine to cool. Open the engine door.

The fuel filter is located at the right rear of the machine.

Figure 69

10. Place the valve of the fuel filter in the OPEN (B) position.

11. Turn the ignition starter switch to the ON. Fuel pump will work after approximately 2 minutes and air will automatically be eliminated.

3. Place a drip pan under the filter.

12. If the machine does not have an automatic fuel system and cup does not automatically fill, Push and hold button (4) until the filter cup is filled with fuel. Release button.

4. Place valve A in the closed position to stop fuel flow.

13. Start and run the engine at idle for 5 minutes to check for fuel leaks. Close the engine door.

6-34

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING ENGINE AIR FILTER The air filter should be replaced after being cleaned six times or after 500 hours of operation. If any damage is visible to the filter, replace it regardless of machine time or scheduled maintenance.

BS07N132

Figure 71

5. To clean the outer element, blow compressed air 0.3 MPa (43 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

RH09N032

Figure 70

NOTICE: When cleaning the outer element, do not remove the inner the element. This will prevent dust from entering the air intake.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Release the two clamps from the air cleaner cover.

3. Remove the air cleaner outer element from the housing.

4. Clean the inside of air cleaner casing.

6. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing d a m a g e . R e p l a c e w i t h a n ew e l e m e n t i f necessary.

7. Set outer element in the casing.

8. Install the cover on two clamp positions, directing the mark "TOP" on the cover to the inlet side 9. The TOP position mark should face up. Make certain to avoid interference with the intake hose.

Incline the air filter casing approximately 15° to the engine side.

NOTICE: For machines equipped with double element (optional), the inner element must be replaced together with the outer element. Do not clean inner element. It must be replaced with a new element.

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR (INITIAL) The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil every 2000 hours thereafter.

2

Figure 74

RH09N035

5. After oil has drained completely, clean drain plug.

Use teflon tape on drain plug for additional sealing and install plug. Tighten securely.

1 Figure 72

RH09N033

6. Add oil through the oil fill opening until oil starts flowing out of the port.

1. DRAIN PORT 2. FILL PORT

7. Clean oil fill plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. When parking the machine, make certain the drain port (1) is at the bottom.

8. Check drained oil for any metal particles. If contaminants are present, contact your dealer.

9. Move machine slowly and confirm there are no oil leaks. .

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

RH09N034

Figure 73

3. Stop engine and place an empty 1 L (0.26 gal) container under the drain plug.

4. Remove oil drain (1) and fill (2) plugs to drain oil into the container.

6-36

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE REPLACING ENGINE COOLANT The engine coolant should be replaced every 1000 hours. Check the coolant level every 8 hours as part of daily maintenance.

5

11

Figure 76

BS07N142

9. Operate the engine at a speed slightly faster than low idle (5) to raise the coolant temperature to 80° C (176° F) or within white range on the temperature gauge for coolant temperature.

O pe rate th e e n gi n e for a p pr ox i ma te l y 1 0 minutes.

33

L FUL W

LO

44

22 Figure 75

UPU00400019JS1

1. RADIATOR CAP 2. DRAIN HOSE 3. RADIATOR 4. RESERVOIR TANK

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Open the engine cover and secure it with strut.

3. Check the hoses for leakage due to loose clamps, or cracked and worn hoses.

4. Tighten any loose clamps.

5. Replace any hoses that are damaged. See replacing radiator hoses for further information.

6. To drain radiator, place a rag or paper towel on the radiator cap (1) and slowly remove it to release the pressure.

7. Drain the radiator with drain hose (2). After draining, install the drain plug. Fill the cooling system with system cleaner according to cleaner container instructions.

10. Stop the engine. Allow the system to cool.

Loosen the radiator cap (1) slowly. After ensuring that the pressure has been released, push the cap down and hold while turning to remove.

Loosen the radiator drain plug (2). Flush the radiator with clean water until the water runs clear.

11. Install the radiator drain plug. Fill the radiator with a mix of 50% clean water and 50% KOBELCO LONG LIFE COOLANT. Start and run the engine to fully release air from the cooling system.

12. Stop the engine. Allow the engine to cool. Check the coolant level. The reservoir tank (4) water level should be between FULL and LOW. Adjust level to specifications.

13. Check the system for leaks and repair. Close the engine door.

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

8. Replace radiator cap.

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPAIRING HOSES

CHECK VALVE CLEARANCES

1. Drain coolant into clean container for reuse if not changing coolant.

Check and adjust the engine valve clearance every 1000 hours of engine operation. Contact your Kobelco Construction Dealer’s Service Department for assistance.

2. Clean the areas where the new hose will be connected.

3. Remove the clamps (if reusing old clamps) from the old hose and install them to the new hose.

4. Coat the inside ends of the new radiator hose with grease and install it. Tighten clamps properly.

CHECK STARTER AND GENERATOR Have the starter and generator checked every 1000 hours of engine operation. Contact your Kobelco Construction Dealer’s Ser vice Depar tment for assistance.

5. Fill radiator with coolant.

6. Install radiator cap, start engine, and bring engine temperature to about 90°C (194°F).

7. Run engine at low idle, check for leaks and repair as needed.

8. Install radiator lower cover and close engine cover.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

9. Inspect radiator cap for proper fit and pressure, and replace if needed.

6-38

CHANGE HYDRAULIC OIL - BREAKER/NIBBLER The hydraulic oil should be changed on the machine if operations are performed primarily with a breaker or nibbler when the hourmeter registers 1000 hours.

For standard excavation operations, change the hydraulic oil when the hourmeter registers 5000 hours or sooner if conditions so require. See Changing Hydraulic Oil in this section.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER

33

44

11 22 88

Figure 77

BS07M861

R e p l a c e th e hy d ra u l i c re tu r n f i l t e r w h e n t h e hourmeter registers 1000 hours and every 1000 hours thereafter.

55

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

66

77 UPUX1404023J01

Figure 78

5. Slowly loosen the cap (2) about a half turn to release tank pressure.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

6. Remove bolt (5) and cover (6) from the side surface of the tank.

7. Remove the element (7) from the tank.

8. Replace O-ring (8) fitted on the face of the cover (4).

9. Clean the parts removed with clean hydraulic oil.

10. Install the element in the reverse order.

3. Open the left cover (1) to the hydraulic tank and secure with the strut.

11. Install the cover (6) and element (7).

Tightening torque: 90-95 NM (18-25 lb ft).

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

12. Connect hoses (3) and (4) to original position.

13. Tightening torque: PF1/4 24-34 Nm (18-25 lb ft).

Tightening torque: PF3/4 108-128 Nm (80-94 lb ft).

14. Install cover bolts. Tightening torque 21-25 Nm (15-18 lb ft).

15. Verify the cap (2) is properly installed.

16. Start and run the engine at idle. Move the machine controls to remove air from the system.

Then place the machine in hydraulic oil level check position. Stop the engine and check the oil level. Add oil if needed.

17. Install the left cover (1).

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE HYDRAULIC SUCTION STRAINER CLEANING The hydraulic tank suction strainer should be cleaned when the engine hourmeter registers 2000 hours and every 2000 hours there after.

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

4 1

.

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

Figure 80

RH09N036

5. Slowly loosen the cap (2) about a half turn to relieve pressure.

6. Relieve the remaining pressure and remove the cap.

7. Put an oil pan under the hose. Loosen the union nut (1) on the hose and drain the remaining oil.

8. Tighten the union nut (1) to 68.5 - 78.5 Nm (50.5 - 70 lbf ft).

2

BS07M861

Figure 79

3

1. Park the machine on a firm, level surface with attachments resting on the ground. Keep all unauthorized personnel clear of the area.

2. Swing the machine so hose (1) on the hydraulic oil tank is midway between both crawlers. Turn the engine off. Place the safety lock lever in the locked position.

1 4

3. Remove the left side guard (3).

4. Clean dirt and oil from the tank to avoid contaminating the hydraulic system.

6-40

RH09N037

Figure 81

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Figure 83

RH09N038

12. Remove strainer (5) and clean with light oil or by washing. If damaged, replace.

5

13. Check O-ring (6) for wear or damage. If damaged, replace O-rings.

6 7

8

14. Insert strainer (5) and install cover (7). Torque to: 21 - 25 Nm (15 18 lbf ft).

15. Refill the hydraulic tank with hydraulic oil.

RH09N039

Figure 82

9. Remove four bolts (8) and remove the suction 10. Remove any dirt adhered to the suction strainer (5) and clean it with cleaning solvent. Replace strainer if suction strainer is damaged.

11. Check the bottom of the strainer (5) and O-ring (6) for possible damage. Replace if worn or damaged.

16. Start the engine and operate at low idle for 5 to 7 minutes. Operate each cylinder and swing.

Retur n the machine to the hydraulic level checking position.

17. Stop the engine and check the hydraulic oil. If level is low, add oil.

18. Reinstall the left side guard.

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PILOT VALVE AND SOLENOID VALVE Clean the pilot valve filter and solenoid filter when the hourmeter registers 2000 hours.

4

The “P port” of right and left pilot valves (for operation and travel) and the solenoid valve are equipped with a connector with a filter. Dirt that adheres on the filter will decrease oil flow.

5 11

2

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

3 3

33

.

UPAX0604065B01

WARNING Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

Figure 85

3. Loosen 2 bolts (3) on the operating box to remove the cover.

4. Disconnect the hose (1) connected to P port on the pilot valve (4), then remove elbow (2).

5. After removal, put a plug into the bore to prevent entry of foreign matter.

6. Wear face protection, wash the filter with cleaning solvent. Use compressed air to remove any material.

7. Check the O-ring (5) for damage, and replace if necessary.

8. After cleaning, install it to the original position in reverse order. See torque charts for tightening torque.

BS07M861

Figure 84

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Release all pressure in the hydraulic system.

6-42

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

7A

7B

7C 7D 7E 7F

8 6

7

Figure 87

RH09N041

9

7A O-RING 7B ADAPTER RH09N040

Figure 86

7C FILTER

9. Remove the in-line filter (7) of solenoid valve (6) for cleaning.

7D ADAPTER

10. Remove the left-hand guard (8).

7F ELBOW

11. After removal of the hose (9) , remove the in-line filter assembly (7) from the tee installed on the solenoid valve (6). After removal, the oil holes of tee and hose should be plugged.

7E O-RING

12. Clean area to prevent contamination. Remove the adapters (7B) and (7D). Remove filter (7C).

13. Clean filter. Check O-rings (7A) and (7E).

Replace O-rings with new ones.

14. After cleaning all components, assemble filter (7C) with adapter (7D). Install the assembly to adapter (7B).

15. Install the in-line filter assembly.

16. Remove plug from hose (9) and install to elbow (7F).

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

9

12

11

12 13

10 9 RH09N043

Figure 89

20. Check the O-ring (12) for damage, and replace, if damaged.

21. After cleaning, install to the original position in the reverse order of disassembly. Refer to torque charts for tightening hose (11).

22. Install the floor mat and floor plate.

RH09N042

Figure 88

17. Remove the elbow with filter (9) of pilot valve (10) for cleaning.

18. Remove the floor mat and floor plate. Disconnect the hose (11) connected to P port on the pilot valve (10). Remove the elbow (9). After removal, put a plug into the bore to prevent entry of foreign matter.

19. Dust tends to accumulate on the inside elbow (9) (dented por tion). Clean par ts to avoid contamination (projected portion).

6-44

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION GEAR The travel reduction gear oil should be changed at 500 hours for a new machine. Change the travel reduction gear oil when the hourmeter registers 2000 hours and every 2000 hours thereafter.

2

Figure 92

RH09N035

5. After oil has drained completely, clean drain plug.

Use teflon tape on drain plug for additional sealing and install plug. Tighten securely.

1

6. Add oil through the oil fill opening until oil starts flowing out of the port.

Figure 90

RH09N033

7. Clean oil fill plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

1. DRAIN PORT 2. FILL PORT

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. When parking the machine, make certain the drain port (1) is at the bottom.

8. Check drained oil for any metal particles. If contaminants are present, contact your dealer.

9. Move machine slowly and confirm there are no oil leaks. .

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

RH09N034

Figure 91

3. Stop engine and place an empty 1 L (0.26 gal) container under the drain plug.

4. Remove oil drain (1) and fill (2) plugs to drain oil into the container.

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOWER ROLLER AND IDLER OIL CHANGE

5 6

5

3 4

2

1 Figure 93

RH09N046

Figure 94

BS07N260

1. TRAVEL MOTOR 2. SPROCKET 3. LOWER ROLLER 4. CRAWLER BELT 5. SHOE SLIDE 6. IDLER

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Loosen the rubber crawler shoe. Loosen the cap screws (1) of the lower roller about one turn.

Change the gear oil in idlers when the hourmeter r e g i s t e r s 2 0 0 0 h o u r s a n d eve r y 2 0 0 0 h o u r s thereafter. Idlers must be removed from the crawler frame to change the gear oil. Refer to the oil and grease specification for the required volume.

3. Start the engine and lift up the side of the machine with the boom and arm.

4. Stop the engine. Support the machine with a suitable safety support (5).

(5) 5

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

4 (4)

2 (2) (1) 1

(1) 1 (2) 2

5(5) 3 (3)

WARNING UPU00400044ES1

WARNING: Travel reduction gear is under pressure.

Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

Figure 95

5. Remove the capscrews (1) with washers (2) which install the lower roller to the crawler frame at two positions. Remove the lower roller (3).

6. Remove the feeding port plug (4) with allen wrench, and discharge the old gear oil.

7. Fill with the specified volume (60 cc or 3.7 cu.in) of gear oil through the feeding port.

8. Apply sealing (teflon) tape to thread on the plug (4), and securely tighten it. Thoroughly wipe off oil adhered to periphery.

9. Apply Loctite #262 to thread on the capscrews (1), and temporarily install the lower roller (3) to the crawler frame.

6-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 10. Remove the safety support which supports the machine, then tighten the capscrew (1).

Tightening torque: 103 - 127 Nm {76 -94 lbf ft}

3

11. 11.Lift up the machine to adjust the track tension.

Refer to Adjusting Track Tension in this section.

IDLER OIL CHANGE

2 1 6

BS07N263

5 3

NOTICE: Check the drained waste oil. If there are metal flakes in the oil, contact your Kobelco Construction Service Dealer. DO NOT reuse the oil filter.

4

Figure 96

BD07N262

Figure 97

WARNING Check and adjustment for track tension requires the machine to be lifted off the ground one track at a time. Unexpected lowering of the machine could result in injury or death. Do not operate the boom while adjusting the crawler belt. Failure to comply could result in death or serious injury.

1. This is a two person procedure. See procedure for removing and installing crawler belt in this section.

2. Remove the rubber crawler belt. Place a safety support under the machine.

6. Apply sealing (teflon) tape to the threads on the plug (3), and securely tighten it. Wipe off any remaining oil.

7. Apply grease to the sliding face (A) on the piston (4) and cylinder (5) of the idler adjuster (2).

8. Install the idler so that the fill - drain port plug (3) of idler and the grease fitting (6) of idler adjuster (2) are facing to outside.

9. Install the rubber crawler belt.

10. Adjust the tension on the rubber crawler belt.

Refer to procedure for adjusting belt tension.

Raise the machine off the safety support, remove the safety support and slowly lower the machine to the ground.

3. Remove the idler (1) and adjuster (2) from the crawler frame.

Weight of idler + Idler Adjuster = approximately. 22 kg (49 lb) 4. Remove the fill drain plug (3) with Allen wrench to drain old gear oil.

5. Fill the idler with (80 cc {4.8 cu.in.}, {0.085 qts}) of the specified oil through the fill drain port.

6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE SWING GEAR GREASE If the machine is operated in a water depth close to the swing gear grease bearing, the water may become mixed with the grease and cause it to deteriorate. Continued operation with deteriorated grease will cause damage to the gears and bearing.

Contact your dealer for service and inspection.

This procedure should be completed by a qualified service professional.

FUEL INJECTION TIMING CHECK AND ADJUSTMENT To ensure proper fuel injection time checks and adjustments, contact your dealer for service and inspection to ensure proper engine performance.

INTAKE AND EXHAUST VALVE CHECK To ensure the seal of the exhaust and intake valves, contact your dealer for service and inspection.This procedure should be completed by a qualified service professional.

6-48

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL

22 F

33

44 1 11 44 UPU00400025JS2.

Figure 98

UPU00400024JS1

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393 1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Position the machine so the drain plug (1) on the hydraulic oil tank comes midway between both crawlers. Make certain all pressure is removed from the hydraulic system.

Figure 99

6. Slowly loosen cap (2) about one half a turn to release pressure inside tank.

7. Place a suitable container beneath the drain plug (1). Remove the drain plug (1) and drain the remaining oil.

8. Tighten the drain plug (1). Tightening torque 68.5-78 Nm (50.5-57.5 lbf. ft.)

NOTICE: Use caution not to drop bolts or nuts inside hydraulic tank. Do not allow fluid to come in contact with skin.

9. Fill the hydraulic oil tank with hydraulic oil at filling por t (F) according to machine specifications.

10. Install cover (3) and all guards.

11. After starting the engine, run at low idle. Perform several telescopic movements of each cylinder and the swing operation.

Ｈ

3. Remove the left side guard.

A

4. Open the cover on the hydraulic tank with the engine key, and hold it open with the strut.

Ｌ

5. Clean around the tank to avoid contaminating the hydraulic system.

UPUX1704009B01

Figure 100

12. Stop machine and check oil level at gauge.

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL PROCEDURES BUCKET

4

3

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

1 2

M110B.

5

ABRASION OR DAMAGE ON TOOTH POINTS AND SIDE CUTTERS Check for wear and/or looseness of bucket tooth points. Tooth point life cannot be determined only by the number of operating hours.

Figure 102

BS07N271

1. ADAPTER 2. TOOTH POINT 3. RUBBER LOCK PIN 4.LOCKING PIN 5. ADAPTER NOSE

7

8

6 Figure 101

BS07N270

WARNING When replacing a bucket tooth or side cutters, securely block the bucket to avoid injury. Failure to comply could result in death or serious injury.

Replace the bucket tooth is small holes appear on the tooth point or when the edge lines of the tooth point are worn.

6-50

Figure 103

BS07N272

6. SAFETY BLOCK 7. HAMMER 8. PUNCHING TOOL

1. Using a hammer and punch, hammer out the locking pin. Take care not to damage the rubber lock pin (3).

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING THE SIDE CUTTERS

2

BS07N273

Figure 104

2. Inspect the locking pin (4) and rubber lock pin (3). Replace them if the locking pin (4) is too shor t or the r ubber lock pin (3) is in poor condition.

3. Clean the surface of the adapter nose (1) with a putty knife to remove any adhered soil.

4. Fit the tooth point (2) onto the adapter nose (1).

5. Push the rubber lock pin (3) in the hole of the adapter nose (1).

Figure 105

BS07N274

1. Remove all sand and soil adhering around the bolts. Use an acetylene torch to cut off the bolts, then remove the side cutter.

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, replace the bolts and nuts with new ones.

3. Tightening torque: 115±12 Nm {84.6±8.7 lbf•ft} 4. After tightening the nuts, spot-weld them.

6. Drive the locking pin (4) until it is aligned with the point face.

2

2

1

4 3 Figure 106

BS07N275

1. NUTS 2. SIDE CUTTER 3. BOLT 4. TOOTH POINT

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING BUCKET

INSTALLING BUCKET

7

7 8

8 5

4

6 6

6 1

Figure 108

BS07N277

1. Clean each pin and pin hole and grease sufficiently.

2. Move the bucket cylinder to match the pin bores or the bucket (6) and bucket link (8) with each other, then insert the pin (4).

3. Raise the boom and slightly raise the bucket from the ground.

9

3

2 2

9

4

5

Figure 107

BS07N276

3

9

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

1. Carefully operate the boom and the arm to remove load from the pins.

2. Roll O-rings (1) onto the bucket boss. After removing the pins, place them back in the original position.

3. Remove the lock ring (2) and lock pin (3), remove the pins (4) and (5) in order to remove the bucket (6).

NOTICE: Keep pins free of sand, dirt or other contaminants when removed. Do not damage the dust seals (9) on both ends of the arm.

6-52

4 5 BS07N278

4. Align bucket (6) with the pin hole of arm (7) moving arm (7), and insert pin (5).

5. Insert pin (3) and fit lock ring (2).

Fit O-ring (1) to the normal position.

6. Apply grease on the grease nipples for respective pin until the grease comes out through the gap between pins and bore.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RUBBER CRAWLER TRACK Rubber track offers many benefits over metal track, but must be used in accordance to the m a nu fa c t u r e r ’s s p e c i f i c a t i o n s. T h e m a c h i n e guarantee does not cover improper operation at job sites. Do not operate the machine over objects such as steel plate, steel pipes, concrete rod, stones and r o ck s w i t h s h a r p e d g e s. O b s e r ve o p e r a t i n g conditions and characteristics of rubber track to gain optimum performance.

RUBBER TRACK OPERATION BS07N287

Figure 111

DO NOT operate or travel over river beds with stones of different sizes. Rubber crawler belts may be damaged or come off the rollers. The service life of the rubber crawler belts will be reduced if the belt is not maintained with the correct tension.

Figure 109

BS07N292

TRACK COMPARISON

BS07N288

Figure 112

DO NOT operate on oil contaminated surfaces. Oil will damage the rubber crawler belts.

BS07N286

Figure 110

DO NOT operate in gravel mixed land, rugged and solid rock bed, over iron scraps, or edges of iron plates such as concrete rebar.

BS07N293

Figure 113

DO NOT operate near open fires, or on steel plates exposed to the sun or use in asphalt leveling. Heat will damage rubber crawler belts.

When storing the machine for long periods indoor storage is recommended. Rubber crawler belts can be damaged if exposed for long periods of time to harsh environments in a non-operational mode.

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BS07N290

Figure 114

DO NOT operate the crawler belt on the ground if the other track has been lifted. The additional weight may damage the track or cause the track to come off.

BS07N291

I f m a c h i n e i s o p e ra t e d i n s a l t y o r c o r r o s i ve conditions, the bonding of the rubber to the metal core can be damaged. Clean the belts after use. The normal temperature operating range for rubber crawler belts is between -25° to 55° C (-13 to 131° F).

BS07N296

Figure 118

Avoid changing direction of the machine on ground with a difference in level of 20 cm (8 in.) or more.

Travel at right angles over ground when there is a significant difference in level.

Figure 116

Use care not to damage the track with the machine attachment.

Do not apply side load force or side impact on the bucket or attachment during operation.

If the machine is raised with the bucket, lower machine slowly.

6-54

Figure 117

Figure 115

Use caution when operating on ice or snow. Rubber belts can easily slip. Avoid making sudden turns on concrete. Avoid sudden direction changes, as this may cause premature wear on the crawler belts.

BS07N294

BS07N295

BS07N297

Figure 119

When moving up a slope, avoid changing direction of the machine when the machine is at a point between the level ground and the slope.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK INSPECTION

1

5

2 3 BS07N298

4

Figure 120

Do not travel on a slope with one side of the machine lifted. Always travel with both sides level to avoid damage to the track.

Figure 122

BS07N280

1. LOWER ROLLER 2. RUBBER CRAWLER BELT 3. LUG 4.STEEL CORD 5. METAL CORE

Repair or replace rubber crawler belt if it is damaged.

Contact your dealer for assistance in replacing belts or refer to the machine Repair Manual.

HEIGHT OF LUG

BS07N299

Figure 121

Do not change direction of the machine with the rubber crawler on high spots as illustrated. This can cause the rubber crawler belt to be damaged or come off.

4 BS07N281

Figure 123

Replace the belt with a new one if the height of the lug is below (A) 5 mm (0.2 in.). The low height of lug will decrease traction.

If the lug wears and the steel cord (4) in the belt is exposed over two links, replace the belt.

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RUBBER TRACK METAL CORE

STEEL CORD DAMAGE

1 2 4

5 3 Figure 124

BS07N282

If the steel cords (B) are over one half broken in one row, replace the crawler belt.

Figure 126

BS07N284

1. LOWER ROLLER 2. METAL CORE 3. RUBBER 4. STEEL CORD

CRACKED CRAWLER BELT

5. INTERFERENCE WITH ROLLER

Depending on the usage of the rubber crawler belt, there occasionally may be peeling of the metal core (2). Peeling occurs on the inner side due to contact with the rollers (1), idlers, and sprockets. The lug side (outer side of belt) may appear undamaged.

4

BS07N283

NOTICE: Unapproved or prohibited operation of the machine can cause damage to the rubber crawler belt. The warranty is not applicable for any damage due to prohibited or unapproved usage of the rubber track or the use of it with improper tension.

Figure 125

Repair the belt if a crack approximately 60 mm (2.4 in) is seen between the lug of the rubber belt. Repair immediately if the steel cord (4) is exposed even though the crack is minimal.

2

BS07N285

Figure 127

Cracked rubber belts showing metal core (2) must be replaced with new belts.

Minute cracks will not effect performance, and it is not necessary to replace belt.

6-56

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOVING A DISABLED MACHINE

1. Place blocks at front and rear of tracks to prevent machine from moving when brakes are released.

WARNING

2. Lower attachment to the ground.

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

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. Failure to comply could result in death or serious injury.

M1087

WARNING

M1723

The following procedures should only be performed by an experienced service technician familiar with this machine. Failure to comply could result in death or serious injury.

RELEASING LOCK ON TRAVEL MOTOR

Figure 130

BS07N378

3. Place a pan under the travel motor to drain oil.

Slowly remove upper plug, then remove drain plug to drain reduction unit oil.

4. Plug (1) Opposing flat 6 mm (0.24) BS07N300

Figure 128

The travel motors of a disabled machine are locked by the hydraulic control valve and by the mechanical brake system. If the machine is locked and unable to run, it can be moved by releasing the travel motor lock by one of the following methods.

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. heat increases travel reduction gear oil pressure. Loosen plugs slowly and wear face protection. Never attempt to service a hot machine. allow machine to cool before performing any service. Failure to comply could result in death or serious injury.

REMOVING GEARS FROM TRAVEL REDUCTION UNIT

M1721 .

UPU00900001ES1

Figure 129

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ASSEMBLING THE TRAVEL MOTOR

66

1 66

1

3 3 55 55

2 2 2 2

4

4

Figure 131

UPU00900003ES1

5. Insert a flat blade screwdriver into space between the body (1) and O-snap ring (3) to remove the O-snap ring (3).

6. Remove the cover (2) along with the side ring (5).

7. Remove the carrier assembly (6) from the reduction unit. Protect the reduction unit from contamination and/or damage.

8. Temporarily install the cover (2).

UPU00900003ES1

Figure 133

1. After all repairs are completed, assemble the travel motor units in reverse order.

2. Reinstall the carrier assembly (6) on both travel reduction units in reverse order.

3. Make certain to use new, clean gear oil.

4. Replace the O-ring with new components and install the drain plug (4).

9. Repeat steps 1 through 7 on the opposite side of travel unit. Remove the carrier assembly (6) from both sides of the machine.

5. Tightening torque:

10. Tow the machine to an appropriate location and proceed with necessary repairs.

7. Add the specified gear oil through the oil fill plug until oil flows from the oil level plug.

3

2

1

UPU00900004ES1

Figure 132

NOTICE: Do not allow hydraulic ports or lines to become contaminated. Cap all ports and lines.

6-58

6. 49-69 Nm (36-51 lbf ft).

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOWERING BUCKET ATTACHMENT ON A DISABLED MACHINE

BS07N384

Figure 134

BS07N383

WARNING Before attempting to release the swing brake, make certain the attachment is on the ground. This will help prevent sudden and unexpected rotation of the upper structure. Failure to comply could result in machine damage, injury or death.

M1724

The following procedure is to be used only in an emergency if the machine is disabled. Proceed with extreme caution. Keep people away from the bucket/attachment and excavator boom.

Figure 135

To lower the bucket position, proceed carefully as follows: When the bucket is in digging position (A) (bucket cylinder completely extended, (see figure) disconnect hose head (H) side. When the bucket is in dump position (B) (bucket cylinder completely retracted), disconnect the hose rod (R) side NOTICE: Do not allow the hydraulic line or components to become contaminated. This could cause severe system damage to the hydraulic system. Contact your dealer to obtain the proper caps and plugs to be used.

NOTICE: Clean up all spilled oil. Dispose of any hazardous waste in compliance with local environmental regulations.

Block the bucket/attachment to avoid unexpected movement. Release the pressure in the hydraulic lines slowly until pressure is completely released.

Control the bucket/attachment movement by slowly removing the lock.

6-59

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Figure 136

BS07N385

BS07N386

Figure 137

LOWERING THE ARM

LOWERING THE BOOM

Gradually loosen the hose of rod side connected to the arm (R).

G ra d u a l l y l o o s e n t h e h o s e o f h e a d ( H ) s i d e connected to the boom cylinder.

WARNING

Stop lowering the attachment at 30 - 40 cm (12 - 16 in.) above ground level to allow for moving the machine.

To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

6-60

1. Tighten the hose fitting.

2. After moving the machine to the service area, slowly loosen the hose fitting to lower the attachment to the ground.

3. Contact your dealer for machine repairs.

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fusible Starter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Starting Machine Engine with Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL FUSIBLE STARTER LINK

ELECTRICAL COMPONENTS

.

FUSES .

2

11

2

Figure 2

UPU00200017JS1

Figure 1

UPU00200015JS1

Fuses protect the electrical system from excess current. Replace a blown fuse or any fuse generating white powder on it.

Make certain the starter switch is in the OFF position before replacing fuses.

Always replace fuses with a fuse of the same capacity. The spare fuses are stored in the back side of the fuse box cover.

AMPS

FUNCTION

1

30A

WIPER, HEATER

2

20A

RELAY, SOLENOID

3

30A

WORK LAMP

4

10A

HORN, CAB LIGHT

5

30A

ENGINE STOP SOLENOID

6

10A

BATTERY RELAY, CLUSTER GAUGE ENGINE STOP

NO.

If the electrical power does not come on when the starter key switch is in the on position, the fusible link may be the cause. Inspect and replace the red fusible link (1).

The fusible link protects the electrical system from current over load. The fusible link functions like a fuse.

WARNING Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

Failure to comply could result in death or serious injury.

M1728

7-3

CHAPTER 7 - ELECTRICAL BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte every 50 hours.

11

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

Figure 4

UPW00300007E01

1. BATTERY COVER 2. BATTERY .

2

1

SD104

1. Stop the engine. Set the safety lock lever in the LOCKED position. .

BS07N391

Figure 5

3. Remove battery cell caps (1) and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

1

4. If necessary, fill each cell to proper level with DISTILLED WATER ONLY.

22

UPU00300011JS1

Figure 3

2. The battery is located at the rear of the machine.

The electrical system for the machine is 12 V DC.

7-4

5. 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.

6. If cables are found to be in poor condition, replace with new parts immediately.

CHAPTER 7 - ELECTRICAL 8. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

WARNING Prevent Battery Explosion: Batteries give hydrogen gases that can explode and cause personal injury.

Keep sparks, open flames and cigarettes away from the 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. Failure to comply could result in death or serious injury.

M512

NOTICE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or is difficult to charge.

9. 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.

NOTICE: 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.

7. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTICE: Use hydrometer manufacturer’s instruction.

according

to

the

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

7-5

CHAPTER 7 - ELECTRICAL STARTING MACHINE ENGINE WITH BOOSTER CABLE CONNECTING BOOSTER CABLE

3

1

2

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion: 1.

When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2.

When you connect the battery cables, always connect the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery. 5. Always wash your hands after handling battery or battery components. Failure to comply could result in death or serious injury.

M512A

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

NOTICE: 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.

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

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

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B

4 1

2

3

4

DC04D588

Figure 6

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY BEING USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY BEING USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

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

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 (-) te r minal of th e ba tte r y being used fo r boosting.

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

STARTING BOOSTING MACHINE ENGINE 1. Start engine boosting machine in normal manner according to climate conditions.

2. Allow 5 minutes or more to provide partial charge to the discharged batteries.

STARTING DISABLED MACHINE ENGINE

WARNING Battery electrolyte is an acid and can cause injury or blindness if it makes contact 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. Failure to comply could result in death or serious injury.

M1714

7-6

1. Start engine of disabled machine in normal manner according to climate conditions.

CHAPTER 7 - ELECTRICAL DISCONNECTING BOOSTER CABLES

3

1

2

4 4

3

2

1

DC04D588

Figure 7

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

After disabled machine engine is running: 1. Disconnect the negative (-) cable from disabled machine upper frame.

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

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

4. Disconnect positive (+) cable from terminal of disabled machine.

NOTICE: When using booster cables remember: 1. Connect positive (+) cable first.

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

7-7

CHAPTER 7 - ELECTRICAL WORK LAMPS

.

.

1

4 3

2

5

6

7

BS07N393

Figure 8

BS07N392

A 55W bulb is used for the work lamps.

Figure 9

1. To replace the bulb, place the attachment on the ground, and set the safety lock lever to the LOCKED position, then stop the engine.

2. Disconnect the electrical connector, then remove the work lamp from the machine with a wrench.

WARNING Do not tamper with the ballast on the high intensity discharge head lamps, they contains high voltage.

Failure to comply could result in death or serious injury.

639S

NOTICE: The service life of a bulb is shortened if oil or grease is on the bulb at the time of installation.

When replacing the bulb, hold it at the flange area. Do not touch the bulb glass with your fingers. Wipe the bulb with a clean cloth after installation.

3. Remove screw (1), then remove rim (2) and lens (3) from the casing (4).

4. Remove spring (6) that secures the socket (5).

5. Remove the bulb (7) from the socket (5) and replace the bulb with a new one.

6. Assemble the work lamp using the reverse order.

NOTE: If the replacement bulb does not light, check the fuse.

ALTERNATOR Ask your Dealer to check the Alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

WELDING SAFETY If welding on the machine is necessary: 1. Turn the machine OFF. Wait 4 seconds for the electrical power to disconnect.

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

3. Attach welder ground cable within 1 m (3 ft 3 in) away from component being welded. Do not locate welder ground at a seal or bearing.

7-8

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Machine Dimensions - Canopy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Machine Dimensions - Cab Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Crawler type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Capscrews and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Nuts & Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS

)

0”

0

.

2’2

(

6 R6

55

MAX 1,320 (4’4.0”) / MIN 990 (3’3.0”) 540 (1’9.3”) 530 (1’8.9”) 70 (2.8”)

160 (6.3”)

MACHINE DIMENSIONS - CANOPY MODEL

40 (1.6”)

65

990 (3’3.0”)

1200 (3’11.2”)

MIN. 990 (3’3.0”) MAX. 1320 (4’4.0”)

UPUX1206001E01

250 (9.8”)

230 (9.1”)

175 (6.9”)

2410 (7’10.9”)

445 (1’5.5”)

640 (2’1.2”)

1150 (3’9.3”) 740 (2’5.1”) 1210 (3’11.6”) 1560 (5’1.4”) 3420 (11’2.6”)

Figure 1

8-3

CHAPTER 8 - SPECIFICATIONS

R755

55

MAX 1,320 (4’4.0”) / MIN 990 (3’3.0”) 540 (1’9.3”) 530 (1’8.9”) 70 (2.8”)

160 (6.3”)

MACHINE DIMENSIONS - CAB MODEL

”)

(2’5.7

40 (1.6”)

65

1320 (4’4.0”) 755 (2’5.7”)

230 (9.1”)

MIN. 990 (3’3.0”) MAX. 1320 (4’4.0”)

250 (9.8”)

175 (6.9”)

445 (1’5.5”)

2350 (7’8.5”)

990 (3’3.0”)

1150 (3’9.3”) 740 (2’5.1”) 1210 (3’11.6”) 1560 (5’1.4”) 3440 (11’3.4”) PU15Z00044P1

UPUX1306003E01.

8-4

Figure 2

CHAPTER 8 - SPECIFICATIONS ENGINE Model

MITSUBISHI L3E-W431KBS

Type

Water cooled, 4 cycle type swirl chamber diesel engine 3 - 76mm X 70mm (3 - 2.99in. X 2.76inch)

Number of cylinders - Bore X Stroke

952 ml (58.1 cubic inch)

Total Displacement Output Rating

11.3 kW (2200 min1) - ISO 9249 15.4 PS (2200 RPM)

Maximum Torque

53.5 Nm (1800 min1) - ISO 9249 39.4 lbf ft (1800 RPM)

Starting Motor

12 V (1.7 kW)

Generator

12 V (40 A)

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston plus gear pump

Hydraulic Motor

Axial piston Variable displacement axial piston, 2-speed motor

Hydraulic Motor with Reducer (Travel)

11- spool multiple control valve

Control Valve

Double action cylinder

Cylinder (Boom, Arm, Swing, Bucket, Dozer)

Filter type

Return Filter

SPEED AND GRADEABILITY Rubber Track 8.6 min

Swing Speed

Travel Speed

Gradeability

Steel Track 1 (8.6 RPM)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.0 km/h (1.2 mph)

4.0 km/h (2.5 mph)

2.0 km/h (1.2 mph)

4.0 km/h (2.5 mph)

58% (30°)

SIDE DIGGING AND DOZER Type

Boom swing by hydraulic cylinder

Boom Swing Angle Right

55°

Boom Swing Angle Left

65°

Dozer Blade Travel (Up/Down)

280/270 mm (11.0/10.6 in)

8-5

CHAPTER 8 - SPECIFICATIONS CRAWLER TYPE Length between center of idler and center of travel motor mm (ft - in)

Width mm (inch)

Type

Ground Pressure kPa (psi) Canopy - Cab

Rubber Belt

230 mm (9.1 in)

1210 mm (47.6 inch)

27 (3.9)

29 (4.2)

Iron Shoe (Optional)

230 mm (9.1 in)

1210 mm (47.6 inch

28 (4.1)

30 (4.3)

Number of teeth

Weight

BUCKET TYPE Bucket

Heaped Capacity m3 (cubic yard)

Outer Width with side cutter

0.044 cu m (0.058 cu yd)

450 mm (17.7 in)

Outer Width without side cutter

3

420 mm (16.5 in)

MACHINE WEIGHTS

Rubber Track

Steel Track

Canopy

Cab

Canopy

Cab

1650 kg (3640 lb)

1730 kg (3810 lb)

1710 kg (3770 lb)

1790 kg (3950 lb)

* With 165 lb (75 kg) operator, 137 lb (62 kg) bucket, full fuel and standard equipment

8-6

35 kg (77 lb)

CHAPTER 8 - SPECIFICATIONS

Y X

CANOPY TYPE MACHINE WORKING RANGES

Figure 3

UPU00600002JS2.

Units: m (ft-in) Machine equipped with 0.38 m3 (0.50 yd.3) Bucket WORKING RANGES

Standard Arm .98m (38.6 in)

Long Arm 1.2 m (47.2in)

Bucket 0.044 m3 (0.058 cu. yd.)

Bucket 0.044 m3 (0.058 cu. yd.)

A

Maximum digging reach

3890 m (12 ft. 9 in.)

4120 m (13 ft. 6 in.)

A’

Maximum digging reach at ground level

3790 m (12 ft. 5 in.)

4270 m (13 ft. 2 in.)

B

Maximum digging depth

2150 m (7 ft. 1 in.)

2370 m (7 ft. 9 in.)

C

Maximum digging height

3680 m (12 ft. 1 in.)

3880 m (12 ft. 9 in.)

D

Maximum dumping clearance

2650 m (8 ft. 8 in.)

2750 m (9 ft. 0 in.)

E

Minimum dumping clearance

1000 m (3 ft. 3 in.)

810 m (2 ft. 8 in.)

F

Maximum vertical wall digging depth

1660 m (5 ft. 5 in.)

1920 m (6 ft. 4 in.)

G

Minimum swing radius

1560 m (5 ft. 1 in.)

1680 m (5 ft. 6 in.)

H

Height at minimum swing radius

2750 m (9 ft. 0 in.)

2850 m (9 ft. 4 in.)

J

8-ft. level digging depth

1510 m (4 ft. 11 in.)

1830 m (6 ft. 0 in.)

K

Horizontal digging stroke at ground level -stroke

1700 m (5 ft. 7 in.)

1210 m (4 ft. 0 in.)

L

Horizontal digging stroke at ground level - minimum

1240 m (4 ft. 1 in.)

1960 m (6 ft. 5 in.)

X

Dozer blade - Above

280 m (11 in.)

280 m (11 in.)

Y

Dozer blade - Below

270 m (10.6 in.)

270 m (10.6 in.)

8-7

CHAPTER 8 - SPECIFICATIONS

Y X

CAB TYPE MACHINE WORKING RANGES

Figure 4

UPU00600002JS2

Units: m (ft-in) Machine equipped with 0.38 m3 (0.50 yard3) Bucket WORKING RANGES

8-8

Standard Arm .98m (38.6 in)

Long Arm 1.2 m (47.2in)

Bucket 0.044 m3 (0.058 cu. yd.)

Bucket 0.044 m3 (0.058 cu. yd.)

A

Maximum digging reach

3890 m (12 ft. 9 in.)

4120 m (13 ft. 6 in.)

A’

Maximum digging reach at ground level

3790 m (12 ft. 5 in.)

4270 m (13 ft. 2 in.)

B

Maximum digging depth

2150 m (7 ft. 1 in.)

2370 m (7 ft. 9 in.)

C

Maximum digging height

3240 m (10 ft. 8 in.)

3410 m (11 ft. 2 in.)

D

Maximum dumping clearance

2280 m 78 ft. 6 in.)

2440 m (8 ft. 0 in.)

E

Minimum dumping clearance

800 m (2 ft. 8 in.)

590 m (1 ft. 11 in.)

F

Maximum vertical wall digging depth

1660 m (5 ft. 5 in.)

1920 m (6 ft. 4 in.)

G

Minimum swing radius

1890 m (6 ft. 2 in.)

1920 m (6 ft. 4 in.)

H

Height at minimum swing radius

2550 m (8 ft. 4 in.)

2550 m (8 ft. 4 in.)

J

8-ft. level digging depth

1510 m (4 ft. 11 in.)

1830 m (6 ft. 0 in.)

K

Horizontal digging stroke at ground level -stroke

1700 m (5 ft. 7 in.)

1210 m (4 ft. 0 in.)

L

Horizontal digging stroke at ground level - minimum

1240 m (4 ft. 1 in.)

1960 m (6 ft. 5 in.)

X

Dozer blade - Above

280 m (11.0 in.)

280 m (11 in.)

Y

Dozer blade - Below

270 m (10.6 in.)

270 m (10.6 in.)

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radii and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

5. Capacities apply to the machine as originally manufactured and normally equipped by Kobelco Construction.

WARNING Operator should be fully acquainted with the Operator’s Manual before operating this machine.

Rules for safe operation of equipment should be followed at all times. Failure to comply could result in death or serious injury.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. Example: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the Lifting Chart accordingly.

2. If a bucket is changed for a larger bucket, which weight is 350 kg (770 lbs) more than the bucket indicated in the Lifting Chart, then you have to subtract this additional weight from every value indicated in the Lifting Chart accordingly.

3. If a bucket is changed for a smaller bucket, which weight is 350 kg (770 lbs) less than the bucket indicated in the Lifting Chart, then you can add 350 kg (770 lbs) to every value indicated in the Lifting Chart accordingly.

8-9

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

CAPSCREWS & NUT METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES Make certain to tighten all Capscrews & Nuts to proper torque values.

Metric Coarse Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

1.77 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1)

14.6 ± 1.5 (105 ± 10.8)

12.3 ± 1.2 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6)

12.8 ± 1.3 (92.5 ± 9.4)

10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50.5 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

TORQUE VALUE UNIT: kgf (ft-lbs)

8-10

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES Tighten all Capscrews & Nuts to proper torque values.

Metric Fine Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M8

P=1

1.15 0.11 (8.3 ± 0.8)

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190)

212 ± 21 (1530 ± 150)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ±43 (3090 ± 310)

357 ± 36 (2580 ± 260)

TORQUE VALUE UNIT: kgf (ft-lbs)

ORS JOINT (O-RING SEALING TYPE) ORS Joint (O-ring Sealing Type)

Hose mouth ring and Coupling

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgfm (ft-lbs)

1 - 14 UNS

30 - 32

14 ± 1.4 (101 ± 10)

1 - 3/16 12 UN

36 - 41

18 ± 1.8 (130 ± 13)

1 - 7/16 12 UN

41 - 46

21 ± 2.1 (152 ± 15)

WORKING PRESSURE kgf/cm2 (psi) 350 (4980) 385 (5475) Power Boost

8-11

CHAPTER 8 - SPECIFICATIONS NUTS & SLEEVES Nuts and Sleeves

MANUFACTURER’S NAME

WORKING PRESSURE kgf/cm2 (psi)

350 (4980) Travel line only

NIPPON A.M.C.

350 (4980) Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS Flare Type Fitting Joints

TUBE SIZE O.D. X THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE kgfm (ft-lbs)

10 X 1.5 (0.394 X 0.059)

19

4.5 ± 0.5 (33 ± 4)

15 X 2.0 (0.591 X 0.079)

27

15 ± 2 (108 ± 14)

18 X 2.5 (0.709 X 0.098)

32

18 ± 2 (130 ± 14)

22 X 3.0 (0.866 X 0.118)

36

22 ± 2 (159 ± 14)

28 X 4.0 (1.10 X 0.157)

41

28 ± 3 (203 ± 22)

35 X 5.0 (1.38 X 0.20)

55

35 ± 4.5 (253 ± 29)

N2 (NYLON) TUBE FITTING JOINTS N2 (Nylon) Tube 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.

NOMINAL SIZE (PIPE THREAD)

TORQUE VALUE

1/4”

2.5 ± 0.3 (18.1 ± 1.8)

3/8”

5 ± 0.5 (36.2 ± 3.6)

1/2”

6 ± 0.6 (43.4 ± 4.3)

3/4”

12 ± 1.2 (86.8 ± 8.7)

1”

14 ± 1.4 (101 ± 10)

1-1/4”

17 ± 1.7 (123 ± 12)

1-1/2”

21 ± 2.1 (152 ± 15)

2”

42 ± 4.2 (304 ± 30) Unit: kgfm (ft.-lbs)

8-12

1. Clean Tube and make sure certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

CHAPTER 8 - SPECIFICATIONS WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Material (Loose Weight)

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted & broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

8-13

CHAPTER 8 - SPECIFICATIONS UNITS OF PRESSURE

CONVERSION UNITS UNITS OF WEIGHT

Units of Pressure From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

Bars

UNITS OF LENGTH psi

From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

0.0703

Pa (Pascal)

6894.76

psi

145.04

kg/cm

Units of Length

0.06895 2

MPa (MegaPascal)

UNITS OF VOLUME

UNITS OF POWER

Units of Volume From

Units of Power

Into

Multiply by

From

Into

Multiply by

Gal (US Liquid)

0.264

HP

kW

0.7457

in3

61.02

kW

HP

1.341

yard3

0.00131

quarts

1.0567

ounces (US)

33.81

m3

0.765

in3

46656

ft3

27

cm3

764554.9

liters

764.555

Liters

UNITS OF FLOW Units of Flow Into

From

Lit/min Gal/min (US liquid)

Liter/min

Lit/sec

Multiply by 3.79 0.0631

cm3/min

3785.4

ft3/min

0.1337

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

8-14

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgfm

0.1382552

N·m

1.35582

lbf-in

12

Yard3

CHAPTER 9 - INDEX

Chapter 9

INDEX A Alternator ............................................................. 7-6 Attachment Lubrication ...................................... 6-16

B Back Filling & Leveling with Front Attachment .. 4-21 Basic Operation of Hydraulic Controls ............... 4-10 Before Operating the Hydraulic Breaker ............ 4-33 Before Operating the Machine ............................. 4-3 Boom Operation ................................................ 4-13 Bucket ................................................................ 6-49 Bucket Operation ............................................... 4-15 Bucket Selection Guide ..................................... 4-26 Burn Prevention ................................................... 2-8

C Cab Door Latch ................................................... 3-3 Canopy Machine Dimensions ....................... 8-3, 8-4 Cleaning Parts ..................................................... 6-4 Cleaning Sand & Soil from Bucket .................... 4-20 Components & Controls Nomenclature ............... 3-9 Connecting Booster Cable ................................... 7-6 Control Decal ....................................................... 4-8 Counter Rotating Machine ................................. 4-12

D Decals ................................................................ 2-10 Disposal of Hazardous Waste ............................. 6-3 Document Pouch ................................................. 3-6

E Emergency Engine Shut Down ............................ 4-5 Engine ................................................................. 1-4 Engine Coolant Level ........................................ 6-12 Engine Coolant Tank & Engine Air Cleaner Access Doors ............................................................. 3-7 Engine Electrical ................................................ 6-12 Engine Fluid Leaks ............................................ 6-12 Engine Oil Level ....................................... 6-17, 6-25 Engine Oil Type ................................................... 5-6 Environment ........................................................ 5-6

F Fire Extinguisher .................................................. 2-9 Fire Prevention .................................................... 2-9 Flare Type Fitting Joints .................................... 8-12 Frame Structure ................................................... 6-5

Fuel Handling Precautions ...................................2-8 Fuel Level ...........................................................6-13

G General Information ..............................................1-1 Ground Transportation .......................................4-27 Guidelines for Attachment Lubrication .................6-7 Guidelines to Replace Ground Tools ...................6-7

H Hand Signals ......................................................2-25 Hazardous Chemical Precautions ........................2-8 Hot Surface & Fluids ............................................6-3 How to Handle Life Hammer ................................2-9 Hydraulic Breaker ...............................................4-33 Hydraulic Oil Leaks ............................................6-15 Hydraulic Oil Level .............................................6-14

I Identification Numbers ..........................................1-4 Inspect Waste Oils and Filters ..............................6-4

K Keep Machine Clean ............................................6-3 Key Switch ............................................................3-9

L Lifting Capacities ..................................................8-9 Lifting Machine ...................................................4-31 Lifting Machine With Attachment Installed .........4-31 Locking/Unlocking Cab Door ................................3-3

M Machine Access Compartments and Doors .........3-7 Machine Attachment and Swing .........................4-13 Machine Components ..........................................1-3 Machine Dimensions .................................... 8-3, 8-4 Machine Electrical ..............................................6-16 Machine Operation in Adverse Weather Conditions .

4-25 Machine Storage ................................................4-32 Machine Travel Controls ....................................4-11 Maintenance Precautions .....................................2-7 Manual Warm Up .................................................4-6 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-10 Metric Fine Thread Standard Tightening Torque Values ..........................................................8-11 9-1

CHAPTER 9 - INDEX Model, Serial Number, and Year of Manufacture 1-4 Mounting and Dismounting Precautions .............. 2-5

N N2 (Nylon) Tube Fitting Joints ........................... 8-12 Nuts & Sleeves .................................................. 8-12

O Opening and Closing Door Glass ........................ 3-5 Operate Boom Smoothly ................................... 4-20 Operating Both Travel Levers Together ............ 4-11 Operating Pattern ................................................ 4-8 Operating Pattern Decal ...................................... 4-8 Operating Precautions ......................................... 2-6 Operating the machine ........................................ 4-3 Operating the Machine in Water ........................ 4-16 Operating the Shovel ......................................... 4-21 Operation at Seashore or Salty Climate ............ 4-25 Operation in Extreme Cold ................................ 4-25 Operation in Extreme Heat ................................ 4-25 Operation in High Altitudes ................................ 4-25 Operation in Humid Climate .............................. 4-26 Operation in Sandy and Dusty Areas ................ 4-25 Operator Cab Nomenclature ............................... 3-9 Operator Precautions ................................... 2-4, 2-5 Operator Seat Adjustments ................................. 3-6 Operator’s Compartment Controls and Accessories .

3-8 ORS Joint (O-ring Sealing Type ........................ 8-11

P Personal Safety ................................................... 2-3 Practices to Improve Efficiency ......................... 4-20 Prevent Contamination ........................................ 6-4

R Releasing Hydraulic System Pressure ................ 6-6 Removing and Storing Lower Front Window ....... 3-5 Removing Machine from Storage ...................... 4-32 Removing the Bucket ........................................ 6-55 Required Filters ................................................... 5-4 Required Fluids/Lubricants and Capacities ......... 5-3 Right Hand Operator Console and Monitor ......... 3-9 Right, Left, Front, and Rear of the Machine ........ 1-2 Roll-Over Protective Structure (If equipped) ........ 2-8

S Safety Area .......................................................... 2-3 Safety Rules ........................................................ 2-3 Seals & O-Rings .................................................. 6-4 Seat Belt .............................................................. 3-6 9-2

Seat Belt Precautions ...........................................2-9 Seat Height Adjustment ........................................3-6 Securing Machine to Trailer ...............................4-30 Selection of the Hydraulic Breaker .....................4-33 Specific Precautions to this Machine ....................2-9 Starter Motor ........................................................7-8 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) .....................4-4 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) ......................4-5 Starting and Stopping Precautions .......................2-5 Starting Boosting Machine Engine .......................7-6 Starting Disabled Machine Engine .......................7-6 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable .......7-6 Steps and Handrails ...........................................6-16 Stop Engine ..........................................................6-4 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Operation .................................................4-15

T Torque Specifications .........................................8-10 Track Links .........................................................6-21 Tracks and Components ....................................6-18 Transportation ....................................................4-27 Transporting Precautions .....................................2-8 Travel Safety ......................................................4-16

U Units of Flow .......................................................8-14 Units of Length ...................................................8-14 Units of Power ....................................................8-14 Units of Pressure ................................................8-14 Units of Torque ...................................................8-14 Units of Volume ..................................................8-14 Units of Weight ...................................................8-14 Use Arm in Action ...............................................4-20 Use of Optional Attachment ...............................4-33 Utility Safety .........................................................2-4

W Warm Engine Oil ..................................................6-4 Warming of Hydraulic Oil ......................................4-7 Warming Up of Engine .........................................4-6 Wear Safety Equipment .......................................6-4 Weight of Materials Table ...................................8-13 Welding Safety .....................................................6-5 Work Mode Switch ...............................................4-6