Kobelco 215SR Acera Tier 3 Excavator Operator's Manual PDF

OPERATOR'S MANUAL EXCAVATOR

215SR ACERA TIER 3

87722039 NA

Issued 01Sept 07

OPERATOR’S MANUAL EXCAVATOR

215SR ACERA TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Sept 07 Printed in U.S.A. • Book/Form Number 87722039 NA Copyright © 2007. Kobelco Construction Machinery America, LLC. All Rights Reserved

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

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

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Sept 07

215SR Acera Tier 3 Excavator

87722039 NA

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

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

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

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

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

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

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

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

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

Any use of editorial or pictorial content is strictly prohibited without express written permission from Kobelco Construction Machinery America, LLC . Carol Stream, IL 60188 U.S.A..

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 B1. I.T.C.S. Controller CPU Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Operating Levers and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 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 Machine Engine with Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Basic Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Using Auto Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Recommendation for Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Use of Optional Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 daily Inspection & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 250 hour maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 500 hour maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Periodical Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Maintenance for Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 215SR General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 215SR Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION TO THE OWNER 215SR ACERA 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 so as 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 to carry out this kind of work. For this type of application, 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 sure: 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 the seat back, behind the operator's seat). 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.

Figure 1 below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the 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

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 12 11 10

13 8

4 14

7 9

15

6 5 25

17

32 16

3 2

27 18

1

19 29 20

26 21 22

33

23 24

30 28

31

34

27 Figure 2

DC03H141

MACHINE COMPONENTS

1. HINO ENGINE 2. HYDRAULIC PUMP 3. ENGINE MUFFLER 4. MAIN CONTROL VALVE 5. HYDRAULIC OIL TANK 6. FUEL TANK 7. SWING MOTOR 8. SWIVEL JOINT 9. BOOM CYLINDER

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10. BOOM 11. ARM CYLINDER 12. ARM 13. BUCKET CYLINDER 14. IDLER LINK 15. BUCKET LINK 16. BUCKET 17. OPERATOR CAB 18. TRACK SHOE ASSEMBLY

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19. TRACK IDLER 20. TRACK SPRING 21. ENGINE AIR CLEANER 22. LOWER ROLLER 23. TRACK GUIDE 24. UPPER ROLLER 25. ROTARY MULTI-CONTROL VALVE 26. SWING RING 27. SWING FLASHER

28. TRAVEL MOTOR 29. BATTERY 30. ENGINE RADIATOR 31. OIL COOLER 32. ENGINE HOOD 33. COUNTERWEIGHT 34. INTER COOLER

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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

DC03H139

ENGINE ➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump ➤ Swing Reduction Gear Figure 3

DC03H140

➤ Travel Reduction Gears

PRODUCT IDENTIFICATION PLATE ➤

➤ Travel Control Valve

Model ➤

➤ Attachment Control Valve

Serial Number ➤

➤ Swing Control Valve

Manufacturing Year

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Counterweight Lifting Eyes - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Keep Surface Clean - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Pressurized Hot Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Do Not Step On - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Stop Engine - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hot Coolant - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Handling Battery - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 handling battery - danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 prevent battery explosion - warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 adjusting track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 swing brake release switch - caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Hot parts - caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Rotating Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Swing - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Machines Equipped With Pattern Control Change Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Located Inside Cab, on Right Window Glass Lower Corner - Part Number YN20T01863P1 . . . . . . . . . . . . 2-21 Machines Equipped With Pattern Control Change Valve (Optional) - Warning . . . . . . . . . . . . . . . . . . . . . . . 2-22 Attachment Operation By Foot Pedal - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Nibbler & Breaker Hydraulic Oil Maintenance (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Machines Equipped With Special Attachment (Optional) - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Do Not Pinch Your Hand(s) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Falling Front Window - (Lock - Unlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Swing Brake Release - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Nibbler & Breaker Operation (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Keep Clear Of Machine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Issued 10-07

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES PERSONAL SAFETY WARNING: 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.

M171C

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. See your dealer if you have any questions.

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 used, are RED.

and STOP if

SAFETY AREA

1

1

2 Figure 1

BS06H091

Figure 2

BC02N198

1. OPERATOR’S MANUAL STORAGE SPACE

1. WORKING AREA 2. SAFETY AREA

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 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.

IMPORTANT: 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.

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2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS UTILITY SAFETY Safety precaution 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 IMPORTANT: 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.

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

Figure 3

RH99G001

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 hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

OPERATOR PRECAUTIONS PERSONNEL

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• 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 vest are no longer as highly visible as new vest.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

• 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.

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• DO NOT OPERATE this machine or perform

• Use jumper cables only in the recommended

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

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

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

• Wear the seat belt to maximize the protection capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

• 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 object stored in the machine.

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

• 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 function cancellation lever into the locked or up position.

• Remove the starter key or disconnect switch when leaving the machine parked or unattended.

MOUNTING AND DISMOUNTING PRECAUTIONS

OPERATING PRECAUTIONS

• Use the hand holds and steps with at least three

• Check brakes, steering and other machine control

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

devices in accordance with the manufacturers 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.

• 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 machines 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, and disengage the PTO, if so equipped, 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.

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

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• 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.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• 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.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Know and understand the job site traffic flow

• Before you drive or operate in an area with high

patterns and obey signalmen, road signs and flagmen.

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.

• 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.

• When roading a machine, know and use the signaling devices required on the machine.

Provide and escort for roading where required.

• 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

• 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.

• 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.

windows are clean and that the windshield wipers and washers work correctly.

• Stay away from hazardous areas such as ditches,

• Engine exhaust fumes can cause death. If you

overhangs, etc. Walk around the work area before you start and look for hazards.

operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

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

2-6

• 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.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Use extreme caution when removing radiator

MAINTENANCE PRECAUTIONS

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

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 manufacturers. recommendations.

• When absolutely necessary to tow the machine,

Figure 4

DC04E084

• Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operators 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.

• Wear gloves to protect hands when handling cable.

• 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.

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.

• 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.

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 spill on 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.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Use the correct fuel grade for the operating season.

• 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.

BURN PREVENTION 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: 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.

• When the battery electrolyte is frozen, the 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

• 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) 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.

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 on this machine.

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

• 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 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.

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SPECIFIC PRECAUTIONS TO THIS MACHINE

SEAT BELT PRECAUTIONS

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

1

• Never smoke while refueling.

• Do not use tractive force of the machine for loading the bucket attachment nor to push or pull any objects.

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

• Do not perform “hammering” operation with the

2

bucket.

• Do not use this machine for anything other than its Figure 5

BC02N375

intended purpose.

• DO NOT OPERATE bucket and arm cylinders to

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

stroke end repeatedly.

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

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

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

• Do not use the long reach attachment for general construction work at any time.

WARNING: Before starting the engine ensure 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

EMERGENCY EXIT HAMMER

Figure 6

DC04D572

An emergency exit hammer is provided on the right side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab. In addition, the life hammer is equipped with a cutter on the lever side to cut seat belt, etc.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary.

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.

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.

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.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT LIFTING EYES - DANGER Located on top of counterweight (2 Required) - Part Number YN20T01221P1

Figure 7

BS06J019

KEEP SURFACE CLEAN - WARNING Located on top of fuel tank (front left corner), and top of counterweight - Part Number 2432T6111

Figure 8

BS06L019

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2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS PRESSURIZED HOT OIL - WARNING Located on top of hydraulic tank - Part Number YN20T01405P1

Figure 9

BS06J019

HOT PARTS - CAUTION Located on top of engine cover (muffler side) - Part Number YN20T01220P1

Figure 10

BS06J037

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT STEP ON - WARNING Located on top of engine cover - Part Number ZL11M02708

Figure 11

BS06J019 / BS06J021

STOP ENGINE - WARNING Located on of engine fan shroud - Part Number YN20T01009P1

Figure 12

BS06J032

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT COOLANT - WARNING Located on top of engine fan shroud - Part Number YN20T01010P1

Figure 13

BS06J032

BOOSTER CABLE - WARNING Located on battery cover - Part Number YN20T01015P2

Figure 14

BS06J033

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOSTER CABLE - WARNING Located on battery cover - Part Number YN20T01338P1

Figure 15

BS06J033

CALIFORNIA PROPOSITION 65 - WARNING Located on battery cover - Part Number YN20T01495P1

Figure 16

BS06J033

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING BATTERY - WARNING Located on battery cover - Part Number YN20T01017P1

Figure 17

HANDLING BATTERY - DANGER Located on battery cover - Part Number PY20T01069P1

Figure 18

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS PREVENT BATTERY EXPLOSION - WARNING Located on battery cover - Part Number YN20T01001P1

Figure 19

ADJUSTING TRACK TENSION Located on crawler frame (2 Required) - Part Number YN20T01813P1

Figure 20

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2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SWING BRAKE RELEASE SWITCH - CAUTION Located on rear cover - Part Number YN20T01639P1

Figure 21

HOT PARTS - CAUTION Located on counterweight right side - Part Number YN20T01867P1

Figure 22

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ROTATING PARTS - CAUTION Located on opening side of the engine cover - Part Number YN20T01012P1

Figure 23

BS06J035

SWING - DANGER Located on each side of the rear counterweight (2 Required) - Part Number YN20T01003P2

BS06J017 / BS06J005

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) Located on fuel tank - Part Number YN20T01197P1

Figure 24

BS06H451

2-20

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LOCATED INSIDE CAB, ON RIGHT WINDOW GLASS LOWER CORNER - PART NUMBER YN20T01863P1

Figure 25

BS06J023

WARNING - AUTOMATIC TWO SPEED TRAVEL WARNING - TURNING OFF HEAVY LIFT SWITCH WARNING - CALIFORNIA PROPOSITION 65 WARNING - RELEASING POWER BOOST SWITCH WARNING - MACHINE MAY MOVE SUDDENLY WARNING - DO NOT INSTALL ANY OBJECT ON HANDHOLD WARNING - EXTREME HIGH PRESSURE IN TRACK ADJUSTMENT CAUTION - SLOW OR UNEXPECTED MOVEMENT NOTICE - STOPPING ENGINE WITHOUT COOL DOWN CAUTION - ATTACHMENT INTERFERENCE WITH CAB WARNING - READ AND UNDERSTAND OPERATORS MANUAL DANGER - ELECTRICAL POWER CONTACT

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2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) - WARNING Located inside cab, on right window glass lower corner - Part Number YN20T01039P1

Figure 26

BS06J024

ATTACHMENT OPERATION BY FOOT PEDAL - CAUTION Located inside cab, on right window glass lower corner - Part Number PY20T01062P1

Figure 27

BS06J024 / BS06J025

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS NIBBLER & BREAKER HYDRAULIC OIL MAINTENANCE (OPTIONAL) - CAUTION Located inside cab, on right window glass lower corner - Part Number YN20T01414P1

Figure 28

BS06J024 / BS06J026

MACHINES EQUIPPED WITH SPECIAL ATTACHMENT (OPTIONAL) - NOTICE Located inside cab, on right window glass lower corner - Part Number YN20T01640P1

Figure 29

BS06J024 / BS06J027

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2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT PINCH YOUR HAND(S) - CAUTION Located inside cab, on seat stand - Part Number YN20T01339P1

Figure 30

BS06J024 / BS06J028

FALLING FRONT WINDOW - (LOCK - UNLOCK) Located inside cab, on right hand window - Part Number ZL11M06008

Figure 31

DC03J143

2-24

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SWING BRAKE RELEASE - CAUTION Located inside cab rear panel cover - Part Number YN20T01639P1

Figure 32

BS06J029 / BS06J030

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2-25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS NIBBLER & BREAKER OPERATION (OPTIONAL) - CAUTION Located on Right Hand operator console - Part Number YT20T01054P1

Figure 33

BS06J024

KEEP CLEAR OF MACHINE - DANGER Located on both sides of the arm (2 Required) - Part Number YN20T01337P1

Figure 34

DC03J147

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS IMPORTANT: 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 Operation. 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 37

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

MOVE LOAD OUT HORIZONTALLY

Figure 35

DC04E038

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 38

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

RAISE BOOM

Figure 36

DC04E039

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

DC04E042

Figure 39

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

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

DC04E043

ARM IN

Figure 40

Figure 43

DC04E046

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 41

Figure 44

DC04E047

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 42

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.

2-28

Figure 45

DC04E048

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.

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87722039NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTER ROTATE RIGHT

CLOSE BUCKET (BUCKET IN OR DIG)

Figure 46

DC04E049

DC04E052

Figure 49

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)

Figure 47

DC04E050

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

DC04E053

Figure 50

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

Figure 48

DC04E051

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

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DC04E054

Figure 51

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.

2-29

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS TURN RIGHT

DE04E055

STOP

Figure 52

Figure 55

DC04E058

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 53

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

Figure 56

DC04E059

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 54

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).

2-30

Figure 57

DC04E060

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

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87722039NA

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 Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Opening and Closing Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Opening and Closing Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Document Pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Front and Rear Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Back Reclining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Forward & Backward Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Arm Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Head Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Engine Coolant Tank & Engine Air Cleaner Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Main Pump Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Components & Controls Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Right Hand Operator Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Buzzer Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 windshield Wiper & Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Screen Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Screen display switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Auto Accel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 L.C.D. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 A. Normal Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 B. Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Warning Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Buzzer Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 B1. I.T.C.S. CONTROLLER CPU DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 LCD Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Monitor Time Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Pump Flow Rate Adjustment (A mode / B mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Draining Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Power Boost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 24 Volt Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Location for Optional Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Cup Holder and Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Issued 10-07

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CHAPTER 3 - INSTRUMENTS AND CONTROLS How to Select Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 How to Adjust the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 right Hand Operator Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Climate Control - Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Air Outlet Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 basic Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Hydraulic Function Cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Double Pump Flow Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Swing Parking Brake Release Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 OPERATING LEVERS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Left Hand (LH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 Right Hand (RH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 Left and Right Travel Levers & Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

1

1 Figure 3

DC04D505

Figure 1

DC04D503

1. DOOR LOCK

Use the key switch key to lock or unlock cab door.

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

1. DOOR RELEASE LEVER

2. Release door latch by pushing release lever down to release door from latch.

WARNING: Never use the lever for door latch release as a handle to mount and/or dismount from the machine.

CAB DOOR LATCH

1 1 Figure 2

DC04D504

1. DOOR LATCH

1. PUSH RELEASE LEVER

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

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Figure 4

DC04D506

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3. Push release lever located inside the door, and door opens from the inside of cab.

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING WINDSHIELD Front window (upper) can be stored in ceiling.

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

WARNING: Special attention must be paid not to injure hands and others when the front window is closed. Always make sure to properly lock the front window in place to avoid injury.

REMOVING AND STORING LOWER FRONT WINDOW

1

1 2

Figure 5

BS06J091

Figure 7

DC04D509

1. LOWER FRONT WINDOW

1. LOCK LEVER 2. UPPER CENTER HANDLE

1. Pull lock lever down on front window upper section to unlock the window.

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

2. Securely store the removed lower front window in holder in the rear of cab, behind the operator’s seat.

1

3 2 BS06J092

3 1

2 Figure 6

1. LOCK LEVER 2. CENTER HANDLE 3. WINDSHIELD STORED IN CEILING POSITION

2. Hold handles on upper central and lower left sides of the front window. Lift the front window up and slide overhead all the way to the back. The window will automatically lock when in position.

3-4

2

2

Figure 8

DC04D510

1. LOWER FRONT WINDOW 2. HOLDER 3. REAR WINDOW

3. To store it, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame.

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87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING DOOR GLASS

1. Slide the sun visor backward.

WARNING: Make sure to secure front window with locks when placed in the upper position.

1 2

1

1

2

Figure 9

DC04D511

1. CAB DOOR UPPER GLASS 2. LOCK

1. Open cab door upper glass sliding it to front side after unlocking it.

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

OPENING AND CLOSING SUNROOF

Figure 12

DC04D514

1. SUNROOF LOCK

2. Pull locks on right and left sides inward, and sunroof opens through the aid of gas spring.

Close sunroof pulling locks inward, and lock it.

Also the sunroof can be left slightly open to ventilate air in cab by placing lock “A” section on “B” section.

CAB DOME LIGHT

1

1 Figure 10

DC04D512

1. SUN VISOR IN CLOSED POSITION

Figure 13

BS06H100

1. CAB DOME LIGHT

1. Turn Cab Dome Light “ON” by pushing the Dome Light Switch downward.

1

2. Turn “OFF” by pushing switch all the way up.

Figure 11

DC04D513

3. Place Dome Light Switch in the “CENTER” position and the light will be operated by the door switch. When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

1. SUN VISOR IN OPEN POSITION 87722039NA

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3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS 2. Seat Back Reclining Adjustment

DOCUMENT POUCH

1 1

Figure 14

BS06H091

Figure 16

DC04D523

1. SEAT BACK RECLINING ADJUSTMENT LEVER

1. DOCUMENT POUCH

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 a pouch located to the right of the operators seat. Keep the Operator and Parts Manual for this machine in this location at all times for quick, easy reference.

• Pull reclining adjustment lever up to set desired reclining angle.

• Release reclining adjustment lever to lock seat in position.

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

The adjustment areas are as follows: 1. Seat Front and Rear Height adjustment

1

Figure 15

ART

1. SEAT FRONT & REAR HEIGHT ADJUSTMENT LEVER

• Pull height adjustment lever up to raise or lower rear of seat.

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

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Issued 10-07

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87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. Seat Forward & Backward Adjustment

4. Arm Rest Adjustment

1

1 Figure 18

DC04D524

Figure 17

DC04D526

1. SEAT ARMREST ADJUSTMENT WHEEL

1. SEAT FORWARD & BACKWARD ADJUSTMENT BAIL

• Pull up on top bail for seat adjustment and move seat forward or backward to desired position.

• Release bail to lock seat in position.

• Lower arm rest and with finger, turn adjustment wheel until arm rest is in desired position.

5. Seat Head Rest Adjustment

1 Figure 19

DC04D525

1. SEAT HEAD REST

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

• Raise or lower head rest to desired height.

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3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

2 1 Figure 20

DC04D529

1. BUCKLE 2. RED BUTTON

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. Draw out the right side seat belt and fasten it to the buckle located on the left side.

NOTE: If the belt stops while you’re pulling it out, release the tension and continue pulling it out.

3. When the seat belt is used, draw it out moderately long and insert it in the buckle until rattling sound is heard. Release hands, and the length is automatically adjusted and the belt is locked.

4. After locking, the belt can be adjusted about 25 mm (1 in) to fit comfortably.

5. Press the red button of the buckle, and the belt is unfastened.

WARNING: Always wear seat belt while sitting in operator seat. Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS ENGINE COOLANT TANK & ENGINE AIR CLEANER ACCESS DOORS

3 2 1 Figure 21

DC04D592

1. ENGINE AIR CLEANER ACCESS DOOR 2. ENGINE COOLANT TANK 3. ENGINE AIR CLEANER

Located on the left side of the machine the engine coolant tank access door allows access to the engine coolant tank. It also holds the engine air cleaner access door closed.

ATTENTION: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

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

IMPORTANT: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

MAIN PUMP ACCESS DOOR .

1 Figure 22

DC04A037

1. MAIN PUMP

Located on the right side of the machine this door allows access to the main pump.

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3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL CAP

1

Figure 23

DC04D530

1. FUEL TANK CAP

Stop engine and remove cap on fuel tank. Use key switch to unlock cap if locked. Fill to desired level or to full capacity. See Chapter 5 for proper tank capacity.

WARNING: Make sure engine is OFF and keep battery cover and engine hood closed when fueling.

ENGINE COVER Open engine cover with key switch (if locked) after stopping engine. Use stay to support it.

ATTENTION: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

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Issued 10-07

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES 3

4

5

6 7 20 8

22 21

9 2

11 10

1 12 13 14

26 15

18

27

17 23

16 18 19 24

A

25 Figure 24

BS06H114

COMPONENTS 1. LEFT HAND OPERATOR 7. HOUR METER CONTROL LEVER (HORN SWITCH)

14. WORKING LIGHT SWITCH (BOOM, DECK) 15. TRAVEL ALARM SELECT SWITCH (OPTION) 16. RADIO 17. AIR CONDITIONER CONTROL PANEL

21. SWING PARKING BRAKE RELEASE SWITCH 22. FUSE & RELAY BOX

2. SAFETY LOCK LEVER

8. GAUGE CLUSTER

3. LEFT TRAVEL PEDAL

9. CUP HOLDER

4. LEFT TRAVEL LEVER

10. ASH TRAY

5. RIGHT TRAVEL LEVER

11. RIGHT HAND OPERATOR CONTROL LEVER 18. OPTIONAL SWITCHES (POWER BOOST SWITCH)

25. 12 VOLT SUPPLY

6. RIGHT TRAVEL PEDAL

12. STARTER KEY SWITCH

19. CIGARETTE LIGHTER

26. CONFLUX/SINGLE FLOW CHANGE SWITCH

13. THROTTLE POTENTIOMETER

20. KPSS RELEASE SWITCH

27. HEAVY LIFT SWITCH

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23. OPERATOR SEAT 24. LIFE HAMMER

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR CAB NOMENCLATURE The Operator Cab Nomenclature (see Figure 24), points out locations of operator controls of the Kobelco 215SR hydraulic excavator. Study these areas and locate these components on the machine.

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

WARNING: DO NOT OPERATE this machine unless you have read and understand the instructions in this manual.

Improper machine operation is dangerous and could result in injury or death.

COMPONENTS & CONTROLS NOMENCLATURE The following information provides a brief description and function of the components and controls of the Kobelco 215SR hydraulic excavator.

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

RIGHT HAND OPERATOR CONSOLE AND MONITOR

“START” - When key is turned to this position, electr ical power is supplied to the star ter solenoid causing the starter to start the engine.

After engine starts key should be released to go back to the “ON” position.

2. Throttle Potentiometer The throttle potentiometer is located on the right hand operator console and controls engine RPM. When the throttle potentiometer is rotated to any position, it increases or decreases engine RPM and maintains engine at the programed RPM for that particular position on the dial.

NOTES: a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 1 second, and if the position of the throttle potentiometer is higher than 1050 rpm, the auto acceleration actuates automatically and engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto acceleration speed, the engine speed is maintained to the throttle potentiometer position.

Auto Acceleration Function:

1. Key Switch

With the attachment, swing, travel control lever or control pedal operation, the engine speed returns to accel dial set position gradually according to the respective operating pilot valve movement.

NOTE: The auto acceleration function can be activated by pressing the auto accel switch located on the monitor panel. When the auto acceleration function is active, the red light indicator above this switch is turned ON. Press the auto accel switch to cancel the auto acceleration function and the light will turn OFF. Figure 25

BS06H116

1. KEY SWITCH 2. THROTTLE POTENTIOMETER

The Key Switch is located on the right hand operator console and has 4 operating functions.

“OFF” - When key is turned to this position, the e n g i n e s t o p s a n d e l e c t r i c a l p owe r to th e machine’s electrical system is stopped after approximately 3 seconds.

“ACC” - With key in the “ACC” position, only the cigarette lighter, tuner, and horn will have power.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. Monitor

11

1

2 3

10 6 4

9

8

5

7 Figure 26

BS06H115

1. ENGINE COOLANT TEMPERATURE GAUGE 2. FUEL LEVEL GAUGE 3. SCREEN CHANGE SWITCH 4. BUZZER STOP SWITCH 5. KPSS MODE SELECT SWITCH 6. WASHER SWITCH

WORK MODE SWITCH

7. WIPER SWITCH 8. TRAVEL SPEED SELECT SWITCH 9. AUTO ACCEL SWITCH 10. SELECT SWITCH 11. L.C.D. DISPLAY

When the engine star ts, it is set to “H” mode automatically. To select the proper work mode from the 4 modes shown below according to the work conditions. The work modes are “H”, “B”, “A”, and “S”.

“H” mode is for heavy duty digging work which gives priority to the workload at high engine rpm’s.

“B” mode is for work with breaker.

“A” mode is for demolition work with crusher (nibbler).

“S” mode is for standard digging and loading.

Figure 27

BS06H065

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Buzzer Stop Switch

2: Washer Switch

• Press this switch, and washer fluid is sprayed while it is depressed.

1

Figure 30

BS06H101

Figure 28

BS06H065

When the engine coolant temperature is too high, or var ious sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently.

To stop the sound, press the Buzzer Stop button.

NOTE:

• Buzzer sounding due to engine overheating can

1. WASHER FLUID RESERVOIR

The washer fluid reservoir is located back of floor plate in cab.

• Remove floor mate.

IMPORTANT: Make certain the Washer Reservoir has washer fluid before operating washer.

not be stopped.

• The buzzer sounding, because the preheat complete and E/G oil pressure are displayed, stops by turning the key switch OFF. WINDSHIELD WIPER & WASHER SWITCH

2

1 BS06H066

Figure 29

1: Wiper Switch

• Press it once - Wiper moves intermittently.

• Press it again - Wiper moves continuously.

• Press it once more - Wiper stops moving.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SCREEN CHANGE SWITCH

A

1

2 B

4

3

Figure 31

BS06H102 / BS06H071

SCREEN DISPLAY SWITCH. After turning the key switch on or starting the engine, the display screen (A) is changed each time that the display switch (B) is pushed. This will display the remaining time until the next service interval for each of the displays shown on the screen.

1. Remaining time until oil change.

2. Remaining time until fuel filter change.

3. Remaining time until hydraulic filter change.

4. Remaining time until hydraulic oil change.

NOTE: If the change screen switch (B) is not operated for 30 seconds keeping the screen for maintenance displayed, the screen will automatically return to the main screen.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Travel Speed Select Switch

AUTO ACCEL SWITCH

Figure 33

BS06H067

BS06H068

Figure 32

This switch is used to activate and cancel the auto accel function.

When the key switch is turned on, the auto-accel system activates. The auto-accel system reduces the e n g i n e s p e e d t o t h e i d l e l eve l r e d u c i n g f u e l c o n s u m p t i o n a n d n o i s e u n d e r t h e fo l l ow i n g conditions.

The travel speed select switch is located on the gauge cluster switch panel. Each time engine is started, travel speed is automatically set to LOW 1st speed. Press the travel speed switch on the gauge cluster, the speed is changed to the HIGH 2nd, the fast speed travel icon is indicated on the multi display, and the light indicator above the switch is turned ON.

1. The auto-accel dial position is set over the idle level.

Set to LOW when moving the machine on a rough or soft road, slope, or in narrow place, or when powerful tractive force is required.

2. The control lever or pedals are not operated for 4 seconds or more.

Set to HIGH when moving the machine on flat, hard ground.

When the control lever or pedals are operated, the engine speed goes back to the accel dial setting gradually.

WARNING: Never attempt to load or unload machine with the Auto Accel function activated. Sudden change of engine speed could be experienced causing possible damage, serious injury or death.

WARNING: Do not use high speed when performing delicate operations such as pipe laying, fine grading or loading machine onto a trailer.

Do not change travel speed while loading, machine could become unstable and cause serious injury, equipment damage and/or death.

NOTE: All Kobelco excavators will default to the auto acceleration function when the key switch is turned to the OFF position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS A4. Engine Lubrication Cumulative Time

L.C.D. DISPLAY

256 hours have elapsed since the change of engine oil.

This icon shows the total cumulative time since the last time the engine oil was changed.

A5. Fuel Filter Cumulative Time 256 hours have elapsed since the change of fuel filter.

This icon shows the total cumulative time since the last time the fuel filter was changed.

A6. Hydraulic Filter Cumulative Time Figure 34

DC04D540

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

A. NORMAL DISPLAYS

256 hours have elapsed since the change of hydraulic oil filter.

This icon shows the total cumulative time since the last time the hydraulic oil filter was changed.

A7. Hydraulic Oil Cumulative Time

A1. System Status Display This icon will display after key switch is turned “ON” and all machine system and components are checked by CPU and found to be good working order.

256 hours have elapsed since the change of hydraulic oil.

This icon shows the total cumulative time since the last time the hydraulic oil was changed.

A8. Travel Independent Mode Display

A2. Day Time Display Five seconds after the system status is shown on the LCD, the time will be displayed on the monitor. See “Monitor Time Adjustment” in this section for details on how to set the 24 hour clock feature.

This icon will display every time the independent travel mode is activated (Optional).

A3. Engine R.P.M. Display Actual engine speed. When auto accel is deactivated, RPM shown corresponds to the throttle potentiometer position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS B. Warning Displays Warning Condition Priority of Group

Warning Level

Screen

Condition

Buzzer Sounds

Key On Only

Engine Running

Type

Auto Stop

Manual Stop

Trouble History Code

1

DATA COMMUNICATION ERROR

Data from the mechatro controller is not received.

O

O

3

X

O

1

SWING BRAKE DISENGAGED

The swing parking brake switch is turned ON.

O

O

2

O

O

1

ENGINE STOP

Engine is stopped after Engine oil pressure Low Warning.

O

1

O

X

2

Hydraulic System Backup Mode

KPSS release switch is switched to “Release” side, this display appers.

O

O

2

X

O

1

SELECTOR VALVE FAILURE

Selector valve malfunction

O

2

X

O

2

FINISH WARM-UP

After finishing warming up control

O

2

O

X

3

LOW ENGINE OIL PRESSURE

Low Engine oil pressure disconnection.

O

2

X

O

W005

3

HIGH ENGINE WATER TEMPERATURE

The engine water is more than 105° C (221° F)

O

O

3

X

O

W006

3

DRAIN WATER SEPERATOR

Water in water separator is increased

O

O

3

X

O

W010

3

CLOGGED AIR FILTER

The Air Filter is clogged

O

O

3

X

O

W008

3

(SELF DIAGNOSIS SCREENS)

According to the self diagnosis control

O

O

3

X

O

4

LOW ENGINE WATER LEVEL

Water in engine coolant reservoir is low.

O

O

3

X

O

W001

A

W009

B

Warning Level 1. These may effect safety and the machine performance 2. These warn that the machine control mode is switched.

3. Equipment/System failure.

4. Normal priority warning.

5. Low priority message Buzzer Sounds 1. Constant 2. Beep ON 0.2 sec. OFF 0.3 sec.

3. Beep ON 0.5 sec. OFF 0.5 sec.

4. Beep ON 0.5 sec. OFF 1.0 sec.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

B1. I.T.C.S. CONTROLLER CPU DISPLAY

B4. Engine Pre-Heat Complete Display

This icon will display when a problem exists in the I.T.C.S. ( I n t e l l i g e n t To t a l C o n t r o l System).

This icon is displayed when the PREHEAT is completed.

The monitor alarm will sound continuously.

Turn key switch “OFF”, wait for 4 seconds until the system shuts down completely, then turn the switch back to “ON” to reset the CPU program.

Should this icon remain on display, stop operation, shut down the engine, remove rear panel cover and flip the Swing Parking Brake switch to the “RELEASE” position. Contact a Ko b e l c o C o n s t r u c t i o n technician for repair.

If alarm can’t be cancelled by the buzzer stop switch, turn the key switch to the OFF position., wait for 4 seconds until the electrical system is turn off completely. Then start the engine. Continuous preheat after this icon is d i s p l ay e d c o u l d c a u s e damage to the engine. DO N OT O P E R AT E THE P R E H E AT P O S I T I O N O F THE KEY SWITCH FOR MORE THAN 20 SECONDS AT THE TIME.

B2. Swing Parking Brake Release Display Turn the “Swing Parking Brake Release Switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed.

While this war ning is displayed, the swing parking brake does not actuate. This switch should be used only in t h e eve n t o f e m e r g e n c y.

Contact a Ko b e l c o Construction technician for repair.

B3. Engine Pre-Heating Display This symbol is displayed when the water temperature is 50° F (10° C) or lower. The glow plug will start automatically when the key is turned on.

T h i s d i s p l ay g o e s o u t a t completion of pre-heating, at which time FINISH PREHEAT is displayed.

B5. Engine Oil Pressure Display This icon will display and the alarm will sound should the Engine Oil Pressure drop b e l o w a s a fe o p e r a t i n g pressure.

Stop the engine immediately and check engine oil level.Fill engine to proper level with approved motor oil. If engine has LOW OIL PRESSURE, it will automatically go to “LO” Idle, and immediately shut down.

This icon will Display only if alternator is charging.

B6. Engine Coolant Temperature Display This icon will display and the alarm will sound should the Engine Coolant Temperature r ise above safe operating temperature.

Reduce engine RPM to idle and stop operation until engine coolant temperature rea ches a sa fe o pera tin g Temperature range.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS B7. Engine Air Cleaner Display This icon will display should the Engine Air Cleaner Element(s) ( F I LT E R S ) become too dir ty to allow proper air flow to the engine.

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

This icon will Display only if alternator is charging.

B8. Over Load Alarm Display (Europe only) This icon will display and the buzzer will sound should the Boom Cylinder Circuit P r e s s u r e ex c e e d t h e s e t specified pressure.

Should this icon display and the buzzer sound, immediately stop all operation, stop engine and contact an authorized Kobelco Construction Service Dealer for service assistance.

B9. Battery Charging System Display T h i s i c o n w il l d i s p l ay t h e electrical charging system not functioning properly.

Should this icon display, have the electrical charging system repaired immediately.

I c o n d i s p l ay s o n l y w h e n engine is running with normal oil pressure and a problem occurs in the charging system.

B10. Fuel Level Display This icon will display should the Fuel Level in Fuel Tank reaches 54 L (14 Gal).

Should this icon display, refill fuel tank immediately using approved diesel fuel.

B11. Hydraulic Oil Level Display This icon will display should the Hydraulic Oil Level in hydraulic oil reser voir fall below safe operating level.

S h o u l d t h i s i c o n d i s p l ay before starting engine, place m a c h i n e i n H y d ra u l i c O i l Check position and check hydraulic oil level. Refer to M a i n t e n a n c e S e c t i o n fo r p ro p e r in str u ction s to fi ll hydraulic reservoir to proper l ev e l u s i n g a p p r o v e d hydraulic oil.

This icon will not display during machine operation and a loss of hydraulic oil is experienced.

B12. Engine Coolant Level Display This icon will display should the Engine Coolant Level fall below safe operating level.

S h o u l d t h i s i c o n d i s p l ay before star ting the engine, check and fill coolant level in the radiator and coolant reservoir.

This icon will not display if alternator is charging and a sudden loss of coolant is experienced.

B13. Engine Oil Level Display This icon is displayed when the engine oil level of the engine oil pan is low.

Check the engine oil level immediately and make up the shortage of the engine oil.

This icon will not display with engine running and a loss of engine oil is experienced.

B14. Attachment Boost Pressure Display This icon will display when the Po w e r B o o s t S w i t c h i s depressed.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS B18. Replace Engine Oil Display

B15. Heavy Lift Pressure Display This icon will display when the Heavy Lift Switch is in the “ON” position.

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

B16. Auto Warming Up display T h i s i c o n i s d i s p l aye d t o indicate the war ming up operation of the engine and hydraulic oil when this system is activated.

Turn off the auto war m up switch, or the key switch OFF to cancel the warm up system and the display disappears.

B17. Auto Warming Up Finish Display This icon is displayed when the warming up of the engine and hydraulic oil is finished or when the warming up system is forced to stop.

The monitor alarm will sound continuously for 5 seconds.

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This icon display every 500 hours of machine operation to remind operator of scheduled engine oil change.

The recommended oil change interval for NEF engines is every 500 hours of operation.

Proceed with oil change and make sure to recalibrate the engine oil change interval.

B19. Hydraulic Pressure Drain Display This icon will display when the hydraulic system pressure drain is activated. The alarm will sound intermittently during the draining process.

B20. Hydraulic Pressure Drain Fail Display This icon will display when the hydraulic system pressure drain process fails. The alarm will sound continuously.

Turn the key switch OFF to cancel the alarm and repeat hydraulic pressure drain procedure before servicing the machine.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD CONTRAST ADJUSTMENT

A

B

C

D

E

A

F Figure 35

BS06H076 / BS06H077

1. Turn key switch on and display main screen (A), and press select switch and display ”SWITCH STATUS CLOCK CONTRAST” select screen (B).

2. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “SWITCH STATUS CLOCK CONTRAST” screen (C) and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (D) is displayed.

3. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “ADJUST CLOCK ADJUST CONTRAST” and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (E) is displayed.

4. Press select switch and the “ADJUST CONTRAST 55555” screen (F) is displayed.

5. Vary the values by pressing the desired figure in operations UP ARROW (washer switch) and DOWN ARROW (wiper switch). The available setting range is in 9 steps from “11111” to “99999”. (Example) 11111 (faint) to 99999 (clear). *Initial setting value is 55555.

6. Press select switch and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to the main screen (A).

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CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR TIME ADJUSTMENT

A

B

A

C

D

E Figure 36

BS06H076 / BS06H078

1. Turn key switch on and display main screen (A) for the operator, and press select switch and display “SWITCH STATUS CLOCK/CONTRAST” select screen (B).

2. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “CLOCK/CONTRAST” screen (C) and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (D) is displayed.

3. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “ADJUST CLOCK” and then press select switch and the “ADJUST CLOCK” screen (E) is displayed.

4. Select any of “Y-M-D-H-M” in operation of UP ARROW (washer switch) and DOWN ARROW (wiper switch) and vary the values in operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch).

5. After adjustment, press the select switch and the adjusted values are stored as memory and time setting is completed, and then the screen returns to the main screen (A).

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Auto Warm Up Use this feature to warm-up the engine oil and hydraulic oil in cold temperatures.

A

B

C

F

D

E

2 1

Figure 37

BS06H-95 / BS06H076

1. Turn the key switch to the ON position, the main display screen (A) will illuminate.

2. Press the select switch (1) and the “CLOCK/CONTRAST” screen (B) is displayed.

3. Press the select switch (1) again and the “AUTO WARM-UP OFF” screen (C) is displayed.

4. Press the select switch (1) again to highlight “OFF” (D) in the “AUTO WARM-UP OFF” screen.

NOTE: 1. If a pilot control lever is activated while the warm up system is active, the warm up system is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

2. In climate below -18°C (0°F) it may be necessary to use a coolant heater, fuel heater, engine heater jacket and/or additional battery power to aid in starting the engine.

5. Switch the “AUTO WARM-UP OFF” to “ON” (E) by pressing the up arrow (Washer switch) (2).

6. Press the select switch (1) to set the “AUTO WARM-UP ON” (F).

7. Turn key switch OFF to save the “AUTO WARM-UP ON” setting. When the engine is s t a r t e d i n c o l d t e m p e r a t u r e s t h e “ AU TO WARM-UP” operation will start automatically.

NOTE: The Auto Warm UP System will not activate if the Ambient temperature is above 10°C (50°F).

8. During the engine oil and hydraulic oil warming the “AUTO WARM-UP” will be displayed in the multi-function display.

9. When the “AUTO WARM-UP” is complete the buzzer will sound for approximately 5 seconds and the multi-function display will have “FINISH WARM-UP” in the display.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Pump Flow Rate Adjustment (A mode / B mode)

1

A

B

B

D

C

D

C Figure 38

BS06H076 / BS06H244

1. Turn key switch on and display main screen (A).

2. The display in the lower left corner of the screen can be changed from “H”, “B”, “A” or “S” each time the “MODE” switch is pressed where the main screen (A) is displayed.

3. Select “A” and A mode screen (B) is displayed, or “B” and B mode screen (C) is displayed.

4. Press the select switch (1) in either “A” or “B” mode display screens and the value of flow rate reverses to black, and screen (D) is displayed.

5. To increase flow, press the up arrow (Washer switch), or to decrease flow press the down arrow (Wiper switch).

6. When the desired setting has been selected, press the select switch (1) and the flow rate is set to the desired value.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS DRAINING HYDRAULIC SYSTEM PRESSURE A new convenient feature is now incorporated in the electro-hydraulic system to help the operator release the pressure in the hydraulic system directly from the operator’s cab for machine service or to switch auxiliary attachments. Proceed as follows to release hydraulic system pressure.

1 2 Figure 40

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

d. Depress air release button of the hydraulic tank breather to release tank pressure and proceed to ser vice or change auxiliar y attachments.

BS06H102 / BS06H103

Figure 39

a. With the engine running and the throttle potentiometer in low idle position, press and hold the screen change switch and the buzzer stop switch simultaneously for at least 5 seconds. The engine speed will switch to low idle and the monitor display will show, and the monitor alarm will sound intermittently.

WARNING: Stabilize the attachment on the ground before activating the hydraulic pressure drain system.

WARNING: While releasing the hydraulic system pressure, if the monitor displays, and the monitor alarm sounds continuously, turn the key switch to the OFF position to shut down the engine. The alarm will quit sounding and the monitor display will disappear 4 seconds after the key switch is turn OFF. Repeat the process again starting from step a.

WARNING: Do not attempt to service the machine or switch auxiliary attachment without releasing the hydraulic system pressure.

b. Operate the control lever, corresponding to the circuit required several times to release the system pressure. c. Turn the key switch to the OFF position to shut down the engine. The alarm will quit sounding and the monitor display will disappear after the key switch is turned OFF.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 6. Location for Optional Switches

4. Power Boost Switch

1

1

Figure 41

DC04D547

Figure 43

BS06H093

1. POWER BOOST SWITCH

1. LOCATION FOR OPTIONAL SWITCHES

Located on the right hand control lever, this switch should only be used for increased break out force during digging.

This additional switch panel is provided on the right side console for any machine customizing if desired.

NOTE: Use of power boost is prohibited when arms longer than standard are installed.

7. Cup Holder and Ashtray

1

WARNING: Do not use Power Boost for lifting operations. Instead use the Heavy Lift switch.

5. 24 Volt Cigarette Lighter

2

Figure 44

BS06H094

1. CUP HOLDER 2. ASHTRAY

1

A cup holder is provided on the right side panel, below the monitor, and the ashtray is located on the right side console.

Figure 42

BS06H093

1. CIGARETTE LIGHTER

The cigarette lighter is located on the right side control panel. To use the cigarette lighter the key switch must be in the ON position. Push the lighter in and wait approximately 30 seconds for it to “POP” out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 8. Radio

HOW TO SELECT STATIONS (Refer to Figure 46). a. How to select the radio station manually: Press the Power switch to turn ON the radio and press the station selector buttons up or down to select the desired radio station. This radio function in two main frequency bands: AM and FM. When the frequency band reaches the upper or lower limit, the radio automatically switches to the opposite limit., that is: from the upper to the lower or vice versa.

1

b. How to preset the radio stations: Figure 45

BS06H093

1. RADIO

The radio is located on the right side control panel.

The LCD Display shows the radio station selected as well as its frequency band.

CONTROL SWITCHES The following table describes the different functions available to use the radio:

Once the desired radio station is selected manually, press any of the preset station buttons (1 ~ 6) for more than 1.5 seconds to record it in i t s r e s p e c t i ve m e m o r y. T h e r e c e p t i o n i s tem po rar ily lost du r in g the me mo r ization process. Once the reception is recovered, the station is preset on the desired preset station button. Repeat this procedure to preset a total of 6 different radio stations.

NOTE: The preset stations are cancelled when the radio is removed for maintenance or the batteries are disconnected.

HOW TO ADJUST THE CLOCK (Refer to Figure 46) a. After the radio is turned ON, press button (4) to activate the time function. Then press button (8): H, M and RST to set the time accordingly. Use H to set the hour and M to set the minutes.

Figure 46

DC04D548

NOTE: The radio LCD screen will return to normal functioning after 5 seconds of inactivity on the time control button. b. The RST button works as follows: (If trying to adjust time to 10:00 hours):

SWITCH

FUNCTION AND USAGE

1

Power switch and volume control

2

Tone control

3

FM & AM selector

• If minutes are within 30 and 59 - when pressing

4

Time set selector

5

Station selector

RST button, minutes will be taken to “10:30”. Then press M to set the proper minutes.

6

Preset selector buttons

7

LCD display

8

Time adjusting buttons

3-28

• If minutes are within 0 and 29 - when pressing RST button, minutes will be taken to “10:00”. Then press M to set the proper minutes.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL PANEL

RIGHT HAND OPERATOR CONSOLE 1. Climate Control - Air Conditioner

2

3

4

5

1 2 1

9 2

2 Figure 47

BS06H079

1. AIR CONDITIONER CLIMATE CONTROL PANEL 2. AIR OUTLETS

The Air Conditioner Climate Control provides a comfor table indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reduces window glass fogging.

The Climate Control - AC unit is installed behind the operator’s seat and send cold air or hot air into the cab.

AIR OUTLET DIFFUSER Select a preferable air diffuser direction that is most comfortable by moving the diffuser grill by hand.

DC03D550

8

7

6 Figure 48

1. AIR OUTLET MODE SELECTOR SWITCH 2. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 3. LCD DISPLAY 4. COMPRESSOR SWITCH 5. AUTO CONTROL SWITCH 6. MAIN POWER SWITCH 7. FAN SPEED SELECTOR SWITCH 8. TEMPERATURE SETTING SWITCH & °C / °F SELECTOR SWITCH 9. DEFROSTER SWITCH

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

The background of the control panel is illuminated whenever the A/C system is activated.

BASIC USE Before turning the Air Conditioner ON, close the door and windows to achieve the best performance. a. Press the “AUTO” control switch to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (65 .3°F) to 31.5 °C (8 8.7°F). th e AUTO indicator in the LCD display will come on.

The outlet temperature, outlet opening and fan speed are adjusted automatically so that indoor temperature of the cab comes closer to the set temperature. b. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF. c. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control is not preferable.

The “AUTO” indicator in the LCFD display goes out. Press “AUTO” switch to return to automatic climate control.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Control Panel Functions

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

A. Main Power Switch and Display

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

2

c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power sw i t c h i s p r e s s e d a g a i n , t h e C l i m a t e Control-AC will come on in the auto control mode.

C. Temperature Setting Switch and Display

1 Figure 49

DC04D550

2

1. MAIN POWER SWITCH 2. LCD DISPLAY

a. LCD display is illuminated when the Climate Control-AC is operating. When the Climate Control-AC is stopped, LCD will turned off. b. Press main power switch, and all functions for the Climate Control-AC switch ON or OFF. Each time when this switch is pressed, the f u n c t i o n sw i t c h e s O N a n d O F F. W h e n switched ON, the Control Climate-AC starts operating at the point set before switching OFF (When it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

NOTE: The key switch will switch air-conditioner OFF, but the operating condition just before switching off may not be restored when the key switch is turned ON. B. Auto Control Switch and Display

2

3

1 Figure 51

DC04D550

1. TEMPERATURE SETTING SWITCH & °C / °F SELECTOR SWITCH 2. LCD DISPLAY

a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from °C to °F or vice-versa in the LCD display. c. Press the temperature set switch Down or UP to change the set temperature. The temperature goes up or down by 0.5°C (0.9°F) in graduation. The set Temperature may be raised or lowered by continued pressing of the switch.

1 Figure 50

DC04D550

d. The set temperature 18°C (64.4°F) is the lowest cooling temperature, and 32°C (89.6°F) is the highest heating temperature. Control beyond either of these limits is not possible.

1. MAIN POWER SWITCH 2. LCD DISPLAY 3. AUTO CONTROL SWITCH

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CHAPTER 3 - INSTRUMENTS AND CONTROLS D. Air Outlet Mode Selector Switch and Display

E. Defroster Switch and Display

2 2 1

1 Figure 54

DC04D550

Figure 52

DC04D550

1. DEFROSTER SWITCH 2. LCD DISPLAY

1. AIR OUTLET MODE SELECTOR SWITCH 2. LCD DISPLAY

a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet Mode Switch in the condition where auto display light is on, and the display mode is fixed, “AUTO” indicator lamp on LCD display goes out, and “AUTO” control of the air outlet opening is released. Press it again, and the level is change to: VENT

BI-LEVEL

FOOT

FACE

a. Press Defroster Switch, the defroster indicator will be displayed. b. Press Air Outlet Mode selector Switch, and it returns to air outlet mode just before pressing defroster switch. c. Press Defroster Switch in the condition where AUTO display is indicated, “AUTO” indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

F. Fresh and Recirculate Air Selector Switch and Display

1

2

Figure 53

DC04D551

DC04D550

Figure 55

1. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 2. LCD DISPLAY

a. Suction (fresh air intake) mode is indicated on LCD display. b. Each time Fresh and Recirculate Air Selector Switch is pressed, the mode is switched to either recirculate or fresh air intake.

87722039NA

Issued 10-07

Bur

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS G. Compressor Switch and Display

2

1

Figure 57

DC04D552

Figure 56

DC04D550

1. COMPRESSOR SWITCH 2. LCD DISPLAY

a. Press the Compressor Switch (1), and the snow flake icon will be indicated on LCD display (2).

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

2. Horn Switch

b. Press it again, the compressor turns off, and its indicator icon on the LCD display goes out.

H. Fan Speed Selector Switch and Display

1

2

Figure 58

DC04C340

1. HORN SWITCH

The horn switch is located on the operator’s left control handle.

1 DC04D550

1. FAN SPEED SELECTOR SWITCH 2. LCD DISPLAY

NOTE: Always sound horn before starting engine to alert personnel that the machine is going to be operated.

When it is set to MANUAL mode, fan speed on LCD display is as follows.

Display

Fan Speed

LCD 4 bars are lit up.

MAX.

LCD 3 bars are lit up.

HIGH

LCD 2 bars are lit up

MEDIUM

LCD 1 bar is lit up.

LOW

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Issued 10-07

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87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 4. Double Pump Flow Selector Switch

3. Hydraulic Function Cancellation Lever

1

2

1

Figure 59

BS06H080

1. FUNCTION CANCELLATION LEVER IN LOCKED (UP) POSITION 2. FUNCTION CANCELLATION LEVER IN UNLOCK (DOWN) POSITION BS06H090

A hydraulic function cancellation lever is provided on the left control console to avoid activation of any unwanted hydraulic function. When the function cancellation lever is placed in the unlock (down) position, the alarm will sound intermittently for one (1) second and the hydraulic system becomes active.

Always, before leaving the cab, shut down the engine, and place the function cancellation lever in the locked (up) position.

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

87722039NA

Issued 10-07

Bur

Figure 60

1. DOUBLE PUMP FLOW SELECTOR SWITCH

Use this switch, located on the right hand control console, to select a single or double pump flow to the auxiliary system.

• Press top of switch to activate the double pump flow for the auxiliary system.

• Press bottom of switch to cancel the double pump flow and activate the single pump flow for the auxiliary system.

CAUTION: Do not set this switch to double pump flow, unless the attachment (e.g.: breaker) requires more than one pump flow. If in doubt, contact Kobelco Construction service representative.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 6. 12 Volt Power Supply

5. Swing Parking Brake Release Switch When ever the “CPU MECHATRO CONT. FAIL” is displayed on the LCD screen, use the Swing Parking Brake release switch to override the computer control system. To release the parking brake, proceed as follows:

2

a. Stop the engine.

1 1

Figure 62

BS06H105

1. 12V POWER SUPPLY 2. COVER

The 12 Volt power supply is located beside the right side switch panel.

BS06H097 / BS06H098

Figure 61

1. SWING PARKING BRAKE RELEASE SWITCH

b. Locate the switch to release the Swing Parking Brake, located on the left side behind the seat and flip it to its release position.

For use of common auto accessories such as a fan or other accessories requiring 12 volt (DC) power.

Pull cover away from 12 volt power supply and insert 12 volt male socket into power supply. Replace cover after use.

MAXIMUM CONTINUOUS OUTPUT - 180 Watt CAUTION: Do not use the cigarette lighter as a power supply source for 12 volt accessories. It is a 24 volt outlet. Plugging a 12 volt accessory into a 24 volt connector may result in shorting and/or fire.

c. Start the engine and move the machine to a safe place.

NOTE: Contact your Kobelco Construction dealer service department for repairs. d. Return swing parking brake release switch to normal operating position after repairs have been made.

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87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 8. Hour Meter

7. Fuse Box

1

1 Figure 64

BS06H106

1. HOUR METER Figure 63

BS06H104

1. FUSE BOX COVER

The Hour Meter indicates the total time that the engine has run. It meters the time continuously as long as the engine is running.

The fuse box is located behind the operator’s seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by pressing the locks on each end of the cover inward to unlock and lift up. Should a fuse require replacement, use a replacement fuse of the same type and amperage. Turn key switch “OFF” and wait for all electrical power to stop before removing or replacing a bad or blown fuse. The fuse cover incorporates a fuse puller to remove fuses. Refer to the Maintenance Section of this manual for a detailed diagram and description of fuse box.

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Issued 10-07

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATING LEVERS AND CONTROLS 1 . L e f t H a n d ( L H ) O pe r a t o r C o n t rol L ev e r (ISO/SAE Pattern)

Figure 65

DC04D562

WARNING: Hydraulic controls are designed for and set to ISO operating pattern.

Changing the control pattern will effect the operation of the machine controls.

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

• “FORWARD” - Variable speed ARM out.

• “BACKWARD” - Variable speed ARM in.

• “LEFT” - Variable speed left SWING. • “RIGHT” - Variable speed right SWING. • “CENTER” - Neutral position.

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2. Right Hand (RH) Operator Control Lever (ISO/SAE Pattern)

Figure 66

DC04D563

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

• “FORWARD” - Variable Speed BOOM down.

• “BACKWARD” - Variable speed BOOM up.

• “LEFT” - Variable speed BUCKET in (Digging).

• “RIGHT” - Variable speed BUCKET out (Dump).

• “CENTER” - Neutral position.

Issued 10-07

Bur

87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS NOTE: An optional Pattern Control Change Valve is available. Contact your closest Kobelco Construction representative for more information. If your Excavator already has this valve installed follow the following instructions (BHL Pattern) regarding its operation.

3. Pattern Control Change (BHL Pattern) A. To change the machine’s control pattern from ISO (SAE) to Back Hoe Loader (BHL) pattern, proceed as follows: 1. Place the attachment on the ground, throttle control in low idle, and turn the key switch off.

1 Figure 68

BS06H546

1

1. PATTERN CHANGER VALVE

3. Open the air cleaner compartment door, locate the pattern changer valve and change valve’s handle position from “I” (ISO/SAE) to “D” (BHL).

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 do so could result in injury.

Figure 67

DC04C344

1. HYDRAULIC FUNCTION CANCELLATION LEVER IN LOCKED (UP) POSITION

WARNING: 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. See Figure 69 & Figure 70.

2. Place the hydraulic function cancellation lever in the lock (UP) position before leaving the cab.

1

Figure 69

DC04D565

1. ISO/SAE PATTERN DECAL CARD

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Issued 10-07

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3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS C. Left Hand Operator Control Lever (BHL Pattern)

1

Figure 70

DC04D566

1. BHL PATTERN DECAL CARD

Figure 72

DC04D567

Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

D. Right Hand Control Lever (BHL Pattern)

1 DC04A001

Figure 71

1. HYDRAULIC PATTERN DECAL CARD HOLDER

B. Make sure to place the BHL pattern decal card in its respective holder, located below the cab door handle. Make sure BHL patter n is showing.

Figure 73

DC04D568

Slowly operate Right Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

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87722039NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 4. Left and Right Travel Levers & Pedals

3 2

4 5

1

6

Figure 74

BS06H089

1. LH FOOT REST 2. LH TRAVEL PEDAL 3. LH TRAVEL LEVER 4. RH TRAVEL LEVER 5. RH TRAVEL PEDAL 6. RH FOOT REST

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.

• “CENTER” - Neutral position.

87722039NA

Issued 10-07

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) . . . . . . . . . . . . . . . 4-4 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F) . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Emergency Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 STARTING MACHINE ENGINE WITH BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 MACHINE WARM UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming of Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming of Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 BASIC OPERATION OF HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Function Cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Use of Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Turning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Machine Attachment and Swing - ISO/SAE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Swing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Using Power Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 USING AUTO ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Auto Accel Operation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Operate Boom Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Issued 10-07

Bur

87722039NA

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Bucket Teeth Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 Maximum Digging Force position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 Cleaning Sand & Soil from Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19 Stop Swing Motion Early . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Back Filling & Leveling with Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Operating the Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 RECOMMENDATION FOR LONGER UNDERCARRIAGE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 BUCKET SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 USE OF OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Selection of the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Before Operating the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Hydraulic Oil Level Check and Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Basic Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 Extra (Grapple, Clamshell, etc.) and Extra & Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Securing Machine to Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

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CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE 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.

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

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

Before operating this machine, be sure to do the following:

10. Remove any obstructions which hinder visibility.

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

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.

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

2. Carry out the daily maintenance operations.

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

The operator must be alone on the machine.

CE-NA000

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or replace as necessary. See Chapter 6.

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

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

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

5. Check the track assemblies.

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over.

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

16. Before undertaking any travel or working operations during hours of darkness, make sure 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.

CE-NA000

When operating the machine, be sure to do the following: 1. When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See Star ting The Engine in this chapter.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 5.

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

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

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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.

6. When working on a public highway, use standard traffic signs 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. See Operating instructions in the Job Site Operation section.

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

10. Operate all controls gradually to ensure smooth machine operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS 11. See Operating in water if the machine will be standing in water during use.

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

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

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 (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, report it if necessary and take the necessary steps to warn others not to attempt to operate 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 have to 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 and not pointing in the direction of the cab.

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

STOPPING ENGINE - NORMAL CONDITIONS

1. Move throttle control to “LO” position.

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

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.

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

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

NOTE: 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.

4-4

Figure 1

DC04B674

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

2. Move throttle to “LO” position. Allow engine to idle for 5 minutes.

3. Turn Key Switch to “OFF” position.

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CHAPTER 4 - OPERATING INSTRUCTIONS EMERGENCY ENGINE SHUT DOWN

1. ENGINE EMERGENCY STOP CONTROL

In only cases of emergency, when the key switch fails to shut down the engine, should this method be used.

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

1 Figure 2

DC04C344

STARTING & STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F) STOPPING ENGINE - NORMAL CONDITIONS

STARTING ENGINE 1. Move throttle control to “LO” position.

2. Turn the key switch to “ON” and preheat for 20 seconds to make star t-up easier. The E/G 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.

IMPORTANT: 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.

NOTE:

• 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

DC04B674

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 “LO” position. Allow engine to idle for 5 minutes.

3. Turn key switch to “OFF” position.

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS EMERGENCY ENGINE SHUT DOWN

1. ENGINE EMERGENCY STOP CONTROL

Only in cases of emergency, when the key switch fails to shut down the engine, should this method be used.

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

1 Figure 4

DC04C344

STARTING MACHINE ENGINE WITH BOOSTER CABLE CONNECTING BOOSTER CABLE WARNING: Improper booster cable connections can cause an explosion resulting in personal injury.

Always follow the correct procedures when connecting and disconnecting the booster cables.

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

CAUTION: 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.

WARNING: AVOID ACID BURNS Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

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

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

WARNING: The negative (-) cable, when connected to the upper frame of disabled machine, may arc causing sparks. Sparks coming in contact with batteries could trigger an explosion. Never connect negative (-) terminal of disabled battery.

CAUTION: 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: Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries.

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CHAPTER 4 - OPERATING INSTRUCTIONS DISCONNECTING BOOSTER CABLES

3

1

2

3

1

2

4 4 1

2

3

4 Figure 5

DC04D588

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 (-) ter minal of the ba tter y being used for 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.

4 DC04D588

3

2

1 Figure 6

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, follow these steps to disconnect the cables.

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.

CAUTION: When using booster cables remember: 1. Connect positive (+) cable first.

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

STARTING DISABLED MACHINE ENGINE 1. Start engine of disabled machine in normal manner according to climate conditions.

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE WARM UP AUTO WARM UP NOTE: The Auto Warm Up System will not activate if the Ambient temperature is above 10°C (50°F).

1. Warming Up of Engine The “WARMING UP” is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1050 rpm). When the accel dial set value is the value for deceleration or lower, the engine speed returns to the speed set by the accel dial (throttle potentiometer).

2. Warming of Hydraulic Oil

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 anytime machine is started in climate temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation.

The warm up of hydraulic oil is performed as follows:

MANUAL WARM UP

• Operation of pump max. flow rate at the engine

1. Warming Up of Engine

speed 1050 rpm for 3 minutes.

• Pump max. flow rate with control valve closed at the engine speed 1600 rpm for 5 minutes.

• Pump max. flow rate with control valve fully open at the engine speed 1600 rpm for 5 minutes.

• Pump max. flow rate at the engine auto accel

a. Allow the engine to run for 5 minutes under no load conditions with Throttle Control at “LO” idle 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.

speed (1050 rpm) for 10 minutes.

“WARMING UP” is displayed on the multi-display during warming up operation.

3. Warming Up Complete

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

After an elapsed time of about 26 minutes of warming of hydraulic oil, or when the hydraulic oil temperature switch turns OFF, the warming up indication “WARMING UP” on the multi-display disappears and concurrently buzzer sounds for 5 seconds. Turn the auto warm up switch OFF. NOTE: 1. If a pilot control lever is activated while the warm up system is active, the war m up is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

2. If the auto warm up switch is pressed to the OFF position, the warm up system is disconnected.

3. In climate below -18°C (0°F) it may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid in starting the engine.

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CHAPTER 4 - OPERATING INSTRUCTIONS 2. Warming of Hydraulic Oil

Figure 7

DC04D595

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.

DC04D474

Figure 9

d. Operate the Boom and Arm controls for 5 to 10 minutes each.

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 anytime machine is started in climate temperature below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation.

Figure 8

DC04D473

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 the operations for 5 to 10 minutes. c. Move Throttle Control to Mid position.

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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.

OPERATING PATTERN DECAL Figure below is a representation 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 damage or missing, install a new decal.

WARNING: Check and make sure that operation’s pattern control matches the decal provided inside the right side window.

WARNING: If your machine is set to the operational BHL pattern control, changer. 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) in chapter 3 page 3-37 for detail information on how to operate the pattern control changer.

Figure 10

BS06H096

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

Before any Hydraulic Operation is possible the Function Cancellation lever must be placed in the “UNLOCKED” (down) position. Placing the Function Cancellation Lever in the “UNLOCKED” (down) position also positions the left hand Operator’s Console in its operating and lock position.

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

WARNING: Always place the Function Cancellation Lever in the Locked (up) position before leaving cab to prevent any operation of hydraulic controls.

1 Figure 11

DC04D475

1. TRAVEL MOTOR

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.

WARNING: Failure to place Function Cancellation Lever in “Locked” (up) position could result in serious injury or death as well as serious damage to the machine and its components.

WARNING: Always know the location of travel motors before operating any hydraulic controls.

FUNCTION CANCELLATION LEVER 1. Unlocked Position

2

1

Figure 12

BS06H080

1. UNLOCKED POSITION 2. LOCKED POSITION

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CHAPTER 4 - OPERATING INSTRUCTIONS WORK MODE SWITCH

BS06H065

Figure 13

Press the work mode selector switch, and modes “H”, “B”, “A”, or “S” can be selected.

NOTE: By default, all Kobelco standard excavators start in “S” mode; and all excavators equipped with long reach attachment start in “S” mode also.

NOTE: When using “S” (standard) mode: The monitor display will show the operation control pattern after approximately 5 seconds of repetitive motion of the joystIck control levers.

During fine control operations, use the throttle potentiometer as needed, for better control of the attachment.

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CHAPTER 4 - OPERATING INSTRUCTIONS 2. Use of 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 simultaneously counter rotate the machine or to travel straight.

1. Operating Both Travel Levers Together With the travel motors positioned behind the cab:

BS06H067

Figure 14

DC04D477

a. Push both travel levers or press the pedals toward front of machine and machine will travel “FORWARD”.

Figure 16

a. For fast travel speed, depress and release the travel speed select switch once befo re operating the travel controls. This puts the travel motors in “FAST” travel speed and the lamp for “FAST” on the gauge cluster display will illuminate. b. To return to “SLOW” travel speed, stop travel and depress and release travel speed select switch once.

IMPORTANT: 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.

3. Turning Machine

Figure 15

DC04D478

b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”. c. Return both travel levers to “NEUTRAL” (center) position and machine will stop travelling. Parking brakes are automatically applied when travel levers are in neutral position.

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

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

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

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DC04D479

Figure 17

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

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CHAPTER 4 - OPERATING INSTRUCTIONS 4. Counter Rotating Machine

DC04D480

Figure 18

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

DC04D481

Figure 21

DC04D483

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

Figure 19

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

Figure 22

DC04D484

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.

IMPORTANT: A. Depending on the shoe type and ground conditions, this machine has a maximum climbing ability of 35° (70% grade) max., limited by engine lubrication.

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

DC04D482

Figure 20

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

4-14

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS 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.

5. Travel Safety a. Make certain the travel motor location is known before performing any travel operation. b. Travel on firm, level surfaces as much as possible. 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.

NOTE: 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. Immediately replacement of grease in grease bath and flushing of the swing bearing is required. See Maintenance Section.

MACHINE ATTACHMENT AND SWING - ISO/SAE PATTERN The following operation instruction are to be used with hoe bucket attachment only. If other attachment are being used, consult the operators manual for the particular attachment.

WARNING: Read, understand and follow all safety precautions during all operations of this machine and its attachment.

1. Boom Operation 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.

h. Use decking or planks to protect road surfaces as much as possible. Be careful when turning or counter rotating machine on asphalt pavement. i. Do not allow large or heavy objects to strike travel motors. j. Do not travel over large objects such as boulders, rock, etc. k. The machine can sink on soft ground or mud.

Avoid these areas.

6. Operating the Machine in Water DC04D485

Figure 24

a. Pulling right control lever BACK raises boom.

Figure 23

DC03N003

If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the chart.

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DC04D486

Figure 25

b. Pushing right control lever FORWARD lowers boom. c. Returning right control lever to the neutral (center) position stops operation of the boom.

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CHAPTER 4 - OPERATING INSTRUCTIONS 2. Arm Operation 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.

IMPORTANT: 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.

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

DC04D487

Figure 26

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

Figure 29

DC04D489

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

DC04D488

Figure 27

b. Pulling the left control lever BACK brings arm in.

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

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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.

3. Bucket Operation

BS06H081

Figure 30

DC04D490

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CHAPTER 4 - OPERATING INSTRUCTIONS 4. Swing Operation

USING POWER BOOST

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.

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

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

NOTE: Use swing flashers during swing operations.

1

Figure 33

DC04D493

1. POWER BOOST SWITCH Figure 31

DC04D491

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

Operate the bucket in digging control. While bucket is digging, depress the power boost switch with right thumb. This will increase bucket digging power by approximately 10%.

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

Figure 32

DC04D492

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS

USING AUTO ACCELERATION

1

Figure 34

BS06H064

1. THROTTLE POTENTIOMETER

The throttle potentiometer is located on the right side operator console, and it is used to control the engine RPM. When the throttle potentiometer is rotated to any position, it increases or decreases engine RPM to maintain the engine speed for that par ticular position.

With the attachment, swing, travel control lever or control pedal operation, the engine speed returns to the accel dial set position gradually according to the respective operating pilot valve movement. Thus, m a k i n g t h e o p e r a t i o n e a s i e r, l o w e r i n g f u e l consumption, and reducing noise level.

AUTO ACCEL OPERATION AND CONTROL a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 4 seconds, if the position of the throttle potentiometer is higher than 1050 rpm, the auto accel actuates automatically and the engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto accel speed, the engine speed is maintained to the throttle potentiometer position.

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CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY USE ARM IN ACTION

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

MAXIMUM DIGGING FORCE POSITION

Figure 35

DC04E074

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.

DC04E077

OPERATE BOOM SMOOTHLY

Figure 38

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

CLEANING SAND & SOIL FROM BUCKET

Figure 36

DC04E075

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.

DC04E078

Figure 39

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.

BUCKET TEETH DIRECTION

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

Figure 37

DC04E076

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE SHOVEL

STOP SWING MOTION EARLY

DC04E079

Figure 40

To stop swing action, release the swing lever before you get to your final point of digging or dumping.

Figure 42

DC04E081

Digging with the shovel differs slightly from digging with backhoe.

1. Using the arm cylinder, scrape the ground.

BACK FILLING & LEVELING WITH FRONT ATTACHMENT

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

3. Be careful not to hit the cab with the reversed bucket.

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

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

DC04E080

Figure 41

For back filling and leveling work after digging, move the bucket back and forth horizontally.

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

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

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

3. In the above operation, bucket motion may be used together with the boom and arm for a slope facing operation.

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

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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 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. Also 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.

NOTE: 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 cluster 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.

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.

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

7. Keep a close watch on the cluster gauge for w a r n i n g i c o n s d u r i n g o p e r a t i o n . Av o i d unnecessary low speed running of the engine during operation.

OPERATION IN HIGH ALTITUDES

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

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.

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

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

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, it is recommended to remove the batteries and store in a warm area.

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.

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 is displayed. change filters immediately regardless of time intervals.

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

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

OPERATION AT SEASHORE OR SALTY CLIMATE

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.

1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electr ical components and cylinder rods.

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

2. Frequently check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems.

3. Keep all belts properly tensioned.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION IN HUMID CLIMATE 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.

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

RECOMMENDATION FOR LONGER UNDERCARRIAGE LIFE Undercarriage life varies upon operation method.

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

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

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 inclination of the slope. Operating machine across the inclination of the slope will not only shorten the machine’s undercarriage 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 must be carried put accordingly, as mentioned in the Maintenance Section. DO NOT OPERATE machine with loose track shoes, and maintain proper track tension adjustment at all times during operation.

BUCKET SELECTION GUIDE Bucket selection is extremely impor tant to a machine’s productivity, durability, and stability.

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.

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

The Bucket Selection char ts listed in the SPECIFICATION’S Section are to be used as general guidelines.

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

If a machine is used exclusively to load trucks at close radius then the bucket loads can be adjusted up 5% to 7% from the Lift Chart Values listed in the Specification’s Section, due to a close in dump radius.

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 listed in the Specification’s Section or stability complaints may occur.

NOTE: See the “Bucket Selection chart” in the Specification’s Section to select the appropriate bucket size according to the application for the 215SR.

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

If the machine is to continuously dig rock, wasted shale, river cobbel 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.

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CHAPTER 4 - OPERATING INSTRUCTIONS

USE OF OPTIONAL ATTACHMENT 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 table accordingly.

1

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 safely add 350 kg (770 lbs) to every value indicated in the Lifting chart accordingly.

Figure 43

DC04D574

1. BUCKET QUICK COUPLER

If a machine is equipped with optional attachments such as a bucket quick coupler, and/or thumbs (either hydraulic or mechanical), 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 complaints.

Additionally the weights of such attachments must be considered when the Lift Chart is referred to before lifting a load. See Lift Charts in the Specification’s Section.

Use of quick couplers for bucket interchangeability will reduce effective arm digging force and particularly bucket breakout force due to an increase of tooth tip radius.

Example: Some couplers can increase tooth tip radius up to 12 inches. If this is used with 48” tooth tip radius, effective bucket breakout force can be reduced 25%, a 5% reduction in effective arm force, a reduction in lift capacities of up to 272 kg (600 lbs).

It is also impor tant to mention that some quick couplers offer a great advantage, particularly when lifting loads. Some quick couplers allow the operator to quickly remove the bucket for lifting purposes; therefore, increasing lifting capacity, height and visibility. Always follow coupler manufacturing instructions for safe operation.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC BREAKER

4. Basic Operation

1. Selection of the Hydraulic Breaker

WARNING: Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

W h e n m o u n t i n g a B r e a ke r o n t h e H y d ra u l i c Excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each Breaker. To select H y d r a u l i c B r e a k e r s , c o n t a c t y o u r Ko b e l c o Construction Dealer or vendor source.

2. Before Operating the Hydraulic Breaker Consult your Kobelco Construction 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 FOR NIBBLER/BREAKER in the MAINTENANCE AND ADJUSTMENT Section.

Thoroughly read the Hydraulic Breaker Operation Manual and SAFETY PRECAUTIONS from this Section, as well as the Safety Precaution’s Section on this Manual to avoid damaging the machine or hydraulic breaker during operation. Select the appropriate hydraulic flow for the breaker by following the instruction detailed in the NIBBLER/BREAKER BASIC MACHINE OPERATION in this section.

3. Hydraulic Oil Level Check and Contamination Prevention

1

Figure 44

BS06H080

1. FUNCTION CANCELLATION LEVER

a. Start machine and place the hydraulic function cancellation lever in “UNLOCKED” (down) position.

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 fixing clamps for looseness, and the connection of the tubes and hoses for oil leakage.

Figure 45

BS06H082

b. Make sure to select the Breaker Mode. Move throttle control to HI idle position. c. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

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CHAPTER 4 - OPERATING INSTRUCTIONS 1. Machine Set-Up A. Setting return flow Selector Valve. a. Use a 5 mm allen type wrench to loosen and remove the socket head capscrew. b. Use a 24 mm wrench to turn the selector valve to the proper position. c. After the valve is set in the proper position, install the 5 mm socket head capscrew and tighten it.

B. Setting Stop Valve.

Figure 46

DC04E082

d. Release control pedal lock rod. e. Make certain breaker or nibbler is in desired position and against material to be broken. f. Place right foot on pedal and depress with toe to activate breaker or nibbler. g. Operate breaker or nibbler at one (1) minute intervals.

IMPORTANT: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine.

If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute intervals.

WARNING: Never leave the operator cab with engine running.

NIBBLER/BREAKER WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform any inspection or maintenance on this machine.

WARNING: Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

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DC04D498

1. NIBBLER & BREAKER STOP VALVE

NOTE: Make sure to relieve hydraulic system and tank pressure as instructed in RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE in Section 6. a. Locate the stop valves on both sides of the Arm. b. Use a 24 mm wrench to turn the stop valve to the proper position.

NOTE: Make sure to switch the position of the stop valves to the “CLOSED” position before removing the attachment.

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CHAPTER 4 - OPERATING INSTRUCTIONS Each time the work mode is pressed, the work mode indicator will show in the lower left side of LCD display in order of “H”, “B”, “A”, or “S”.

2. Basic Machine Operation

Adjustment of maximum flow rate:

• Turn key switch on.

• Select the Breaker “B” mode.

• Press the up or down arrows to increase or

1

decrease the flow rate.

Flow rate display: The flow rate stored last time is displayed. Maximum flow rate is displayed as standard value.

• Press the up arrow to increase the flow rate setting or press the down arrow to decrease the flow rate setting.

• Press the select switch again to store the desired BS06H093 / BS06H090

Figure 48

1. CONFLUX/SINGLE FLOW CHANGE SWITCH

The standard 215SR is equipped with a bi-directional auxiliary hydraulic valve. The double pump flow switch is provided on the right side control panel to select a single or double pump flow to the auxiliary system.

flow rate value, and the adjust mode is cancelled. b. CONTROL PEDAL Hydraulic Breaker Single Circuit

• Press it Forward when using the nibbler for demolition work.

• Press it Backward when using the breaker.

CAUTION: Never turn switch on bi-directional flow (two pump flow) to operate Breaker. It may cause damage to the machine. a. B (Breaker) MODE

Figure 50

DC04E083

Release pedal lock on the right front side of driver’s seat to operate pedal.

IMPORTANT: Pedal operation varies upon specifications. Make sure to read the operator’s manual carefully before operating optional attachment.

BS06H082

Figure 49

In case of optional attachment such a breaker, etc. are used, the flow rate can be autom atically controlled.

Adjust the maximum flow rate by the following procedure:

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Pedal Operation - Breaker Only Foot Pedal Depressing Section

Operating Condition

Depress toe section

Breaker starts operation

Pedal in neutral position

Breaker stops operating

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Figure 51

DC04D575

DC04D576

Figure 53

If the machine is equipped with optional hand control grip levers, operate as shown.

If the machine is equipped with optional control grip levers, operate as shown.

Nibbler and Breaker Combined (Conflux)

IMPORTANT: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine.

If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute intervals.

WARNING: Never leave the operator cab with engine running.

Figure 52

DC04E083

Release pedal lock on the right front side of driver’s seat to operate pedal.

Pedal Operation - Breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operating

Depress heel section

Breaker starts operation

Pedal operation - Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress hell section

Nibbler open

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CHAPTER 4 - OPERATING INSTRUCTIONS D. CYLINDERS

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

WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.

A. USE FOR INTENDED PURPOSE

Figure 56

DC04E063

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 54

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. PASSENGERS Never allow passengers on the attachment or machine.

Figure 57

DC04E064

C. PROTECTIVE EQUIPMENT

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 possibly pump damage.

DC04E062

Figure 55

When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and 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.

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CHAPTER 4 - OPERATING INSTRUCTIONS F. HOSE SURGE

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.

I. DO NOT LIFT

Figure 58

DC04E065

Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an a u t h o r i ze d Ko b e l c o C o n s t r u c t i o n d e a l e r fo r assistance. This problem often is a result of damaged accumulators and can also result in valve failure.

G. DO NOT USE DROPPING FORCE

DC04E068

Figure 61

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

Figure 59

DC04E066

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

Figure 62

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

Figure 60

DC04E067

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

C. BREAKING OVERSIZE ROCKS

WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.

A. BREAKER PROPER POSITIONING

DC03M065

Figure 63 Figure 64

DC03M066

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 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.

When the excavator boom is lowered, it normally follows a curved path, which changes the original perpendicular position of the breaker. therefore, it is very impor tant to keep adjusting the operator’s controls to maintain constant per pendicularity 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.

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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.

D. SURFACE ROCK DEMOLITION

Figure 65

DC03M067

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS 9. DO NOT OPERATE breaker for more than a minute at a time.

E. EXCAVATING AND TRENCHING

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

EXTRA (GRAPPLE, CLAMSHELL, ETC.) AND EXTRA & BREAKER 1. Machine Set-Up WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.

A. Setting Boom Selector Valves

Figure 66

DC03M068

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: 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.

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

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

DC03M069

Figure 67

a. Locate the two (2) selector valves on the boom. b. Use 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until the stamped letter “E” is aligned with the socket head cap screw mounting hole. d. Reinstall the 5 mm socket head cap screw and tighten securely.

8. DO NOT OPERATE breaker submerged in water.

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CHAPTER 4 - OPERATING INSTRUCTIONS 2. Basic Operation

B. Setting Selector Valves

WARNING: Read, understand and follow all safety precautions and operating procedures found in this manual before operating the machine or any attachment.

1

Figure 69

BS06H080

1. FUNCTION CANCELLATION LEVER

a. Start machine and place the hydraulic function cancellation lever in the “UNLOCKED’ (down) position. b. Move throttle control to the HI idle position.

DC03M070

Figure 68

a. Locate the two (2) selector valves on the arm. b. Use a 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until stamped letter “E” is aligned with the socket head cap screw mounting hole.

1

d. Reinstall the 5 mm socket head cap screw and tighten securely.

NOTE: All selector valves MUST be turned to the “E” position or the ATTACHMENT WILL NOT FUNCTION PROPERLY.

Figure 70

BS06H088

1. NIBBLER/BREAKER SELECTOR SWITCH

c. Place the Nibbler/Breaker selector switch, located on the RH control console, to the operating position being performed. d. Use the boom, arm, and bucket controls to position the attachment.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 71

BS06H214 / BS06H216

e. Unlock pedal and place right foot on pedal.

Depress with toe to close attachment and depress back of pedal with heel to open attachment. f. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, operate the attachment in hydraulic oil check position, move throttle control to LO idle position, and place the Nibbler/Breaker selector switch in the neutral position.

WARNING: Never leave the operator cab with engine running.

WARNING: Set the pedal lock to the “LOCKED” position while the breaker or nibbler is not used. Unexpected contact with the pedal in the “UNLOCKED” position may cause serious injury or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION GROUND TRANSPORTATION 1. Machine Preparation a. Know the total weight, length, width and height of the machine being transported. b. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

c. Obtain any permits required from proper gover nment agencies for machine transportation. d. Use only a trailer with a rated capacity sufficient to transport the machine. e. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

Figure 72

DC03N007

2. Loading the Machine WARNING: Never attempt to load or unload machine without ramps. a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower ramps of trailer. c. Start the machine. d. Set travel speed to LOW 1st speed. e. Move throttle control to low idle position. f. Put Auto Accel function OFF.

Figure 73

DC03K083

g. Raise the attachment and slowly travel machine up trailer ramps and over rear axles of trailer.

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CHAPTER 4 - OPERATING INSTRUCTIONS h. Slowly travel machine completely onto trailer until in proper transport position. i. Slowly swing machine 180° until attachment is toward rear of trailer.

Figure 74

DC03K084

j. Slowly lower boom until attachment rest on trailer bed. k. Do Not have bucket and arm cylinder at full stroke during transport as this may cause damage to cylinders.

1

Figure 75

DC04C344

1. FUNCTION CANCELLATION LEVER

l. Place hydraulic function cancellation lever in the “LOCKED” (up) position. m.Turn machine “OFF”, remove key and lock all doors, filler caps and access panels.

IMPORTANT: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine, and possible turbo damage.

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CHAPTER 4 - OPERATING INSTRUCTIONS 1. Lifting Machine With Attachment Installed

3. Securing Machine to Trailer

WARNING: Always use proper lifting equipment and devices. Use of improper lifting equipment could allow the load to shift or fall causing severe damage, serious injury or death. a. Locate lifting locations at the front and rear of each crawler frame. b. Attach cables or wire ropes with a capacity rating sufficient to lift the machine, at lifting locations.

1 Figure 77

DC04D582

1. HARDWOOD OR STEEL BLOCK

WARNING: Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting.

DC04D581

Figure 76

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.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS NOTE: It may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting.

c. Bring loose ends of cable together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine.

Figure 78

DC03N009

WARNING: DO NOT USE COUNTER WEIGHT LIFTING EYES TO LIFT MACHINE. USING COUNTER WEIGHT LIFTING EYES MAY CAUSE MACHINE TO FALL RESULTING IN SERIOUS INJUFY OR DEATH.

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE PREPARE MACHINE Perform the following procedure to prepare the machine for long term storage.

1. Perform all inspection and maintenance proce dure s as de scr ibed in Mainte nance Section.

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

1

IMPORTANT: 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.

2 2

2 Figure 79

DC04D586

1. MACHINE IN STORAGE POSITION 2. CYLINDER RODS HEAVILY GREASE TO PREVENT CORROSION DURING STORAGE

5. Operate bucket and arm completely “IN” extending cylinders. then lower boom until attachment is resting on the floor.

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

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

CARE DURING STORAGE 1. Every 30 days during storage, it will be necessar y to star t and run the machine to circulate the fluids through the systems. Before starting, clean cylinder rods and after running, re-grease cylinder rods.

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.

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

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

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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 Swing Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Upper Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Ring Gear Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 USE OF BIO-DEGRADABLE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES

Capacity ------------- 300 cc (10.1 Fluid Oz.) Each x 18 NOTE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

ENGINE Type of Oil ------------------------ Engine Oil SAE 15W40 Capacity:

TRACK IDLERS

Engine Oil Pan (H Level) -----18.0 liters (4.8 gal) Filter Capacity --------------------1.1 liters (0.3 gal) Total Engine Oil Volume -----20.5 liters (5.4 gal) NOTE: See ENGINE OIL LEVEL in Chapter 6 for proper oil filling and/or checking engine oil level.

HYDRAULIC

Type of Oil ------------------------ Engine Oil SAE 15W40 Capacity -------------- 250 cc (8.5 Fluid Oz.) Each x 2 NOTE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

OPERATING LEVER JOINT

Type of Oil ---------------------------- Hydraulic Oil AW 46 Capacity: Hydraulic Tank ---------------- 126 liters (33.0 gal) Hydraulic System ------------230 liters (61.0 gal)

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

NOTE: 1. See HYDRAULIC OIL LEVEL in Chapter 6 for proper filling and/or checking hydraulic oil level.

UPPER ATTACHMENT PINS

SWING MOTOR REDUCTION UNIT

Capacity -------------------------- As required in each pin

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

NOTE: See ATTACHMENT LUBRICATION Chapter 6 for proper lubrications.

Capacity -------------------------------3.0 liters (0.8 gal)

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

in

NOTE: See SWING MOTOR REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

SWING BEARING

TRAVEL MOTOR REDUCTION UNIT

Capacity --------- As required (1 place - swing 90° x 4)

Type of Oil ------------------------- SAE 90 GL4 Gear Oil Capacity ------------------ 5.3 liters (1.4 gal) Each x 2

NOTE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

NOTE: See TRAVEL MOTORS REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

TRACK TENSION ADJUSTMENT

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

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

TRACK UPPER ROLLERS Type of Oil ------------------------ Engine Oil SAE 15W40 Capacity ---------------- 30 cc (1.01 Fluid Oz.) Each x 4

Capacity ---------------------------- As required (2 places) NOTE: See TRACK TENSION in Chapter 6 for proper procedures in injecting grease.

NOTE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

SWING RING GEAR BATH

TRACK LOWER ROLLERS Type of Oil ------------------------ Engine Oil SAE 15W40

Type of Oil ------------ Lithium base grease with MOS2 Capacity ---------------------------------- 8.6 kg (19.0 lbs)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS NOTE: See SWING RING GEAR LUBRICATION in Chapter 6 for proper lubrications.

REQUIRED FILTERS NOTE: Refer to the Parts Manual for the correct part numbers to order.

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

HYDRAULIC

• Return Filter Element for Standard Machine ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

Capacity:

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

Radiator --------------------------7.4 liters (1.9 gal) Cooling System -------------------22 liters (5.8 gal) NOTE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

ENGINE

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

FUEL TANK Type of Fuel --------------------- Diesel Fuel grade No. 2

FUEL

Capacity ---------------Fuel Tank - 300 liters (79 gal)

• Engine Fuel Filter

NOTE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

• Priming Pump Gauze Filter OPERATOR CAB

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

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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

*Note: All engines shipped from factory with SAE15W40 engine oil.

CLIMATE ZONE

LUBRICANT

FUEL

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

LUBRICANT

For ROLLERS and IDLERS

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

(For General Purpose Lubrication)

LUBRICANT

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL (For General Purpose Lubrication)

A.P.I. Classification for "Service CD" - SAE15W40

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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. Take into consideration Wind Chill Factors.

USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. You are recommended to use the synthetic based type, because the vegetable based oil has a maximum usage temperature of 80°C (176°F). Because of this, the degradation of vegetable based oil occurs more rapidly, and causes reduced service life.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. In the case that you would like to use BIO OIL, it is required to flush the hydraulic system that was filled with mineral oil twice, 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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Warm Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 “Tag-Out” Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Seals & O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Releasing Hydraulic System and Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Special Considerations for Hand Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 DAILY INSPECTION & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Engine Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Machine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Steps and Handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Boom & Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 50 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Fuel Tank Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Radiator, Oil Cooler & Debris Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Engine Accessory Belt Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Swing Ring Gear and Swing Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Swing Ring Gear Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Swing Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Issued 10-07

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Checking Swing Gear Attaching Bolts for Proper Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 Check Swivel Valve for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 Oil Level in Swing and Travel Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 Inspecting Counterweight Attaching Bolts for Proper Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Control Lever Joint Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Swing Motor Reduction Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Travel Motors Reduction Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 Engine Accessory Belt Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Air Conditioning Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Climatizer - AC Unit Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Recirculate Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Checking the Radiator Cap & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 500 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Bleeding Air From Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Change Oil in Travel Motor Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Change Oil in Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Checking and Cleaning Fuel Tank and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Checking the Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Checking the Air Conditioning Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Engine Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Cleaning Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Maintenance on Rollers and Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Change Swing Ring Bath Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 PERIODICAL INSPECTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Dust Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Bucket, Arm, & Link Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Reversing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Removing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Installing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Bucket Teeth and Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Windshield Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Hydraulic Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Boom Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Arm Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Fuel Lines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Hydraulic Suction Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Rear View Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 MAINTENANCE FOR NIBBLER/BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Releasing Travel Motor Brakes Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 6-2

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Lowering Attachment When Sudden Engine Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 Releasing Swing Brake Manually With Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Releasing Swing Brake Manually Without Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Bleeding the Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION WARNING: Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components.

WARNING: Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

1. It is recommended by Kobelco Construction that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

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 a n d m a i n t e n a n c e a s t h ey w i l l g u i d e t h e technician step by step for each procedure. Also, refer to the inspection and maintenace charts for general service interval recommendations.

NOTE: 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.

3. Use only oils, fluids, lubricants, filters and r e p l a c e m e n t p a r t s s u p p l i e d b y Ko b e l c o Construction to keep machine in optimum operating condition.

Figure 1

DC04B668

GENERAL SAFETY HOT SURFACE & FLUIDS

DISPOSAL OF HAZARDOUS WASTE Dispose waste oils, fluids, lubricants, filters, and other hazardous waste properly.

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

KEEP MACHINE CLEAN

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 down before performing maintenance procedure.

WARM ENGINE OIL Figure 2

DC04B669

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

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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.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PREVENT CONTAMINATION

“TAG-OUT” MACHINE

DC04B671

Figure 4

Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operators console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine.

INSPECT WASTE OILS AND FILTERS

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.

IMPORTANT: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

SEALS & O-RINGS Always replace seals and O-rings with new parts.

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

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

WEAR SAFETY EQUIPMENT

DC04B672

Figure 5

Before disposal, inspect all waste oils, fluids, and f i l t e r s fo r d e b r i s a n d fo r e i g n m a t e r i a l . I t i s recommended to cut open the oil filters to determine any abnormal wear.

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.

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

WARNING: Never use gasoline, diesel fuel or other flammable solvents to clean parts.

Always clean parts in a well ventilated area.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY

3. Lower the function cancellation lever to unlock the hydraulic system.

1. Turn key switch to “OFF” position.

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

3. Attach the welder ground cable within 1 m (3’ 3”) 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.

RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm, not hot. Release hydraulic tank pressure before working with any hydraulic components.

Figure 9

BS06H208

4. Shift the right and left travel control levers forward and backward, also operate the right and left control levers to full strokes several times.

1 2 Figure 7

DC04B674

1. Move the machine to firm level ground and place the attachments on the ground in the oil check position.

2. Put the machine in drain mode to drain pressure.

NOTE: Engine will be running during this operation.

Figure 10

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

5. Remove the cap on the hydraulic tank breather and push the air release button down to release the pressure in the hydraulic tank.

6. Carry out the inspection and/or maintenance of hydraulic system.

WARNING: When replacing any hose or seal, make sure the attachment is well secured to avoid sudden movement. Slowly remove bolts to release any remaining hydraulic pressure during disassembly.

1 Figure 8

DC04A001

1. FUNCTION CANCELLATION LEVER

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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 tighten. 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 lubr ication 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 splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

1

• 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.

• For best results, strike all head bolts with a heavy hammer to seat them properly before final torque.

WARNING: Wear safety glasses whenever striking metal objects with a hammer.

• When new parts are used, the mating surfaces will seat more uniformly and the bolts 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.

6-8

3

2

Figure 11

DC04C280

1. BUSHING 2. PIN 3. ROUGH SURFACE REQUIRING BREAK-IN.

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 machine 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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SPECIAL CONSIDERATIONS FOR HAND LUBRICATION

3

1

4

2

Figure 12

DC04C281

1. BUSHING 2. PIN 3. HAND LUBE FILL 4. LOAD AREA

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. See the pin load and grease cavity illustration shown above. 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.

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6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

6-30

Fan and air conditioning drive belt

6-38

Air filter

6-22

Fuel tank filter

AR

6-17

Steel track shoe bolt torque

AR

6-12

Engine oil level

8

6-41

Coolant level

8

6-14

Hydraulic reservoir level

8

6-23

Radiator and oil cooler

8

6-10

Swing Motor Reduction Unit

8

6-30

Fan/alternator belt tension

8

6-20

Attachment

6-22

Drain fuel tank sediment

drain

lubricate

replace AR

AR

6-28

AR

50 50

6-55

Hydraulic system lines

6-39

Hydraulic return filter

6-17

Track shoe bolt torque

Run-in

50

8-13

Bolt and nut torque

Run-in

50

50 50

6-24

Battery check

50

6-18

Idler wheel and rollers

250

6-43

Hydraulic Breaker return filter

6-32

Radiator hoses & clamps

250 250

6-26

Swing reduction gear

Run-in

250

6-29

Travel reduction gears

Run-in

250

6-17

Track shoe bolt torque

250

8-13

Bolt and nut torque

250

6-25

Fan/alternator belt tension

250

6-24

Battery electrolyte level

250

6-21

Engine oil

50

500

6-21

Engine oil filters

50

500

Every 500 hours 6-20

Every 1000 hours

check

page

Service points

Intervals in hours

clean

Service intervals

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

Machine Grease Points

500

6-26

Turntable bearing

500

6-33

Fuel filter

6-20

Attachment

500 1000

6-43

Hydraulic fluid condition

6-43

Reservoir breather filter

1000

6-39

Hydraulic return filters

6-38

Primary air filter element

250

6-38

Secondary air filter element

250

RM

Tappet clearances

1000 1000 1000 1000 1000

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Every 2000 hours

drain

lubricate

replace

check

page

Service points

Intervals in hours

clean

Service intervals

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-43

Hydraulic Fluid

2000

6-28

Swing reduction gear

6-46

Pilot Filter

6-34

Travel reduction gears

2000

6-41

Draining and filling cooling system

2000

6-44

Suction Strainer

2000 2000

2000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen to serve as a reminder that service work is due. See “Systems display and control panel” in the “Controls/Instruments/Accessories” Section.

NOTE: RM = See Repair Manual or contact Authorized Dealer

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION & MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

ENGINE COOLANT LEVEL

WARNING: Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work cloths, and work gloves to perform inspection and maintenance on this machine.

1

ENGINE OIL LEVEL 1. Raise the engine cover.

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

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

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

Check swing reduction oil when on top of machine.

Figure 13

BS06H211

1. ENGINE COOLANT RESERVOIR

1. Open left rear compartment cover and inspect coolant level in engine coolant reservoir.

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.

1

Figure 14

BS06H205

1. RADIATOR CAP

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.

WARNING: Never remove radiator cap when engine is hot. Allow engine to cool down before removing radiator cap.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE FLUID LEAKS 1. Inspect complete engine for signs of fluid leaks.

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.

Repair or replace faulty components immediately.

FUEL LEVEL

Figure 15

DC04C286

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

1

Figure 18

DC04D600

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.

Figure 16

DC04C287

WARNING: Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

ENGINE ELECTRICAL

2

1 Figure 19

DC04C294

1. FUEL TANK CAP 2. FUEL TANK CAP LOCK

Figure 17

DC04C292

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

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2. To refuel the machine, use the key from key switch to unlock the cap (if locked) and 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 r usting and fuel freezing, as well as other associated problems.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL

3. To add hydraulic oil, proceed as follows:

1 2 DC04B674

Figure 20

Figure 22

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1. Place the machine in the oil check position on a firm level surface.

A. Depress air release button hydraulic tank pressure.

to

release

WARNING: Gasses from hydraulic tank may be hot. Wear personal safety equipment.

1 2

DC04C297

Figure 21

3

2. Check the sight glass through the opening of the hydraulic tank side cover.

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°.

Figure 23

DC04C298

1. CAP SCREW & WASHER 2. SUCTION FILTER COVER PLATE 3. O-RING

B. Slowly remove the six mounting bolts from the hydraulic suction filter cover plate.

C. Add hydraulic oil, filling hydraulic tank to the proper level.

D. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic oil and install the O-ring.

E. Install cover plate, cap screws and washers.

Tighten the cap screws to torque specification.

Refer to Torque Specification Table in the Specifications Section.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING: Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

IMPORTANT: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

HYDRAULIC FUNCTIONS

DC04C286

Figure 26

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 allowing any operation.

Figure 24

BS06H208

Check all hydraulic controls for proper functionality before operating the machine.

WARNING: Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

WARNING: Never operate the machine with faulty control or function. Make all necessary repairs before allowing any operation.

HYDRAULIC OIL LEAKS

Figure 25

DC04C287

WARNING: Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

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6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MACHINE ELECTRICAL

STEPS AND HANDHOLDS

1. Check all switches for proper operation.

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

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

Figure 28

DC04A040

1. Inspect daily all mounting steps and handholds on the machine to make sure they are clean and in safe working condition.

DC04C299

Figure 27

4. Check all gauges and L.C.D. display on the gauge cluster for proper operation.

WARNING: Damaged or faulty electrical components can cause severe damage to the machine and cause serious personal injury or death.

6-16

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

IMPORTANT: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FRAME STRUCTURE

TRACKS AND COMPONENTS

1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

1. Track Shoes

1

Figure 30

DC03K215

Figure 29

DC03K221

NOTE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding is required, consult an authorized Kobelco Construction Service Dealer for proper procedures. Use only certified welding personnel familiar with str uctural welding methods to perform repairs requiring welding.

Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

1. TRACK SHOES

A. Visually inspect track shoes for signs of excessive wear or damage.

B. Have all repair or replacement work done by an authorized Kobelco Construction Service Dealer.

C. Check tightness of shoe mounting bolts and nuts. If loose, remove bolt, clean thread, apply engine oil and torque to 853 ± 27 N·m (628 ± 36 ft-lbs).

2. Track Links

WARNING: Disconnect batteries before welding on this machine. Connect welder ground cable within 1 m (3’ 3”) of area to be welded.

1

Figure 31

DC04C300

1. TRACK LINK

A. Inspect link for signs of excessive wear or damage.

B. Have all repair or replacement work done by an authorized Kobelco Construction Service Dealer.

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6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Sprockets

4. Idlers

1 1

2

Figure 32

DC04C301

Figure 33

DC04C302

1. SPROCKET 2. SPROCKET BOLT

1. IDLER

A. Inspect Idlers for excessive wear and damage.

A. Inspect sprockets for excessive wear and damage.

B. Should the sprockets require service, contact an authorized Kobelco Construction Service Dealer.

C. Check and make sure all sprocket bolts are properly torqued.

NOTE: If any sprocket bolt is loose, proceed as follow:

B. Should the Idlers require service, contact an authorized Kobelco Construction Service Dealer.

NOTE: Every 8 hours of operation, make sure to check Idlers and Rollers for leakage and repair as needed. Contact your Kobelco Construction dealer’s Service Department for any assistance.

NOTE: Change oil in Idlers and Rollers every 2000 hours of operation. See 2000 hour maintenance in this section for specific details.

C1 - Remove bolt and clean threads.

C2 - Apply Loctite #262 to the bolt.

5. Rollers

C3 - Torque to 55 Kgf·m (397 lbs-ft)

1 Figure 34

DC04C303

1. ROLLERS

A. Inspect Rollers for excessive wear and damage.

B. Should the Rollers require service, contact an authorized Kobelco Construction Service Dealer for assistance.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. To decrease track tension, carefully loosen grease fitting to allow grease to escape.

TRACK TENSION

5. Tighten grease fitting to 6 kgf·m (45 lbf-ft) torque.

6. Keep others away from machine start engine and operate the travel motor for the track being adjusted, back and forth. Recheck track tension and adjust if needed.

7. Keep others away, start and lower machine to the ground.

8. Perform steps 1 through 6 on the opposite track if needed.

BOOM & ARM 1. Inspect Boom and Arm structures for signs of excessive wear and damage.

Figure 35

DC04C304

1. On a firm level surface operate swing, arm, bucket, and boom controls until machine is set up as shown. Stop the engine.

WARNING: Support suitable blocks.

lower

frame

with DC03K221

2. Measure the sag in the center of the track, between the bottom of the track frame and the track shoe surface.

Figure 37

NOTE: Remove any excessive grease from the attachment pin connecting areas for inspection.

2. Should repair or replacement be necessary, contact an authorized Kobelco Construction Service Dealer for assistance.

NOTE: Visually check every eight (8) hours for excessive lateral play between boom and arm, and arm and bucket connections. Measure clearances every fifty (50) hours. Refer to shop manual for details regarding attachment lateral clearance.

Figure 36

DC04C307

WARNING: 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 an authorized Kobelco Construction service dealer for assistance.

WARNING: Should welding be necessary, disconnect batteries before welding on this machine. Connect welder ground cable within 1 m (3’ 3”) of area to be welded.

3. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting with a grease gun until proper tension is reach.

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6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 50 HOUR MAINTENANCE: ATTACHMENT LUBRICATION

1

3 2 1 Figure 38

DC04C305

Figure 40

DC04C308

1. ARM TO BOOM PIN 2. ARM CYLINDER ROD PIN 3. BUCKET CYLINDER HEAD PIN

1. BOOM CYLINDER HEAD

1. Boom cylinder head pins.

5. Arm to boom pin.

6. Arm cylinder rod pin.

4

7. Bucket cylinder head pin.

3

5

2 1

4 1

3 2 Figure 39

DC04C306

1. BOOM FOOT 2. BOOM FOOT PIN (EACH SIDE) 3. ARM CYLINDER HEAD PIN 4. BOOM CYLINDER ROD PINS

2. Boom foot pin.

Figure 41

DC04C309

1. BUCKET CYLINDER ROD END 2. TOP BUCKET LINK PIN 3. BOTTOM BUCKET LINK PIN 4. ARM TO BUCKET PIN 5. IDLER LINK TO ARM PIN

3. Arm cylinder head pin.

8. Bucket cylinder rod pin.

4. Boom cylinder rod pins.

9. Top bucket link pin.

10. Bottom bucket link pin.

11. Arm to bucket pin.

12. Idler link to arm pin.

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.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE ENGINE OIL AND FILTER ELEMENT Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

NOTE: One new oil filter is shipped with the machine in the support kit. This is to be used at the 50 hour oil & filter change.

2

1 Figure 44

DC04C310

1. BELLY PAN COVER 2. BELLY PAN COVER BOLTS

3. Remove bolts and engine belly pan covers

Figure 42

DC04B674

1. Move the machine to a firm, level surface, and run engine for 5 minutes to warm the oil.

4. Locate the engine oil drain plug and place an empty oil container [20 l (5 gal) capacity] under the engine.

5. Remove engine oil drain plug and let the engine oil drain out completely.

WARNING: Do not change oil on a machine that has just stopped working. The oil will be extremely hot. Allow the engine to cool until oil is just warm before changing.

1

BD06H022

Figure 45

6. Use a filter wrench and turn counter clockwise to remove the oil filter.

Figure 43

BS06H205

1. ENGINE OIL FILLER CAP

2. Raise the engine cover and secure it open.

Remove the oil filler cap.

7. To install the oil filter, apply a thin coat of engine oil to the gasket of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 3/4 ~ 1 complete turn by hand after the gasket comes in contact with the oil filter head. The amount of oil to be added into the filter is approximately 1.8 liter (0.5 gal).

NOTE: Check the waste oil. If there are metal flakes in the oil, contact your Kobelco Construction Service Dealer. Do not reuse the oil filter.

8. Clean oil drain plug and install it. Tighten securely.

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6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 9. Refer to LUBRICATION, FILTERS, and FLUIDS Section for the proper oil to use and fill engine oil to proper level.

1

10. Add oil and install oil filler cap. Clean up all spilled oil.

11. Keep others away from machine, start engine, run for 5 minutes. While running, check for oil leaks.

12. Should any oil leaks be found, stop engine, check for the source of leakage, and repair immediately and refill with proper oil.

2

13. Check oil level and close engine cover.

14. Reinstall engine belly pan covers and tighten bolts to 83.3 N·m (38 Ft-lbs).

WARNING: Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

FUEL TANK DRAIN

Figure 47

BS06H084

1. FUEL FILTER 2. DRAIN VALVE

1. The fuel filter is located in front of counterweight on the right rear side of the machine.

2. Stop the engine. Open right side door and place container under drain hose to collect water.

Drain the fuel tank every 50 hours or weekly.

3. Loosen drain plug and air bleeder plug to drain water in fuel filter.

4. After draining, tighten drain plug and air bleeder plug securely.

WARNING: Clean up all spilled fuel to avoid fire. Dispose of all hazardous waste in accordance with government environmental regulations.

1

Figure 46

BD06H023

1. FUEL TANK DRAIN VALVE

1. Stop the engine. Place an empty container below the fuel tank drain valve.

2. Locate and open fuel tank drain valve on bottom of fuel tank.

3. Drain water and sediment from fuel tank into a waste container, then close the drain valve.

WATER SEPARATOR The water separator isolates water that mixes in with the fuel.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system, including turbo charger and intercooler, on a new machine after the first 50 hours of operation. Then at every 500 hours of engine operation.

NOTE: When working in extremely dusty environments, it is recommended to check the radiator, oil cooler, Inter-Cooler, and A/C condenser at the end of the working shift and clean regardless of working hours.

1. Stop the engine. Open the engine cover, secured it open, and inspect all hoses for damage.

Tighten all hose clamps.

2. Replace any damaged hose before allowing any operation of the machine.

RADIATOR, OIL COOLER & DEBRIS SCREEN Clean radiator after every 50 hours of operation using pressurized air.

Remove and clean filters in front of radiator.

1 Figure 50

DC04C317

1. RADIATOR LOWER ACCESS COVER

1

2. Remove radiator lower access cover from bottom of machine.

3. Rinse all dirt and debris from engine compar tment. Reinstall debris screen and radiator lower access cover.

1 Figure 48 1. RADIATOR FILTERS

IMPORTANT: Be careful not to bend or damage cooling fins of the radiator, A/C condenser, Inter-Cooler, and oil cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator, oil cooler, Inter-Cooler,and A/C condenser.

1 2

3

4 Figure 49

BS06H213

1. RADIATOR 2. OIL COOLER 3. A/C CONDENSER 4. INTER-COOLER

1. Stop the engine. Open radiator compartment door and engine cover and secure them open to clean the radiator, oil cooler, Inter-Cooler, and A/C condenser.

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6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE BATTERIES

.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

WARNING:

Figure 52

BS06H237

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

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.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

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.

NOTE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

GRAPHIC20

Figure 51

1. Stop the engine. Open the battery access door by removing protective cover, nut, and washers.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

ENGINE ACCESSORY BELT WEAR AND TENSION

NOTE: Use hydrometer manufacturer’s instruction.

Inspect belt wear and tension on a new machine after the first 50 hours of engine operation. Then, every 250 hours.

according

to

its

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

1

7. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging:

3

a. Disconnect battery cables from terminals.

2

b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

NOTE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

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Figure 53

BS06M391

1. ALTERNATOR/FAN BELT 2. CRANK PULLEY

3. A/C COMPRESSOR BELT

Belt tension on the Alternator and Fan belt is 98 N (22 lbf), and 28 N (6.3 lbf) on the Air Conditioner belt.

Measure the belt deflection and compare to the Belt Deflection table.

BELT

DEFLECTION

Alternator/Fan Belt

8 mm ~ 10 mm (0.31” ~ 0.39”)

Air Conditioner Belt

6 mm ~ 7 mm (0.24”~0.28”)

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SWING RING GEAR AND SWING BEARING LUBRICATION 1. Swing Ring Gear Lubrication Check the grease level and condition of the swing ring gear grease bath on a new machine after the first 50 hours of engine operation. Then, check every 250 hours. Replace the grease in the swing ring gear b a t h ev e r y 2 , 0 0 0 h o u r s ( S e e 2 , 0 0 0 h o u r maintenance in this section for details).

CAUTION: Do not overfill sump bath. If overfilled, sump bath grease could be pumped into swing motor reduction unit and cause severe damage. Use only N.L.G.I. lithium base with MOS2 grease in swing ring gear sump bath.

If the swing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

Refer to 2,000 Hour Maintenance for specific instruction.

2. Swing Bearing Lubrication Lubricate the swing bearing on a new machine after the first 50 hours of engine operation. Then, lubricate every 500 hours, or as conditions dictate.

1 DC04C329

Figure 54 1. SWING RING GREASE INSPECTION COVER

a. Stop the engine. Locate the swing ring grease inspection cover between the tool box and the boom suppor t frame. Remove bolts and inspection cover plate.

1 Figure 56

DC04C331

1. SWING BEARING GREASE FITTING

a. Stop the engine. Locate the grease fitting at the front of the swing bearing. b. Using a grease gun filled with general purpose EP grease, lubricate swing bearing with several pumps from grease gun. c. Keep others clear of machine, swing machine 90° right, and repeat step 2. See label on frame. d. Repeat the process at 90° increments and lubricate swing bearing until ring has been completely greased. e. Check and make sure the swing bearing seal is in good condition. It is nor mal to see excessive grease come out of the seal.

DC04C330

Figure 55

b. If water is present, remove the lower plate (drain plate). c. Keep others away from machine, start the engine and slowly rotate the upper structure to inspect the swing gear. d. Should any grease be needed, add N.L.G.I. No. 2 Lithium base with MOS2 grease only.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING SWING GEAR ATTACHING BOLTS FOR PROPER TORQUE

Stop the engine. Check the swivel valve for leakage on a new machine after the first 50 hours of engine operation. Then, every 250 hours. If needed, contact your Kobelco Construction Ser vice Dealer for assistance.

NOTE: Make sure to inspect the upper and lower side of the Swivel Valve. Repair any leakage as needed.

OIL LEVEL IN SWING AND TRAVEL REDUCTION UNITS

2

1 1 Figure 57

DC04C331

1. SWING GEAR ATTACHING BOLTS

Stop the engine. Check the swing ring bolts torque on a new machine after the first 50 hours of engine operation. Then, Check every 250 hours. Check the swing ring bolts for proper torque across each other and in sequence. If bolts are loose, remove one bolt at a time, clean it and apply Loctite #262 and torque accordingly.

Figure 59

DC04C333

1. FILL PLUG

SWING RING TORQUE SPECIFICATIONS 215SR Inner Race: 56.3 ± 5.6 kgf·m (415 ± 41 ft-lbs) Outer Race: 39.2 ± 3.9 kgf·m (289 ± 29 ft-lbs)

2. DIPSTICK

Stop the engine. Check the oil level on swing motor reduction unit on a new machine after the first 50 hours of engine operation then check every 250 hours.

CHECK SWIVEL VALVE FOR LEAKAGE

2

1

Figure 60

DC04C334

1. DRAIN PLUG 2. FILL/LEVEL PLUG Figure 58

DC04C332

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Stop the engine. Check the oil level on travel motor reduction unit on a new machine after the first 50 hours of engine operation then check every 250 hours.

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR PROPER TORQUE.

SWING MOTOR REDUCTION UNIT OIL WARNING: Never perform maintenance on a machine that has just finished working.

Allow sufficient time for machine to cool down.

Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation. Then, change every 250 hours.

1

2

1 Figure 61

DC04C335

1. COUNTERWEIGHT BOLTS

Stop the engine. Check bolts and nuts for proper torque.

CAUTION: Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after the first 50 hours of engine operation. Then, every 250 hours.

NOTE: If a counterweight bolt is found loose, remove it, clean threads, apply Loctite #262 before installing it. See Specification Section for torque reference.

WARNING: Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

CONTROL LEVER JOINT LUBRICATION

Figure 63

DC04C333

1. FILL PLUG

2. DIPSTICK

1. Stop the engine. Locate the dipstick on the side of the swing motor. Pull dipstick, wipe clean and reinsert all the way in.

2. Pull dipstick and read oil level.

3. If necessary to add oil, remove plug from oil fill port and fill to full level with proper oil. Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper oil specifications.

1 1

2

2

Figure 64

DC04C337

Figure 62

DC04C336

1. VENT HOLE

2. FULL MARK

1. UNIVERSAL JOINT 2. TOP OF THE SLIDING AREA

4. Check and make sure the vent hole on dipstick is clean.

Stop the engine. Remove the rubber boots from the control levers and lubricate the universal joint and the top of the sliding area every 250 hours.

5. To drain oil from the swing motor reduction unit:

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2 1

1 Figure 65

DC04C338

Figure 66

DC03N026

1. DRAIN PORT

1. DRAIN PLUG 2. FILL/LEVEL PLUG

WARNING: Reduction unit may be under pressure. Remove the plug slowly. a. Locate drain port under the center opening of the lower frame.

1. Move machine to a firm, level surface. Operate travel until “DRAIN” plug is positioned at 6:00 o’clock. Oil “FILL/LEVEL” plug should be on the top side at about 10:00 o’clock.

b. Place an empty container under drain port and remove plug allowing excess oil to drain into container.

NOTE: Total volume for the 215SR swing reduction unit is 3.0 L (0.8 gal).

A

c. Replace plug and tighten securely after all oil is drained. d. Fill through fill port using proper oil. e. Recheck oil level and make sure it is within specifications.

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

DC03N026

Figure 67

2. Stop engine and remove the travel motor reduction unit oil LEVEL plug (A). If oil just seeps from the port, oil level is correct.

TRAVEL MOTORS REDUCTION UNIT OIL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then, check every 250 hours.

WARNING: Reduction unit may be under pressure. Remove plug slowly.

3. To add oil, add oil in the FILL/LEVEL port until it just begins to flow out of the port.

4. Use teflon tape on the plug for better sealing.

Install plug and tighten securely.

NOTE: Capacity of 215SR Travel Reduction Unit is 5.3 liter (1.4 gal).

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

NOTE: Perform all pre-start (every 8 Hour and 50 Hour) inspection & maintenance procedures along with the 250 Hour inspection & maintenance procedures.

ENGINE ACCESSORY BELT WEAR AND TENSION Inspect belts and tensioner assembly on a new machine after the first 50 hours of engine operation.

Then, every 250 hours.

With the engine off, measure belt tension on longest span of belt. Apply a 10 kgf·m (72 lbf-ft) on the belts and measure the belt deflection and compare to the Belt Deflection table.

2

1

4 3 Figure 68

BS06H111

1. ALTERNATOR/FAN BELT 2. IDLER PULLEY

3. CRANK PULLEY 4. A/C COMPRESSOR BELT

Belt tension on the Alternator and Fan belt is 98 N (22 lbf), and 28 N (6.3 lbf) on the Air Conditioner belt.

Measure the belt deflection and compare to the Belt Deflection table.

BELT

DEFLECTION

Alternator/Fan

8 mm ~ 10 mm (0.31” ~ 0.39”)

Air Conditioner

6 mm ~ 7 mm (0.24”~0.28”)

1. Fan Belt Check fan belt for excessive wear and cracks and replace them if needed.

When replacing the Alternator/Fan belt, replace both.

2. Air Conditioning Compressor Belt Check belt for excessive wear and cracks and replace as needed. To adjust the AC compressor belt, proceed as follows:

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2

1

3 1 Figure 70

BD06H019

1. COVER

Figure 69

BS06M391

1. IDLER PULLEY 3. A/C COMPRESSOR 2. ADJUSTING BOLT

a. After adjustment, start engine and run it at low idle for about 5 minutes with AC turned ON. Then recheck belt tension.

1

CLIMATIZER - AC UNIT FILTER INSPECTION Inspect the fresh air filter every 250 hours of engine operation and the recirculate air filter every 500 hours of engine operation.

NOTE:

• If the working environment is extremely dusty, it

2

is recommended to reduce the inspection schedule to at least half of the above specified working hours.

• The fresh air filter is a paper filter. DO NOT WASH. Wear safety glasses. Clean with air only below 40 psi. Do not clean more than 10 times or replace it every 2 years.

• Wear safety glasses. Clean the recirculate air filter with compressed air or by washing and rinsing.

• Do not wash the recirculate air filter with any organic solvent, such as: gasoline, paint thinner, etc.

Removing the Climatizer - AC unit filters:

1. RECIRCULATE AIR FILTER

2. FRESH AIR FILTER

b. With handle remove the fresh air filter (2) for inspection and cleaning or replacement. c. After cleaning or replacement, use this procedure in reverse for assembling.

2. Recirculate Air Filter a. Move floor mat on left front side of operator seat. b. Pull out recirculating air filter.

1. Fresh Air Filter a. Remove cover on the left rear side of operator seat and pull up.

87722039NA

Figure 71

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Issued 10-07

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c. After cleaning or replacement, use this procedure in reverse for assembling.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE RADIATOR CAP & HOSES Inspect the radiator cap and hoses every 250 hours of engine operation.

1

2

1. RADIATOR DRAIN VALVE

3 Figure 72

BS06H205

1. RADIATOR HOSE CLAMP 2. RADIATOR CAP

Figure 74

BS06H209

1

3. RADIATOR HOSE

1. Stop the engine. Raise the engine cover and secure it open.

2. Check the hoses for leakage due to loose clamps, or crack and worn hoses.

3. Tighten any loose clamps.

4. Should you need to replace any cracked or worn hoses, proceed as follows: WARNING: Use extreme caution when removing the radiator cap. The coolant is under high pressure when hot. Never remove the radiator cap when system is hot. Allow sufficient time for machine to cool down. a. Place a rag or paper towel on the radiator cap and slowly remove it to release the pressure.

c. Place an empty clean container under the radiator drain hose. Do not contaminate coolant mixture drained, since it can be reused. d. Turn drain valve counter clockwise to drain coolant. e. Loosen the hose clamp and remove radiator hose. f. Clean the areas where the new hose will be connected. g. Remove the clamps (if reusing old clamps) from the old hose and install them to the new hose. h. Coat the inside ends of the new radiator hose with grease and install it. Tighten clamps properly. i. Fill radiator with coolant drained in step “c” if reusing old coolant mixture. j. Install radiator cap, start engine, and bring engine temperature to about 90°C (194°F). k. Run engine at low idle, check for leakages and repair as needed. l. Install radiator lower cover and close engine cover.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

1

5. Inspect radiator cap for proper operation and replace if needed.

Figure 73

BS06H209

1. RADIATOR LOWER HOSE

b. Locate the radiator lower cover. Remove bolts and cover to obtain access to the radiator drain hose and lower hose.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE: FUEL FILTERS NOTE: To replace the fuel filter and fuel pre-filter, perform the following instructions with the engine off.

1. Replacing Fuel Filter a. Place an empty container below fuel filters.

q. Lubricate O-ring for fuel filter bowl and attach to new fuel filter. r. Lubricate the O-ring seal with diesel fuel and install filter by hand (do not use wrench), and tighten 3/4 ~ 1 turn after the O-ring seal has made contact with support mount surface. s. Open fuel shutoff valve. t. Open air bleeder plug on top of filter support housing and use primer pump to fill filter with clean fuel.

1

WARNING: Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

2

Figure 75

BS06H084

1. FUEL FILTER

2. FUEL SHUTOFF

b. Close fuel shutoff valve. m.Use a filter wrench and turn counter clockwise to remove the fuel filter. n. Remove O-ring seal from the filter support mount.

2 1 2 3 Figure 76

BS06H086

1. FUEL FILTER 2. O-RING

3. FUEL FILTER BOWL

o. Remove fuel filter bowl from bottom of filter. p. With a clean, dry cloth, clean the filter support mount surface.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Bleeding Air From Fuel System If air contaminates the fuel system, the engine may become hard to start or malfunction. Bleed the air whenever the water separator is drained, or the fuel filter elements are replaced.

2

CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS Change the travel reduction units oil on a new machine after the first 500 hours of engine operation.

Then change every 2000 hours.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

4

WARNING: Never change oil or filters on a machine that has just finished working. Allow sufficient time for the machine to cool down before performing any maintenance.

1

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

3 1 2 Figure 77

BS06H087

1. FUEL FILTER 2. PRIMING PUMP

3. DRAIN VALVE 4. AIR PLUG

a. Loosen the air plug located on top of the fuel filter support mount.

3

b. Push button by hand to supply fuel until air bubbles stop coming out of the air plug.

Figure 78

DC03N026

NOTE: Use paper towel or rags to contain any fuel spill. c. Tighten the air plug when no more bubbles are present.

1. FILL PLUG 2. LEVEL PLUG

3. DRAIN PLUG

d. Continue pumping even after tightening the air plug. Stop pumping with the handle in the lower position and tighten the knob completely.

1. Move machine to a firm, level surface. Operate travel until “DRAIN” plug is positioned at 6:00 o’clock. Oil “FILL” plug should be on the top side at about 12:00 o’clock. Oil LEVEL plug should be at 3:00 o’clock.

NOTE: The air in the injection pump will automatically be forced out when the engine starts.

2. Stop engine and place an empty container under the drain plug.

e. Run engine at low idle for 5 minutes to check and make sure there is no fuel leakage.

3. Remove oil FILL, LEVEL, and DRAIN plugs to drain oil into the container.

WARNING: Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations.

4. After oil has been drained out completely, clean “DRAIN” plug. Use teflon tape on “DRAIN” plug for additional sealing and install plug. Tighten securely.

5. Add engine oil through the oil “FILL” opening until oil starts flowing out of the LEVEL port.

6. Clean oil FILL plug. Use teflon tape on plug for additional sealing and install plug. Tighten plug securely.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION UNIT CAPACITY 215SR: 5.3 liters (1.4 gal) CHANGE OIL IN SWING REDUCTION UNIT

1

Change the Swing Reduction Unit oil on a new machine after the first 500 hours of engine operation.

Then, change every 2000 hours.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

WARNING: Never change oil or filters on a machine that has just finished working. Allow sufficient time for the machine to cool down before performing any maintenance.

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

Figure 80

DC04C333

1. DIPSTICK

4. Remove the dipstick and fill the unit with oil.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper capacities and oil specifications.

1. Move machine to a firm, level surface and place attachment on the ground. Stop the engine.

1

Figure 79

DC04C338

1. DRAIN PORT

2. Locate drain port under the center opening of the lower frame. Place an empty container under drain port and remove plug allowing oil to drain into container 3. Clean the drain plug. Use teflon tape on plug for additional sealing and install it. Tighten securely.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Swing Reduction Unit Capacity 215SR: 21.5 liters (5.7 gal) WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

WARNING: Never change oil or filters on a machine that has just finished working. Allow sufficient time for the machine to cool down before performing any maintenance.

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

Figure 83

DC04C386

3. Remove the fuel tank strainer and clean it.

Replace the strainer if it is damaged.

4. Install fuel tank strainer and use the key switch to install the cap.

CHECKING THE ENGINE RPM

DC04C337

Figure 81

5. Using the dipstick, confirm that the oil level is within the designated range.

6. Clean the fill plug. Use teflon tape on plug for additional sealing and install it. Tighten securely.

CHECKING AND CLEANING FUEL TANK AND STRAINER

Figure 84

BS06H082

1. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system by pressing the switch located on the monitor.

2. Keep others clear of machine. Start the engine and set the engine to the High Idle position.

DC04C387

Figure 82

1. Stop the engine. Use key switch and remove the fuel tank cap.

Figure 85

DC04C398

2. Check the cap seal and replace it if needed.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Press the Monitor’s display screen change switch ONCE to switch to the Tachometer Mode display.

4. Compare RPM value displayed on the LCD to the machine specifications. If RPM value differs from specification, contact your Kobelco Construction Dealer’s Service Department for assistance.

NOTE: See SPECIFICATIONS Section for proper engine RPM specifications.

CHECKING THE AIR CONDITIONING REFRIGERANT 1. Keep others clear of machine. Start the engine.

2. Set the engine speed to the Middle speed position.

4

3

Figure 87

DC04C383

4. Check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver-dryer.

1

1

2 Figure 86

DC04C384

1. TEMPERATURE SETTING SWITCH 2. MAIN POWER SWITCH 3. COMPRESSOR SWITCH 4. AIR CAPACITY SELECTOR SWITCH

3. Set machine to the conditions shown when checking the refrigerant.

• Air Conditioner ---------- ON • Fan Switch --------------- HI position (Max.) • Temp. Adjustment Switch -- Lower Temp • Door/window ------------ Close • Compressor Switch --- ON (The lamp lit up)

Figure 88

GRAPHIC1

1. SIGHT GLASS

a. Figure (A) shows that the refrigerant volume is proper. b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system. c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your Kobelco Construction Dealer.

NOTE:

• New Refrigerant HFC-134a is used in this machine. Do not mix HFC-134a with CFC-12.

• Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

• Air Conditioning Unit should only be serviced by a qualified technician.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE ENGINE VALVE CLEARANCE

2. Remove air cleaner cover.

Check and adjust the engine valve clearance every 1000 hours of the engine operation. Contact your Kobelco Construction Dealer’s Service Department for assistance.

2 1

AIR CLEANER

Figure 91

DC04C289

1. AIR CLEANER OUTER ELEMENT 2. AIR CLEANER INNER ELEMENT

3. Remove the air cleaner outer element from the housing.

4. Remove the air cleaner inner element from the housing.

Figure 89

DC04C288

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

]

1. Stop the engine. Open engine air cleaner access door. If door is locked use key switch key to unlock it.2. Loosen wing bolts and open the air cleaner access door.

Figure 92

DC04C291

5. To clean the outer element, use compressed air less than 0.2 MPa (29 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

1

WARNING: Wear protective glasses goggles when using compressed air.

Figure 90

BD06H021

1. AIR CLEANER COVER

or

6. After cleaning, use light to check the inside of the element for tearing, pinholes, or cracking.

Replace with new element if necessary.

7. Assemble elements in the reverse order of disassembly.

IMPORTANT: Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element. Failure to do so could cause engine failure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 1000 hours.

NOTE: If Breaker is used replace return filter every 250 hours.

1 Figure 95

DC04B340

1. MOUNTING BOLTS

IMPORTANT: Slowly remove the mounting bolts. The filter cover plate is under spring tension.

Figure 93

DC04B674

3. Remove the six mounting bolts from the hydraulic return cover plate.

1. Place the machine in the oil check position on a firm level surface.

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic components.

1 2

4

5 3 3 6

1 2 Figure 96

BS06H083

Figure 94

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

2. Stop the engine. Depress air release button to release hydraulic tank pressure.

1. BOLT 2. COVER PLATE 3. O-RING 4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

4. Remove O-ring, Spring, Bypass Valve, and Return Filter.

5. Install the new Return filter.

6. Install the Bypass Valve and spring.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 7. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install the O-ring.

8. Install Cover Plate, Bolts, and Lock Washers.

Tighten the Bolts to torque Specification.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE ENGINE COOLANT CHANGE WARNING: Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

Allow sufficient time for the engine to cool down before changing fluids.

1 Figure 99

DC04C317

1. RADIATOR LOWER ACCESS COVER

3. Locate the lower cover beneath the radiator.

Figure 97

DC04B674

1. Move the machine to a firm level area and place the attachment on the ground and shut off the engine.

1 WARNING: Use extreme caution when removing the radiator cap. The coolant is under pressure when hot. Never remove the radiator cap when system is hot. allow sufficient time for machine to cool down.

Figure 100

BS06H209

1. RADIATOR DRAIN VALVE

4. Remove cover to obtain access to the radiator drain hose. Place an empty container, with sufficient capacity for engine coolant, below the radiator drain hose. Turn valve counter clockwise to open drain.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

5. Remove the engine lower covers.

1

6. Locate the engine coolant drain plug on the left side of the engine block. Remove it to drain coolant. Use a funnel with hose attached to direct the drained coolant toward the container.

Figure 98

BS06H205

1. RADIATOR CAP

7. After draining, close the drain valve and install the drain plug. Fill cooling system with fresh water, preferable with hot water.

2. Stop the engine. Raise the engine cover, secure it open, and place a rag or paper towel on the radiator cap. Slowly remove the cap. The system could be under pressure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

• Change contaminated and foamy coolant with new coolant mixture as soon as possible.

• Cooling water other than long life coolant should be changed two times a year, in Autumn and Spring.

16. Install radiator cap. Start engine and run it at low idle for 5 minutes. Check and make sure there is no leakage.

17. Install engine and radiator lower covers. See Specification section for proper torque values.

Figure 101

BS06H082

18. Repeat steps 8, start the engine and run engine at high idle for 5 minutes to bleed out any air from the cooling system.

8. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system by pressing the switch located on the lower side of monitor.

1

9. Keep others away from the machine. Start the engine and bring engine cooling temperature to about 90°C (194°F). Then run engine at low idle.

Remove engine drain plug, open radiator drain plug, and simultaneously feed fresh water into radiator until draining water comes out clear (about 10 minutes flushing is sufficient).

10. When flushing is completed, stop engine and also stop water feeding. Drain engine cooling system completely. Close drain valve and install drain plug.

11. Prepare a mixture of radiator detergent according to the manufacturing specs. and pour the solution into the radiator.

12. Repeat step 8 and start the engine, but run it at low idle for 30 minutes before draining and flushing.

13. After flushing is completed, use teflon tape on the engine drain plug for additional sealing.

Install plug and tighten securely.

14. Close the radiator drain valve.

15. Add a mixture of engine coolant according to specifications indicated in the ENGINE C O O L A N T M I X T U R E t a b l e . R e fe r t o LUBRICATION, FILTERS, AND FLUIDS section for proper system capacity.

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

Figure 102

BS06H211

1. ENGINE COOLANT RESERVOIR

19. Return throttle to low idle and stop engine. Wait about 3 minutes and check engine coolant reservoir for proper level.

CHANGE HYDRAULIC OIL NOTE: The following procedures are to be used for a normal oil change for the hydraulic tank oil only.

NOTE: If it is necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure, or change main pump, contact an authorized Kobelco Construction Dealer’s Service Department for assistance.

WARNING: Be cautious of hot fluids, and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

Allow hydraulic oil to cool before changing.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. Move the attachment control levers several times.

1 2

Figure 103

DC04B674

1. Move the machine to a firm, level surface with the attachment in the hydraulic oil check position.

Lower the attachment to the ground.

NOTE: Warm up hydraulic system before changing hydraulic oil.

2. Shut off the engine.

Figure 106

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

6. Depress air release button to release hydraulic tank pressure.

3. Turn the key switch to the ON position.

CAUTION: DO NOT START THE ENGINE.

1 Figure 104

DC04A001

1. FUNCTION CANCELLATION LEVER

4. Make sure the function cancellation lever is in the unlock (down) position.

Figure 105

BS06H208

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING SUCTION STRAINER

1 1

3 2 4 5

Figure 107

DC04B340

1. MOUNTING BOLTS

6

7. Slowly remove the six retaining bolts from the suction strainer cover plate.

Figure 108

DC04C376

1. BOLT 2. LOCK WASHER 3. COVER

8. Remove cover, hydraulic tank.

4. O-RING 5. SUCTION STRAINER 6. STRAINER O-RING

O-ring,

and

strainer

from

9. Remove the O-ring from the bottom of the strainer.

1 3

2 Figure 109

DC04C375

1. HYDRAULIC TANK 2. SUCTION TUBE

3. SPECIAL SUCTION STOPPER

10. Install special suction stopper over suction tube inside hydraulic tank.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 19. Clean and inspect suction strainer for damage.

Replace strainer if needed.

1

3 2 4

1

5 Figure 110

DC04C374

1. DRAIN PLUG

11. Place a 126 liter (33 gal) empty container under the hydraulic tank drain plug. Remove plug and allow all oil from hydraulic tank to drain into container.

6

12. Remove return filters. See Figure 96, page 6-39.

13. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank.

1. BOLT 2. LOCK WASHER 3. COVER

14. Install hydraulic tank drain plug and tighten securely.

15. Inspect return filter and oil for signs of abnormal wear.

16. Clean hydraulic tank covers, spring, and bypass valve.

17. Install new return filter elements along with the bypass valve and spring. See Figure 96, page 6-39.

Figure 112

DC04C376

4. O-RING 5. SUCTION STRAINER 6. STRAINER O-RING

20. Install a new O-ring seal on the strainer.

Lubricate seal with hydraulic oil and install strainer assembly onto suction tube.

21. Install a new O-ring on cover plate mount surface groove, lubricate seal with hydraulic oil.

NOTE: Make sure to install the correct filter element for a Standard Excavator and for an Excavator with Nibbler & Breaker attachment. Check Parts Catalog.

18. Remove the special suction stopper from suction tube. See Figure 110.

DC04C297

Figure 113

22. Fill hydraulic tank to proper level with fresh clean hydraulic oil through strainer cavity.

23. Install suction strainer cover. Tighten the bolts.

Refer to SPECIFICATIONS Section in this manual for proper torque values.

Figure 111

DC04C373

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 24. Install new O-ring seal, lubricate it with hydraulic oil and install cover for hydraulic tank return filter e l e m e n t . T i g h t e n t h e b o l t s . R e fe r t o SPECIFICATIONS section in this manual for proper torque values.

1

CAUTION: Use the same viscosity oil in the hydraulic tank as it was drained. Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper hydraulic oil.

CAUTION: Always use clean hydraulic oil. Avoid contamination during filling.

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

Figure 115

DC04A037

1. PILOT SYSTEM FILTER

2. Open side door on pump side of machine.

PILOT LINE FILTER

3. Remove hose from pilot line filter.

Clean the pilot system filter/screen on a new machine after the first 50 hours of engine operations.

Then clean it every 2000 hours.

WARNING: Never change oils or filters on a machine that has just stopped working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic components.

4. Clean filter with light oil.

5. Re-connect pilot line filter.

HYDRAULIC TANK BREATHER

1 2 Figure 116

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1 2 Figure 114

DC04B339

1. Remove cap of the hydraulic tank breather and depress air release button to release hydraulic tank pressure.

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1. Depress air release button to release hydraulic tank pressure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

2

3 4 5 6 Figure 117

DC04C372

1. CAP 2. SEAL

3. COVER 4. FILTER

Figure 119

DC04C370

4. Remove idlers and remove side plugs from idler housing. Drain the oil out into an empty container.

5. VALVE BODY 6. GASKET

2. Remove breather filter cover.

3. Remove old filter. Clean mounting surfaces and install new filter.

NOTE: Refer to the Parts Catalog for the correct Filter Part Number.

4. Install breather filter cover.

5. Refill the upper rollers, track rollers, and idlers with clean oil and install the plugs.

6. Install rollers and idlers and torque properly.

Refer to SPECIFICATIONS Section for proper torque values.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper oil and capacity information.

5. Install cap and tighten securely.

MAINTENANCE ON ROLLERS AND IDLERS

WARNING: Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations.

Change the oil in all rollers and idlers every 2000 hours of machine operation.

NOTE: Refer to the machine’s Service Manual for specific instruction regarding removing and installing the undercarriage rollers and idlers. Contact your Kobelco Construction dealer’s Service Department for assistance if necessary.

CHANGE SWING RING BATH GREASE

1

Figure 120

DC04C369

1. SWING RING BATH GREASE Figure 118

DC04C371

1. Remove rollers and idlers as indicated in the Service Manual.

2. Remove side plugs from upper rollers cover plate and drain the oil into an empty container.

3. Remove plugs from track rollers center flanges and drain the oil into an empty container.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Change the Swing Ring grease every 2000 hours of machine operation. To properly replace the grease, it is necessary to remove the upper frame. Refer to the Service Manual or Machine’s Shop Manual and/or contact your Kobelco Construction Dealer’s Service Department for assistance. Proper tools have to be used and specific instructions must be followed to disassemble the machine upper structure from the lower structure.

IMPORTANT: If the Swing Ring ever becomes submerged in water, it is mandatory that the swing ring grease be changed.

REFER TO LUBRICATION, FILTERS, AND FLUIDS SECTION FOR PROPER GREASE AND CAPACITY INFORMATION If the machine is in the field and can’t be brought to a shop to replace the Swing Ring grease, proceed to remove the swing motor assembly. Use eye bolts on top cover of the swing motor and a proper lifting device to remove the Swing Motor Assembly. Use proper caps and plugs for lines and hoses that need to be removed during this process.

WARNING: Lower and block attachment properly before removing swing motor reduction unit.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

PERIODICAL INSPECTION ITEMS DUST SEALS

Inspect dust seals in all pin connections frequently.

The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

7

1

6

8

5

9

2

4

3 Figure 121

DC04C367

1. BOOM FOOT DUST SEALS (2 PCS) 2. ARM TO BOOM DUST SEALS (2 PCS) 3. ARM TO IDLER LINK DUST SEALS (2 PCS) 4. BUCKET CYLINDER TO BUCKET LINK DUST SEALS (4 PCS) 5. ARM TO BUCKET DUST SEALS (2 PCS)

6. BOOM CYLINDER HEAD DUST SEALS (2 PCS) 7. BOOM CYLINDER ROD DUST SEALS (2 PCS) 8. ARM CYLINDER HEAD AND ROD DUST SEALS (4 PCS) 9. BUCKET LINK (AT BUCKET) DUST SEALS (2 PCS)

NOTE: Refer to the Parts Catalog for replacement Dust Seals Part Number.

3 If excessive wear is found, refer to the Machine’s Shop Manual or Ser vice Manual fo r spec ific instructions in regards to disassembly and assembly.

Contact your Kobelco Construction Dealer’s Service Department for assistance if necessary.

1

2 Figure 122

DC04C366

1. DUST SEAL

2. BUSHING

3. BOSS

Install the seals as shown. Make certain that the pin surface and tapered end are smooth and free from burrs or imperfections that could cause damage to the new seals.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BUCKET WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

1. Bucket, Arm, & Link Clearance Frequently check clearance between Bucket and Bucket Link and/or between Arm and Bucket to make sure it is within specifications. If clearance is greater than 1.2 mm (0.05”) adjust clearance. Proceed as follows to correct excessive play:

Figure 125

DC03K235

NOTE: You may have to start the engine and operate the boom and arm slightly to remove the load from pins. d. Carefully slide out, partially, main mounting arm and bucket link to bucket.

pins

e. Insert shims as needed to correct any excessive play. Refer to Parts Catalog for proper Part Numbers. f. Align the shims with pin holes and insert pins into position. Be careful not to damage the seals.

Figure 123

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

2 1 Figure 126

DC04C364

2 1

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

g. Install retaining bolt with nut and jam nut.

Figure 124

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nut, nuts, and retaining bolt.

6-50

h. Roll O-ring onto the grooves between Bucket/Arm, and Bucket/Bucket Link.

NOTE: Inspect O-rings for damage or excessive wear. If worn or damaged replace with new parts to protect the seals, pins, and surfaces from dirt and debris which can cause premature failure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Reversing Bucket

Figure 129

DC03K232

Figure 127

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

f. Rotate bucket 180° or move machine.

1 2

2 1

Figure 130

1. ARM PIN FOR FRONT BUCKET OPERATION 2. ARM PIN FOR BACK HOE BUCKET OPERATION Figure 128

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nuts, nuts and retaining bolts from both pins. d. Carefully slide out main pins mounting arm and bucket link to bucket.

NOTE: You may have to start the engine and operate the boom and arm slightly to remove load from pins. e. Clean pins and pin holes, and apply grease on pins and holes surfaces.

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WARNING: Do Not use fingers to align pin holes. Fingers could be cut off. Follow instructions provided. g. Install arm and bucket link in their respective positions. h. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage the seals. i. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin. Be careful not to damage the seals.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Removing the Bucket

2 1 Figure 131

DC04C364

Figure 133

DC04C363

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

j. Install retaining bolts with nuts and jam nuts on both pins.

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

k. Roll O-rings onto grooves between bucket/arm, and bucket/bucket cylinder link.

IMPORTANT: Slowly cycle bucket, check for interference with arm, particularly if a lifting eye is welded on bucket bottom. Be careful not to confuse the bucket shoveling operation with that of the backhoe.

2 1 Figure 134

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, RETAINING NUT, & JAM NUT

b. Roll O-rings onto bucket bosses. c. Remove jam nuts, retaining bolts.

BS06H081

retaining

nuts,

and

Figure 132

WARNING: Bucket can contact and damage cab when machine is equipped with certain attachments.

Check clearance between bucket and cab before operation. Exercise care when operating a bucket near cab.

Figure 135

DC03K235

NOTE: You may have to start the engine and operate the boom and arm slightly to remove load from pins.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS d. Carefully remove main pins mounting arm and bucket link to bucket. Be careful not to damage the dust seals.

4. Installing the Bucket a. Make certain that the bucket is stable on firm level ground. b. Install O-rings onto bucket bosses. c. Clean pins and pin holes, and apply grease on pin and holes surfaces.

1

f. Install retaining bolts with nuts and jam nuts on both pins, leaving 1 mm gap between the nut and pin boss. g. Roll O-rings onto grooves between bucket/arm and bucket/bucket link. h. Apply sufficient grease to the bucket pin connections.

5. Bucket Teeth and Side Cutters Frequently, check bucket tooth points and side cutters for wear and looseness. The life of the bucket teeth and side cutters can not be determined by wor king hours, but rather by application and operating conditions.

WARNING: Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. a. Parts Description.

Figure 136

DC04C361

6

1

1. BUCKET LINK

WARNING: Do Not use fingers to align pin holes. Fingers could be cut off. Follow instructions provided. d. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage seals.

4

7

3 2

5

Figure 138

DC03K237

1

1. ADAPTER NOSE 2. TOOTH POINT 3. RUBBER LOCK PIN 4. LOCKING PIN

5. SIDE CUTTER 6. CAP SCREW 7. NUT

NOTE: Contact your Kobelco Construction Dealer for assistance in regards to parts for the specific bucket installed on your machine.

3

2 Figure 137

DC03K236

1. ARM 2. BUCKET 3. PIN

e. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin carefully to avoid damaging the seals.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS b. Replace the bucket teeth when their cutting edge and/or when hole for retaining pin on tooth are excessively worn.

1

Figure 140

DC03K239

c.1 - Remove all sand and soil adhered around the side cutters capscrews.

Figure 139

DC03K238

c.2 - Use an impact wrench to remove the capscrews, then remove the side cutters.

1. WOOD BLOCK

b.1 - Place a wood block under the bucket teeth support lip and remove all sand and soil adhered to the teeth pin connection areas.

WARNING: Do not strike teeth with hammer.

This can cause chips to fly causing injury. b.2 - Use a hammer and a punching tool to hammer out the locking pin. Be careful not to damage the rubber lock pin. b.3 - Inspect the locking pin and rubber lock pin. Replace them if the locking pin is too shor t or the rubber lock pin is in poor condition. b.4 - Clean the surface of the adapter nose with putty knife.

Figure 141

DC03K240

c.3 - Clean the mounting surface and install a new side cutter with new cap screws and nuts. c.4 - Torque the cap screws with nuts to 100 ± 5 kgf·m (722 ± 36 ft-lbs).

b.5 - Fit tooth point onto adapter nose. b.6 - Push the rubber lock pin into the hole of the adapter nose. b.7 - Hammer the locking pin until it is aligned with the point surface. c. Replacing the side cutters.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WINDSHIELD WASHER FLUID RESERVOIR

HYDRAULIC LINES, TUBES, AND HOSES

Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

S i n c e t h e r e i s n o d e f i n i t e t i m e t a bl e fo r t h e replacement of hydraulic lines, tubes, and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes, and hoses with new parts. Refer to the Parts Catalog for correct part numbers. when ordering.

1

WARNING:

Figure 142

BS06H101

1. WINDSHIELD WASHER FLUID RESERVOIR

1. The windshield washer fluid reservoir is located in back of floor plate under the floor mat.

2. Pull cap off and fill with proper windshield washer fluid.

3. Replace cap and reposition engine air cleaner access door.

Do not bend, strike or damage high pressure lines. Do not install bent or damaged lines, tubes, or hoses.

Replace all damaged lines, tubes, and hoses immediately to avoid any fire hazard.

Tighten all loose fittings and connections to the proper torque value.

Clean up all fuel and oil spills immediately to prevent fires, slipping, accidents, attachment dropping, etc.

Never use hands to check for leaks.

Carefully inspect all lines, tubes, and hoses for: 1. Fittings and connections damaged or leaking.

2. Outer covering of hoses worn, cut or damaged exposing wire reinforcement.

3. Hose swelling or “ballooning”.

4. Evidence of hose being kinked or collapsed.

5. Steel protective covering worn or damaged.

6. Loose fittings and connections.

Make certain all clamps, guards, and heat shields are in place and secured. This will help prevent vibration, excessive wear of components and excessive heat during operation.

1. Heater Hoses Inspect the heater hose between heater and engine for signs of damage and wear.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Boom Cylinder Hoses and Tubes

1. BUCKET CYLINDER TUBE & HOSES 2. NIBBLER/BREAKER TUBE & HOSES

Inspect bucket cylinder head and rod hoses and tubes for damage, wear and loose connections.

Inspect also the Nibbler/Breaker tubes and hoses if equipped.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

1

6. Hydraulic Suction Tubes and Hoses Figure 143

DC04C359

1. BOOM CYLINDER HOSES

Inspect boom cylinder head and rod hoses and tubes for damage, wear and loose connections

Inspect all hydraulic tubes and hoses for damage, wear and loose connections.

7. Rear View Mirrors.

3. Arm Cylinder Hoses and Tubes

1

Figure 144

DC04C358

1. ARM CYLINDER TUBE & HOSES

Inspect arm cylinder head and rod hoses and tubes for damage, wear and loose connections.

Figure 146

DC04A040

Inspect the rear view mirror. Make certain both sides rear view mirrors and internal rear view mirror are in place, proper ly adjusted, clean, and in good condition. If loose tighten the mounting hardware.

4. Bucket Cylinder and Nibbler/Breaker Hoses & Tubes

1

2 DC04C357

6-56

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE FOR NIBBLER/BREAKER It is necessary to perform the following maintenance schedule in regard to Hydraulic Oil and Filters along with the normal inspection and maintenance.

2. Depress air release button to release hydraulic tank pressure.

REPLACEMENT SCHEDULE Item

1st 2nd Regular Maintenance Maintenance Maintenance

Location

Hyd. Oil Hyd. Tank

-

-

Every 600 Hours

Return Hyd. Tank Filter

50 Hours

250 Hours

Every 250 Hours

WARNING: Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic components.

1 Figure 149

DC04B340

1. COVER MOUNTING BOLTS

WARNING: Slowly remove the mounting bolts. The filter cover plate is under spring tension.

3. Remove the six mounting bolts from the hydraulic return cover plate.

1

4

2

5 Figure 147

DC04B674

1. Move machine to firm level ground and place attachment in oil level check position.

3 3

6

Figure 150

BS06H083

1. CAP SCREW 2. COVER PLATE 3. O-RING

1

4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

Figure 148

DC04B339

1. AIR RELEASE BUTTON

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

4. Remove O-ring, spring, bypass valve, and return filter.

IMPORTANT: Make sure to use the correct return filter on machine using breaker. Refer to Parts Manual for correct part number when ordering parts.

5. Install the new return filter.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Install the bypass valve and spring.

7. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install O-ring.

8. Install cover plate, cap screws, and lock washers.

Tighten the cap screws to torque specification.

SPECIAL PROCEDURES GENERAL

B. Procedures

The 215SR machine incorporate automatically applied spring brake systems in the travel motors and swing motor. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine. These sections contain the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachments to the ground should sudden engine failure be experienced.

WARNING: Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection, maintenance, or repairs of this machine, attachment or any of its system.

WARNING: The procedures found in this section should be performed by a well trained experienced service technician who is familiar with machine.

1

1

Figure 151

DC04C354

1. CHOCK BLOCK

1. Position travel motors with drain plug down and l o w e r a t t a c h m e n t t o g r o u n d . R e fe r t o LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS in this section for proper procedures.

2. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

RELEASING TRAVEL MOTOR BRAKES MANUALLY A. Tools & Equipment Required 1. Four (4) chock blocks.

2. One (1) 14 mm Allen type socket wrench.

3. One (1) 8 mm Allen type socket wrench.

4. Two (2) 10.5 liter (2.8 gal) capacity drain pans.

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.

3. Turn key switch to OFF position and remove key.

4. Place a clean 10.5 liter (2.8 Gal) capacity drain pan under each travel motor drain plug.

5. Two (2) M10-1.5x30mm lifting eyes.

6. Two (2) M12-1.75x20mm Lifting eyes.

7. Overhead lifting device capable of lifting and holding 45 kg (100 lbs).

8. Torque wrench 10~16 kgf·m (72~116 ft-lbs) capacity or better.

9. Thread sealant (for drain and check/fill plugs), and loctite #515 for cover bolts.

10. Rubber or soft face mallet.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

• Install two (2) M10-1.5x30mm lift eyes into the threaded holes provided.

• Attach a lifting device to the lift eyes and remove slack from the chain or cable.

• Remove the two cover bolts. Use a rubber

A

mallet to strike the edge of the cover plate gently to help releasing it from the housing, until oil starts draining.

B

6. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine.

7. Remove the bolts holding the Reduction Unit cover and remove the cover. Be careful not to damage the cover plate seal or its surface lip.

Figure 152

DC03N026

5. Remove oil “FILL” and “DRAIN” plugs (A and B) to drain oil into the container.

1

4

WARNING: Reduction unit may be under pressure. Remove plugs slowly.

NOTE: If the Reduction Unit drain plug is not at its lowest point (6:00 o’clock) for draining, drain as much oil as possible through the plug orifices, then:

2

3

5 Figure 155

DC03M071

1. CARRIER #2 2. SUN GEAR #2 3. SUN GEAR #1

4. CARRIER #1 5. THRUST PLATE

8. Identify the internal parts of the Travel Reduction Unit.

Figure 153

DC04C353

• Loosen all cover bolts. Remove all but the top two bolts leaving them installed half way to keep the cover in place.

1 Figure 156

DC04C351

1. THRUST PLATE

9. Use the tip of a screw driver and remove the thrust plate.

Figure 154

DC04C352

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

1 2 Figure 157

DC04C350

Figure 160

DC04C347

1. CARRIER #1

1. SUN GEAR #1

10. Install the M10 eye bolt onto the Carrier #1 assembly and use the crane or lifting device hook on the eye bolt to pull out the carrier.

Remove most of the slack from the cable or chain. Work the carrier by hand to remove it.

2. CARRIER #1

If the Sun Gear can not be removed due to the loaded condition, remove it together with Carrier # 1.

Then remove the Sun Gear # 2 and Sun Gear # 1 respectively.

IMPORTANT: Protect your hands from pinching at all times when removing or installing planetary gears.

1

1

Figure 161

DC04C346

2

1. SUN GEAR COUPLING

Figure 158

DC04C349

1. SUN GEAR #1

2. SUN GEAR #2

11. Remove the Sun Gear #1.

1

1 Figure 162

DC04C345

1. SUN GEAR # 2

2 Figure 159

DC04C348

1. SUN GEAR #2

6-60

12. Make sure the gear coupling for Sun Gear # 1 and Sun Gear # 2 are properly installed

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 13. Reinstall Carrier # 1 assembly (DO NOT INSTALL SUN GEAR # 1) into reduction unit.

Remove the special eye bolt from the carrier assembly. Use plenty of grease on the thrust plate to hold it in place during assembly.

14. Install the cover plate onto reduction unit housing and tighten all bolts securely.

15. Install drain plug and refill reduction unit with drained oil.

16. Install the fill/level plugs.

17. Repeat steps 4~16 on the opposite travel reduction unit to prepare machine for towing.

18. After all repairs are made, reinstall Sun Gear # 1 on both reduction units in reverse order of r e m o v a l . U s e f r e s h g e a r o i l . R e fe r t o LUBRICATION, FILTER, AND FLUIDS Chapter 5 for Oil specifications and Capacities.

1 Figure 163

DC04C344

1. ENGINE EMERGENCY STOP CONTROL

1. Locate the engine emergency stop control at the lower RH corner of the seat base and pull control out.

NOTE: 1. Apply loctite 515 on cover bolts and torque to 7.5 kgf·m (54 lbf-ft).

2. Use teflon tape on plugs and torque to 16 kgf·m (116 ft-lbs).

IMPORTANT: Avoid oil spills. Use containers, rags, and/or paper towel to contain any leakage. Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to government regulations.

LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS S h o u l d s u d d e n e n g i n e fa i l u r e o c c u r, fo l l o w procedures to place the attachment on the ground.

NOTE: Rotation of the engine with the starter motor is necessary in order to lower the attachment to the ground. If rotation of the engine is not possible, contact an authorized Kobelco Construction service technician for service and assistance.

WARNING: Make certain the area around the machine is clear of people and objects before attempting these procedures.

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1 Figure 164

DC04A001

1. FUNCTION CANCELLATION LEVER

2. Place the function cancellation lever in the UNLOCKED (down) position.

3. Sound horn to alert people in the area of machine movement.

4. Turn key switch to START position to use starter motor to rotate the engine.

IMPORTANT: Only operate the Starter Motor in 20 second intervals and allow 3~5 minutes between intervals to allow the Starter Motor to cool.

6-61

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING SWING BRAKE MANUALLY WITH HYDRAULIC HAND PUMP WARNING: Make certain that the attachment is on the ground to help prevent sudden rotation of the upper structure before attempting to release the swing brake. Refer to “Lowering Attachment When Sudden Engine Failure Occurs” in this section.

Kobelco Construction highly recommends the use of a hydraulic hand pump to release the swing brake manually when the engine fails to start.

Figure 165

DC04C343

5. While engine is rotating, slowly and carefully move the RH control lever forward (boom down) and lower boom completely to the ground.

2

6. After Boom is completely down, leave the key switch in ON position, operate the arm, bucket and swing controls to release hydraulic pressure in these circuits. Turn key switch off.

1 1 2 Figure 166

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

7. Locate hydraulic tank air breather on top of the hydraulic tank. Remove cap and depress air release button until all internal hydraulic tank pressure is released.

Figure 167

DC04C342

1. SWING SHOCKLESS VALVE

WARNING: Use caution when removing or repairing hydraulic components as hydraulic pressure may exist or be trapped in circuits.

6-62

2. LIFTING BOLT HOLES

Code

Name

Size

Torque N·m

ft. lbs

A, B

Main Port

2 - PF 3/4

167

123

M

Make-up Port

PF 3/4

167

123

DB

Drain Port

PF 3/8

74

55

PG

Brake Release Port

PF1/4

36

27

L

Gear Oil Level Port

PT 1/2

65

48

IP

Gear Oil Level Port

PT 3/4

98

72

P11, P12

Pilot Ports

PF 1/4

36

27

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Pressure Measurment Port

PA, PB

PF 1/4

36

27

Remove the hose and install the proper connector on PG port.

1. Lower attachment to ground and block to avoid sudden movement. Refer to previous pages for proper procedures in lowering the attachment.

Install the hydraulic hand pump to the PG port and apply 29 kgf/cm2 (413 psi) pressure.

RELEASING SWING BRAKE MANUALLY WITHOUT HYDRAULIC HAND PUMP

1

If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed with the following procedures.

IMPORTANT: In highly contaminated environments it is recommended to remove the whole swing motor assembly. When the Swing Motor is removed, make sure to use caps and plugs on hoses, tubes, and fittings to protect the hydraulic system from any contamination. Also, a cover must be used to protect the Swing Gear compartment. If this approach is taken, and the swing gear grease bath becomes contaminated, make sure to flush and clean the swing gear compartment. Refer to LUBRICATIONS, FILTERS, AND FLUIDS Chapter 5 for proper grease and component capacity. Contact your Kobelco Construction Dealer’s Service Department for assistance.

Figure 168

DC04C333

1. SWING SHOCKLESS VALVE

2. Remove all hoses and tubes from the swing motor top plate and swing shock valves to gain access to the top mounting bolts.

WARNING: Use safety protection such as: Hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

A. Tools & Equipment Required 1. Hand tools required for removal of hydraulic tubes, hoses and fittings.

2. Plugs and caps for tubes, hoses and fittings.

3. 10 mm allen type socket head wrench.

4. 5 mm allen type socket head wrench.

5. Two M12 - 1.75 x 26 mm Lifting Eye. 6. Overhead lifting device capable of lifting and holding 100 kg (220 lbs).

DC04B673

Figure 169

3. Install the proper plugs and caps onto hoses. tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

IMPORTANT: Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

IMPORTANT: Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

7. Plenty of clean, dry shop rags and/or paper towels.

8. 14 mm allen type socket head wrench.

9. 441 N·m (325 ft-lb) torque wrench.

B. Procedures

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

2 Figure 170

DC03M072

1. LIFTING EYES

2. COVER BOLTS

4. Remove the two (2) plugs on top of the swing motor cover and install 2 x M12-1.75x24 mm eye bolts, and place a reference mark between top cover and housing.

NOTE: Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the Top Plate.

Figure 172

DC03M074

10. Carefully remove all brakes springs and place in a container filled with fresh, clean hydraulic oil.

Then, seal the c ontainer to prevent contamination.

1

5. Carefully loosen the four (4) top plate mounting bolts with the 17 mm socket head wrench.

6. Remove two (2) top plate mounting bolts from corners opposite of each other.

2

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

Figure 173

DC03M075

8. Carefully remove the remaining two (2) bolts from the top mounting plate.

NOTE: The top plate will raise from spring pressure as the last two (2) bolts are removes. Some movement of the upper frame may be experienced as the spring tension is released.

DC03M073

2. GREASE

11. Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing. Use grease to hold the distributor plate on the top cover, aligned with dowel pins, before installing.

Figure 171

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shock valve assembly and away from the swing motor.

6-64

1. DOWEL PINS

Figure 174

DC03M076

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 12. Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate. Slowly lower the top plate into position on the swing motor and install by hand the four (4) top plate mounting bolts

A. Tools & Equipment Required 1. A set of 1/2” drive metric sockets and wrenches including sizes 13~22 mm.

2. A 1/2” drive ratchet.

3. Sufficient rags and paper towels.

B. Bleeding Procedure

Figure 175

DC03M074

13. After the machine upper structure is positioned for towing, remove the swing motor cover again and reinstall the swing brakes springs.

Figure 177

DC04B674

1. Place the machine on firm level ground and the attachment in oil level check position.

1

2

1

Figure 178

DC04B339

1. AIR RELEASE BUTTON

Figure 176

DC03M077

1. DOWEL PINS

2. Depress air release button to release hydraulic tank pressure.

2. GREASE

14. Repeat Steps 11~13 to lock the upper frame into position for proper transportation. Make sure to use grease to hold the distributor plate on top cover before installing.

WARNING: Use safety protection such as: Hard hat, working gloves, safety shoes and safety glasses when needed to perform this job.

IMPORTANT: Make certain the top plate dowel pins and the distributor plate holes mesh together.

BLEEDING THE PILOT SYSTEM Whenever the hydraulic system is opened for repairs, pilot line change, etc., it is highly recommended that you bleed the pilot system to prevent erratic or delayed operation of the machine functions.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING: Avoid oil spills, use containers, rags, and/or paper towels to contain any oil leakage. Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to Government Regulations.

DC04C340

Figure 179

3. Make sure that the throttle control is positioned in LOW idle and sound horn before starting.

4. Start the engine and let run at low idle for about 10 minutes.

WARNING: Use a rag or paper towels on the pilot connections to protect yourself from spraying during bleeding.

DC04C339

Figure 180

5. With the engine running at low idle, loosen the pilot lines from the top side of the spools in the Control Valve, one at a time, and operate the function for the spool being bled to bleed the air out of the pilot system. Make sure to bleed each one of the spools indicated in the figure. Tighten hose connections to 50 N · m (37 ft-lb) after bleeding each line.

6. Make sure hydraulic oil level is within specifications, and clean up any oil spilled.

Check all connections, repair any leakage and reinstall control valve top cover.

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CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 7 - ELECTRICAL

ELECTRICAL COMPONENTS ALTERNATOR Ask your Dealer to check the Alternator.

1

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.

FUSES NOTE: Fuses are also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Figure 1

BS06H104

Follow this procedure to replace “blown” or “faulty” fuses.

1. Move seat and seat base completely forward.

1. FUSE BOX COVER

Open the fuse compartment and remove fuse box cover from fuse box.

2. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

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.

3. Refer to fuse box cover or Figure 2 for fuse amperage and their functions.

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CHAPTER 7 - ELECTRICAL

BS06H108

Figure 2

BS06H110

Figure 3

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87722039NA

CHAPTER 7 - ELECTRICAL BATTERIES NOTE: Batteries is also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

.

WARNING:

BS06H237

Figure 5

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

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.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

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.

Figure 4

BS06H238

1. Batteries are located on the left side of the machine.

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7-5

CHAPTER 7 - ELECTRICAL 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTE: Use hydrometer manufacturer’s instruction.

according

to

its

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. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

NOTE: 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.

NOTE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

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CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS 215SR GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Working Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Attachment Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Bucket Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 215SR PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Travel Speed, Swing Speed & Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Standard Lift - Machine with 2.87 M Arm, 0.8 m3 Bucket, 800 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-9 Heavy Lift - Machine with 2.87 M Arm, 0.8 m3 Bucket, 800 mm Triple Grouser Shoes . . . . . . . . . . . . . . . . . 8-9 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Capscrews & 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 Torque Values For Most Common Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

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8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

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CHAPTER 8 - SPECIFICATIONS

215SR GENERAL SPECIFICATIONS The specifications found in this section are given on the Standard 215SR Hydraulic Excavator as manufactured by Kobelco Construction: Boom 5.62 m (18’ 5”), Arm 2.87 m (9’ 5”), and 0.8 m3 (1.05 yd 3) SAE Bucket. No modification or options are taken into consideration in regard to these specifications.

MACHINE DIMENSIONS

Figure 1

DC03N007

WORKING WEIGHT TRIPLE GROUSER SHOES Track Shoe Width - mm (in)

800 (31.5)

Overall Width - m (ft - in)

3.190 (10’ - 5”)

Ground Pressure - kg/cm

2 (psi)

Working Weight - kg (lbs)

0.386 (5.6) 24,800 (54,700)

Bucket Weight: 630 kg (1,389 lbs)

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8-3

CHAPTER 8 - SPECIFICATIONS ATTACHMENT WORKING RANGES

Figure 2

DC03K130

Units: m (ft-in) Machine equipped with 0.8 m3 (1.05 yrd3) Bucket WORKING RANGES (215SR)

ARM 2.87 m (9’ 5”)

A

Maximum digging reach

9.710 (31’ 10”)

A’

Maximum digging reach at ground level

9.530 (31’ 3”)

B

Maximum digging depth

6.590 (21’ 7”)

C

Maximum digging height

10.570 (34’ 8”)

D

Maximum dumping clearance

7.700 (25’ 3”)

E

Minimum dumping clearance

2.970 (9’ 8”)

F

Maximum vertical wall digging depth

5.960 (19’ 6”)

G

Minimum swing radius

2.290 (7’ 6”)

J

Digging depth for 2.4 m (8’) flat bottom

6.380 (20’ 11”)

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CHAPTER 8 - SPECIFICATIONS BUCKET SELECTION CHART 215SR Bucket Selection Chart

Application

General Purpose

Heavy Duty

Severe Duty

Arm

Capacity m3 (yrd3)

Width m (inches)

Weight kg (lbs)

0.672 (0.880)

0.609 (24)

528 (1,165)

H

0.695 (0.910)

0.762 (30)

601 (1,325)

H

0.871 (1.140)

0.914 (36)

685 (1,450)

H

1.047 (1.370)

1.066 (42)

749 (1,651)

M

1.223 (1.600)

1.219 (48)

807 (1,780)

L

0.519 (0.680)

0.609 (24)

567 (1,250)

H

0.695 (0.910)

0.762 (30)

644 (1,420)

H

0.871 (1.140)

0.914 (36)

708 (1,560)

M

1.047 (1.370)

1.066 (42)

749 (1,651)

L

1.223 (1.600)

1.219 (48)

807 (1,780)

X

0.481 (0.630)

0.660 (26)

660 (1,455)

H

0.573 (0.750)

0.787 (31)

721 (1,590)

H

0.672 (0.880)

0.939 (37)

812 (1,790)

M

0.871 (1.130)

1.092 (43)

907 (2,000)

L

2.87 m (9’ 5”)

H - Used with material weight up to 1,780 kg/m3 (3,000 lb/yrd3).

M - Used with material weight up to 1,483 kg/m 3 (2,500 lb/yrd3).

L - Used with material weight up to 1,186 kg/m3 (2,000 lb/yrd3).

X - Not recommended.

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CHAPTER 8 - SPECIFICATIONS

215SR PERFORMANCE SPECIFICATIONS The following performance specifications are based on the standard machine with standard attachment.

TRAVEL SPEED, SWING SPEED & GRADEABILITY 215SR Travel Speed

6.0 km/hr (3.7 mph) in high speed 3.6 km/hr (2.2 mph) in low speed

Swing Speed

13.3 RPM in M-Mode/High Idle

Gradeability

70% (35°) Limited by engine lubrication

Drawbar Force

257 kN (57,800 lbf)

ENGINE Engine Make

HINO J05E-TA

Type

Diesel - 4 cycle, water cooled, intercooler, turbo-charger

No. of Cylinder - Bore x Stroke

4 cyl. - 104 mm x 132 mm (4.1” x 5.2”)

Output Rating

114 kW (153 HP) @ 2,000 rpm

Cooling System

Circulating by a centrifugal pump.

Lubrication System

Pressurized oil fed by a gear pump.

Air Cleaner

Dry type with safety element

Electric System

24 V DC

Starting Motor

24 V - 4.0 kW

Alternator

24 V - 70 Amps

Batteries

2 x 12V - (136 Amp Hr)

Cooling Fan Drive Method

N type - 7 blades 650 mm Dia. (25.6” dia). Drive pulley ratio: 0.91

ENGINE SPEED ENGINE SPEED Low Idle

800 ± 25 RPM

High Idle

2,400 ± 50 RPM

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CHAPTER 8 - SPECIFICATIONS

HYDRAULIC COMPONENTS Hydraulic Pumps

2 x 210 l/min. (2 x 55.0 gpm) Tandem, variable displacement axial piston pump with 20.5 l/min. (5.4 gpm) Pilot Gear Pump at 4.9 MPa (710 psi).

Swing Motor

Axial piston, fixed displacement 291.0 l/min. (76.9 gpm) @ 29.1 MPa (4,135 psi)

Travel Motors

Axial piston, variable displacement. Max. displacement of 350 l/min (92.5 gpm) at 34.3 MPa (4,980 psi), 32.8 rpm in high speed and 48.8 rpm in low speed.

Control Valve

6 spools in the main control valve

Cylinders (All)

Double action

Return Filter

Safety Valve containing Filter Type

Oil Cooler

Air forced ventilation through finned tubbing.

OPERATING PRESSURES Pilot System

50 (710)

Upper Attachment

350 (4980)

Swing

291 (4135)

Travel

350 (4980) 385 (5425)

Power Boost/Heavy Lift Units: kgf/cm

87722039NA

Issued 10-07

Bur

2 (psi)

8-7

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.

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.

5. Capacities apply to the machine as originally manufactured and normally equipped by Kobelco Construction.

IMPORTANT: 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.

Lifting Capacities Chart Legends:

A - Reach swing center line to bucket hook (Load Radius).

B - Bucket hook height above/below ground.

C - Lifting capacities in pounds (lb) and kilograms (kg).

Front Lifting.

8-8

Side Lifting.

Issued 10-07

Bur

87722039NA

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 2.87 M ARM, 0.8 M3 BUCKET, 800 MM TRIPLE GROUSER SHOES 215SR Lifting Capacities based on machine with: Boom: 16’ 7” (5.05 m) Arm: 9’ 5” (2.87 m) Bucket: 1.05 yd3 (0.8 m3) Shoes: 31.5” (800 mm) triple grouser shoe A

5’ 0” (1.5 m)

10’ 0” (3.0 m)

B

C

25’ 0” (7.6 m)

lb kg

20’ 0” (6.1 m)

lb kg

15’ 0” (4.6 m)

lb kg

10’ 0” (3.0 m)

lb kg

*24870 *11280

5’ 0” (1.5 m)

lb kg

Ground Level

lb kg

-5’ 0”(1.5 m)

lb kg

*13890 *6330

-10’ 0” (-3.0 m)

lb kg

*20400 *9250

-15’ 0” (-4.6 m)

lb kg

15’ 0” (4.6 m)

20’ 0”(6.1 m)

At Maximum Reach

25’ 0” (7.6 m) RADIUS

*7730 *3500

*7730 *3500

*4240 *1920

*4240 *1920

19’ 9” (6.04 m)

*3980 *1800

*3980 *1800

23’ 8” (7.21 m)

*12000 *5440

*12000 *5440

*10260 *4650

10010 4540

*5860 *2660

*5860 *2660

*4010 *1810

*4010 *1810

26’ 0” (7.93 m)

*24870 *11280

*16070 *7290

14870 6740

*12480 *5660

9460 4290

*8600 *3900

6520 2960

*4270 *1930

*4270 *1930

27’ 3” (8.31 m)

*16240 *7360

*16240 *7360

*18980 *8600

13650 6190

*13870 *6290

8880 4020

*11080 *5020

6240 2830

*4800 *2170

*4800 *2170

27’ 6” (8.39 m)

*16570 *7510

*16570 *7510

*20310 *9210

12890 5850

*14650 *6640

8440 3830

*11370 *5150

6020 2730

*5720 *2590

5360 2430

26’ 10” (8.19 m)

*13890 *6330

*22200 *10070

*22200 *10070

*19800 *8980

12610 5720

*14420 *6540

8230 3730

*8540 *3870

5920 2680

*7440 *3370

5850 2650

25’ 2” (7.69 m)

*20400 *9250

*24490 *11100

*24490 *11100

*17450 *7910

12680 5750

*12670 *5750

8270 3750

*10720 *4860

7060 3200

22’ 4” (6.80 m)

*17120 *7760

*17120 *7760

*12490 *5660

*12490 *5660

*10130 *4590

*10130 *4590

17’ 7” (5.37 m)

HEAVY LIFT - MACHINE WITH 2.87 M ARM, 0.8 M3 BUCKET, 800 MM TRIPLE GROUSER SHOES 215SR Lifting Capacities (Heavy Lift) based on machine with: Boom: 16’ 7” (5.05 m) Arm: 9’ 5” (2.87 m) Bucket: 1.05 yd3 (0.8 m3) Shoes: 31.5” (800 mm) triple grouser shoe A

5’ 0” (1.5 m)

10’ 0” (3.0 m)

B

C

25’ 0” (7.6 m)

lb kg

20’ 0” (6.1 m)

lb kg

15’ 0” (4.6 m)

lb kg

10’ 0” (3.0 m)

lb kg

*27880 *12640

5’ 0” (1.5 m)

lb kg

Ground Level

lb kg

-5’ 0” (-1.5 m)

lb kg

*15450 *7000

-10’ 0” (-3.0 m)

lb kg

*22610 *10250

-15’ 0” (-4.6 m)

lb kg

87722039NA

15’ 0” (4.6 m)

20’ 0” (6.1 m)

At Maximum Reach

25’ 0” (7.6 m) RADIUS

*8680 *3940

*8680 *3940

*4830 **2190

*4830 *2190

19’ 9” (6.04 m)

*4450 *2060

*4450 *2060

23’ 8” (7.21 m)

*13400 *6080

*13400 *6080

*11480 *5200

10010 4540

*6630 *3000

*6630 *3000

*4590 *2080

*4590 *2080

26’ 0” (7.93 m)

*27880 *12640

*18100 *8200

14870 6740

*14110 *6400

9460 4290

*9650 *4370

6520 2960

*4880 *2210

*4880 *2210

27’ 3” (8.31 m)

*18020 *8170

*18020 *8170

*21400 *9700

13650 6190

*15690 *7110

8880 4020

11740 5320

6240 2830

*5460 *2470

5300 2400

27’ 6” (8.39 m)

*18390 *8340

*18390 *8340

*22940 *10400

12890 5850

16240 7360

8440 3830

11490 5210

6020 2730

*6490 *2490

5360 2430

26’ 10” (8.19 m)

*15450 *7000

*24600 *11150

24270 11000

*22400 *10160

12610 5720

16000 7250

8230 3730

*9600 *4350

5920 2680

*8380 *3800

5850 2650

25’ 2” (7.69 m)

*22610 *10250

*27750 *12580

24630 11170

*19810 *8980

12680 5750

*14440 *6550

8270 3750

*12250 *5550

7060 3200

22’ 4” (6.80 m)

*19590 *8880

*19590 *8880

*14310 *6490

13110 5940

*11660 *5280

10340 4690

17’ 7” (5.37 m)

Issued 10-07

Bur

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

Issued 10-07

Bur

87722039NA

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

87722039NA

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf·m (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)

Issued 10-07

Bur

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 kgf·m (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: kgf·m (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.

Issued 10-07

Bur

87722039NA

CHAPTER 8 - SPECIFICATIONS TORQUE VALUES FOR MOST COMMON BOLTS [Bolt Size] Units: kgf (ft-lbs) Location

Qty

215SR

5

Fuel Tank sending unit mounting

[M5] 0.2 ± 0.01 (1.4 ± 0.1)

6

A/C condenser mounting

[M6x50] 0.46 (3.3)

1

Hyd. tank sending unit mounting

15 ± 2 (108 ± 14)

6

A/C pulley mounting on damper

[M8x16] 4 (29)

4

Coolant reservoir mounting

1.1 ± 0.1 (8 ± 0.7)

4

A/C compressor mounting

[M8x100] 1.1 ± 0.1 (8 ± 0.7)

1

A/C idler pulley nut

[M10] 4 - 5.5 (29 - 40)

2

Pilot pump mounting bolts

[M10] 4 ± 0.4 (29 ± 3) Apply Loctite # 262

8

Hydraulic oil tank cover mounting

[M10] 4.7 ± 0.6 (34 ± 4)

2

Swing grease bath inspection cover mounting

[M10} 3 ± 0.6 (22 ± 4)

8

Swivel joint dust cover mounting

[M10} 1.5 ± 0.3 (11 ± 2)

6

Muffler support bracket mounting

[M10] 4 ± 0.4 (30 ± 3)

16

Engine mounting (engine body side)

[M10] 6.6 ± 0.4 (48 ± 3) Apply Loctite # 262

4

Travel lever mounting

[M10] 2.4 ± 0.3 (17 ± 2)

3

Stepping motor mounting

[M10] 1.9 (14) Apply Loctite # 242

12

Hydraulic pump housing to engine block mounting

[M10] 6.6 ± 0.6 (48 ± 4) Apply Loctite # 262

35

Lower cover mounting

[M10] 5.3 ± 0.6 (38 ± 4)

2

A/C compressor cover mounting

[M10x45] 6.2 (45)

10

Travel motor cover mounting

8.4 ± 0.8 (61 ± 6) Apply Loctite # 262

16

Cab support mounting bolts

4.7 (34)

3

Swivel joint mounting

11 ± 1 (79 ± 7) Apply Loctite # 262

4

Nuts for cab mounts

19 (137)

4

Idler and idler adjuster connection

[M16] 28.5 ± 3 (206 ± 22) Apply Loctite #262

4

Hydraulic oil tank and fuel tank mounting

[M16] 22 ± 2 (159 ± 14) Apply Loctite # 262

4

Radiator bottom support mounting

[M12] 12.3 ± 1.2 (89 ± 9)

1

Swivel joint locking nut

[M16] 15.9 ± 2 (115 ± 14)

8

Hydraulic pump coupling mounting

[M16] 22 ± 1 (159 ± 7) Apply Loctite # 262

8

track guide mounting

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Engine mounting (Upper frame side)

[M18] 23 ± 2 (166 ± 14) Apply Loctite # 271

44

Sprocket mounting

[M18] 40.4 ± 4(292 ± 29) Apply Loctite # 262

56

Lower roller caps

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Hydraulic pump mounting

[M20] 44 ± 4 (318 ± 29) Apply Loctite # 262

12

Swing reduction unit mounting

[M20] 55 ± 6 (397 ± 43) Apply Loctite # 262

36

Swing bearing inner race mounting

[M20] 57.4 ± 5.8 (415 ± 42) Apply Loctite # 262

33

Swing bearing outer race mounting

[M20] 40 ± 4 (289 ± 29) Apply Loctite # 262

184

Shoe bolt mounting

[M20] 86.8 ± 5 (628 ± 36)

4

Upper roller mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

34

Travel motor mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

4

Counterweight mounting

130 ± 13 (939 ± 94) Apply Loctite # 242

8

Side cutter mounting

[M24] 95 - 105 (686 - 758)

87722039NA

Issued 10-07

Bur

8-13

CHAPTER 8 - SPECIFICATIONS [Bolt Size] Units: kgf (ft-lbs) Location

Qty

215SR

2

Idler adjuster grease fitting mounting

[5/8”-18UNF] 5.9 ± 1 (43 ± 7)

2

Connector for heater hoses

2.5 (18) Apply three bond # 1110B

1

Nut on breather valve

1 - 1.4 (7 - 10)

4

Breather mounting bolts

0.48 (3.5)

1

Hydraulic tank plug

16.5 (119) Apply teflon tape

4

Top nuts for U-bolts muffler mounting

1.1 ± 0.1(8 ± 1)

4

Bottom nuts for U-bolts muffler mounting

0.9 ± 0.1 (6.5 ± 1)

1

Engine temperature sensor

2.5 ± 0.6 (18 ± 4) Apply three bond # 1110B

2

A/C hose connection on Compressor

2.4 ± 0.2 (17 ± 1.4)

2

A/C hose connection on Condenser

1.0 ± 0.1 (7.2 ± 0.72)

4

Cover mounting on swing motor

[M20] 43.8 (317)

1

Swing reduction unit oil plug

5.7 (41) Apply teflon tape

2

Oil plugs on travel reduction unit cover

5.7 (41) Apply teflon tape

WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

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

Material (Loose Weight)

8-14

Issued 10-07

Bur

87722039NA

CHAPTER 8 - SPECIFICATIONS UNITS OF PRESSURE

SOME 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

Multiply by

Lit/min Gal/min (US liquid)

Liter/min

3.79

Lit/sec

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

Yard3

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

87722039NA

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgf·m

0.1382552

N·m

1.35582

lbf-in

12

Issued 10-07

Bur

8-15

CHAPTER 8 - SPECIFICATIONS

NOTES

8-16

Issued 10-07

Bur

87722039NA

CHAPTER 9 - INDEX

Chapter 9

INDEX Symbols “Tag-Out” Machine .............................................. 6-6

A Air Cleaner ......................................................... 6-38 Air Conditioning Compressor Belt ..................... 6-30 Air Intake System .............................................. 6-23 Alternator ............................................................. 7-3 Arm Cylinder Hoses and Tubes ......................... 6-56 Arm Operation ................................................... 4-16 Arm Rest Adjustment ........................................... 3-7 Attachment Lubrication ...................................... 6-20 Attachment Working Ranges ............................... 8-4 Auto Warm Up ..................................................... 4-8

Torque ..........................................................6-27 Checking the Air Conditioning Refrigerant .........6-37 Checking the Engine RPM .................................6-36 Checking the Radiator Cap & Hoses ..................6-32 Cleaning Parts ......................................................6-6 Cleaning Sand & Soil from Bucket .....................4-19 Cleaning Suction Strainer ...................................6-44 Climatizer - AC Unit Filter Inspection .................6-31 Components & Controls Nomenclature ..............3-12 Connecting Booster Cable ...................................4-6 Control Decal ......................................................4-10 Control Lever Joint Lubrication ...........................6-28 Counter Rotating Machine ..................................4-14

D B Back Filling & Leveling with Front Attachment .. 4-20 Basic Operation of Hydraulic Controls ............... 4-11 Batteries ..................................................... 6-24, 7-5 Before Operating the Hydraulic Breaker ............ 4-24 Before Operating the Machine ............................. 4-3 Bleeding the Pilot System .................................. 6-65 Boom & Arm ...................................................... 6-19 Boom Cylinder Hoses and Tubes ...................... 6-56 Boom Operation ................................................ 4-15 Bucket ................................................................ 6-50 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes 6-56 Bucket Operation ............................................... 4-16 Bucket Selection Chart ........................................ 8-5 Bucket Selection Guide ..................................... 4-22 Bucket Teeth and Side Cutters .......................... 6-53 Bucket Teeth Direction ...................................... 4-19 Bucket, Arm, & Link Clearance .......................... 6-50 Burn Prevention ................................................... 2-8 Buzzer Stop Switch ........................................... 3-14

Decals ................................................................2-10 Disposal of Hazardous Waste ..............................6-5 Document Pouch ..................................................3-6 Dust Seals ..........................................................6-49

E

C

Emergency Engine Shut Down .................... 4-5, 4-6 Engine .......................................................... 1-4, 8-6 Engine Accessory Belt Wear and Tension 6-25, 6-30 Engine Coolant Change .....................................6-41 Engine Coolant Level .........................................6-12 Engine Coolant Tank & Engine Air Cleaner Access Doors .............................................................3-9 Engine Cover ......................................................3-10 Engine Electrical .................................................6-13 Engine Fluid Leaks .............................................6-13 Engine Lubrication Cumulative Time ..................3-17 Engine Oil and Filter Element .............................6-21 Engine Oil Level .................................................6-12 Engine Speed .......................................................8-6 Engine Valve Clearance .....................................6-38 Extra (Grapple, clamshell, etc.) and Extra & Breaker 4-31

Cab Dome Light ................................................... 3-5 Cab Door Latch ................................................... 3-3 Change Hydraulic Oil ......................................... 6-43 Change Oil in Swing Reduction Unit ................. 6-35 Change Oil in Travel Motor Reduction Units ..... 6-34 Change Swing Ring Grease Bath ...................... 6-47 Check Swivel Valve for Leakage ....................... 6-27 Checking and Cleaning Fuel Tank and Strainer 6-36 Checking Swing Gear Attaching Bolts for Proper

Fan Belts ............................................................6-30 Fire Extinguisher ..................................................2-8 FIRE PREVENTION .............................................2-8 Flare Type Fitting Joints .....................................8-12 Frame Structure .................................................6-17 Fresh Air Filter ....................................................6-31 Fuel Cap .............................................................3-10

87722039NA

Issued 10-07

Bur

F

9-1

CHAPTER 9 - INDEX Fuel Filter Cumulative Time ............................... 3-17 Fuel Filters ......................................................... 6-33 Fuel Handling Precautions .................................. 2-7 Fuel Level .......................................................... 6-13 Fuel Lines and Hoses ........................................ 6-56 Fuel Tank Drain ................................................. 6-22 Fuses ................................................................... 7-3

G General Information ............................................. 1-1 Ground Transportation ...................................... 4-34 Guidelines for Attachment Lubrication ................. 6-8 Guidlines to Rplace Ground Tools ....................... 6-8

H Hand Signals ..................................................... 2-27 Hazardous Chemical Precautions ....................... 2-8 Head Rest Adjustment ......................................... 3-7 Heater Hoses ..................................................... 6-55 Heavy Lift - Machine with 3.2 M Arm, 0.8 m3 Bucket, 800 mm Triple Grouser Shoes ...................... 8-9 Hot Surface & Fluids ............................................ 6-5 How to Handle Life Hammer ............................... 2-9 Hydraulic Breaker .............................................. 4-24 Hydraulic Components ........................................ 8-7 Hydraulic Filter Cumulative Time ....................... 3-17 Hydraulic Functions ........................................... 6-15 Hydraulic Lines, Tubes, and Hoses ................... 6-55 Hydraulic Oil Cumulative Time .......................... 3-17 Hydraulic Oil Leaks ............................................ 6-15 Hydraulic Oil Level ............................................. 6-14 Hydraulic Return Filter ....................................... 6-39 Hydraulic Suction Tubes and Hoses ................. 6-56 Hydraulic Tank Breather .................................... 6-46

I Identification Numbers ......................................... 1-4 Idlers .................................................................. 6-18 Inspect Waste Oils and Filters ............................. 6-6 Inspecting Counterweight Attaching Bolts for Proper Torque ......................................................... 6-28 Installing the Bucket .......................................... 6-53

K Keep Machine Clean ........................................... 6-5 Key Switch ......................................................... 3-12

L L.C.D. Display .................................................... 3-17 Lifting Capacities ................................................. 8-8 Lifting Machine .................................................. 4-36 9-2

Lifting Machine With Attachment Installed .........4-36 Locking/Unlocking Cab Door ................................3-3 Lowering Attachment When Sudden Engine Failure Occurs .........................................................6-61

M Machine Access Compartments and Doors .........3-9 Machine Attachment and Swing .........................4-15 Machine Components ..........................................1-3 Machine Dimensions ............................................8-3 Machine Electrical ..............................................6-16 Machine Operation in Adverse Weather Conditions .

4-21 Machine Storage ................................................4-38 Machine Travel Controls ....................................4-13 Machine Warm Up ................................................4-8 Main Pump Access Door ......................................3-9 Maintenance on Rollers and Idlers .....................6-47 Maintenance Precautions .....................................2-7 Manual Warm Up .................................................4-8 Maximum Digging Force position .......................4-19 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-10 Metric Fine Thread Standard Tightening Torque Values ..........................................................8-11 Model, Serial Number, and Year of Manufacture .1-4 Monitor ...............................................................3-13 Mounting and Dismounting Precautions ...............2-5

N N2 (Nylon) Tube Fitting Joints ............................8-12 Nibbler/Breaker ..................................................4-25 Nuts & Sleeves ...................................................8-12

O Oil Level in Swing and Travel Reduction Unit ....6-27 Opening and Closing Door Glass .........................3-5 Opening and Closing Sunroof ..............................3-5 Opening and Closing Windshield .........................3-4 Operate Boom Smoothly ....................................4-19 Operating Both Travel Levers Together .............4-13 Operating Pattern ...............................................4-10 Operating Pattern Decal .....................................4-10 Operating Precautions ..........................................2-5 Operating Pressures ............................................8-7 Operating the machine .........................................4-3 Operating the Machine in Water .........................4-15 Operating the Shovel ..........................................4-20 Operation at Seashore or Salty Climate .............4-21 Operation in Extreme Cold .................................4-21 Operation in Extreme Heat .................................4-21 Issued 10-07

Bur

87722039NA

CHAPTER 9 - INDEX Operation in High Altitudes ................................ 4-21 Operation in Humid Climate .............................. 4-22 Operation in Sandy and Dusty Areas ................ 4-21 Operator Cab Nomenclature ............................. 3-12 Operator Precautions .......................................... 2-4 Operator Seat Adjustments ................................. 3-6 Operator’s Compartment Controls and Accessories .

3-11 ORS Joint (O-ring Sealing Type ........................ 8-11

P Personal Safety ................................................... 2-3 Pilot Line Filter ................................................... 6-46 Practices to Improve Efficiency ......................... 4-19 Prevent Contamination ........................................ 6-6 Pump Flow Rate Adjustment ............................. 3-25

R Radiator, Oil Cooler & Debris Screen ................ 6-23 Radio ................................................................. 3-28 Rear View Mirrors .............................................. 6-56 Recirculate Air Filter .......................................... 6-31 Recommendation for Longer Undercarriage Life ......

4-22 Releasing Hydraulic System and Tank Pressure 6-7 Releasing Swing Brake Manually With Hydraulic Hand Pump ................................................. 6-62 Releasing Swing Brake Manually Without Hydraulic Hand Pump ................................................. 6-63 Releasing Travel Motor Brakes Manually .......... 6-58 Removing and Storing Lower Front Window ....... 3-4 Removing Machine from Storage ...................... 4-38 Removing the Bucket ........................................ 6-52 Replacing Fuel Filter .......................................... 6-33 Required Filters ................................................... 5-4 Required Fluids/Lubricants and Capacities ......... 5-3 Reversing Bucket .............................................. 6-51 Right Hand Operator Console and Monitor ....... 3-12 Right, Left, Front, and Rear of the Machine ........ 1-2 Rollers ............................................................... 6-18 Roll-Over Protective Structure (If equipped) ........ 2-8

S Safety Area .......................................................... 2-3 Safety Rules ........................................................ 2-3 Screen Change Switch ...................................... 3-15 Seals & O-Rings .................................................. 6-6 Seat Belt .............................................................. 3-8 Seat Belt Precautions .......................................... 2-9 Seat Front to Back Adjustment ............................ 3-7 Seat Height Adjusment ........................................ 3-6 87722039NA

Issued 10-07

Bur

Seat Reclining Adjustment ...................................3-6 Securing Machine to Trailer ...............................4-36 Selection of the Hydraulic Breaker .....................4-24 SK160-8 Performance Specifications ...................8-6 Special Considerations for Hand Lubrication .......6-9 Specific Precautions to this Machine ....................2-9 Sprockets ...........................................................6-18 Standard Lift - Machine with 3.2 M Arm, 0.8 m3 Bucket, 800 mm Triple Grouser Shoes ..........8-9 Starter Motor ........................................................7-3 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 .......................4-7 Starting Disabled Machine Engine .......................4-7 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable .......4-6 Steps and Handrails ...........................................6-16 Stop Engine ..........................................................6-6 Stop Swing Motion Early ....................................4-20 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Bearing Lubrication ..................................6-26 Swing Motor Reduction Unit Oil .........................6-28 Swing Operation .................................................4-17 Swing Ring Gear and Swing Bearing Lubrication .....

6-26 Swing Ring Gear Lubrication ..............................6-26

T Throttle Potentiometer ........................................3-12 Torque Specifications .........................................8-10 Torque Values For Most Common Bolts ............8-13 Track Links .........................................................6-17 Track Shoes .......................................................6-17 Track Tension .....................................................6-19 Tracks and Components ....................................6-17 Transportation ....................................................4-34 Transporting Precautions .....................................2-8 Travel Independent Mode Display ......................3-17 Travel Motors Reduction Unit Oil .......................6-29 Travel Safety ......................................................4-15 Travel Speed Select Switch ...............................3-16 Travel Speed, Swing Speed & Gradeability .........8-6

U Units of Flow .......................................................8-15 Units of Length ...................................................8-15 Units of Power ....................................................8-15 Units of Pressure ................................................8-15 9-3

CHAPTER 9 - INDEX Units of Torque .................................................. 8-15 Units of Volume ................................................. 8-15 Units of Weight .................................................. 8-15 Use Arm in Action .............................................. 4-19 Use of Optional Attachment ............................... 4-23 Use of Travel Speed Select Switch ................... 4-13 Using Power Boost ............................................ 4-17 Utility Safety ......................................................... 2-4

W Warm Engine Oil ................................................. 6-5 Warming of Hydraulic Oil .............................. 4-8, 4-9 Warming Up of Engine ........................................ 4-8 Washer Switch ................................................... 3-14 Water Separator ................................................ 6-22 Wear Safety Equipment ....................................... 6-6 Weight of Materials Table .................................. 8-14 Welding Safety .................................................... 6-7 Windshield Washer Fluid Reservoir .................. 6-55 Wiper Switch ...................................................... 3-14 Work Mode Switch .................................... 3-13, 4-12 Working Weight ................................................... 8-3

9-4

Issued 10-07

Bur

87722039NA

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

North American English Part Number 87722039 NA Printed in U.S.A. • Bur