Kobelco ED150-2 Hydraulic Excavator (Bladerunner) Operator's Manual PDF

OPERATOR’S MANUAL Hydraulic Excavator (Bladerunner) ED150-2

S2LH00003ZE01 Issued August 2012

APPLICABLE: ED150-2 . . . . . . . . . . . . . LH01-01018 ~

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, left, front, and rear of the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2 SAFETY INFORMATION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

3 CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

OPERATOR'S SEAT Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

FORWARD CONTROLS Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

RIGHT-HAND SIDE CONTROLS Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

4 OPERATING INSTRUCTIONS STARTING THE UNIT Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection after starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

STOPPING THE UNIT Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

PARKING THE UNIT Parking the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

5 TRANSPORT OPERATIONS ROAD TRANSPORT Preparing for road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SHIPPING TRANSPORT Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

6 WORKING OPERATIONS GENERAL INFORMATION Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Work mode select switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Practices to improve efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

7 MAINTENANCE GENERAL INFORMATION Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Biodiesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

MAINTENANCE CHART Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Every 10 hours or daily Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Alternator and drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Every 50 hours of operation or weekly Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Every 120 hours

Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Every 250 hours Engine air filter, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Radiator and coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Bucket grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Every 500 hours Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Every 1000 hours Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

Every 2000 hours Pilot line filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Hydraulic suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Swing reduction lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

Every 5000 hours Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

As required Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61 Bucket teeth and side cutters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

STORAGE

Preparation for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

8 SPECIFICATIONS General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Working ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Bucket and arm combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Lift capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Dozer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

9 ACCESSORIES Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Hydraulic oil - breaker/nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Work mode select switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION Note to the owner

RAIL12CEX0626BA

1

Read this manual before you start the engine or operate the machine. If you need more information, contact your authorized dealer.

This manual contains important information about the safe operation, adjustment, and maintenance of your machine.

Refer to the index at the back of this manual for locating specific items about your machine. The hydraulic excavator conforms to current safety regulations.

Consult an authorized dealer regarding any changes, additions, or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software, and other items can change. These changes can affect the maintenance performed on the machine. Ensure that you have complete and current information from your dealer before you start any machine operation.

ATTENTION: The fuel system and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

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1 - GENERAL INFORMATION

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

The excavator has been designed for digging and earth moving operations through the use of a bucket. Operations that involve the use of hydraulic hammers or crushers are also possible. Other operations, such as moving suspended loads are only possible if the specific variant approved by the manufacturer is present.

DO NOT use this machine for any application or purpose other than those described in this manual, on the safety signs, or other product safety information provided with the machine. These materials define the machine's intended use.

Using the excavator and its equipment for different operations, such as, for example, towing, transporting and lifting people, is considered inappropriate and is prohibited.

Before permitting a new operator on this machine, make certain: •

That the operator has received the necessary training to operate the machine correctly and safely.

•

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

•

All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permits.

This operator’s manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals or manuals in languages other than that of the country of use.

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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 seat when the cab is over the idler wheels. Normal travel mode for the machine is with the cab over the idler wheels and the travel motors below the upper structure (counterweights).

RAPH12CEX0028GA

1 Right side of machine 2 Left side of machine

3 Front of machine 4 Rear of machine

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5 Idler wheels 6 Travel motor

1 - GENERAL INFORMATION

Machine components

RAPH12CEX0030GA

1. Arm cylinder 2 Boom 3. Main control valve 4. Hydraulic oil tank 5. Fuel tank 6. Engine hood 7. Engine muffler 8. Hydraulic pump 9. Engine 10. Counterweight 11. Inter cooler 12. Fuel cooler

13. Travel motor 14. Slewing motor 15. Engine radiator 16. Battery 17. Swivel joint 18. Track guide 19. Upper roller 20. Lower roller 21. Engine air cleaner 22. Slewing ring 23. Track spring 24. Oil cooler

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25. Track idler 26. Dozer cylinder (option) 27. Bucket 28. Idler link 29. Bucket link 30. Bucket cylinder 31. Arm 32. Boom cylinder 33. Cab 34. Dozer blade (option) 35. Track shoe assembly

1 - GENERAL INFORMATION

Note to the owner This manual contains information concerning the adjustment and maintenance of your new equipment. You have purchased a dependable machine, but only by proper care and operation can you expect to receive the performance and long service built into this equipment. Please have all operators read this manual carefully and keep it available for ready reference.

Your KOBELCO dealer will instruct you in the general operation of your new equipment. Your dealer's staff of factory-trained service technicians will be glad to answer any questions that may arise regarding the operation of your machine. KOBELCO Construction Customer Service is also available. Call 1-866-KOB-LC01 (1-866-562-5201) or email customerservicekobelco.na@cnh.com.

Your KOBELCO dealer carries a complete line of genuine KOBELCO service parts. These parts are manufactured and carefully inspected to insure high quality and accurate fitting of any necessary replacement parts. Be prepared to give your dealer the model and product identification number of your new equipment when ordering parts. Locate these numbers now and record them below. Refer to the 'General Information' section of this manual for the location of the model and product identification numbers of your machine.

PLEASE RECORD THE FOLLOWING INFORMATION

Model Product Identification Number (PIN) Date Purchased Engine Model Engine PIN

This is the safety alert symbol. It is used with and without signal words to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

WARNING Illustrations in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.

Replace all shields before operating the machine.

Failure to comply could result in death or serious injury.

W0012A

IMPROVEMENTS CNH America LLC is continually striving to improve its products. We reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

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1 - GENERAL INFORMATION

Product identification Model, serial number, and year of manufacture Record the machine and Product Identification Numbers (PIN). When ordering parts, obtaining information or assistance, always supply your dealer with the type and PIN of your machine or accessories. Keep a record of these numbers and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine identification Model name Product Identification Number (PIN) Model year

The PIN plate is located on the left-hand side of the machine.

RAIL12CEX0602AA

1

RAIL12CEX0601AA

2

Engine make and model Engine serial number

The serial number plate is on the engine block.

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1 - GENERAL INFORMATION

Roll-Over Protective Structure (ROPS) serial number

The serial number plate is on the machine cab.

(1) Falling Object Protective Structure (FOPS) (2) Roll Over Protective Structure (ROPS)

RAPH12CEX0032GA

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1 - GENERAL INFORMATION

Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add‐on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: •

The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

•

The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

•

The add‐on equipment must not interfere with the functioning of the on board electronics.

Failure to comply with these rules will render the KOBELCO warranty null and void.

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2 - SAFETY INFORMATION

2 - SAFETY INFORMATION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine safety signs, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine damage or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine damage or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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2 - SAFETY INFORMATION

Proposition 65 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 posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

BT09A213

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2 - SAFETY INFORMATION

Safety rules General safety rules Use caution when operating the machine on slopes.

Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Never permit anyone other than the operator to ride on the machine.

Never operate the machine under the influence of alcohol, drugs, or while otherwise impaired.

DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion.

Make sure all guards and shields are in good condition and properly installed before operating the machine.

Never operate the machine with shields removed. Always close access doors or panels before operating the machine.

Never allow riders on the machine.

Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

When digging or using ground engaging attachments be aware of buried cables. Contact local utilities to determine the locations of services.

A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

Use a signal person when operating, swinging, or moving the machine in a congested area.

Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

•

DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

•

Stop engine, remove key and relieve the pressure before connecting or disconnecting fluid lines.

•

Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system.

•

If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.

•

Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts.

Never operate engine in enclosed spaces including tunnels and underground sites as harmful exhaust gases may build up.

Before starting the machine, be sure that all controls are in neutral position.

Start the engine only from the operator’s seat. The safety lever must be down in the UNLOCK position for the machine to start. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Always keep windows, mirrors, and all lighting clean to provide the best possible visibility while operating the machine.

Operate controls only when seated in the operator’s seat.

Wear protective equipment when appropriate.

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2 - SAFETY INFORMATION

Parking the machine Before leaving the machine: 1.

Park machine on a firm level surface.

2.

Lower bucket to the ground.

3.

Pull the safety lever to the LOCK position.

4.

Turn the starter key to the off position.

5.

Run engine at slow idle speed without load for 5 min

6.

Remove starter key from the key switch.

7.

Close the windows, cab door, and all panels.

RAPH12CEX0464AA

1

General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

When absolutely necessary to tow, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load.

Service the machine on a firm level surface.

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

Stop the engine, remove key and relieve pressure before disconnecting or connecting fluid lines.

If you doubt your ability to complete maintenance procedures correctly, contact your authorized dealer.

Release all pressure before working on systems with an accumulator. It is your responsibility to know how many, and where accumulators are on the machine.

Observe proper maintenance intervals and procedures, as well as all safety messages within the procedure.

Stop the engine and remove key before disconnecting or connecting electrical connections.

Install guards and shields after servicing the machine.

Scalding can result from incorrect removal of coolant caps. Cooling system operates under pressure. Hot coolant can spray out if a cap is removed while the system is hot. Allow system to cool before removing cap.

When removing a cap turn it slowly to allow pressure to escape before completely removing the cap.

Close all access doors and install all panels after servicing the machine.

Do not attempt to clean, lubricate, clear obstructions or make adjustments to the machine while it is in motion or while the engine is running.

Always make sure working area is clear of tools, parts, other persons and pets before you start operating the machine.

Unsupported hydraulic cylinders can lose pressure and drop the equipment causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless securely supported.

Jack or lift the machine only at jack or lift points indicated in this manual.

Replace damaged or worn tubes, hoses, electrical wiring, etc.

Engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when servicing such components. Allow surfaces to cool before handling or disconnecting hot components.

Wear protective equipment when appropriate.

When welding, follow the instructions in the manual. Always disconnect the battery before welding on the machine. Always wash your hands after handling battery components.

Incorrect towing procedures can cause accidents. When towing a disabled machine follow the procedure in this manual.

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2 - SAFETY INFORMATION

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

Fuel handling safety rules Do not smoke or permit open flames while fueling or near fueling operations.

Never remove the fuel cap or refuel machines with the engine running or the engine hot. Never allow fuel to spill on hot machine components. Avoid spilling fuel on the ground or contaminating the environment.

Tightened the fuel tank cap securely. Should the fuel cap be lost, replace it only with the manufacturer's approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

Use the correct fuel for the operating season.

Never use gasoline for cleaning purposes.

Always maintain control of the fuel filter nozzle when filling the tank. This will help avoid spilling fuel.

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

Travel and general transportation safety Travel speed should be such that complete control and machine stability is maintained at all times.

Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Block upper structure swing to prevent accidental movement.

Keep the bucket in the direction of travel, approximately 20 - 30 cm (8 - 12 in) above the ground during travel on inclines.

Know load limits of bridges and dimensional limits of tunnels.

Lower bucket immediately if machine begins to skid.

Do not travel on slopes with an angle exceeding 30 °

Lift attachments high enough above ground to prevent accidental contact with the ground.

Check distance between boom/arm and dimensional limits.

When transporting equipment or machine on a transport trailer, make sure machine is properly secured.

Be aware of overhead structures or power lines and make sure the machine and/or attachments can pass safely under.

Be aware of undercarriage position relative to the front of the cab. Confirm front idler is in the front of the machine and the travel motor is in the rear of the machine before movement.

Do not travel across hills on slopes exceeding an angle of 15 ° Avoid swing operation or steering the machine on a slope.

Level the work area first if possible.

Operate controls slowly and cautiously on frozen and/or snow covered work sites to prevent unexpected shifts of the machine on flat ground or slopes.

Slow down before turning.

Follow correct towing procedure for equipment with or without brakes.

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2 - SAFETY INFORMATION

Fire and explosion prevention Fuel or oil leaked or spills on hot surfaces or electrical components can cause a fire.

Trash, debris, or flammable material can ignite on hot surfaces.

belts, gears, cleaning fan, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Always have a fire extinguisher on or near the machine.

Inspect the electrical system for loose connections or frayed insulation. Repair or replace loose or damaged parts.

Make sure the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

Do not store oily rags or other flammable material on the machine.

At least once each day and at the end of the day remove all trash and debris from the machine especially around hot components such as engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvents before welding or flame-cutting.

At least once each day, remove debris accumulation around moving components such as bearings, pulleys,

Promptly investigate any unusual smells or odors that may occur during operation of the machine.

Do not expose the machine to flames, burning brush, or explosives.

General battery safety Always wear eye protection when working with batteries.

Follow manufacturer’s instructions when storing and handling batteries.

Do not create sparks or have open flame near battery.

Do not charge a frozen battery; it may explode. Warm battery to 16 °C (61 °F) Ventilate when charging or using in an enclosed area.

Disconnect negative (-) first and reconnect negative (-) last.

When welding on the machine, disconnect both terminals of the battery.

Do not weld, grind, or smoke near a battery.

When using auxiliary batteries or connecting booster cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

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

This is a California Proposition 65 warning.

Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.

Antidote (internal): Drink large quantities of water or milk.

Do not induce vomiting. Seek medical attention immediately.

Keep batteries out of reach of children and other unauthorized persons.

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2 - SAFETY INFORMATION

Seat belts Seat belts must be worn at all times.

Seat belt inspection and maintenance: •

Keep seat belts in good condition.

•

Keep sharp edges and items than can cause damage away from the belts.

•

Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear.

•

Replace all parts that have damage or wear.

•

Replace belts that have cuts that can make the belt weak.

•

Check that bolts are tight on the seat bracket or mounting.

•

If belt is attached to seat, make sure seat or seat brackets are mounted securely.

•

Keep seat belts clean and dry.

•

Clean belts only with soap solution and warm water.

•

Do not use bleach or dye on the belts, as this can weaken the belts.

Fasten the seat belt Fasten the seat belt as follows: 1.

2.

Insert the retaining clip (1) into the buckle (2).

RAPH12CEX0360AA

2

RAPH12CEX0361AA

3

Confirm the belt is securely fastened and adjust belt length.

Unfasten the seat belt Unfasten the seat belt as follows: 1.

Press the button (3) on the buckle (2).

2.

Slide out the retaining clip (1).

NH0194

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2 - SAFETY INFORMATION

Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Falling Object Protective Structure (FOPS), or a cab with ROPS. A ROPS may be a cab frame, a two-posted, or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. The protective structure is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes in the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations: •

The protective structure MUST BE REPLACED.

•

The mounting or suspension for the protective structure, operator seat and suspension, seat belts and mounting components, and wiring within the operator’s protective system MUST be carefully inspected for damage.

•

All damaged parts MUST BE REPLACED.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

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2 - SAFETY INFORMATION

Air-conditioning system The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury.

Service, repair, or recharging must be performed only by a trained service technician.

The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original, intended protection. Faded and/or soiled vests are no longer as visible as the original intent. See the manufacturer‘s recommendations.

Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures and procedures to be taken in the event of a spill or accidental release. MSDS are available from your dealer.

Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, on manufacturer containers, as well as the information in this manual when servicing the machine.

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

Keep hazardous chemicals out of reach or children or other unauthorized persons.

Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or distributor of the chemicals before using them.

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2 - SAFETY INFORMATION

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate to determine the locations of services.

•

Stop the machine movement immediately.

•

Apply the park brake, stop the engine, and remove the key.

•

Check if you can safely leave the cab or your actual position without contact with electrical wires.

If not, stay in your position and call for help. If you must leave your position without touching lines, jump clear of the machine to make sure you do not make contact with the ground and the machine at the same time.

•

Do not permit anyone to touch the machine until power has been shut off to the power lines.

Make sure the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary.

Remove or lower radio antennas or other accessories.

Should a contact between the machine and an electric power source occur, the following precautions must be taken:

Electrical storm safety Do not operate machine during an electrical storm.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform. Do not make contact with the ground or objects outside the machine.

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, or ladders.

Do not jump off the machine.

Make sure steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Face the machine when mounting and dismounting.

Maintain a three-point contact with steps, ladders, and handholds.

Never mount or dismount from a moving machine.

Do not use the steering wheel or other controls or accessories as handholds when entering or exiting the cab or operator’s platform.

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2 - SAFETY INFORMATION

Working at heights When the normal use and maintenance of the machine requires working at heights:

•

•

Correctly use installed steps, ladders, and railings.

•

Never use ladders, steps, or railings while the machine is moving.

Do not stand on surfaces which are not designated as steps or platforms.

Do not use the machine as a lift, ladder, or platform for working at heights.

Lifting and overhead loads Never use loader buckets, forks, etc. or other lifting, handling, or digging equipment to lift persons.

gravity of the machine. This can cause the machine to topple on slopes or uneven ground.

Do not used raised equipment as a work platform.

Load items can fall off the loader bucket or lifting equipment and crush the operator. Care must be taken when lifting a load. Use proper lifting equipment.

Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area of movement while the machine is in operation.

Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.

Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically locked or supported if they are left in a raised position for service or access.

Do not lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the ground and other obstacles.

Never undercut a high bank. The edges could collapse or a landslide could occur.

Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.

Loader buckets, forks, etc. or other lifting, handling, or digging equipment and its load will change the center of

Precautions specific to this machine Walk around the machine’s tool, attachment, or furthermost contact point to view operation danger area.

Before operating at night, make certain all work lamps, driving lights, and tail lights illuminate.

Carry loads in the recommended positions for maximum stability.

Remove the starter key and/or use the disconnect switch when leaving the machine parked or unattended.

Never lift loads in excess of capacity. weights.

Operate the machine complying with the load limits in accordance with the table of lifting load located inside the cab.

Know tipping

Know and understand the job site traffic flow patterns and obey signal personnel, road signs, and flaggers.

Know and understand that job site conditions may change on an hourly basis. It is the operator’s responsibility to monitor the changes and keep the machine, tools, and attachments at a safe distance.

Do not exceed the prescribed load limits.

Do not use the strength of the attachment to travel or move the machine.

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2 - SAFETY INFORMATION

Safety signs WARNING Avoid injury!

An illegible or missing safety sign can have far-reaching consequences. Inspect safety signs daily.

Clean and replace damaged safety signs as necessary.

Failure to comply could result in death or serious injury.

W0167A

The following safety signs are placed on your machine as a guide for your safety and for those working with you. Walk around the machine and note the content and location of these safety signs before operating your machine.

Keep safety signs clean and legible. Clean safety signs with a soft cloth, water, and a gentle detergent. Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety signs.

Replace all safety signs that are damaged, missing, painted over, or illegible. If a safety sign is on a part that is replaced, make sure the safety sign is installed on the new part. See your dealer for replacement safety signs.

Make sure that you read all the safety signs and all instructional signs. The safety signs are intended for the personal safety of you and those working with you. Review the safety signs with all machine operators.

NOTE: Some safety sign locations may vary slightly between various model configurations.

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

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

Safety signs that display the "Read Operator's Manual" symbol are intended to direct the operator to the operator's manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine. When a safety sign displays this symbol, refer to the appropriate page of the operator's manual.

RCIL10WHL168BAL

1

RCIL10WHL169BAL

2

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

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Safety signs

RAIL12CEX0627HA

2-13

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2 - SAFETY INFORMATION

1 - Danger — Crush hazard DANGER Do not use counterweight lifting eyes to lift whole machine.

Lifting eyes can fail under this load resulting in personal injury.

Refer to operator’s manual for proper way of lifting machine.

Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the left and right hand sides of the counterweight.

Part Number — YN20T01221P1 Quantity — 2 YN20T01221P1

2

YN20T01049P1

3

2 - Warning — Fall hazard WARNING When servicing or repairing machine, keep surfaces free of oil, water, grease, tools, etc. to avoid possible slipping and/or falling from machine, which can cause personal injury. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the top of the rear deck.

Part number — YN20T01049P1 Quantity — 1

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2 - SAFETY INFORMATION

3 - Warning — Pressurized system hazard WARNING Pressurized hot oil can cause burns. Depress stem or remove cap slowly with engine off to relieve Hydraulic Tank pressure. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on top of hydraulic tank Part Number —PW20T01007P1 Quantity — 1

4

PW20T01007P1

4 - Warning — Fall hazard WARNING There is a danger of falling from areas on top of the machine. Do not step on the area where this safety sign is attached. Failure to comply could result in death or serious injury.

This WARNING is located on top of the right rear compartment.

Part Number —ZL11N02704 Quantity —1

ZL11N02704

2-15

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2 - SAFETY INFORMATION

5 - Danger — Crush hazard DANGER KEEP CLEAR OF SWING AREA. Failure to comply will result in death or serious injury.

Ensure that any person near the working site is outside the swing area before starting or operating the machine.

Sound the horn before beginning swing operation.

This DANGER safety sign is located on the left and right hand sides of the rear counterweight.

Part Number — YN20T01003P2 Quantity — 2

YN20T01003P2

6

YN20T01015P2

7

YN20TO1338P1

8

6 - Warning — Explosion hazard WARNING Improper booster cable connections can cause an explosion resulting in personal injury.

Connect booster cables using following procedures.

1.

Connect booster cable to positive (+) battery terminal of discharged batter, Connect other end of booster cable to positive battery terminal of normal battery.

2.

Connect other booster cable to negative (-) battery terminal of normal battery. Connect other end of booster cable to upper frame of trouble machine.

3.

Start engine and remove booster cables in reverse order.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the inside battery cover (rear left hand side of the machine).

Part Number — YN20T01015P2 Quantity — 1

7 - Warning — Electrical hazard WARNING Electric hazard may cause injury when mishandling the cable.

Read operator manual for safe and proper handling. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the inside battery cover. (rear left hand side of machine) Part Number — YN20T01338P1 Quantity — 1

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2 - SAFETY INFORMATION

8 - Warning — Burn hazard WARNING Steam of hot coolant can cause injury or blindness.

Never loosen or open radiator cap when coolant is hot and under pressure.

Before opening radiator cap: •

Cool down engine completely.

•

Cover radiator with cloth rag.

•

Loosen cap slowly to relieve pressure.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on top of engine fan shroud.

Part Number — YN20T01010P1 Quantity — 1

YN20T01010P1

9

YN20T01009P1

10

YN20T01012P1

11

9 - Warning — Rotating parts hazard WARNING Rotating parts can cause personal injury.

Keep away from belt when engine is running. Stop engine before servicing. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on top of engine fan shroud.

Part Number — YN20T01009P1 Quantity — 1

10 - Caution — Rotating parts hazard CAUTION Rotating engine fan, not engine parts and drive belt can cause severe injury.

Do not open engine cover or service engine with engine running. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on top of engine hood.

Part Number — YN20T01012P1 Quantity — 1

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2 - SAFETY INFORMATION

11 - Caution — Burn hazard CAUTION Engine may be hot which could cause burns.

Do not touch engine until it cools down. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on hydraulic pump cover.

Part Number — YT20T01352P1 Quantity — 1

YT20T01352P1

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12 - Warning — Pressurized system hazard WARNING Grease in track adjust valve is under extreme pressure and can penetrate the skin causing severe injury. Pressure can cause parts to disengage with extreme force.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the crawler frame.

Part Number — YN20T01813P1 Quantity — 2

YN20T01813P1B

13

13- Warning — Burn hazard WARNING Do not touch hot engine components during operation or immediately after the engine has stopped.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the hydraulic tank cover.

Part Number — ZL11M00508 Quantity — 1 ZL11M00508

2-19

14

2 - SAFETY INFORMATION

14 - Warning — Chemical hazard WARNING AVOID ACID BURNS •

Electrolyte is an acid and can cause injury or blindness if it contacts 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 immediately.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the inside battery cover. (rear left hand side of machine) Part Number — YN20T01017P1 Quantity —1 YN20T01017P1

15

LS20T01202P1

16

PY20T01060P1

17

15 - Warning — Explosion hazard WARNING PREVENT BATTERY EXPLOSION •

Batteries generate hydrogen gases that can explode and cause personal injury.

•

Keep sparks, open flames and cigarettes away from batteries.

•

Keep metal objects away from batteries.

•

Keep the fluid level above LOWER level.

•

Be sure to connect booster cables correctly.

•

To avoid battery leakage, do not fill the battery above the UPPER level.

•

Charge batteries in a well-ventilated area.

Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the inside battery cover. (rear left hand side of machine) Part Number — LS20T01202P1 Quantity — 1

16 - Danger — Explosion hazard DANGER Explosive gases Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and face from battery. Do not charge or use booster cables or adjust post connections without proper instruction and training.

KEEP VENT CAPS TIGHT and level. Poison causes severe burns. Contains sulfuric acid. Avoid contact with skin, eyes, or clothing. In the event of an accident, flush with water and call a physician immediate. KEEP OUT OF REACH OF CHILDREN. Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the battery cover.

Part Number — PY20T01069P1 Quantity — 1

2-20

2 - SAFETY INFORMATION

18 - Caution — Pinch hazard CAUTION Be careful not to pinch your hand(s) when operating the lever.

Failure to comply could result in minor or moderate injury.

This CAUTION safety message is located on seat stand.

Part Number — YN20T01339P1 Quantity — 1

YN20T01339P1

18

ZL11M06008

19

19 - CAUTION — Falling object hazard CAUTION Lock front window at the housed position. The front window can fall if it is not in the locked position. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located inside the cab on the right hand side.

Part Number — ZL11M06008 Quantity — 1

2-21

2 - SAFETY INFORMATION

20- Operational safety Observe and adhere to the multiple warnings located on the right-hand side window of the cab.

Part Number — YN20T01863P1 Quantity — 1

RAIL12CEX0607BA

1.

2.

WARNING Automatic two speed travel system changes travel speed automatically and can adversely effect machine control when descending a slope and loading or unloading on a trailer.

Personal injury can occur from sudden change in machine control.

Put travel speed select switch in LOW speed position when descending a slope and loading or unloading on a trailer. Failure to comply could result in death or serious injury.

20

Stopping engine without allowing it to cool can result in overheating and shortened engine life.

Before stopping engine run at low idle for at least 5 minutes to allow engine and turbocharger to cool down.

3.

NOTICE

2-22

WARNING DO NOT INSTALL ANY OBJECT ON THE HANDRAIL This can cause the welds that fasten the handrail to the operators cab to fatigue and crack due to excessive vibration during machine operation.

Injury to the operator may result if he falls to ground because of the unexpected breakage of the welds.

2 - SAFETY INFORMATION

Failure to comply could result in death or serious injury.

4.

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

5.

WARNING Read and understand operator manual before operating or performing maintenance on this machine.

Failure to follow or pay attention to instructions in operator manual can result in injury or death. It is your responsibility to be aware of and follow all local laws and regulations. Before starting machine, make sure hydraulic control lever is in lockout position and all control levers are in neutral. Sound horn to alert people. Ensure bystanders and obstacles are clear of machine before moving machine or its attachments. Failure to comply could result in death or serious injury.

6.

7.

8.

CAUTION Slow or unexpected movement of the hydraulic functions may result when the hydraulic oil cold.

Always perform the hydraulic oil warm up procedure before attempting normal machine operations.

Always keep personnel away from the area around the machine during warm up procedure. Failure to comply could result in minor or moderate injury.

9.

CAUTION Some type of attachment and the combination of attachment may cause an interference with operator’s cab and other sections of machine during operation.

Before starting operation, make sure to check for the enough space for no interference between the attachment and operator’s cab and the other sections.

Since it is more danger when the attachment is moved close to the cab and machine frame and so on, special attention must be paid. Failure to comply could result in minor or moderate injury.

10.

WARNING Extreme high pressure in track adjustment cylinder can cause personal injury when adjusting crawler tension. Loosen grease nipple with care to relieve pressure gradually. Failure to comply could result in minor or moderate injury.

11.

WARNING Releasing power boost switch while lifting a load can cause unexpected lowering of load, resulting in sever injury or death. Never use power boost switch for lifting a load. Failure to comply could result in death or serious injury.

12.

DANGER Contact with electrical power lines will result in severe injury or death.

Keep machine and attachment a safe distance from electrical power lines as per following instruction.

Failure to comply will result in death or serious injury.

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

Failure to comply could result in death or serious injury.

WARNING Turning off heavy lift switch while lifting a load can cause unexpected lowering of load, resulting in severe injury or death. Never turn off heavy lift switch while lifting a load. Failure to comply could result in death or serious injury.

2-23

VOLTAGE (Volts) 50K or LESS 50K to 200K 200K to 350K 350K to 500K 500K to 750K 750K or over

SAFETY DISTANCE 3.0M (10FT) 4.5M (15FT) 6.0M (20FT) 7.5M (25FT) 10.5M (35FT) 13.5M (45FT)

2 - SAFETY INFORMATION

21 - CAUTION — Work hazard CAUTION Swing parking brake release switch is installed on the rear side of this cover Swing parking brake release switch While operating swing action, when the parking brake cannot be released, set the toggle switch to RELEASE position and the parking brake is released.

Usually, this toggle switch should be set to NORMAL position. Contact your authorized dealer immediately. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the rear cover Part Number — YN20T01639P1 Quantity — 1 YN20T01639P1

21

YN20T01836P2

22

22 - CAUTION — Machine operation hazard CAUTION Improper work mode selection when using nibbler or hydraulic breaker attachment might result in serious failure on hydraulic system. Be sure to select work mode properly as per following switching procedure.

Breaker: B Nibbler: A Note: When the display of work mode has blinked. It is showing that work mode is inappropriate.

Note: For the work with breaker, select B mode. Work mode in any mode other than B mode will cause damage to the oil cooler, the hydraulic equipment, and breaker.

Note: B and A selection will be cancelled automatically once the key switch is turned off. Each time you restart the machine, select the proper mode.

Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the right hand side of the operator’s compartment Part Number — YN20T01836P2 Quantity — 1

2-24

2 - SAFETY INFORMATION

23 - CAUTION — Machine maintenance hazard CAUTION Maintenance: When using nibbler or breaker contamination and deterioration of hydraulics may develop malfunction of control valves, early wear and seizure of hydraulic pumps, and consequential damage of the entire hydraulic circuit. Replace filters and hydraulic oil, referring to the following table.

1. Hydraulic oil change: Every 1000 hours 2. Hydraulic return filter change: First: 50 hours; Regular: Every 250 hours. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located on the right hand side of the operator’s compartment.

Part Number — YN20T01930P1 Quantity — 1

YN20T01930P1

23

YN20T01337P1A

24

PY20T01062P1

25

24 - DANGER — Crush hazard DANGER KEEP CLEAR OF MACHINE Make sure the area is clear of obstacles and persons before beginning the operation of the machine. Sound horn before beginning swing operation. Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the machine arm Part Number — YN20T01337P1 Quantity — 2

25 - CAUTION — Machine operation hazard CAUTION Attachment operation by foot pedal.

Always check the foot pedal control pattern before operation.

Always read operators manual before operating machine.

Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located inside the cab on the right hand side window.

Part Number — PY20T01062P1 Quantity — 1

2-25

2 - SAFETY INFORMATION

26 - WARNING — Machine contact hazard WARNING Dozer wings should be folded for transport only. Do not load or off load with wings in folded position. Do not operate machine or dozer blade with dozer wings in the folded position. Contact is possible with counterweight and/or track resulting in damage to the dozer blade. Operate the machine only with the dozer wings fully extended and locked into position. Failure to comply could result in death or serious injury.

This WARNING safety sign is located on the right hand side of the operator’s compartment.

Part Number — 2432P4143 Quantity — 1

2432P4143

26

27 - CAUTION — Attachment operation hazard CAUTION Do not set this switch to nibbler combined flow operation position when using breaker. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is located inside the cab on the right hand side window.

Part Number — YT20T01054P1 Quantity — 1

YT20T01054P1

27

YN20T01039P1

28

28 - WARNING — Unexpected machine movement hazard WARNING This machine equipped with a rotary multi-control valve which allows changing of operating lever control patterns.

Operating this machine before checking function of each control lever can cause unexpected machine movement, which can result in serious personal injury. Make sure you check and know function of each control lever before operating. Failure to comply could result in death or serious injury.

This WARNING safety sign is located inside the cab on the right hand side window.

Part Number — YN20T01039P1 Quantity — 1

2-26

2 - SAFETY INFORMATION

29 - DANGER - Unexpected movement hazard DANGER Rotary multi-control lever lock position and control pattern. (SAE BHL) Operation procedure Stop the engine before operation Loosen butterfly bolt and set at request position Tighten butterfly bolt DANGER — stop the engine without fail at the time of changeover. Failure to comply will result in death or serious injury.

This DANGER safety sign is located on the fuel tank.

Part Number — YY20T01208P1 Quantity — 1

YY20T01208P1

2-27

29

2 - SAFETY INFORMATION

30 - WARNING — Unexpected movement hazard WARNING Always lock the safety lock lever before leaving the machine. Always lower the attachment to the ground, and remove the key when leaving the machine. Failure to comply could result in death or serious injury.

This WARNING safety sign is located inside the cab on the left hand side of the seat.

Part Number — ZL11N04204 Quantity — 1

ZL11N04204

30

YY20T01273P1

31

31 - CAUTION — Unexpected movement hazard When pulling up the safety lock lever to the LOCKED position, operate it carefully. Depending on the seat postiion when unlocking the joystick left hand operator control lever may interfere with the armrest to cause unexpected machine movement. Failure to comply could result in minor or moderate injury.

This CAUTION safety sign is locked on the left hand side of the seat.

Part number — YY20T01273P1 Quantity — 1

2-28

2 - SAFETY INFORMATION

Hand signals Raise load vertically Face machine operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

NH0081

1

NH0082

2

NH0083

3

NH0084

4

Lower load vertically Face machine operator, extend right arm down, point index finger down and move hand in a small circular motion.

Move load In horizontally Face machine operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

Move load Out horizontally Face machine operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

2-29

2 - SAFETY INFORMATION

Raise boom Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb up.

NH0085

5

NH0086

6

NH0087

7

NH0088

8

Lower boom Face machine operator, extend right arm out horizontally from shoulder, make a fist with thumb down.

Swing left Face machine operator, extend right arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

Swing right Face machine operator, extend left arm out horizontally from shoulder, make a fist with index finger pointing in swing direction.

2-30

2 - SAFETY INFORMATION

Arm In Face machine operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

NH0089

9

NH0090

10

NH0091

11

NH0092

12

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

Counter rotate left 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.

Counter rotate right 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.

2-31

2 - SAFETY INFORMATION

Travel forward Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion.

NH0093

13

NH0094

14

NH0095

15

NH0096

16

Travel reverse Face machine operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

Close bucket 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 reverse circular motion.

Open bucket Face machine operator, hold left hand in, open 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.

2-32

2 - SAFETY INFORMATION

Turn left 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.

NH0097

17

NH0098

18

NH0099

19

NH0100

20

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

Move this much Face machine operator, raise both forearms up, hands open and facing each other , move hands in laterally indicating how far to go.

Move slowly Face machine operator, raise left arm out 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).

2-33

2 - SAFETY INFORMATION

Stop Face machine operator, raise left arm out horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

NH0101

21

NH0102

22

NH0103

23

Emergency stop Face machine operator, raise both arms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

Stop engine Face machine operator, right arm at side, draw left thumb or index finger across throat.

2-34

3 - CONTROLS/INSTRUMENTS

3 - CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM

Cab CAUTION Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in minor or moderate injury.

C0075B

Before getting on the machine: •

Keep the access to the machine clean and clear of foreign objects. Remove grease or mud from steps and handrails to minimize the risk of slipping.

•

Check that the fasteners of steps and handrails are tightened and undamaged.

•

Always face the machine and maintain a three point contact with the steps and handrails.

SP0008

1

NHC0055

2

Opening the door from the outside NOTE: Use the ignition key for starting and stopping the engine and for opening and closing the cab door, the radiator compartment panel, the hydraulic pump compartment panel, the tool compartment, the fuel tank cap and the engine hood.

Pull the door handle to open door from the outside (1).

Make certain it locks into the latch on the cab.

Closing the door from the outside Close the door and turn the key in the lock (2).

3-1

3 - CONTROLS/INSTRUMENTS

Opening the door from the inside Pull the opening lever (3).

NHC0056

3

NHC0058

4

Releasing the door from the inside To keep the door open during machine operation, open it until it securely locks into the latch on the cab side.

To release the door, push down the lever (4).

Opening and closing the front windshield Before adjusting or opening the front window, park the machine on level ground, lower the attachment to the ground, pull up on the safety lock lever, and stop the engine.

To open the front windshield: •

Push the lock lever (5) on the upper center of the window forward, and release the lock.

•

Hold and push up the handles located on the upper and lower side of the windshield. After the windshield reaches the rear side of the roof, it locks automatically.

RAIL12CEX0628AA

5

RAIL12CEX0629AA

6

To close the front windshield: •

Unlock the windshield by pushing the right and left sides of the window forward. Pull the lock lever (6) and lock the window securely.

•

Slide the windshield using handles

3-2

3 - CONTROLS/INSTRUMENTS

Removing and storing the lower front window •

Open and lock the front windshield as described above.

•

Hold lower front window, and remove it from the window frame.

•

Store the lower window in the holders (7) located on the left rear side of the cab.

RAIL12CEX0630AA

7

Inside cab light The inside cab light switch (8) has two positions: •

Down: light OFF

•

Up: light ON

NHC0054

8

Emergency exit If the cab door cannot be opened in an emergency, an escape from the cab can be made using other means of exit. Be proactive and exam other means of escape.

•

Use the front windshield as an escape route by opening the front window and escaping through the opening. .

•

The machine is equipped with an emergency life hammer (9) if it is necessary to break the windows to escape.

•

Break the rear window with the emergency life hammer if emergency escape becomes necessary and other routes are blocked.

RAIL12CEX0631AA

9

OPERATOR'S SEAT

Operator's seat WARNING Loss of control hazard!

DO NOT make seat adjustments while the machine is in motion. All seat adjustment should be made with the machine stationary and the parking brake applied.

Failure to comply could result in death or serious injury.

W0293A

3-3

3 - CONTROLS/INSTRUMENTS

Before operating the machine, adjust and lock the seat in the correct position to guarantee maximum driving comfort and maximum control accessibility.

Suspension adjustment 1.

Seat suspension is adjusted by turning the seat suspension knob (1). Set the scale according to the operator’s weight for optimum ride comfort.

RAIL12CEX0633AA

1

RAIL12CEX0633AA

2

RAIL12CEX0632AA

3

Forward and backward adjustment The seat can be adjusted back and forward.

2.

Use the bail in the front of the seat (2) to make a comfortable adjustment for reaching the pedals.

The operator’s back should be against the seat back and all pedals should be within comfortable leg reach.

Height and reclining adjustment The seat can be raised and lowered. Recline the seat to operator preference.

3.

Use the height adjustment lever (3) to raise and lower the seat.

3-4

3 - CONTROLS/INSTRUMENTS

4.

Use the reclining lever (4) to set the desired reclining angle.

RAIL12CEX0632AA

4

RAIL12CEX0633AA

5

RAIL12CEX0633AA

6

Arm rest adjustment 5.

Lower or raise the arm rest (5). Turn the control dial (6) to fine adjust the angle of the arm rest.

Head rest adjustment 6.

Move the head rest (7) up and down or backward and forward to the desired position.

3-5

3 - CONTROLS/INSTRUMENTS

FORWARD CONTROLS

Front console

RAIL12CEX0634GA

1. Left hand control lever 2. Safety lock lever 3. Left travel pedal 4. Left travel lever

1

5. Right travel lever 6. Right travel pedal 7. Right hand control lever 8. Gauge cluster

3-6

3 - CONTROLS/INSTRUMENTS

WARNING Avoid injury!

If the machine responds to the controls with the safety lever in the LOCK position, stop the engine immediately and contact your dealer.

Failure to comply could result in death or serious injury.

W0937A

Safety lever The safety lever is used to disable travel and swing controls and the attachment movements. It has two positions: •

•

NH0002

2

NH0003

3

NHC0201A

4

LOCK: with the machine stationary and the engine running or stopped, it prevents the possibility of machine movement if the control levers/pedals are moved UNLOCK: the safety lever enables the operation of all controls. When operating the machine, the safety lever is in the unlock position.

Left control lever (ISO pattern) The left control lever activates the following operations: 1.

Swing right

2.

Swing left

3.

Arm roll-out

4.

Arm roll-In

Neutral: The boom and bucket are held in position NOTE: When the control lever is released, it returns automatically to the neutral position and the associated work function stops.

The horn button (1) is located on the left control lever handle. Press to sound.

Right control lever The right control lever activates the following operations: 5.

Boom lower

6.

Boom raise

7.

Bucket dig

8.

Bucket dump

Neutral: The boom and bucket are held in position NOTE: When the control lever is released, it returns automatically to the neutral position and the associated work function stops.

3-7

RAPH12CEX0137AA

5

3 - CONTROLS/INSTRUMENTS

Travel control pedals and levers NOTE: The words right, left, front, back, clockwise and counterclockwise are to be referred to the operator position facing forward with the machine positioned forward over the travel motor.

N (a) + (b) (c) + (d) (b) + (c)

Neutral Machine moves forward Machine moves backward Opposite simultaneous rotation of the tracks with consequent counterclockwise rotation of the machine around its center axis. (a) + (d) Opposite simultaneous rotation of the tracks with consequent clockwise rotation of the machine around its center axis. (a), (b), (c), (d) Positions to move one track only.

Consequently the machine steers pivoting on the stationary track.

NH0159

3-8

6

3 - CONTROLS/INSTRUMENTS

Instrument cluster

RAIL12CEX0635BA

1

1.

Liquid Crystal Display (LCD)

7.

Auto accel switch

2.

Engine coolant temperature gauge

8.

Work mode select switch

3.

Fuel level gauge

9.

Washer switch

4.

Alarm stop switch

10.

Wiper switch

5.

Screen change switch

11.

Travel speed select switch

6.

Select switch

3-9

3 - CONTROLS/INSTRUMENTS

Liquid Crystal Display (LCD) The LCD displays machine operations and warnings. It displays: •

Main screen display for the operator

•

Time in 12 or 24 hour increments

•

Switch operations

•

Warnings

•

A/B mode

•

Maintenance requirements

WARNING

RAIL12CEX0608AA

2

RAIL12CEX0608AA

3

Avoid injury and/or machine damage!

If the main warning light comes on and the warning system sounds, immediately stop the machine and shut off the engine. Lower the working equipment and follow the instructions on the display to locate the cause of the problem.

Failure to comply could result in death or serious injury.

W1025B

Engine coolant temperature gauge The engine coolant temperature gauge (2) indicates the temperature of the engine coolant. The temperature is normal in the white range. If the indicator enters the red range, let the engine low idle until the coolant temperature drops, and the indicator moves back into the white range.

1.

BLUE: cold condition. Warm up the engine and hydraulic oil

2.

WHITE: operating condition

3.

RED: overheat

NOTICE: If the indicator enters the red range, the relevant warning icon is displayed and the alarm sounds at the same time. Stop operations and let the engine low idle. If overheating continues, stop the engine, allow the engine to cool, and check the coolant level.

3-10

3 - CONTROLS/INSTRUMENTS

Fuel level gauge The fuel level gauge (3) indicates the remaining amount of fuel. Refuel when the indicator is approaching the E range.

NOTICE: In the event the amount of fuel is insufficient, the relevant warning icon is displayed. Refill the fuel tank with diesel fuel only.

RAIL12CEX0608AA

3-11

4

3 - CONTROLS/INSTRUMENTS

Alarm stop switch The alarm stop switch (4) stops the warning buzzer sound in the event the machine malfunctions. The LCD monitor will display the warning icon. If the warning icons coupled with the buzzer alarm occurs, change the work operation or stop the machine. Check and service machine immediately.

RAIL12CEX0608AA

5

Buzzer characteristics Priority

A

Level

Description

Auto stop

ManTyp- Key ual e ON stop

Engine running

1

Data from the controller is not received

no

yes

3

yes

yes

1

Swing brake disengaged

yes ( 5 s)

yes

2

yes

yes

KPSS release switch is switched yes ( 5 s) to Release

yes

2

yes

yes

1

B

Icon

1

Selector valve (optional) malfunction

no

yes

2

no

yes

2

Excessive engine coolant temperature

yes ( 5 s)

no

2

no

yes

3

Engine coolant is above 105 °C (221.0 °F)

no

yes

3

yes

yes

3

Coolant level is low

no

yes

3

yes

yes

3

Water level is high in water separator

no

yes

3

yes

yes

3

Air filter is clogged

no

yes

3

yes

yes

3

Self diagnosis (sensor, valve, etc.)

no

yes

3

yes

yes

3-12

3 - CONTROLS/INSTRUMENTS

Screen change switch When the ignition key is turned ON or when starting the engine, the screen changes in order of Time for engine oil change — Time for fuel filter replacement — Time for hydraulic oil filter change — Time for hydraulic oil change — Main Screen. The maintenance intervals are displayed in a loop each time the switch is pressed. If the switch is inactive for 30 seconds, the screen will automatically default to the main screen.

RAIL12CEX0612AA

6

RAIL12CEX0615AA

7

Select switch Use the select switch to auto warm, auto idle stop, set clock, adjust screen contrast, and set flow rate for attachments (breaker mode).

3-13

3 - CONTROLS/INSTRUMENTS

Auto warm up •

Use the select switch to warm up the engine and hydraulic oil in cold temperatures.

1.

Turn the ignition key on, and display the main screen. Press the select switch. The clock/contrast screen will be displayed.

2.

Press the select switch and the Auto Warm Up Off screen will be displayed.

3.

Press the select switch again, and the color of OFF will reverse and Auto Warm Up On will be displayed.

4.

Select ON by pressing the washer switch. Press the select switch to set into memory.

5.

Turn the ignition switch off and the auto warm up is stored into memory. When the engine is started, and if the temperature is low, the automatic warm up operation starts.

6.

Pull up the safety lock lever. Auto warm up will be displayed. Once the warm up is complete, Finish warm up will be displayed and the warm up alarm buzzer will sound for about 5 seconds.

RAIL12CEX0616AA

8

RAIL12CEX0617AA

9

NOTE: If the control lever is operated, the warm up operation is interrupted. .

3-14

3 - CONTROLS/INSTRUMENTS

Swing flasher 1.

Press the select switch and display Switch status clock/contrast select screen.

2.

Press the select switch again and display Auto Warm up Off screen.

3.

Use the wiper key (UP) switch and the Swing Flasher Off screen will display. Switch the swing flasher from off to ON and set by pressing the selector switch again.

4.

Store into memory by pressing the select switch again. When the ignition key is turned on, the swing flasher will flicker to warn others during swing operations. The swing flasher and the rear work lights are synchronized and are turned on and off simultaneously.

RAIL12CEX0646BA

3-15

10

3 - CONTROLS/INSTRUMENTS

Clock adjustment switch 1.

Press the select switch and display Switch status clock/contrast select screen.

2.

Use the Washer (UP) switch and the wiper (DOWN) switch to move the cursor to the clock/contrast screen.

3.

Use the UP and DOWN switch to move the cursor to Adjust clock. Press the select switch. Adjust Clock screen will be displayed.

4.

Select any of the Y (year) M (month) D (date) H (hour) M (minute) and use the UP and DOWN switches to vary the values.

5.

After setting the correct times and dates, press the select switch again and the dates and times will be stored into memory. The screen will return to the main screen.

RAIL12CEX0618AA

3-16

11

3 - CONTROLS/INSTRUMENTS

Contrast adjustment switch 1.

Press the select switch and display Switch status clock/contrast select screen.

2.

Use the Washer (UP) switch and the wiper (DOWN) switch to move the cursor to the clock/contrast screen.

3.

Use the UP and DOWN switch to move the cursor to Adjust clock. Press the select switch. Adjust Contrast screen will be displayed.

4.

Select any of the values from 11111 to 99999. The initial set value is 55555. Smaller numbers are faint and larger numbers are higher contrast. Use the UP and DOWN switches to vary the values.

5.

After setting the desired value, press the select switch again and the contrast values will be stored into memory. The screen will return to the main screen.

RAIL12CEX0621AA

3-17

12

3 - CONTROLS/INSTRUMENTS

Attachment mode buttons — pump flow fate and relief pressure NOTICE: Before starting operation, make sure to select the proper attachment mode.

The attachment mode switch enables to select three operating modes, depending on the attachment which has been installed. Select between digging mode, nibbler mode, or breaker mode. The flow rate must be changed to match the attachment.

NOTE: For flow rate adjustment and relief pressure adjustment, contact your authorized dealer.

Nibbler Flow (Crush- rate er) Pressure A Pressure B

L/min

SET 1 130

MPa

25

MPa

25

Breaker Flow rate Pressure B

L/min

SET 1 130

MPa

34

SET 2 Not set yet Not set yet Not set yet

SET 3 Not set yet Not set yet Not set yet

SET 4 Not set yet Not set yet Not set yet

SET 5 Not set yet Not set yet Not set yet

SET 6 Not set yet Not set yet Not set yet

SET 7 Not set yet Not set yet Not set yet

SET 8 Not set yet Not set yet Not set yet

SET 9 Not set yet Not set yet Not set yet

SET 2 Not set yet Not set yet

SET 3 Not set yet Not set yet

SET 4 Not set yet Not set yet

SET 5 Not set yet Not set yet

SET 6 Not set yet Not set yet

SET 7 Not set yet Not set yet

SET 8 Not set yet Not set yet

SET 9 Not set yet Not set yet

Both nibbler and breaker are preset as a factory default to set 1. If selecting a not set yet from the other sets, take note of the relief pressure, as the pressure is approximately 20 MPa. 1.

Press the select switch and display the main screen.

2.

The display on the left lower corner of the screen can be changed in order H — S — B — A each time the MODE switch is pressed when the main screen displayed.

3.

Press the select switch in A/B mode display screens and press SET number screen. The SET number contains set flow rate and relief pressure. Select the flow rate and relief pressure.

4.

Once flow rate and relief pressure are chosen, press the select switch to the desired choice.

5.

When conflux flow switch is selected, double volume of oil flows. Check the flow rate and position of the switch before beginning any operation to make certain they are the correct setting for the attachment.

Check the relief pressure for correct settings.

NOTICE: Incorrect settings can cause machine damage.

If you doubt your ability to chose the correct settings, contact your authorized dealer for additional information.

3-18

3 - CONTROLS/INSTRUMENTS

Travel speed button WARNING Loss of control hazard!

Avoid pressing the travel speed button while traveling. Avoid shifting to FAST speed when traveling downhill or when loading/unloading from a trailer.

Failure to comply could result in death or serious injury.

W0390A

By pressing the travel speed button, speed can be changed between high and low speed.

SLOW: select the slow travel speed when the machine operates on rough or soft ground, on slopes or tight spaces or when a high traction capacity is required.

RAIL12CEX0615AA

13

RAIL12CEX0615AA

14

FAST: select the fast travel speed when the machine operates on hard and flat ground.

The travel speed selected is indicated on the display of the monitor with the relevant icon.

NOTE: Every time the engine is started, the travel speed is automatically set on SLOW.

Windshield washer button By pressing windshield washer button the washer is activated as long as it is pressed. The wiper is automatically activated.

NOTE: Make sure that the windshield washer liquid tank is filled prior to activating the wiper.

Windshield wiper button By pressing wiper button the front wiper is activated. It is possible to select two operating modes, indicated on the display of the monitor by the relevant icons: Intermittent. Press button once.

Continuous. Press button twice.

To deactivate the wiper, press button until the icon on the monitor disappears.

3-19

3 - CONTROLS/INSTRUMENTS

Warning icons Warnings of machine malfunctions can appear on the display. If warnings are displayed, take appropriate action to prevent machine damage.

Icons (priority A) Icon

Level

Description

Solution

1

CPU icon: this icon appears when the controller sends no data.

Stop the machine and contact your authorized dealer.

1

Swing brake disengaged icon: this icon appears when the parking brake release switch is moved into position RELEASE LOCK.

Stop the machine and contact your authorized dealer.

1

KPSS release switch is switched to Release Stop the machine and contact your side authorized dealer.

Icons (priority B)

1

Selector valve malfunction

Attachment does not correspond to work mode selection.

If the correct mode does not cancel the warning, Stop the machine and contact your authorized dealer.

2

Displays when warm-up is complete

Start engine

3

Coolant temperature high

Run engine at idle speed to lower temperature. If warning does not cancel, stop the engine, allow the engine to cool and check the coolant level.

3

Low coolant level

Stop the engine, allow engine to cool. Check coolant level.

3

Contaminants in water separator

Drain water and contaminants.

3

3

4 4

5

5

Clogged air filter — engine output is lowered Check engine air filter and/or clean.

Pressure sensor, proportional valve malfunction

Contact your authorized dealer

Battery recharge icon: this icon appears Check the fuse and the battery when the battery recharge system does not recharge circuit. operate properly.

Fuel level icon: this icon appears when the Stop the engine and top up the fuel fuel level in the tank is insufficient. level.

Engine oil change icon: this icon appears every 500 hours of operation of the machine Change the engine oil. to remind the operator the periodic oil change.

Turn switch off if travel independent Travel independent select switch is on function is not needed.

3-20

3 - CONTROLS/INSTRUMENTS

RIGHT-HAND SIDE CONTROLS

Console controls

RAIL12CEX0634GA

1. Nibbler close 2. Nibbler open 3. Hour meter 4. Ignition switch 5. Engine speed throttle — potentiometer 6. Work light switch 7. Conflux/single flow switch 8. Cap (optional switch) 9.Independent travel switch

1

9. Independent travel switch 10. Cap (optional switch) 11. Blade control switch 12. Cap (optional switch) 13. 12 Volt power supply 14. Lighter 15. KPSS release switch 16. Swing parking brake release switch

3-21

3 - CONTROLS/INSTRUMENTS

Starter switch The starter switch has four positions: OFF: the engine is stopped and the electric system is deactivated after about 4 s.

ACC: radio, horn and 12 V socket are energized.

ON: electrical power is supplied to all the machine's electrical systems.

START: the starter solenoid is energized to start the engine. Once the engine is started, the key is released to return into ON position.

NHC0011A

2

NHC0012A

3

NHC0002

4

Engine speed throttle The engine speed throttle is used to increase or decrease engine RPM. Turn the throttle clockwise to increase engine RPM. Turn the throttle counterclockwise to decrease engine RPM. NOTE: Turn the engine speed throttle fully counterclockwise (engine slow idle) before stopping the engine.

Work lights switch The work lights switch controls the activation of the lights located on the boom and turret. The switch has the following positions: OFF (side without symbol pressed): both lights are inactive.

ON (side with symbol pressed): position for the activation of both lights.

Independent travel select switch Use the independent travel switch when travel and attachment operation are both required. The travel control lever/pedals must be in the neutral position before activating this switch.

RAPH12CEX0215AA

3-22

5

3 - CONTROLS/INSTRUMENTS

Conflux/single flow change switch Use this switch to change between single flow and conflux hydraulic flow.

Use the double flow when performing nibbler work.

Use single flow when using the breaker.

RAIL12CEX0650AA

6

RAIL12CEX0652AA

7

RAIL12CEX0653AA

8

Dozer control switch Push the dozer switch in order to activate the dozer circuit.

24 Volt lighter A cigarette lighter is located on the right wall of the cab.

Push the lighter in and wait approximately 30 seconds.

Pull lighter from the socket to use. Replace after use.

If the lighter does not return after 30 seconds or more, remove the lighter, as it may overheat.

3-23

3 - CONTROLS/INSTRUMENTS

12 Volt power supply A 12 V socket is located on the right side of the rear panel.

The socket can be used to power small electrical equipment

RAIL12CEX0654AA

9

RAIL12CEX0656AA

10

RAIL12CEX0655AA

11

Hour meter The hour meter indicates the total time the engine has run. Even if the machine is not moving, the hour meter will continue to run as long as the engine is running. Use the hour meter to effectively schedule maintenance.

Nibbler breaker switch (option) Switches on top of the right hand control are used to actuate the nibbler and breaker. With single oil flow control, this switch is not available.

3-24

3 - CONTROLS/INSTRUMENTS

Kobelco Power Supply System (KPSS) switch TheKobelco Power Supply System (KPSS) release switch is a toggle switch that will release the electrical system controls to place the machine in the CPU hydraulic system back up mode. Should CPU data communication error appear on the console screen, the pump flow rate may be locked into a minimum flow. Switch the toggle switch (1) to allow the machine to be moved to a safe area for service.

Swing parking brake release switch The swing parking brake is normally locked. The swing parking brake is released during the swing and arm in operation. Should the brake malfunction and remain locked, move the toggle switch (2) to the unlocked position. Move the machine to a safe parking area and contact your authorized dealer for service. When the machine is returned to operation, make certain that the switch is in the normal position.

RAIL12CEX0657AA

12

RAIL12CEX0658AA

13

NOTICE: Using the release switches is only a temporary measure. Make certain that these switches are returned to the standard or normal position after repairs.

Operating levers The left and right control levers operate the machine attachment functions. When using the control levers, the attachment will stop moving when the lever is released.

The control lever will return to the neutral position when released.

Make certain the ISO pattern information sign matches the machine movement. If informational signs do not match the control lever pattern, replace the informational signs with the correct ones.

Left control lever 1. Swing right 2. Swing left 3. Arm out 4. Arm in N (neutral) Right control lever 5. Boom down 6. Boom up 7. Bucket dig 8. Bucket dump N (neutral)

3-25

3 - CONTROLS/INSTRUMENTS

Radio

RAPH12CEX0095FA

1

1.

Power switch

5.

Preset key

2.

AM/FM switch

6.

DISP (display change) key

3.

Volume control

7.

Sound control key

4.

UP/DOWN key

8.

Display (time/frequency)

1 – Power control Press the power switch (1) and the power is switched from off to on. The band AM or FM will display briefly followed by the frequency or the time.

RAPH12CEX0101AA

2

RAPH12CEX0102AA

3

2 – Band switching Press the AM/FM key (2) to switch the band from AM to a FM frequency. Each time the key is pressed the band displays in the following order: FM1 — FM2 — AM. When the frequency band is switched, the station last received is selected.

3-26

3 - CONTROLS/INSTRUMENTS

3 – Volume control To increase volume level, press the + side of the volume control key (3). To reduce volume level, press the — side of the volume control key. The level of volume is displayed along with station, balance, treble, bass. After adjustments, the display will return to frequency or time display.

RAPH12CEX0121AA

4

RAPH12CEX0123AA

5

RAPH12CEX0122AA

6

4 – Selecting stations Radio stations can be selected by: •

Manual tuning

•

Auto select

•

Preset memory

Manual tuning Press UP or DOWN key (4) to change the frequency.

Auto select Press and hold UP or DOWN key (for more than one second) to change the frequency to the next detected frequency. Auto tuning is interrupted and stops at the received frequency.

3-27

3 - CONTROLS/INSTRUMENTS

5 – Preset memory Auto preset Received frequencies detected can be memorized into six preset memory keys (5). Press sound control key (7) for at least one second. Detected stations are automatically memorized by the preset buttons.

Manual preset Press one of the six preset keys (5) for at least one second. After the preset key number pressed flashes three times on the display, the current station being received is memorized and the frequency is displayed.

Press one of the six preset keys (5) and the frequency memorized in the preset key is available.

RAPH12CEX0124AA

7

RAPH12CEX0126AA

8

RAPH12CEX0362AA

9

6 – DISP (display change) key To change the display from the frequency display to the time display, press the DISP key (6) The display key will show either the time or the frequency, dependent on which display is selected.

7 – Sound control key Sound control key (7) adjusts tone and balance. The display changes to BAL, TRE, and BAS in order when the sound control key (7) is pushed.

Balance control •

To raise the volume of the left speaker push the UP key (4) while BAL is displayed.

•

To raise the volume of the right speaker, push the DOWN key (4) while BAL is displayed.

Treble control •

To emphasize the treble, push the UP key (4) while TRE is displayed.

•

To weaken the treble, push the DOWN key (4) while TRE is displayed.

Bass control •

To emphasize the bass, push the UP key (4) while BAS is displayed.

•

To weaken the bass, push the DOWN key (4) while BAS is displayed.

3-28

3 - CONTROLS/INSTRUMENTS

8 – Display (time/frequency) Time setting 1.

Press DISP key (6) for one second or more while the time is displayed. The hour display will flash.

2.

Press the UP key (4) to increase the hour.

3.

Press the DOWN key (4) to decrease the hour.

4.

Press DISP key (6) again and the minute display flashes.

5.

Press the UP or DOWN keys (4) to increase or decrease the minutes.

6.

Press the DISP key (6) again and the time setting will be complete.

RAPH12CEX0128AA

3-29

10

3 - CONTROLS/INSTRUMENTS

Climate control panel

1

NHC0016A

1. Main power button 2. Auto control button 3. Fan speed regulation button 4. Temperature setting button 5. Air distribution selection button

6. Recirculation/fresh air button 7. Defroster button 8. Air conditioner button 9. LCD display

Operating the climate control system

•

NOTE: Before turning on the air conditioner, close the cab door and windows to achieve better performance.

To start the air conditioner system, press the main power button (1).

•

Press the auto control button (2). The display shows the wording AUTO. The fan speed and the air distribution are automatically regulated.

•

Set the desired temperature using the relevant buttons (4). The system gradually changes the temperature until the set value is reached.

Select between recirculation and fresh air mode by pressing the relevant button (6).

NOTE: During the operation in automatic mode, it is possible to change the fan speed and the air distribution. The AUTO function is deactivated until the relevant button is pressed again.

NOTE: Pay special attention to prevent the liquid spills in the zone marked (A). Also, avoid using detergent liquids or steam to clean the zones. Never use alcohol or alcohol based products.

3-30

3 - CONTROLS/INSTRUMENTS

Fan speed regulation buttons NOTE: If the fan speed regulation buttons (3) are pressed while the air conditioner system is in AUTO mode, auto is deactivated.

Buttons (3) provide the velocity of air flowing from the ducts. The air flow from the ducts is indicated by the display.

NHC0018

2

NHC0019

3

NHC0020

4

NHC0021

5

Temperature setting buttons Buttons (4) provide the temperature setting in the cab.

The range of the temperatures that can be selected is 18 °C (64 °F) ( LO ) through 32 °C (90 °F) ( HI ). When buttons (4) are pressed, you can increase/decrease the temperatures by 0.5 °C ( 0.9 °F) .

Air distribution selection button NOTE: If the air distribution selection button (5) is pressed while the air conditioner system is in AUTO mode, auto is deactivated.

Button (5) provides the manual choice of 4 air distribution positions in the cab. The air distribution is indicated on the display.

Recirculation/fresh air button Button (6) provides the air recirculation inside the cab or the inlet of fresh air from the outside.

3-31

3 - CONTROLS/INSTRUMENTS

Defrosting button NOTE: if defrosting button (7) is pressed while the air conditioner system is in AUTO mode, auto is deactivated.

When pressing button (7) air flows out the vent located under the seat and from the vents located under the monitor to defrost the windshield.

NHC0022

6

NHC0023

7

Air conditioner activation button Press button (8) to activate the air conditioner.

3-32

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS STARTING THE UNIT

Starting the engine WARNING Inhalation hazard!

Make sure there is proper ventilation before starting the engine.

Failure to comply could result in death or serious injury.

W0928A

Starting the engine in normal conditions 1.

Securely fasten seat belt.

2.

Confirm safety lever is in LOCK position.

3.

Confirm all control levers are in neutral position.

4.

Confirm engine speed throttle (2) is turned to engine idle speed position LO.

5.

Turn starter key (1) to ON position, and verify instrument cluster display for normal operating conditions.

6.

Turn the ignition key (1) to START position until the engine starts. Release the key as soon as the engine is started. When released, the key returns automatically to ON position.

NOTICE: Do not hold ignition key in START position for more than 15 s. Should the engine fail to start, return the key to OFF position. Wait for 30 s, then re-start the engine.

4-1

NH0002

1

NHC0245A

2

4 - OPERATING INSTRUCTIONS

Starting the engine in cold conditions 1.

Repeat the above procedure from step 1 to 5.

2.

If the engine coolant temperature is below -5 °C (23.0 °F), the automatic preheating is activated, signalled by the preheat icon (3) on the instrument cluster display.

NOTICE: Before starting the engine, wait for icon (3) to disappear.

NOTICE: If during the preheating phase the warning icon (4) should appear on the instrument cluster display, turn ignition key to OFF position and contact your authorized dealer.

3.

Turn ignition key (1) to START position until the engine starts. Release the key as soon as the engine is started. When released, the key returns automatically into ON position.

4-2

4 - OPERATING INSTRUCTIONS

Starting the engine with booster batteries WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Explosion hazard!

Booster batteries or jumper cables must be connected properly to prevent battery explosion and/or damage to the electrical system.

Connect positive to positive and negative to negative.

Failure to comply could result in death or serious injury.

W0343A

NOTICE: Use only booster batteries with the same machine battery characteristics ( 12 V - 160 A·h).

Connecting booster batteries 1.

Confirm starter key is in OFF position and the safety lever is in LOCK position.

2.

Connect one terminal of the red cable (R) to the positive (+) pole of machine batteries.

3.

Connect the other terminal of the red cable (R) to the positive (+) pole of the booster batteries.

4.

Connect one terminal of the black cable (B) to the negative (-) pole of the booster batteries.

5.

Connect the other terminal of the black cable (B) to the upper frame of the machine (ground).

Cables connecting order: 1 --> 2 --> 3 --> 4 Disconnecting booster batteries 1.

Disconnect the terminal of the black cable (B) from the upper frame of the machine (ground).

2.

Disconnect other terminal of the black cable (B) from the negative (-) pole of the booster batteries.

3.

Disconnect the terminal of the red cable (R) from the positive (+) pole of the booster batteries.

4.

Disconnect one other terminal of red cable (R) from the positive (+) pole of the machine batteries.

Cables disconnecting order: 4 --> 3 --> 2 --> 1

NHC0248B

4-3

3

4 - OPERATING INSTRUCTIONS

Inspection after starting the engine Safety lever WARNING Avoid injury!

If the machine responds to the controls with the safety lever in the LOCK position, stop the engine immediately and contact your dealer.

Failure to comply could result in death or serious injury.

W0937A

With the engine running and the safety lever in LOCK position: 1.

Operate right and left control levers. Confirm attachment does not move.

2.

Operate travel control levers. does not travel.

NH0002

1

Confirm machine

RAPH12CEX0491AA

4-4

2

4 - OPERATING INSTRUCTIONS

STOPPING THE UNIT

Stopping the engine 1.

Park machine on a firm, level surface.

2.

Place safety lever in LOCK position.

3.

Deactivate Auto Idle function and turn engine speed throttle (2) to idle speed position LO.

4.

Let the engine run at low idle for several minutes to allow the turbocharger to cool.

5.

Turn ignition key (1) to OFF position.

6.

Remove ignition key from the ignition switch.

NOTICE: Stopping the engine while running at high speed may cause the turbocharger turbine shaft to rotate without proper lubrication. This can cause severe damage to the turbocharger.

4-5

NH0002

1

NHC0245A

2

4 - OPERATING INSTRUCTIONS

PARKING THE UNIT

Parking the machine 1.

Release both travel levers and pedals (1) into neutral position.

2.

Deactivate Auto Idle function and turn engine speed throttle (2) to idle speed position LO.

3.

Position front attachment as shown and lower bucket to the ground.

4.

Turn starter key (3) to OFF position and remove starter key from the starter switch.

5.

Place safety lever in LOCK position.

6.

When leaving the machine, lock windows, cab door and all panels with the starter key.

RAPH12CEX0489AA

NHC0332

2

RAPH12CEX0268AA

NH0002

4-6

1

4

3

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS ROAD TRANSPORT

Preparing for road transport •

Know the total weight, length, width, and height of the machine to be transported. Refer to the chapter SPECIFICATIONS.

•

Use only a trailer with a rated capacity sufficient to transport the machine. Make sure that the trailer has ramps or a ramp is available for loading the machine. Use ramps which have sufficient width, length, thickness, and strength. The ramp slope should be 15 ° or less.

•

Know the conditions of the transport route, the route weight and size limits, and special local traffic regulations.

•

Obtain any permits required from proper government agencies for machine transportation.

•

Position the trailer on firm and level ground. Block the tires of trailer.

•

Clean the machine undercarriage and tracks of mud or debris to prevent skidding during transport.

Loading the machine WARNING Loss of control hazard!

Turn off the Auto Idle function when traveling downhill or when loading/unloading from a trailer.

Failure to comply could result in death or serious injury.

W0927A

WARNING Loss of control hazard!

Avoid pressing the travel speed button while traveling. Avoid shifting to FAST speed when traveling downhill or when loading/unloading from a trailer.

Failure to comply could result in death or serious injury.

NH0057

1

NH0058

2

W0390A

1.

Turn the auto Idle function off, and select the slow travel speed.

2.

Align the machine to the ramp. Position the front attachment as shown in figure, lowered as much as possible in order not to interfere with the trailer.

Slowly move the machine up the trailer ramp.

3.

Prevent the attachment from striking the bed of trailer.

NOTICE: Use care at the connection point between the trailer and the ramp. The machine could drop suddenly at this connection point. Do not fully extend the arm and bucket cylinders to prevent damaging them due to accidental impacts of the attachment with the trailer bed.

5-1

5 - TRANSPORT OPERATIONS

4.

Once in a secure transport position, turn the upper structure 180 ° slowly. Slowly lower the attachment to the trailer bed. Place a wooden block between the attachment and the trailer bed.

5.

Place the safety lever in LOCK position. Stop the engine and remove the starter key. Lock all windows and the cab door.

NH0060

3

NHC0324

4

NH0065A

5

Loading machine without front attachment If loading the machine when the front attachment is removed, back the machine onto the trailer.

Securing the machine After the machine is loaded and positioned, secure the machine.

1.

Position blocks (B) at the front and rear of the tracks in order to prevent the machine from moving during transport.

2.

Secure the machine properly using safe and proper rigging for transport.

5-2

5 - TRANSPORT OPERATIONS

Unloading the machine NOTICE: Before unloading the machine, make sure all tie-down chains are removed and the trailer wheels are blocked.

1.

Position the trailer on firm and level ground. Put blocks against the trailer tires to prevent trailer movement.

2.

Remove chains or wire ropes used to secure the machine.

3.

Start the engine, and move the safety lever to UNLOCK position.

4.

Make sure that the auto Idle function is deactivated and the travel speed is set to SLOW.

5.

Raise attachment and travel slowly. Stop the machine at the rear end of trailer.

6.

Set arm and boom to angle between 90 to 110° and travel down slowly from trailer to ramps.

7.

Travel down on ramps slowly while operating boom and arm carefully until the machine completely passes from the ramp.

5-3

NHC0325

6

NHC0326

7

5 - TRANSPORT OPERATIONS

SHIPPING TRANSPORT

Lifting the machine The following procedures are for lifting the machine, as built by KOBELCO. This procedure does not take into account modifications made to the machine that affect machine mass or center of gravity.

RAIL12CEX0665BA

1

NOTE: This lifting procedure is applicable for machines in standard specification. The lifting procedure differs for each attachment type and each machine in option. In such cases, contact your authorized dealer.

WARNING

etc. that could fall or cause a problem or injury during the procedure. Remove or secure loose items.

Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

2.

Use wire rope and expander of sufficient length to prevent interference with the machine body when lifting machine. Cover wire rope with cloth to protect machine from damage, if necessary.

3.

Pass wire ropes between 1st and 2nd lower rollers on both front and rear sides of machine as shown in figure (lifting point signs).

4.

Lift up machine with an angle of two wire ropes adjusted within the range of 25 ° to 30 ° slowly.

5.

Lift the machine slightly, wait until the machine stabilizes, then complete lift.

W0256A

Lift the machine from firm level ground as follows: 1.

Stop the engine and move safety lock lever to LOCK position. Remove starter key. Do don't allow anyone on the machine during lifting. Check the operator's seat and area for any loose item, tools,

5-4

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS GENERAL INFORMATION

Operating the controls The following instructions inform the operator of the basic function of each hydraulic control. Learning these instructions and practicing with the hydraulic controls will increase operator efficiency during machine operation.

Prior to machine operation, each operator must read carefully, learn and implement the safety rules described in this manual and located on the machine.

Inside the cab, on the right window, the decal (1) illustrating the various movements of the machine as a function of the controls is applied. Read and heed the functions associated with the respective controls listed on this decal prior to operating the machine.

6-1

NHC0301

1

NHC0302

2

NHC0303

3

6 - WORKING OPERATIONS

Work mode select switch Selecting work modes Press the work mode select switch to change between H (heavy duty) and S (standard digging). The work mode will be displayed in the lower left corder of the LCD screen.

The mode at engine start always defaults to the H mode.

Use H mode for heavy duty digging work. This mode gives priority to the workload at high speed.

Use the S mode for standard digging and loading. This mode will offer a fuel savings and is in good balance to a normal workload.

RAIL12CEX0610AA

6-2

1

6 - WORKING OPERATIONS

Machine travel Traveling forward/reverse 1.

Confirm safety lever is lowered in UNLOCK position. Raise attachment from the ground.

2.

To move the machine forward (F) push both travel levers (right and left) toward the front of the machine. To travel the machine in reverse (R) pull both travel levers backward. The speed changes in relation to the forward or backward stroke of the levers.

The same operation can be done by actuating the right (1) and left (2) travel pedal. To move the machine forward (F) press with the tip of the feet or with the heel for reverse travel (R). When the control pedals (or levers) are released, the neutral position is automatically reached.

NH0108

1

NH0109

2

NH0110

3

NH0111

4

Steering the machine 1.

Push the left travel lever forward to steer RIGHTWARD.

2.

Push the right travel lever forward to steer LEFTWARD.

3.

Pull the left travel lever backward to steer LEFTWARD in reverse

4.

Pull the right travel lever backward to steer RIGHTWARD in reverse.

Counter rotating the machine (Spin turn) This maneuver actuates the simultaneous counter rotation of the track chains, letting the machine to turn on its axis.

1.

To counter rotate the machine to the left, pull left travel lever back and push right travel lever forward.

2.

To counter rotate the machine to the right, pull right travel lever back and push left travel lever forward.

Travel stop 1.

Release right and left travel levers into neutral position (N). The machine stops traveling.

6-3

6 - WORKING OPERATIONS

Attachment controls Boom operation The boom is actuated by pushing or pulling the right control lever forward or backward. The speed of the movement is determined by the stroke of the lever.

•

When pulling the right control lever BACKWARD the boom is raised.

•

When pushing the right control lever FORWARD the boom is lowered.

•

When returning the right control lever centrally (neutral position) the boom stops moving.

NH0113

1

NH0114

2

NH0115

3

Arm operation The arm is actuated by pushing or pulling the left control lever forward or backward. The speed of the movement is determined by the stroke of the lever.

•

When pushing the left control lever FORWARD the arm is extended.

•

When pulling the left control lever BACKWARD the arm is retracted.

•

When returning the left control lever centrally (neutral position) the arm stops moving.

Bucket operation The bucket is actuated by moving the right control lever rightward or leftward. The speed of the movement is determined by the stroke of the lever.

•

When moving the right control lever leftward, the bucket is rolled back (digging).

•

When moving the right control lever rightward, the bucket is extended (dumping).

•

When returning the right control lever centrally (neutral position) the bucket stops moving.

6-4

6 - WORKING OPERATIONS

Swing control Swinging the upper structure The upper structure swings when the left control lever is moved rightward or leftward. The swinging speed is determined by the stroke of the lever.

•

When moving the left control lever leftward, the upper structure swings leftward.

•

When moving the left control lever rightward, the upper structure swings rightward.

•

When returning the left control lever centrally (neutral position) the upper structure stops moving.

NH0118

6-5

1

6 - WORKING OPERATIONS

Practices to improve efficiency Use arm in action 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.

NH0119

1

NH0120

2

NH0121

3

NH0122

4

Operate boom smoothly 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.

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

6-6

6 - WORKING OPERATIONS

Cleaning sand and soil from bucket 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.

NH0123

5

NH0124

6

NH0125

7

NH0127

8

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

Grading Position the arm slightly forward of its vertical position with the bucket fully rolled back, as shown. Retract the arm and at the same time slightly lift the boom. Once the arm moves past its vertical position, slightly lower the boom to allow the bucket to obtain a smooth surface.

Operating in water or mud The machine can wade or work into a river, providing that: •

The terrain is firm enough to prevent the machine from sinking excessively.

•

The water level (A) does not exceed the track support rollers.

•

The stream is not excessive.

Avoid dipping the bullgear, the swing motor reduction unit and the centre joint below the water level. In the event they are accidentally submerged, please contact a Dealer.

The non compliance with these due precautions could cause a premature wear of some components of the machine.

6-7

6 - WORKING OPERATIONS

Machine operation in adverse weather conditions Operation in extreme cold

•

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

•

Follow procedures on page Engine starting system - Start (Starting the engine in cold conditions) as starting engine may be difficult due to extremely cold temperatures.

•

Use an engine oil, hydraulic oil and diesel fuel designed for use in cold climates.

•

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

•

Keep batteries fully charged.

•

•

Make certain to activate the AUTO WARM-UP function to prevent premature wear or damage to pumps, motors and other components.

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

During slow, or no work periods, place engine speed throttle to LO idle position.

NOTICE: In extremely frigid climates, covering the radiator is a method to aid the machine warm-up. If necessary to maintain operating temperatures, cover the outer edges of the radiator, leaving an opening in the center part of the cover - thus avoiding fan overloading. Keep a close watch on the instrument cluster for warning icons during operation. It may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting.

•

•

Keep batteries terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine systems. Check the batteries 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.

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

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

Operation in high altitudes •

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

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

•

Keep close watch on the coolant temperature meter to avoid overheating of the engine.

Operation in sandy and dusty areas •

Check the engine air filter elements frequently in sandy or dusty conditions.

•

If the engine air filter icon appears on the instrument cluster, clean or change filters immediately regardless of time intervals.

•

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

Operation at seashore or salty climate •

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

•

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

Operation in extreme heat •

Use an engine oil, hydraulic oil and fuel oil designed for use in hot climates.

•

Keep batteries fully charged.

•

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

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

•

Keep all belts properly tensioned.

•

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

Operation in Humid Climate •

6-8

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

7 - MAINTENANCE

7 - MAINTENANCE GENERAL INFORMATION

Preparing machine for maintenance DANGER Improper operation or service of this machine can result in an accident.

Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information.

Failure to comply will result in death or serious injury.

D0010A

WARNING NH0002

1

SP0043

2

NHC0272

3

Maintenance hazard!

Before you start servicing the machine, attach a DO NOT OPERATE warning tag to the machine in a visible area.

Failure to comply could result in death or serious injury.

W0004A

Before following the maintenance procedures detailed in the following chapters, always perform the following operations if not otherwise specified: 1.

Park machine on a level surface.

2.

Lower bucket to the ground.

3.

Deactivate Auto-Idle function, turn engine speed throttle to LO position, stop engine, extract starter key and place safety lever in LOCK position.

4.

Attach a "DO NOT OPERATE" tag. This tag can be applied to the left control lever, safety lever or cab door.

Checking the hour meter Read machine worked hours on the hour meter (1) located inside the cab and determine, on the basis of the Maintenance Chart, when and which type of servicing is required.

Service intervals indicated in the table refer to a machine working under normal operating conditions. During the first period of use of the machine and under particularly heavy operating conditions shorter service intervals may be required than shown in the table.

7-1

7 - MAINTENANCE

Releasing pressure in the hydraulic system WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.

Failure to comply could result in death or serious injury.

W0161A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

WARNING Escaping fluid!

Do not disconnect hydraulic quick coupler under pressurized conditions. Make sure all hydraulic pressure is removed from the system before disconnecting hydraulic quick coupler.

Failure to comply could result in death or serious injury.

W0095A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

7-2

7 - MAINTENANCE

Releasing pressure in the hydraulic system 1.

Park the machine on firm, level ground, lower the bucket/attachment to the ground, and stop the engine.

2.

Keep all unauthorized personnel clear of the machine. Depress and hold the pressure release switch on the right side of the control console. The symbol Draining Hyd. Press will be displayed on the LCD and a buzzer will sound for approximately five seconds. When the buzzer stops, the operation is complete.

3.

Turn the key off. Operate the control levers from right to left and front to rear approximately a dozen times.

4.

Always release the internal pressure of the hydraulic tank before performing inspection or maintenance.

Remove the cap and press down on the valve to release any remaining hydraulic pressure in the tank.

RAIL12CEX0666BA

7-3

1

7 - MAINTENANCE

Biodiesel fuel Biodiesel usage in KOBELCO products

•

Introduction to Fatty Acid Methyl Ester (FAME) biodiesel FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: •

B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.

•

B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

•

B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels.

•

B100: indicates pure biodiesel, or 100 % biodiesel fuel. Do not use.

Biodiesel fuel has several positive features in comparison with diesel fuel: •

Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel.

•

Biodiesel has a greater cetane number and burns cleaner.

•

Biodiesel produces less particulate matter and reduces smoke emissions.

•

Biodiesel is fully biodegradable and non-toxic.

Diesel and biodiesel fuel specifications

•

United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009.

United States fuel suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network.

United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20.

Pure biodiesel (B100) specification is covered by the following requirements:

NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place.

Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a by-product usually sold for use in soaps or other products).

NOTICE: Biodiesel fuels approved for use in the KOBELCO equipment must be transesterified and comply with the North America Standard ASTM D6751.

NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any KOBELCO product.

NOTICE: Any engine and fuel injection equipment fitted to a KOBELCO vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by KOBELCO.

Biodiesel fuel usage conditions You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and after treatment system.

The main concerns related to operation with biodiesel fuels are:

Biodiesel blends are covered by: •

ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.

•

Filters and injector blockage caused by poor fuel quality.

•

Wear and corrosion of internal components due to water content, which affects lubricity.

•

Deterioration of some rubber sealing compounds in the fuel system.

•

Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.

NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following 7-4

7 - MAINTENANCE

conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by KOBELCO.

B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines.

Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information.

Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first.

The use of biodiesel blends above B5 through B7 will not void the KOBELCO warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system.

NOTICE: KOBELCO may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced down to 50% of the standard value when using biodiesel blends greater than B5 up to

Regular oil sampling is highly recommended to monitor for oil and engine deterioration.

NOTE: Oil sampling kits are available from your authorized KOBELCO dealer.

When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

Storage The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 diesel fuel is used.

NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.

Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week.

7-5

7 - MAINTENANCE

Break-in period Within the first 50 hours Within the first 50 hours it is necessary to perform the following operations: •

Lubricate the bucket links every 8 hours.

•

Lubricate boom and arms every 8 hours.

•

Replace the hydraulic oil return filters at 50 hours.

Within the first 100 hours Within the first 100 hours it is necessary to perform the following operations: •

Change engine oil and filter at 100 hours.

Within the first 500 hours Within the first 500 hours it is necessary to perform the following operations: •

Lubricate the bucket links every 250 hours.

•

Lubricate boom and arms every 250 hours.

•

Replace the swing reduction units oil at 500 hours.

•

Replace the travel reduction units oil at 500 hours.

7-6

7 - MAINTENANCE

Fluids and lubricants Engine Type of oil Total volume Cooling system System capacity Fuel system System capacity Hydraulic system Type of fluid Total system capacity Reservoir capacity Gear oil Type of oil

Tutela Unitek 10W40 18.5 l (19.5 US qt) 8 l (23.2 US qt) 200 l (52.8 US gal) CNH MAT3509 140 l (37.0 US gal) 98.5 l (26.0 US gal) NEW HOLLAND AMBRA HYPOIDE 90 LS 1.65 l (1.7 US qt) 2.1 l (2.2 US qt)

Swing motor reduction unit Travel motor reduction unit Grease Type of oil

NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE 500 g (17.6 oz) 8.2 kg (18.1 lb) 16 locations 1 location 2 As required

Swing motor reduction unit housing Swing gear Attachment pins Slewing ring gear Track tension adjustment Operating lever — pilot valve

NOTICE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 13 l (3.4 US gal) .

Temperature operating ranges Viscosity SAE 15W-40 SAE 10W-30 SAE 80W-90 ISO VG 32 ISO VG 46 ISO VG 68

Engine Swing and travel reduction units Hydraulic system

7-7

Temperature operating range -15 - 40 °C (5 - 104 °F) -25 - 25 °C (-13 - 77 °F) -26 - 45 °C (-15 - 113 °F) -20 - 30 °C (-4 - 86 °F) -5 - 40 °C (23 - 104 °F) 5 - 55 °C (41 - 131 °F)

7 - MAINTENANCE

Coolant solution

Fuel storage

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent leakage. Do not use non-approved anti-rust additives.

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

NOTICE: Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer for a suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the ambient temperature is over -36 °C (-32.8 °F), use a blend of 50 % ethylene-glycol based anti-freeze.

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

Engine oil Tutela Unitek 10W40s recommended for your engine.

This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures.

If Tutela Unitek 10W40 cannot be obtained, use only oil of the API SERVICE CJ-4 category.

For areas where the temperature is below -36 °C (-32.8 °F), it is advisable to use a blend of 40 % water and 60 % anti-freeze.

NOTE: Do not put any performance additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing the recommended lubricants.

Fuel

Hydraulic fluid

Use diesel fuel suitable for the ambient temperature conditions.

CNH MAT3509 is specifically designed for high pressure applications and for this machine’s hydraulic system.

Your authorized dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

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

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

In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier for appropriate fuel supply.

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

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

Grease The type of grease to use depends on ambient temperature such as NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE.

Environment Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental recycling center or your dealer for correct disposal information.

7-8

7 - MAINTENANCE

MAINTENANCE CHART

Maintenance Chart

Interval

Page no.

Every 10 hours or 7-10 daily 7-11 7-12 7-13 Every 50 hours 7-14 of operation or 7-16 weekly 7-17 7-19 Every 120 hours 7-20 7-21 Every 250 hours 7-22 7-24 7-26 7-27 7-28 7-29 7-30 7-32 Every 500 hours 7-34 7-36 7-38 7-39 7-40 7-41 Every 1000 hours 7-42 7-43 7-45 Every 2000 hours 7-46 7-47 7-48 7-49 7-50 7-51 Every 5000 hours 7-54 7-57 As required 7-59 7-61 7-63 7-65 7-66

Adjust Change fluid Grease Replace Cleaning Lubricate Drain fluid Check Maintenance action No. of pts.

Hydraulic oil level X Engine coolant X Engine oil X Alternator and drive belts X Battery X Fuel tank X Track tension X Dozer blade lubrication X X Swing reduction unit oil Travel reduction unit oil X X Engine air filter, primary Radiator and coolers X X Hydraulic return filter (Breaker use only) Hydraulic oil tank X X Counterweight X Bucket grease fittings X Cab air filters Fan, alternator, and air conditioner belts X X Engine oil and filter X Fuel filter X Fuel tank filter X Control lever lubrication Air conditioner X X Swing bearing X Engine air filters X Hydraulic oil return filters Hydraulic reservoir breather X X Pilot line filter X Hydraulic suction filter X Swing reduction lubrication X Swing reduction unit oil Travel reduction unit oil X Engine coolant X Hydraulic oil X Fuses and relays X Installing the bucket X X Removing and installing the dozer blade in the field X Bucket teeth and Side cutter Moving a disabled machine X Manually lowering attachment X

7-9

7 - MAINTENANCE

Every 10 hours or daily

Hydraulic oil level WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.

Failure to comply could result in death or serious injury.

W0161A

Check the hydraulic reservoir level every 10 hours of operation or daily.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position, stop the engine and remove the ignition key. Place the safety lock lever in the LOCK position.

Fluid level check 1.

Before you start the engine, check the oil level in the sight gauge.

2.

Check oil level through sight level gauge (1) located on the side of the hydraulic oil tank. Oil level should be between the H and L reference marks.

3.

If oil is required, relieve all pressure in the system.

RAPH12CEX0505AA

1

RAPH12CEX0506AA

2

4.

Slowly loosen the tank cap and top off until the proper level is reached Do not overfill. An excessive quantity of hydraulic oil could damage the hydraulic system and cause oil spills.

Oil level varies depending on oil temperature.

Before starting: L level oil temperature — 10 - 30 °C (50.0 - 86.0 °F) Normal operation: H level oil temperature — 50 - 80 °C (122 - 176 °F)

7-10

7 - MAINTENANCE

Engine coolant WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position, stop the engine and remove the ignition key. Place the safety lock lever in the LOCK position.

Check the coolant reservoir level every 10 hours of operation or daily. Perform this check when the coolant is cold, and the engine is stopped.

1.

Do not remove the radiator cap during this check.

The coolant level must be between the full (2) and add (3) marks on the reservoir.

2.

Add coolant as required to raise the coolant level to the full mark. Remove reservoir cap (1) to add coolant, if required. Fill to full mark.

RAIL12CEX0661AA

NOTICE: Use the proper ratio of water and antifreeze/coolant if the system coolant level is low. Do not overfill.

7-11

1

7 - MAINTENANCE

Engine oil The engine oil level should be checked every 10 hour shift or each day, whichever occurs first.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position, stop the engine and remove the ignition key. Place the safety lock lever in the LOCK position.

Open the engine hood. Lock the engine hood in the open position.

1.

Remove the dipstick (1) to check the engine oil level.

2.

Wipe the dipstick clean and reinsert. The oil level should register at the full mark.

3.

The fill location (2) is located in the main engine compartment. Add oil, if necessary. Do not over fill engine oil.

RAIL12CEX0664AA

1

RAIL12CEX0662AA

2

NOTE: This procedure is best performed at the beginning of the work day with the engine cool and all oil drained to the pan.

7-12

7 - MAINTENANCE

Alternator and drive belts WARNING Entanglement hazard!

Always stop the engine and engage the parking brake, unless otherwise instructed in this manual, before checking and/or adjusting any drive belt or chain.

Failure to comply could result in death or serious injury.

W0097A

Visually check the fan belt for tension, wear, or damage every 10 hours or daily. Incorrect belt tension can cause wear and/or damage to the engine.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position, stop the engine and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Check the fan and alternator belt for tension, wear, and damage. Insufficient belt tension can cause battery charge failure, engine overheating, or abnormal belt wear. Visually inspect for cuts or surface separations. Keep oil and grease away from the belt, as lubricants may shorten belt life.

RAIL12CEX0663AA

7-13

1

7 - MAINTENANCE

Every 50 hours of operation or weekly

Battery WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0120A

WARNING Electrical shock hazard!

Before working on any part of the electrical system, disconnect the battery ground cable. Complete all electrical work before connecting the cable.

Failure to comply could result in death or serious injury.

W0129A

WARNING Improper operation or service of this machine can result in an accident.

Before working on any part of the electrical system, disconnect the battery ground cable. Complete all electrical work before connecting the cable.

Failure to comply could result in death or serious injury.

W0137A

WARNING Chemical hazard!

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

Failure to comply could result in death or serious injury.

W0349A

Check the fluid level in the battery cell caps when the hour meter registers 50 hours and every 50 hours thereafter.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position, stop the engine and remove the ignition key. Place the safety lock lever in the LOCK position.

7-14

7 - MAINTENANCE

Checking battery fluid level 1.

Open the battery compartment door with the starter key. Lock door in the open position.

2.

Remove battery cell caps (2) and visually inspect electrolyte level. Proper level (3) is 10 15 mm (0.4 - 0.6 in) above the cell plates (4).

3.

Clean vent of battery cap and tighten cap (2) securely.

4.

Close battery compartment door. Lock door with the starter key.

NOTICE: Clean battery terminal. Apply grease or commercial lube oil rust preventive spray.

NOTICE: Replace both batteries if one is required to be replaced.

NOTICE: Dispose of used battery properly.

7-15

RAPH12CEX0284AA

1

RAPH12CEX0285AA

2

7 - MAINTENANCE

Fuel tank WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

Drain the sediment and water from the fuel tank when the hour meter registers 50 hours and every 50 hours thereafter.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Draining condensation 1.

Turn the upper structure 90 ° to obtain easy access to the drain valve.

2.

Locate drain valve on bottom of fuel tank.

Place a suitable container below the drain valve.

3.

Open the drain valve (1), drain water and sediment from fuel tank.

4.

Close the drain valve (1).

NOTE: When the temperature is above 0 °C (32 °F), draining can be done before engine startup. When working in temperatures below 0 °C (32 °F), the tank should be drained at the end of machine operations and the engine has been stopped. Allow the machine to cool slightly, and drain sediment. Freezing temperatures can cause water and sediment to freeze resulting in improper drainage.

A. B.

Open Closed

7-16

RAPH12CEX0457AA

1

7 - MAINTENANCE

Track tension Check the track tension when the hour meter registers 50 hours and every 50 hours thereafter. Check more often in severe conditions.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground.

Check tension .

1.

Rotate the upper structure 90 °.

2.

Keep the angle between boom and arm 90 ° to 110 ° and lower the bucket to raise one track off the ground as shown in figure.

3.

Place blocks under the frame to support the machine.

4.

Thoroughly remove dirt stuck on the track by pressure washing.

5.

Rotate the raised track in reverse two full rotations, then forward two full rotations.

6.

Measure distance (A) at the middle of the frame and from the bottom of the track frame to the back face of the track shoe. Distance should be between 270 - 300 mm (10.6 - 11.8 in).

7-17

NHC0333

1

NHC0334

2

7 - MAINTENANCE

Loosening the track WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

W0959A

1.

Turn the valve (1) to loosen the track chain slowly counterclockwise. Grease will begin to exit the base of the valve (1).

2.

When proper track sag is obtained, turn valve (1) clockwise to tighten.

NOTE: If grease does not come out evenly, slowly rotate the raised track.

NHC0335

Tightening the track 1.

To tighten the track, inject grease from a grease gun into the grease nipple (2) on the valve (1) until proper tension is reached.

7-18

3

7 - MAINTENANCE

Dozer blade lubrication Lubricate dozer blade pins when the hour meter registers 50 hours and every 50 hours thereafter. Lubricate more frequently if conditions are severe or attachment has been digging in or submerged in water.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

•

Lubricate the dozer blade pins at all indicated locations.

Blade cylinder pin (head, rod) Tilt cylinder pin (head, rod) Angle cylinder pin (head, rod) Connection of blade and frame

RAIL12CEX0667BA

7-19

1

7 - MAINTENANCE

Every 120 hours

Swing reduction unit oil Check the swing motor reduction oil when the hour meter registers 120 hours and every 120 hours thereafter. Check more often if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Level check Check the swing reduction unit oil level: 1.

Remove the oil level dipstick (1) and check the oil level. Level should be between the MIN and MAX marks on the dipstick.

2.

Add oil through the filler neck (2) if oil level is low.

3.

Reinstall the oil level dipstick (1).

RAIL12CEX06668B

7-20

1

7 - MAINTENANCE

Travel reduction unit oil Check the oil level in the travel reduction unit when the hour meter registers 120 hours and every 120 hours thereafter.

Check more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Level check Check the travel reduction unit oil level: 1.

Position the reduction units so the fill (1), drain (2), and level (3) plugs are as shown.

2.

Slowly remove level plug (3) to gradually relieve pressure from inside the reduction unit.

Check for proper oil level and contamination.

Oil level should be at the top of the plug and seep out if the oil level is correct.

3.

Add oil through the fill plug (1) if oil level is low.

4.

Clean the level plug (3) and the fill plug (1) with light oil.

5.

Reinstall plugs (1).and (3)

6.

Repeat the procedure for the other side of the machine.

RAPH12CEX0487AA

7-21

1

7 - MAINTENANCE

Every 250 hours

Engine air filter, primary WARNING Flying debris!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in death or serious injury.

W0307A

Clean the primary engine air filter when the hour meter registers 250 hours and every 250 hours thereafter. Clean more frequently if conditions so require or the LCD display indicates an engine air filter fault. Change both the primary and secondary filter filters when the hour meter registers 1000 hours.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Cleaning 1.

Open air filter compartment panel. Use the support strut to lock the panel cover in the open position.

2.

Release the cover clamps, and remove the engine air filter cover (1) .

3.

RAIL12CEX06669A

1

RAIL12CEX06670A

2

Extract the primary filter (2). Do not remove secondary filter (4). The secondary filter cannot be cleaned. It must be replaced.

7-22

7 - MAINTENANCE

4.

5.

6.

Clean the primary filter using low pressure compressed air. Use air less that 0.2 MPa (29.0 psi).

Direct the air jet from the inside to the outside of the filter.

NHC0349

3

RAIL12CEX06670A

4

Replace the primary filter and the O-ring (3) making certain that the primary filter and O-ring seat properly in the engine air cleaner housing (5).

Replace the engine air filter cover (1) and secure in place with clamps.

7-23

7 - MAINTENANCE

Radiator and coolers WARNING Hot liquid under pressure!

Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.

Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.

Failure to comply could result in death or serious injury.

W0296A

Check hoses and connections when the hour meter registers 250 hours and every 250 hours thereafter.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Cooling system hoses Radiator hose check 1.

Open the engine hood. Lock hood in the open position.

2.

Check for coolant leaks.

3.

Tighten loose clamps (1) .

4.

Inspect hoses (2) for fatigue, damage, and cracks.

5.

Replace hose and clamp if leaks, cracks, or fatigue are found.

RAIL12CEX06672A

7-24

1

7 - MAINTENANCE

Replace radiator hose 1.

Loosen bolts on the lower radiator cover. Remove cover.

2.

Loosen radiator cap slowly to completely bleed the pressure inside the radiator. Remove the cap.

3.

Open drain valve (3) and drain coolant into a container until coolant level is lower than the hose to be replaced.

4.

Loosen clamp (1) and remove damaged hose.

(2).

5.

Replace with new hose and clamp.

6.

Close the drain valve.

7.

Fill the radiator and reserve tank with the required amount of coolant.

8.

Replace radiator cap.

9.

Replace under cover of radiator.

11.

Start engine and check for leaks.

7-25

RAIL12CEX06673A

2

RAIL12CEX06674A

3

7 - MAINTENANCE

Hydraulic return filter (Breaker use only) WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

Replace the hydraulic return filter if using a breaker attachment when the hour meter registers 250 hours and every 250 hours thereafter. Replace more frequently if conditions so warrant. When using other attachments the hydraulic return filter requires replacement at 1000 hours.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Remove the breather cap on the hydraulic tank and release pressure by pressing the valve several times.

2.

Loosen the mounting bolts on the hydraulic tank cover (1), and remove the cover and O-ring (2).

3.

Remove spring (3), and return filter assembly (4), (5), (6), (7), and (8).

4.

Replace with new return filter kit. The kit will contain O-ring (1), new filter (6) and two new O-rings (5) and (8).

5.

Reassemble kit into return filter housing (4). Replace plate (7) and O-ring (8).

6.

After kit reassembly, replace spring (3), O-ring (2), and cover (1).

7.

Replace cover bolts and torque to: 41.9 - 51.1 N·m (30.9 - 37.7 lb ft).

8.

Start the machine and move through each operating lever function. Turn off engine. Recheck hydraulic oil level and check for leaks.

7-26

RAIL12CEX0666BA

1

RAIL12CEX0987AA

2

7 - MAINTENANCE

Hydraulic oil tank Draining condensation To drain the condensation inside the hydraulic oil tank, proceed as follows: 1.

Park the machine on a level surface and turn the upper structure 90 ° to obtain easy access.

2.

Lower the bucket to the ground.

3.

Deactivate the Auto-Idle function, turn the engine speed throttle to LO position, stop the engine, extract the starter key and place the safety lever in LOCK position.

4.

Press the button (1) located on the tank to bleed the pressure inside the tank several times

5.

Release the drain plug (2) when the oil is cold.

Drain condensation water and sediments into a suitable container. Do not fully remove the plug, release it enough to allow condensation and sediments to drain. Otherwise, also hydraulic oil would be drained out.

6.

Fully tighten the plug (2) after draining.

7-27

NHC0266

1

RCPH11EXC001BAD

2

7 - MAINTENANCE

Counterweight Check counterweight bolt torque when the hour meter registers 250 hours and every 250 hours thereafter. Check more frequently if conditions so warrant. Counterweight bolts can loosen if the counterweight is hit against solid objects.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Tap the bolts lightly with a hammer to check for looseness.

2.

Apply Loctite and torque to: 1519.9 - 1140.2 N·m (1121 - 841 lb ft).

7-28

7 - MAINTENANCE

Bucket grease fittings Lubricate bucket pins when the hour meter registers 250 hours and every 250 hours thereafter. Lubricate more frequently if conditions warrant or bucket has been submerged in water.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Clean the area around the bucket pins.

2.

Using a grease gun, inject grease into bucket pins.

NOTE: Lubricate every 10 working hours if the machine has been operated in water or mud.

RAPH12CEX0452BA

7-29

1

7 - MAINTENANCE

Cab air filters CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Clean the cab air filters when the hour meter registers 250 hours and every 250 hours thereafter. Change more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Fresh air filter 1.

The fresh air filter is located on the left side of the operator’s seat.

2.

Remove cover panel (1).

3.

Lift fresh air filter (2) vertically and check its condition. Clean with low pressure compressed air.

4.

Reposition fresh air filter (2).

5.

Reinstall cover. (1).

RAPH12CEX0462AA

7-30

1

7 - MAINTENANCE

Clean recirculation air filter 1.

Locate the recirculation air filter (2) on the operator’s seat.

2.

Remove the floor mat.

3.

Pull the air filter out with the handle attached.

4.

Clean with low pressure compressed air.

5.

Replace air filter and floor mat.

RAIL12CEX0988AA

7-31

2

7 - MAINTENANCE

Fan, alternator, and air conditioner belts WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

Check the condition of the alternator and fan belts when the hour meter registers 250 hours and every 250 hours thereafter. Check more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Belt check 1.

Open the engine hood and lock the engine hood in the open position.

2.

Remove the belt cover.

3.

Check the alternator/fan (1) belt and the air conditioner belt (2) for wear and damage.

4.

Check the belt tension by pressing on the center of the belt. Refer to the table below for the proper tension.

5.

Install the belt cover, close and lock engine hood if no replacement or adjustment is needed.

NOTE: Replace the belts if cuts or surface separations are found during the inspection.

Belt Alternator, Fan Air conditioner

Tension — new belt 4 - 6 mm (0.16 - 0.24 in) 3 - 4 mm (0.12 - 0.16 in)

RAIL12CEX0989AA

1

Tension — belt inspection Force 8 - 10 mm (0.31 - 0.39 in) 98 N (22 lb) 5 - 6 mm (0.20 - 0.24 in) 24 N (5.4 lb)

Adjustment — alternator and fan belt 1.

Loosen the retaining bolts (2) of the alternator (1) Loosen the retaining bolts of the adjusting plate.

2.

Adjust the belt tension with the adjusting bolt (3) .

3.

Tighten the retaining bolts of the alternator (2). Tighten the retaining bolts of the adjusting plate.

4.

Start and run the engine at low speed for approximately 5 min.

5.

Stop the engine and check the fan belt tension.

6.

Install the belt cover.

7.

Close and lock the engine hood.

RAIL12CEX0991AA

7-32

2

7 - MAINTENANCE

Adjustment — air conditioner compressor belt 1.

Open the engine hood and lock the engine hood in the open position.

2.

Loosen the nut for the idler pulley (1) Adjust the belt tension while turning the adjusting bolt. (2)

3.

Tighten the nut. Torque to 42 - 51 N·m (31 - 38 lb ft)

4.

Start and run the engine at low speed for approximately 5 min.

5.

Stop the engine and check the belt tension.

6.

Close and lock the engine hood.

RAIL12CEX0990AA

7-33

3

7 - MAINTENANCE

Every 500 hours

Engine oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Change the engine oil and filter when the hour meter registers 100 hours for a new machine during the initial run-in period. The engine oil and filter should be changed every 500 hours thereafter or more frequently when the engine operating conditions are severe.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Make certain all pressure has been relieved in the system. Place the safety lock lever in the LOCK position.

1.

Remove the panel under the engine by removing the bolts.

2.

Open engine hood and lock in the open position.

3.

Extract dipstick (1). Clean around and remove the fill cap (2). Oil will drain faster if it is slightly warm and the dipstick and fill cap are removed.

RAIL12CEX0664AA

7-34

1

7 - MAINTENANCE

7.

Loosen drain valve (3). Drain oil into a suitable container.

8.

Close and tighten drain valve.

10.

Clean contact area around the filter (4).

11.

Place a drip pan under the filter .

12.

Remove oil filter (4) turning counterclockwise.

13.

Wipe oil off oil filter mounting surface with a cloth.

14.

Check gasket for proper placement on the new oil filter. Lubricate the gasket of the new filter with clean engine oil.

15.

Install the new filter. Turn filter by hand until the gasket comes into contact with the filter head.

Tighten another 3/4 turn by hand.

RAIL12CEX0992AA

2

RAIL12CEX0664AA

3

RAIL12CEX0662AA

4

NOTICE: Tighten new oil filter by hand. Do not use a filter wrench to avoid possible damage to the filter.

16.

Fill the engine fill port (2) with new engine oil in the specified amount for the engine.

17.

Start the engine, let it run a few minutes then stop it. Use the dipstick (1) to check the oil level. Top off, if necessary.

NOTE: Handle and dispose the used engine oil and filters in accordance with environmental regulations. Use only authorized disposal procedures.

7-35

7 - MAINTENANCE

Fuel filter WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

Replace the fuel filter when the hour meter registers 500 hours and every 500 hours thereafter. Replace more often if conditions warrant or fuel quality is poor.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Open right rear door and lock in the open position.

2.

Clean area around fuel filter (1).

3.

Close fuel shut off valve (2) and loosen air bleed plug (3) and the drain valve (6).

4.

Drain water from the fuel filter (1) into a suitable container.

5.

Disconnect sensor (7) from the fuel filter.

6.

Use a filter wrench, and remove fuel filter element (4) from the bowl (5).

7.

Clean the bowl with clean oil for reuse.

8.

Clean the mounting surface of the filter element head.

9.

Apply a thin film of oil to the O-ring of the bowl, and turn the bowl clockwise by hand until it contacts the filter element. Turn an additional half turn.

10.

Apply a thin film of oil to the gasket of the new filter element and tighten the element to the filter head. Turn filter an additional half turn by hand.

11.

Tighten the air bleed plug and the drain plug.

12.

Connect the connector to the sensor.

13.

Open the fuel cut off valve.

14.

Bleed air from the fuel filter.

7-36

RAIL12CEX0994AA

1

RAIL12CEX0995AA

2

7 - MAINTENANCE

Bleeding air from the system 1.

Open fuel shut off valve (1).

2.

Turn the priming pump cap (2) counterclockwise to unlock.

3.

Use the pump to prime the fuel filter. When fuel is free of air bubbles, stop priming and tighten the air vent plug.

RAIL12CEX0995AA

7-37

3

7 - MAINTENANCE

Fuel tank filter WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

Clean the fuel fill filter when the hour meter registers 500 hours and every 500 hours thereafter. Clean more frequently if conditions so warrant or if fuel quality is poor.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Unlock and remove the fuel cap.

2.

Check the cap for damage. If damaged, replace with an approved cap for proper fuel tank pressure.

3.

Remove the fuel cap filter, and clean the filter with light oil.

4.

Reinstall fuel cap filter, and replace the fuel cap.

RAIL12CEX0996AA

7-38

1

7 - MAINTENANCE

Control lever lubrication Lubricate the control lever when the hour meter registers 500 hours and every 500 hours thereafter. Lubricate more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Remove the rubber boot from the control lever. Turn boot up and use a Phillips screw driver to loosen bolts. Release boot from console.

2.

Apply a small amount of grease to the push rod and top end of the rotation of the control lever.

RAIL12CEX1000AA

7-39

1

7 - MAINTENANCE

Air conditioner WARNING Explosion hazard!

Air-conditioning refrigerant boils at -12 °C (10 °F)!

-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.

-NEVER disconnect or disassemble any part of the air-conditioning system.

Discharging refrigerant gas into the atmosphere is illegal in many countries.

Failure to comply could result in death or serious injury.

W0340A

WARNING Maintenance hazard!

Never try to service the air-conditioning system yourself. Contact your dealer for service.

Failure to comply could result in death or serious injury.

W0268A

Check the air conditioning system at the sight glass when the hour meter registers 500 hours and every 500 hours thereafter. Check more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Start the engine and idle at a moderate speed.

2.

Turn the air conditioner switch ON, the fan switch to the HI position, the temperature adjustment to the lowest temperature position. Keep all doors and windows closed. Allow the machine to idle.

3.

Check the sight glass. After the air conditioner is turned on, small bubbles appear, the refrigerant becomes transparent, and then turns a light milky white.

This sequence indicates the air conditioner is operating properly.

If there are no bubbles, the system is overcharged.

If bubbles appear constantly, the system has insufficient charge. DO NOT attempt to work on the system unless qualified. Contact your authorized dealer for service.

7-40

RAIL12CEX0999AA

1

7 - MAINTENANCE

Swing bearing Lubricate the slewing ring when the hour meter registers 500 hours and every 500 hours thereafter. Lubricate more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Inject grease through the grease fitting (1). Rotate the upper structure 90 ° and repeat step 4.

2.

Continue to rotate the upper structure at 90 ° increments and inject grease until the entire slewing ring is greased.

3.

Do not inject excess grease. Grease should be injected until it is seen coming out of the seals.

NHC0292

7-41

1

7 - MAINTENANCE

Every 1000 hours

Engine air filters Replace the primary and secondary engine air filter when the hour meter registers 1000 hours and every 1000 hours thereafter. Check the engine air filter if the LCD display indicates an engine air filter fault.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Open air filter compartment panel. Use the support strut to lock the panel cover in the open position.

2.

Release the cover clamps, and remove the engine air filter cover (1) .

3.

Extract the primary filter (2) .Remove the secondary filter (4). Do not attempt to clean the secondary filter.

It must be replaced.

4.

Cover the air outlet to prevent the intrusion of dust.

5.

Clean the air filter housing.

6.

Replace with a new secondary filter, seating it properly against the housing.

7.

Replace with a new primary filter and O-ring (3) making certain that the primary filter and O-ring seat properly in the engine air cleaner housing (5).

8.

Replace the engine air filter cover (1) and secure in place with clamps.

7-42

RAIL12CEX06669A

1

RAIL12CEX06670A

2

7 - MAINTENANCE

Hydraulic oil return filters WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

Replace the hydraulic return filter if using a breaker attachment when the hour meter registers 250 hours and every 250 hours thereafter. Replace more frequently if conditions so warrant. When using other attachments the hydraulic return filter requires replacement at 1000 hours.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Remove the breather cap on the hydraulic tank and release pressure by pressing the valve several times.

RAIL12CEX0666BA

7-43

1

7 - MAINTENANCE

2.

Loosen the mounting bolts on the hydraulic tank cover (1), and remove the cover and O-ring (2).

3.

Remove spring (3), and return filter assembly (4), (5), (6), (7), and (8).

4.

Replace with new return filter kit. The kit will contain O-ring (1), new filter (6) and two new O-rings (5) and (8).

5.

Reassemble kit into return filter housing (4). Replace plate (7) and O-ring (8).

6.

After kit reassembly, replace spring (3), O-ring (2), and cover (1).

7.

Replace cover bolts and torque to: 41.9 - 51.1 N·m (30.9 - 37.7 lb ft).

8.

Start the machine and move through each operating lever function. Turn off engine. Recheck hydraulic oil level and check for leaks.

RAIL12CEX0987AA

7-44

2

7 - MAINTENANCE

Hydraulic reservoir breather WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

Replace the hydraulic breather filter when the hour meter registers 1000 hours and every 1000 hours thereafter.

Replace more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Unscrew the breather cap (1) and press the valve several times to bleed the pressure inside the hydraulic tank.

2.

Remove the nut (2).

3.

Rotate and remove the filter cover (3).

4.

Remove and replace the breather filter (4).

5.

Reinstall the filter cover (3), nut (2) and breather cap (1).

Nut tightening torque: 10 - 14 N·m (7.4 - 10.3 lb ft).

NHC0357

7-45

1

7 - MAINTENANCE

Every 2000 hours

Pilot line filter WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

Replace the pilot line filter when the hour meter registers 2000 hours and every 2000 hours thereafter. Replace more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Make certain all pressure is released in the hydraulic system. Place the safety lock lever in the LOCK position.

1.

Press the button (1) located on the hydraulic tank several times to release the residual pressure inside the hydraulic tank.

2.

Open the hydraulic pump compartment panel and lock it in open position.

3.

Remove hose (1).

4.

Remove elbow connector (2) and (3).

5.

Remove pilot line filter (4) and clean with light oil.

6.

Reinstall pilot filter (4), elbow connector (2), (3), and hose (1).

7-46

RAIL12CEX0666BA

1

RAIL12CEX1002AA

2

7 - MAINTENANCE

Hydraulic suction filter WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

Clean the hydraulic suction strainer when the hour meter registers 2000 hours and every 2000 hours thereafter. Clean more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Make certain all pressure is relieved in the hydraulic system. Place the safety lock lever in the LOCK position.

1.

Remove the breather cap on the upper surface of the hydraulic tank, and release residual pressure from the hydraulic tank by pressing the valve several times.

2.

Loosen the mounting bolts on the tank upper cover, and remove the cover (1) and O-ring (2).

3.

Remove the suction strainer (3).

4.

Check O-rings (2) and (4) for damage.

O-rings and/or strainer if damaged.

5.

Clean the strainer with light, clean oil.

6.

Replace O-ring (2) on the bottom of the strainer, and insert the strainer into suction tube.

7.

Replace O-ring (2) and cover (1).

8.

Torque cover bolts to: 41.9 - 51.1 N·m (30.9 - 37.7 lb ft).

Replace

RAIL12CEX1001AA

7-47

1

7 - MAINTENANCE

Swing reduction lubrication WARNING Burn hazard!

Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding.

Failure to comply could result in death or serious injury.

W0362A

Lubricate the swing reduction unit when the hour meter registers 2000 hours and every 2000 hours thereafter. Lubricate more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Make certain all pressure is relieved in the hydraulic system. Place the safety lock lever in the LOCK position.

1.

Clean the area around grease nipple (1).

2.

Use a grease gun and inject grease through grease nipple (1) until grease seeps from the relief valve (2)

NOTICE: Check for grease deterioration at pinion shaft and swing bearing. If grease has deteriorated, contact your authorized dealer.

RAIL12CEX1003AA

7-48

1

7 - MAINTENANCE

Swing reduction unit oil WARNING Burn hazard!

Be very careful to avoid contact with hot fluids. If fluid is extremely hot, allow it to cool to a moderately warm temperature before proceeding.

Failure to comply could result in death or serious injury.

W0362A

Change the swing reduction unit oil when the hour meter registers 2000 hours and every 2000 hours thereafter. Service more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Make certain all pressure is relieved in the hydraulic system. Place the safety lock lever in the LOCK position.

1.

Locate drain port (1) under the center opening of the lower frame.

2.

Place a suitable container under the drain port (1) and remove drain plug allowing oil to drain into the container.

3.

Clean drain plug with light oil, dry and tape plug. Reinstall drain plug. Torque to: 108 N·m (80.0 lb ft).

4.

Remove fill plug (3). Pour new oil through the fill port to the correct level.

5.

Use the dipstick (2) to confirm oil level is in the specified range.

6.

Clean fill plug (3) with light oil, dry and tape plug.

7.

Reinstall fill plug (3) and tighten securely.

RCPH11EXC003AAQ

1

RAIL12CEX1003AA

2

NOTICE: Contact your authorized dealer if metal chips or contaminants are found in the drained oil.

7-49

7 - MAINTENANCE

Travel reduction unit oil Change the travel motor reduction unit oil when the hour meter registers 2000 hours and every 2000 hours thereafter.

Change more frequently if conditions so warrant.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Replacement 1.

Park the machine on a level surface. Position the reduction units as to have the fill (1), drain (2), and level (3) plugs as indicated.

2.

Slowly remove drain plug (2), gradually relieving pressure from inside the reduction unit. After relieving pressure, fully remove plug (2)

3.

Remove level (3), and fill (1) plugs. Drain oil into a suitable container.

4.

Clean and reinstall plug (2).

5.

Tighten plug (2) securely.

6.

Add new oil through the fill level port until the oil starts flowing out of the level port.

7.

Clean and reinstall plugs (1), and (3)

8.

Tighten plug (1), and (3) securely.

9.

Repeat the process on the other side of the machine.

NOTICE: Contact your authorized dealer if the drained oil contains any metal chips or other contaminants.

7-50

RAPH12CEX0487AA

1

7 - MAINTENANCE

Engine coolant CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

Drain, flush and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system, and replace the coolant if it becomes dirty or is rust colored.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

Drain coolant 1.

Position the machine on a flat surface and swing the upper structure 90 ° to facilitate access.

2.

Deactivate the auto-Idle function, turn the engine speed throttle to LO position, stop the engine, remove the starter key and place the safety lever in LOCK position.

3.

Allow the machine to cool. Open the engine hood and the radiator compartment doors, locking them in the open position.

4.

Loosen radiator cap (1) slowly to completely bleed the pressure inside the radiator, then remove the radiator cap (1).

5.

Remove the panel under the radiator.

7-51

RAPH12CEX0318AA

1

7 - MAINTENANCE

6.

Open drain valve (2), and drain plug (3) and let the coolant drain into an appropriate container.

Close the drain valve (2) and drain plug (3) after coolant has drained.

7.

Inspect radiator hoses and clamps. Tighten clamps if necessary. Check radiator for leaks, damage, or dirt /debris accumulation.

7-52

RAPH12CEX0319AA

2

RAIL12CEX1008AA

3

7 - MAINTENANCE

Flushing and filling the cooling system 1.

Fill the radiator with fresh water and a cleaning agent until the radiator is completely filled.

Tighten the radiator cap (1).

2.

Start the engine, and run at slightly over idle until the coolant temperature reaches the white range on the coolant temperature gauge. Operate the engine for about 10 min.

3.

Stop the engine and allow the engine and components to cool.

4.

Drain the water and cleaning agent following the above procedure for draining the coolant.

5.

Refill the cooling system with fresh water only, and flush the system again. Repeat this operation until the water drained is clean.

6.

Make sure that drain valve (2), and drain plug (3) are closed. Fill the system using the specified mixture of water and coolant through the radiator fill port.

7.

Install radiator cap (1). Check the expansion tank (4).

8.

Close the engine hood. Reinstall the panel located under the upper structure.

9.

Start the engine, and operate the engine several minutes.

10.

Stop the engine. Allow the engine and components to cool. Check the coolant level in expansion tank (4). The coolant level must be between the marks FULL (A) and LOW (B) In the event the coolant is insufficient, top-off.

11.

Close the radiator compartment panel.

RAIL12CEX1009AA

7-53

4

7 - MAINTENANCE

Every 5000 hours

Hydraulic oil CAUTION Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in minor or moderate injury.

C0104A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

Change the hydraulic oil every 5000 hours of operation. Change the hydraulic oil more frequently when operating conditions are severe.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Relieve all pressure in the hydraulic system. Place the safety lock lever in the LOCK position.

7-54

7 - MAINTENANCE

1.

Position the machine on a flat surface. Swing the upper structure 90 ° to facilitate access.

2.

Lower all attachments to the ground.

3.

Deactivate the auto-Idle function, turn the engine speed throttle to LO position, stop the engine, remove the starter key, and place the safety lever in LOCK position.

4.

Allow the machine and components to cool.

5.

Clean the top of the hydraulic oil tank to prevent contamination of the hydraulic system.

6.

Remove the breather cap and press the valve (1) several times to relieve the pressure inside the hydraulic tank.

7.

Loosen securing bolts (2), and remove the cover (3).

8.

Remove the hydraulic oil return filters cover (6).

7-55

RAIL12CEX1010AA

1

NHC0260

2

NHC0261B

3

7 - MAINTENANCE

9.

Locate and remove drain plug beneath upper structure. Allow the residual oil to drain into a suitable container.

10.

Clean, install, and tighten drain plug . Tightening torque: 108 N·m (80 lb ft).

11.

Replace the hydraulic oil return filters..

12.

Clean suction filter (4).or replace if necessary.

13.

Install a new O-ring (5) and suction filter assembly (4).

14.

Pour specified type and amount of hydraulic oil through the suction filter. Hydraulic oil level should register between MIN and MAX on hydraulic oil sight gauge (8) located inside the hydraulic pump compartment.

15.

NHC0261B

4

NHC0356

5

Install cover (3) ensuring that the suction filter assembly is correctly seated. Tighten the bolts (2). Tightening torque: 162 N·m (119 lb ft).

7-56

7 - MAINTENANCE

As required

Fuses and relays

RAPH12CEX0309EA

FUSE number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1

FUSES BOX PROTECTED CIRCUIT Cab work light 1 Cab work light 2 Instrument cluster / Rear camera Windscreen wiper and washer Optional Flasher alarm, lifting magnet Air conditioner (main) Air conditioner (compressor) Option (Hand Control) Hour meter Optional Horn DC-DC Converter Starter key switch Cab room lamp Optional Optional Bucket dump cut solenoid Air conditioner Work light Seat heater DEF/AdBlue® supply module Optional Travel alarm Safety lever Mechatro controller Mechatro controller Optional GPS system Mechatro controller Fuel transfer pump 7-57

RATING ( A ) 20 20 5 20 20 20 15 5 5 5 10 10 10 20 5 10 10 10 5 20 10 5 15 20 10 5 20 15 15 5 15

7 - MAINTENANCE

32 33 34 35 36

Mechatro lifting magnet backup Spare Spare Spare Spare

1.

Move operator's seat fully forward, lower the backrest and remove cover (1) to reach the fuse and relay box.

2.

Press lock (2) inward and remove fuse box cover (3).

5 5 10 15 20

NOTICE: make sure that the starter key is in OFF when replacing fuses. Install fuses with correct capacity to prevent damages from an overload of the electrical system.

7-58

RAPH12CEX0310AA

2

RAPH12CEX0311AA

3

7 - MAINTENANCE

Removing and installing the bucket WARNING Crushing hazard!

Always use approved attachments. Make sure the attachment is compatible with the machine mounting system.

Failure to comply could result in death or serious injury.

W0183A

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Release all pressurized systems on the machine. Place the safety lock lever in the LOCK position.

Removing the bucket 1.

Rest the bucket on a firm, level surface. Make certain that the bucket is stable.

2.

Roll O-rings (1) onto the bucket boss (2).

3.

Open the retaining ring (3) and remove pins (4). Remove pins (5) and (6).

4.

Remove bucket.

7-59

RAIL12CEX1011AA

1

RAIL12CEX1012AA

2

7 - MAINTENANCE

Installing the bucket WARNING Avoid injury!

Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W0208A

CAUTION Pinch hazard!

Always use suitable tools to align mating parts. DO NOT use your hand or fingers.

Failure to comply could result in minor or moderate injury.

C0044A

5.

Clean each pin and pin holes. Grease pin and pin holes.

6.

Move the cylinder to match the pin holes of the bucket and bucket link (8). Insert pin (4).

7.

Raise the boom, and raise the bucket slightly from the ground.

8.

Align the bucket with the arm pin hole (7). Insert pin (6).

9.

Insert pin (4) and retaining ring (3).

10.

Replace O-ring (1) into the normal position.

RAIL12CEX1012AA

7-60

3

7 - MAINTENANCE

Removing and installing the dozer blade in the field DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

Removing the dozer blade 1.

Move the machine to a firm level surface, and place wood blocks under both sides of the dozer blade frame.

2.

Disconnect the angling cylinder rod from the blade, and manually push the blade out as far as it can go to obtain sufficient access to the trunnion cap bolts (1).

3.

Loosen the trunnion cap bolts, but DO NOT remove.

4.

5.

RAIL12CEX1033AA

1

RAIL12CEX1034AA

2

RAIL12CEX1035AA

3

Repeat steps 2 and 3 on the opposite side of the blade. Place wood blocks under both blade wing frames to stabilize the blade.

Install cable with hooks through the top brackets located on both sides of the dozer blade.

7-61

7 - MAINTENANCE

6.

Use the upper frame front attachment to hold the blade. Start the engine and carefully operate the upper front attachments and position the bucket above the blade.

7.

Pass the cables hooked to the blade brackets through the bracket welded on the bottom of the bucket. Remove the slack from the cable.

8.

Disconnect the upper link (2) from the top of the blade, and disconnect the tilt cylinder rod end (3) from the blade frame.

9.

Remove the trunnion cap bolts, and carefully operate the front attachment to remove the blade.

Installing the dozer blade 10.

To reinstall blade, reverse the process. Mark the trunnion cap bolt heads, and make sure that the bolt threads are clean. Apply Loctite.

11.

Install cap ends, bolts, and washers. Snug tight the bolts. (Sufficient access is needed to the trunnion cap bolts in order to torque.

12.

Torque trunnion bolts to: 279 N·m (205.8 lb ft).

13.

Manually place the blade in a straight position on the angle cylinder rods. Start the engine, and remove the wood blocks.

7-62

RAIL12CEX1036AA

4

RAIL12CEX1037AA

5

7 - MAINTENANCE

Bucket teeth and side cutters WARNING Crushing hazard!

Always use approved attachments. Make sure the attachment is compatible with the machine mounting system.

Failure to comply could result in death or serious injury.

W0183A

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Release all pressurized systems on the machine. Place the safety lock lever in the LOCK position.

Replacing bucket teeth 1.

Rest the bucket on a safety block that is firm and level. Make certain that the bucket is stable.

2.

Use a hammer and punch to remove the lock pin (4).

Use care not to damage the rubber lock (3).

3.

Inspect the lock pin (4) and rubber lock (3). Replace if the lock pin is too short or the rubber lock is in poor condition.

4.

Clean the surface of the adapter nose (1).

5.

Fit the tooth point (2) into the adapter nose (1).

6.

Push the rubber lock pin (3) in the hole of the adapter nose (1).

7.

Hammer the locking pin (4) until it is aligned with the point surface.

7-63

RAIL12CEX1014AA

1

RAIL12CEX1013AA

2

7 - MAINTENANCE

Replacing side cutters WARNING Avoid injury!

Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W0208A

CAUTION Pinch hazard!

Always use suitable tools to align mating parts. DO NOT use your hand or fingers.

Failure to comply could result in minor or moderate injury.

C0044A

8.

Remove all sand and mud adhering on bolts and bucket.

9.

Use an acetylene torch to cut off the bolts.

10.

Remove the side cutter (5).

11.

Clean the mounting face, and replace with a new side cutter (5), new bolts, and new nuts.

12.

Torque to: 485 - 593 N·m (357.7 - 437.4 lb ft).

13.

Spot weld bolts after tightening.

RAIL12CEX1015AA

7-64

3

7 - MAINTENANCE

Moving a disabled machine WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

The machine incorporates automatically applied spring brake systems. If these systems automatically engage the brakes when the engine is stopped, it may be impossible to move the machine without manually releasing the travel motor brakes. This procedure should only be performed by a experienced technician. If you doubt your ability to perform this procedure, contact your authorized dealer.

Prior operation: Keep all unauthorized personnel clear of the area. If possible, lower the attachment to the ground. Remove the ignition key. Place the safety lock lever in the LOCK position.

1.

Chock the tracks both front and rear to prevent unexpected movement.

2.

Place a clean drain pan of suitable capacity under each drain plug.

3.

Remove the drain plug from each travel motor, and allow the oil to drain.

4.

Cover the drain pans to prevent contamination, and move them to an area away from the machine.

5.

Remove the covers from both travel reduction plates by removing the bolts.

6.

Remove the thrust plate and sun gear.

7.

Install cover plates onto housings, and tighten all bolts securely.

8.

Install fill and drain plugs into cover plates, and replace the gear oil into the travel reduction units through the fill port.

9.

The machine can be towed to a repair location. After repairs are complete, reinstall the drive gear in reverse order.

10.

Torque to: Cover bolts: 63.7 - 70 N·m (47.0 - 51.6 lb ft) Plugs: 78.1 - 70 N·m (57.6 - 51.6 lb ft)

7-65

RAIL12CEX1029AA

1

RAIL12CEX1030AA

2

7 - MAINTENANCE

Lowering bucket attachment on a disabled machine WARNING Crushing hazard!

Use care when adjusting the release arm assembly. Stand clear of the boom and keep hands away from hinge points.

Failure to comply could result in death or serious injury.

W0475A

Prior operation: 1.

Use the relief valve incorporated in the holding valve to lower the attachment. The holding valve is located on the boom cylinder head side.

2.

DO NOT stand under the boom when lowering the attachment.

3.

Mark the position of the adjustment screw (1) before loosening. The adjustment screw is located on the relief valve (2).

4.

Loosen the screw, and allow the attachment to lower to the ground.

5.

After lowering, retighten screw to original, marked position.

7-66

RAIL12CEX1031AA

1

RAIL12CEX1032AA

2

7 - MAINTENANCE

STORAGE

Preparation for storage The following procedure applies when the machine is to be stored for a month or more. Store the machine on firm, level ground, inside a building or, if not possible, outside and covered with a tarpaulin. Before storing the machine: 1.

Clean the machine.

2.

Retract the arm cylinder rod as far as possible, and lower the boom until the attachment is resting on the ground.

3.

Park the machine on planks if parking the machine outside in freezing temperatures. Do not attempt to move the machine if tracks are frozen to the ground.

4.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your authorized dealer.

NOTE: When the machine resumes service, the film will disappear automatically 1.

Drain the fuel tank, and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anticorrosive oil to reach the lines, filters, pump and injectors.

2.

While the engine is still warm, drain the oil sump, fill with anti-corrosive oil, and replace the engine oil filter.

3.

When the engine is cold clean the outer parts of the engine.

4.

Clean or replace the air filter element.

5.

Drain the cooling system. Leave the drain valves open, and do not tighten the radiator cap.

6.

Grease the cylinder rods.

7.

Remove the batteries. Clean the battery housing, and make sure not to leave any traces of acid. Store the batteries safely in a cool and dry location, where the temperature will be higher than 0 °C (32.0 °F).

8.

Paint any areas where the paint shows signs of deterioration.

9.

Plug the air filter inlet and the exhaust pipe.

10.

Remove the starter switch key and place a DO NOT OPERATE label on the right-hand control arm.

11.

Lock the hoods and the cab door.

7-67

7 - MAINTENANCE

Every 30 days Periodic checks Every month, check: 1.

The battery charge and battery electrolyte level. Recharge the batteries if required.

2.

The grease on the cylinder rods and/or perform attachment functions monthly.

3.

The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4.

The condition of all lines, connectors and clamps (rust). Grease if necessary.

5.

The condition of the paint work. Apply a coat of anti-rust treatment where necessary.

7-68

7 - MAINTENANCE

Removal Starting up after storage WARNING Inhalation hazard! Risk to operators and bystanders.

Avoid running the engine in confined areas. Make sure there is adequate ventilation at all times.

Failure to comply could result in death or serious injury.

W0156A

1.

Close the drain valves, and fill the cooling system.

2.

Check the condition and tension of the track.

3.

Drain the fuel reservoir and top up with suitable fuel.

4.

Drain the engine sump, fill with clean engine oil, and check the oil level.

5.

Replace the filtering element of the fuel filters.

6.

Install the batteries.

7.

Grease the machine thoroughly.

8.

Check the condition of the engine accessory drive belt, and replace the belt, if necessary.

9.

Check the condition of the air conditioning drive belt and replace belt, if necessary.

10.

Check the hydraulic fluid level, and add more fluid, if necessary.

11.

Check the travel reduction gears and swing reduction gear oil level, and add more oil, if necessary.

12.

Clean the cylinder rods.

13.

Unplug the air filter inlet and the exhaust pipe.

14.

Remove the DO NOT OPERATE tag and start the engine, following the starting up procedure. Keep non-authorized personnel clear of the machine.

15.

Keep a careful watch on all systems display panel lamps and indicators.

7-69

7 - MAINTENANCE

7-70

8 - SPECIFICATIONS

8 - SPECIFICATIONS General specifications ENGINE Make Model Type Rated output power at 2000 RPM ( ISO 14396 ) Number of cylinders Total displacement Bore x Stroke

MItsubishi D0FR-KDP2TAAC Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger.

74 kW (101 Hp) 4 3.331 l (203.27 in³) 94 mm (3.70 in) x 120 mm (4.72 in)

ELECTRICAL SYSTEM Voltage Battery Battery capacity Alternator Starter motor

24 V 2 x 12 V 100 Ah 50 A 3.2 kW

HYDRAULIC SYSTEM Pump Hydraulic motor Hydraulic Motor with Reducer (Travel) Control Valve Cylinder (Boom, Arm, Swing, Bucket, Dozer) Return filter

Variable displacement axial piston pump Axial piston 2 - Axial piston, 2-speed 10- spool multiple control valve Double action cylinder Filter type with bypass valve (30 microns)

TRAVEL Parking brake Reduction unit Maximum climbable gradient TRAVEL SPEED Slow Fast

3.0 km/h (2.0 mph) 6.5 km/h (4.0 mph)

SWING Hydraulic motor Parking brake Reduction unit Swing speed

Axial piston type Oil disk brake 2 stage planetary gear unit 11.5 RPM

Oil disk brake 2 stage planetary gear unit 70 %

8-1

8 - SPECIFICATIONS

Dimensions and weights

RAPH12CEX0478EA

Overall length Overall width Height to top of cab Ground clearance of under carriage Ground pressure Operating weight Shoe

1

3600 mm (141.7 in) 2590 mm (102.0 in) 3020 mm (118.9 in) 505 mm (19.9 in) 44 mm (1.7 in) 16500 kg (36376.3 lb) 600 mm (23.6 in)

8-2

8 - SPECIFICATIONS

Working ranges

RAIL12CEX1016BA

1

Arm A A' B* C* D* E* F* G H* J* K L

Maximum digging reach Maximum digging reach at ground level Maximum digging depth Maximum digging height Maximum dumping clearance Minimum dumping clearance Maximum vertical wall digging depth Minimum swing radius Height at minimum swing radius 2440 mm (96.0 in) level digging depth Horizontal digging stroke at ground level: Stroke Horizontal digging stroke at ground level: Minimum

Marked * dimensions do not include height of shoe lug.

8-3

2380 mm (93.7 in) equipped with 0.5 m³ (0.65 yd³) bucket 8340 mm (328 in) 8160 mm (321.3 in) 5360 mm (211.0 in) 9340 mm (367.7 in) 6900 mm (271.7 in) 2740 mm (107.9 in) 4730 mm (186.2 in) 2000 mm (78.7 in) 6990 mm (275.2 in) 5130 mm (202.0 in) 4230 mm (166.5 in) 2100 mm (82.7 in)

2840 mm (111.8 in) equipped with 0.5 m³ (0.65 yd³) bucket 8780 mm (345.7 in) 8610 mm (339.0 in) 5820 mm (229.1 in) 9710 mm (382.3 in) 7260 mm (285.8 in) 2380 mm (93.7 in) 5390 mm (212.2 in) 2400 mm (94.5 in) 7010 mm (276.0 in) 5630 mm (221.7 in) 4720 mm (185.8 in) 2050 mm (80.7 in)

8 - SPECIFICATIONS

Bucket and arm combinations Type

Bucket (m' ) (cu·yd) SAE (Heaped)

Hoe Bucket

Breaker Nibbler

S O L

X

Outside width of bucket Without With side side cutters cutters

Number of teeth

Can be turned over

Arm

SAE 2.84 m Weight 2.38 m (Struck) 2.38 m Arm 2.84 m 0.20 0.24 (0.31) (0.26) 590 500 3 Yes Yes 280 O O 0.31 (0.41 0.23 ) (0.30) 700 600 3 Yes Yes 300 O O 0.28 0.38 (0.50) (0.37) 800 700 4 Yes Yes 340 O S 0.35 0.45 (0.59) (0.46) 915 815 4 Yes Yes 360 O L 0.38 0.50 (0.65) (0.50) 1,000 900 5 Yes Yes 380 S X 0.43 0.57 (0.75) (0.56) 1,100 1,000 5 Yes Yes 400 L X 0.50 0.70 (0.90) (0.65) 1,150 5 Yes Yes 410 L X O O O O Standard Combination General Operation Excavation or loading of sand, gravel, and clay Light operation Cultivation or Loading of loose gravel or sand.

Prohibited combina- KOBELCO’s warranty does not cover damage resulting from using these combinations. Not tion recommended.

8-4

8 - SPECIFICATIONS

Lift capacities WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE THAT EVERY OPERATOR: -is instructed in the safe and proper use of this machine.

-reads and understands the operator's manual for this machine.

-reads and understands ALL safety signs on the machine.

Failure to comply could result in death or serious injury.

W0188A

Lift capacity guidelines •

Do not lift or hold any load greater than listed lift capacities specifications.

•

Lift capacity specifications are with machine on level, firm, and uniform ground. Operator must make allowances for job conditions such as soft or uneven ground, side loads, sudden stopping of loads, hazardous conditions, personnel experience, etc.

•

Bucket lift hook is defined as lift point.

•

Listed lift capacity specifications are in compliance with SAE J/ISO 10567. Specifications do not exceed 87 percent of hydraulic lift capacity or 57 percent of tipping load.

•

Listed lift capacity specifications apply only to machines as originally manufactured and normally equipped.

NOTICE: The weight of all accessories must be deducted from listed specifications.

8-5

8 - SPECIFICATIONS

Standard lift — Machine with 2.84 m (9.4 ft) arm, 0.38 m³ (0.5 yd³) bucket Lifting capacity specifications are based on the standard machine with 600 mm (23.6 in) shoes, SAE heaped bucket, 2000 kg (4409.2 lb) counterweight, Blade up in front.

RAIL12CEX1017BA

8-6

1

8 - SPECIFICATIONS

Standard lift — Machine with 2.84 m (9.4 ft) arm, 0.38 m³ (0.5 yd³) bucket Lifting capacity specifications are based on the standard machine with 600 mm (23.6 in) shoes, SAE heaped bucket, 2000 kg (4409.2 lb) counterweight, Blade down in front.

RAIL12CEX1018BA

8-7

2

8 - SPECIFICATIONS

Standard lift — Machine with 2.84 m (9.4 ft) arm, 0.38 m³ (0.5 yd³) bucket Lifting capacity specifications are based on the standard machine with 600 mm (23.6 in) shoes, SAE heaped bucket, 2000 kg (4409.2 lb) counterweight, Blade up in rear.

RAIL12CEX1019BA

8-8

3

8 - SPECIFICATIONS

Standard lift — Machine with 2.84 m (9.4 ft) arm, 0.38 m³ (0.5 yd³) bucket Lifting capacity specifications are based on the standard machine with 600 mm (23.6 in) shoes, SAE heaped bucket, 2000 kg (4409.2 lb) counterweight, Blade down in rear.

RAIL12CEX1020BA

8-9

4

8 - SPECIFICATIONS

Dozer specifications

RAIL12CEX1025BA

Dozer overall width Dozer overall width without RH/LH dozer blade Height Maximum depth Digging depth Maximum tilt height Tilt cylinder size Bore (dia.) X rod (dia.) X stroke Angle cylinder size Bore (dia.) X rod (dia.) X stroke Lift cylinder size Bore (dia.) X rod (dia.) X stroke

1

3260 mm (128.3 in) 2480 mm (97.6 in) 815 mm (32.1 in) 25 ° X 25 ° 600 mm (23.6 in) 445 kg (981.1 lb) 102 mm (4.0 in) X 51 mm (2.0 in) X 127 mm (5.0 in) 102 mm (4.0 in) X 51 mm (2.0 in) X 552 mm (21.7 in) 114 mm (4.5 in) X 57 mm (2.24 in) X 210 mm (8.3 in)

8-10

9 - ACCESSORIES

9 - ACCESSORIES Nibbler NOTE: If it is required to install a nibbler to the excavator, select a nibbler model that meets the requirements of stability, flow rate and pressure of the excavator hydraulic system. Contact your authorized Dealer to select a type of nibbler suitable for this machine.

1.

2.

3.

Do not allow the machine weight to be supported by prying with the crusher and cylinders fully extended or retracted. Damage to the front attachment can occur.

NH0212A

1

NH0213A

2

NH0214

3

Do not perform crushing on either side of the machine. Operate the nibbler at the front or rear to prevent the machine from an overturn.

Be careful of falling objects when operating the nibbler raised to a full height.

9-1

9 - ACCESSORIES

4.

When operating on a man made floor, make certain that the floor has sufficient strength to support the load caused by crushing in addition to machine weight.

NH0215

5.

Always operate the crusher on a firm level surface, not on a slope or crushed scraps.

6.

Do not use the crusher to haul or move crushed scraps.

7.

Always remove the crusher from the excavator before transporting the machine. Do not travel with the bucket cylinder fully extended. This can damage the attachment due to high travel vibrations.

9-2

4

9 - ACCESSORIES

Breaker NOTE: If it is required to install a hydraulic breaker to the excavator, select a breaker model that meets the requirements of stability, pressure and oil quantity of the excavator hydraulic system. Contact your authorized Dealer to select a type of hydraulic breaker suitable for this machine.

1.

2.

3.

Avoid hitting objects with breaker. The breaker is heavier than the bucket and lowers faster. This may cause damages to the breaker, attachment, and upperstructure. Always lower the breaker slowly until the chisel point touches the object to be broken before starting breaker operation.

NH0195

1

NH0196

2

NH0197

3

Do not use the hydraulic breaker and/or swing function to push objects as damages to the attachment may result.

Do not operate the breaker with the excavator cylinders fully extended or retracted to avoid attachment and/or cylinder damage.

9-3

9 - ACCESSORIES

4.

5.

6.

7.

Stop working if hydraulic hoses look abnormally bent. Contact your authorized Dealer.

NH0197

4

NH0199

5

NH0200

6

NH0201

7

Do not operate the hydraulic breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components.

Do not use the hydraulic breaker to move objects.

The excavator might overturn and/or the hydraulic breaker may be damaged.

Do not operate the breaker to the side of the machine. The machine may become unstable and undercarriage components life may be reduced

9-4

9 - ACCESSORIES

8.

9.

10.

11.

Operate the excavator carefully to avoid hitting the boom with the hydraulic breaker.

NH0202

8

NH0203

9

NH0204

10

NH0205

11

Do not operate the breaker with the arm positioned vertically. Excessive vibration to the arm cylinder may cause oil leakage.

Press the breaker so that the chisel point thrust is square (perpendicular) to the object to be broken.

Do not operate the hydraulic breaker continuously longer than one minute. Excessive chisel wear will result. If an object could not be broken within one minute, apply chisel to other locations, less than one minute for each location.

9-5

9 - ACCESSORIES

Hydraulic oil - breaker/nibbler When the hydraulic breaker or nibbler are used, the excavator is subjected to working conditions more critical than usual, that speed up hydraulic oil deterioration and contamination. To prevent damages to the excavator hyComponent to be replaced Hydraulic oil (**) Hydraulic oil return filters

draulic system, breaker or nibbler, carefully respect service intervals detailed in this manual. In particular, replace hydraulic oil and filter element according to the instructions below:

Machine with breaker or crusher 1000 (*) 250 (*)

ATTENTION: (*) change intervals shown should be applied if the machine is used 100 % of the time equipped with the hydraulic breaker or nibbler. In case of lower time percentage of breaker or nibbler use, hydraulic oil and filter element change intervals may vary accordingly to the diagram below.

Machine with bucket 5000 1000

ATTENTION: (**) if the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 (optional), this oil must not be mixed with mineral hydraulic oil. Refer to the service intervals shown in the table above for filter element replacement. If in doubt, do not hesitate to contact your Dealer.

1

NHC0320

Change intervals as a function of the breaker or nibbler using percentage 1.

Hydraulic oil return filters change interval

2.

9-6

Hydraulic oil change interval

9 - ACCESSORIES

Work mode select switch Work mode selections •

Use the work mode select switch to switch to specific attachments. Always check that the work mode selected is correct on the monitor, as improper work mode selection can cause machine damage or malfunction.

LC20T01334P1

1

Stop valve 1.

Before removing or changing any attachment, set the stop valve to the STOP position to stop the flow of hydraulic oil to the attachment.

(1) Open (2) Closed

RAIL12CEX1026AA

9-7

2

9 - ACCESSORIES

Rotary multi control valve (SAE and BHL pattern) 1.

2.

Make sure that you know the location and function of each control before operating.

RAIL12CEX1027AA

3

RAIL12CEX1028AA

4

Keep all unauthorized personnel clear of the area.

Park the machine on level ground, in neutral with the attachment lowered to the ground. Deactivate the auto idle function, turn the engine speed throttle to the LO position. Stop the engine, and remove the ignition key. Place the safety lock lever in the LOCK position.

3.

Remove the wing nut (1) and shift the lever (3) to the marked position. Tighten the wingnut.

4.

Operate the machine and make certain the control level pattern is the correct one and the control sign reflects the correct control pattern.

9-8

Index ACCESS TO OPERATOR'S PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Hydraulic oil - breaker/nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Work mode select switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

CONTROLS/INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Every 10 hours or daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Alternator and drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Every 1000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

Every 120 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Every 2000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 Hydraulic suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Pilot line filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Swing reduction lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Engine air filter, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Radiator and coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Every 50 hours of operation or weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Every 5000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

FORWARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Right, left, front, and rear of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Work mode select switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Biodiesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Alternator and drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Biodiesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Engine air filter, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Hydraulic suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 Pilot line filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Preparation for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Radiator and coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Releasing pressure in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Swing reduction lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

PARKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

RIGHT-HAND SIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

ROAD TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Preparing for road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

SHIPPING TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Bucket and arm combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Dozer specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Lift capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Working ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

STARTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Preparation for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

TRANSPORT OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Preparing for road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

WORKING OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Work mode select switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Kobelco dealer.

Copyright © 2012 Kobelco Construction Machinery America, LLC. All Rights Reserved.

Kobelco is a registered trademark of Kobelco Construction Machinery America, LLC. 245 East North Avenue Carol Stream Illinois 60188 U.S.A.