Kobelco ED160-3 Blade Runner™ Tier 4 Excavator Operator's Manual PDF

OPERATOR’S MANUAL Hydraulic Excavator ED160-3 Blade Runner™ Tier 4

S2LH00006ZE01 Issued October 2012

APPLICABLE: ED160-3 . . . . . . . . . . . . . LH02-01501~

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Right, left, front and rear of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Diesel particulate filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

2 SAFETY INFORMATION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

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

OPERATOR'S SEAT Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

FORWARD CONTROLS Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

RIGHT-HAND SIDE CONTROLS Right-hand console - operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

REARWARD CONTROLS Rearward controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

4 OPERATING INSTRUCTIONS COMMISSIONING THE UNIT Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Windshield washer fluid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Draining the fuel filter water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

STARTING THE UNIT Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Inspection after starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

STOPPING THE UNIT Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

PARKING THE UNIT Parking the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Dozer blade control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Practices to improve efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Emergency boom lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

7 MAINTENANCE GENERAL INFORMATION Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Biodiesel fuel - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

MAINTENANCE CHART Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Every 50 hours of operation or weekly Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Every 120 hours Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Every 250 hours Engine air filter: outer element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Checking the radiator hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Bucket grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Outside fresh air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Every 500 hours Cab air recirculation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Boom lift - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Every 1000 hours Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Every 2000 hours Pilot line filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

Every 5000 hours Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

As required Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Bucket teeth and side cutters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Preparing for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Starting up after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Fluids and lubricants Fluids and lubricants ED160-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

8 SPECIFICATIONS General specifications ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Dozer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Dimensions and weights ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Digging data ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Buckets application as a function of the arm ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Lift capacities - Model ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

9 ACCESSORIES Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Hydraulic oil - breaker/nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Hammer and rotating bucket hydraulic system - Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Biodegradable hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

1 - GENERAL INFORMATION

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

Intended use The machine has been designed and constructed in accordance with the most rigorous standards of quality and in compliance with current safety regulations. Never use the machine for applications not included in the manual. If the machine needs to be used for work that involves the use of special equipment, accessories or instruments, consult the dealer to make sure that any adaptations or modifications carried out comply with the technical specifications of the machine and with the safety standards. Any modification or adaptation that is not approved by the manufacturer may invalidate the original conformity of the machine to the safety requirements and the persons that carry out these unapproved modifications will be held responsible for the consequences.

Before handing the machine over to an operator, check that: • The operator has been properly trained in the correct and safe use of the machine.

• The operator has read the instructions in this manual and that they understand them fully.

Always keep this manual in the cab. Make sure that it is always intact and in good condition. Contact the dealer for further copies or a translation into a different language from the country of use.

ATTENTION: The engine and fuel system on your machine is 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.

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

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1 - GENERAL INFORMATION

Introduction The excavator is a hydraulically operated machine. It consists of an undercarriage fitted with tracks and a swing bearing which supports the upper frame. The upper frame supports the attachment, the engine, the hydraulic components, the cab, the fuel tank and the counterweight. When the operator activates the controls (pedals/levers), the hydraulic pumps, operated by the engine, pumps the oil from the tank, sending it to the control valve which sends the oil to perform the requested operation. A cooling system maintains the hydraulic oil at normal operating temperature.

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NOTICE: Do not use the excavator for operations which are foreign to its specifications and not included in this manual in order to prevent serious injury to persons or damage to the machine. The manufacturer/dealer is not responsible for damage caused by improper use.

The excavator has been designed to carry out 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.

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

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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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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).

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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

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Product identification plates Machine identification Model name Product identification number (PIN) Manufacturing year The PIN plate is located on the lower right-hand side of the cab.

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Engine make and model Engine PIN The serial number plate is located on the engine block.

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

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1 - GENERAL INFORMATION

Machine components

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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 27. Bucket 28. Idler link 29. Bucket link 30. Bucket cylinder 31. Arm 32. Boom cylinder 33. Cab 34. Dozer blade 35. Track shoe assembly

1 - GENERAL INFORMATION

Diesel particulate filter (DPF) What is Exhaust Gas Recirculation (EGR)?

Your KOBELCO machine is equipped with additional components to comply with national and local exhaust emissions requirements. EGR works by recirculating a portion of the engines exhaust gasses back into the engine’s combustion chamber to lower combustion temperatures.

The main components of the EGR system include: • EGR valve • Diesel Particulate Filter (DPF) • Diesel Oxidation Catalyst (DOC) • Exhaust gas temperature sensors • Differential pressure sensor • Throttle valve actuator

What is a Diesel Particulate Filter (DPF)?

A Diesel Particulate Filter (DPF) is a filter mounted in the exhaust stream. During normal operating conditions, the exhaust gasses pass through the porous walls of the DPF and trap Particulate Matter (PM) generated by the combustion process of the engine. When channels inside the DPF fill up with PM, the system must be cleaned. The cleaning process is called Regeneration.

How does the regeneration process work?

When the DPF becomes restricted, the system will need to be cleaned or regenerated by raising exhaust temperatures to burn off the trapped Particulate Matter (PM). This process is usually done automatically, but may require a manual regeneration sequence to be activated depending on operating conditions. Burned PM will leave behind traces of ash within the DPF. The ash must be cleaned out by a KOBELCO dealer outfitted with machines specifically designed to clean DPF systems. Refer to the [**Link to maintenance chart**] for service intervals.

Automatic regeneration When the DPF enters automatic regeneration mode, the display will indicate “DPF ON”, several conditions need to be followed to properly let the machine perform this function.

• During this mode do not idle or shut the machine down.

• Hot exhaust gasses will be generated, use in well ventilated area away from combustible materials.

• Use the machine under normal work scenarios until the automatic regeneration process has completed.

• If the machine will be idled during this time, shut the machine down and perform a manual regeneration upon resume of operation.

Manual regeneration When automatic regeneration of the DPF is inhibited, unsuccessful or the machine had to be shutdown during the automatic regeneration process, manual regeneration is used. During the manual regeneration mode, the display will indicate “DPF ON”, several conditions need to be followed to properly let the machine perform this function.

• During this mode, the machine will be unusable • Move the machine to a safe place away from combustible materials.

• Hot exhaust gasses will be generated, use in well ventilated area away from combustible materials.

• Let the regeneration finish before shutting the machine off.

Finding a Diesel Particulate Filter (DPF) cleaning facility To find a KOBELCO dealer that is fully equipped to service your DPF system, please call the number below.

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Kobelco Construction Customer Service: 1-888-562-5201 customerservicekobelco.na@newholland.com

U.S. EPA and California Emissions Control Warranty Statement KOBELCO warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with U.S. Environmental Protection Agency regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations for a period of: • 2 years or 1,500 hours of operation, whichever occurs first, for engines less than 19kW/25HP • 5 years or 3,000 hours of operation, whichever occurs first, for engines greater than or equal to 19kW/25HP NOTE: This warranty applies to all units operated in the United States or Canada.

Coverage The model year, class of diesel engine, and emission application determination for your engine are identified on the Emission Control Information Label. This label is affixed to one of the following areas of the engine: the top of engine's rocker arm cover, the right-hand side of the oil pan, and the right-hand side of the engine front gear cover.

The warranty period begins on the date the new equipment is sold to the first retail purchaser. The presence of the emission control label is the indication that the engine conforms to the applicable standards. Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period.

The engine owner has responsibility to perform all the required maintenance listed in the Owner's Manual. KOBELCO will not deny an emission warranty claim solely because no record of maintenance exists; however, a claim may be denied if failure to perform maintenance resulted in the failure of a warranted part.

It is recommended that replacement parts used for maintenance or repairs be KOBELCO Service Parts to maintain the quality originally designed into your emission certified engine. The use of non- KOBELCO parts does not invalidate the warranty on other components unless the use of such parts causes damage to warranted parts.

The manufacturer is liable for damages to other engine components caused by the failure of any warranted emission control system part. KOBELCO is not responsible for failures resulting from improper repair or the use of parts that are not genuine KOBELCO or KOBELCO approved parts.

Component coverage New engines certified for sale and registered will have the following items covered by the emission warranty, depending on the emission level of the engine, if the items were first installed on the new engine as original equipment: Fuel injection system

Exhaust after treatment Devices (if applicable)

• Fuel injection pump

• Catalytic converter (DOC)

• Fuel injectors

• Diesel particulate filter (DPF)

• Fuel injection lines

• Selective catalytic reduction (SCR)

Air induction system

• Diesel Exhaust Fluid (DEF) tank and dispensing systems

• Intake manifold • Turbocharger system (includes exhaust manifold) • Charge air cooler Positive crankcase ventilation system (if applicable) • PCV valve • Oil fill cap

Exhaust Gas Recirculation Systems (EGR) • EGR valve assembly • EGR cooler Cold Start Enrichment Systems Electronic Control Units, Sensors, Solenoids, and Wiring harnesses used in above systems

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Emissions warranty does not cover • Repairs arising from storage deterioration, failure to maintain the equipment, negligence, alteration, improper use of the equipment, collision or other accident, vandalism, or other casualty, or operation beyond rated capacity or specification.

• Repairs arising from abuse or neglect, including but not limited to: operation without adequate coolant or lubricants, adjustments to the fuel system outside equipment specifications, over-speeding, improper storage, starting, warmup, or shutdown practices, incorrect fuel or contaminated fuel, oil or other fluids.

• Normal maintenance services, such as engine tune-ups, engine fuel system cleaning, checks, adjustments, shimming, etc.

• Items replaced due to customer demand.

• Labor charges performed by anyone except a dealer authorized by contract to repair the equipment, unless they qualify under special provisions (i.e. outside labor).

• Any and all travel costs for items such as towing, service calls, or transporting a unit to and from the place where the warranty service is performed.

• Normal maintenance costs, including but not limited to: lubricants, coolants, fluids, fuel, filters, and associated labor.

Lubricants, filters, and coolants may qualify for warranty reimbursement if they require replacement as a DIRECT RESULT of a defect in material or workmanship.

• Claims involving the inspection or reconditioning of units after storage or prior use.

• Repairs arising from service performed by agents not approved by KOBELCO. • Repairs arising from any unauthorized modification to the product or the use of non- KOBELCO parts, implements or attachments.

• Removal, replacement, or installation of non- KOBELCO optional equipment, attachments or components.

• Premiums charged for overtime labor costs or out of shop expenses.

• Economic loss including lost profits, crop loss, equipment rental, or other expense.

• Unauthorized modification or updating machines without a warrantable failure.

• Any and all costs of dealer shop supplies incurred with repairs, including but not limited to: solvents, cleaners, anti-seize lubricants, loctite, sealant, adhesive, oil-dry, shop towels, etc.

• Failure of the machine, its implements or attachments caused by improper field application or loading.

• Any and all costs for coolant, fuel, or lube (oil) analysis including supplies and lab recommendations.

• Cost associated with cleaning of machine in preparation for servicing.

Glossary Acronym EGR DPD DPF DOC ISO MSDS NOx PPE ULSD PM

Definition Exhaust Gas Recirculation Diesel Particulate Diffuser Diesel Particulate Filter Diesel Oxidation Catalyst International Organization for Standardization Material Safety Data Sheet Nitrogen Oxide Personal Protective Equipment Ultra Low Sulfur Diesel Particulate Matter

Symbol C F ° % <

Centigrade Fahrenheit Degree Percent Less than

Units of measure Definition

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Symbol > mg/kg

Definition Greater than Milligrams per kilogram

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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

BT09A213

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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.

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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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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.

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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.

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.

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YN20T01320P2

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DANGER Do not start engine. Do not operate under inspection/repair.

Part number — YN20T01320P2

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.

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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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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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Seat belts Seat belts must be worn at all times.

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

Seat belt inspection and maintenance: • Keep seat belts in good condition.

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

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

• Keep seat belts clean and dry.

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

• Clean belts only with soap solution and warm water.

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

• Replace all parts that have damage or wear.

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

Fasten the seat belt Fasten the seat belt as follows: 1. Insert the retaining clip (1) into the buckle (2).

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2. 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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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.

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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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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.

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: • 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.

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.

RAPH12CEX0460AA

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

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

• Correctly use installed steps, ladders, and railings.

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

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

2-12

2 - SAFETY INFORMATION

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

Carry loads in the recommended positions for maximum stability.

Never lift loads in excess of capacity. weights.

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.

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

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

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

• Do not exceed the prescribed load limits.

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

• Do not try digging exploiting the mass of the machine.

SP0032

8

SP0033

9

SP0034

10

Pay attention when working deeply When digging deeply, pay special attention to prevent contacts of the attachment and the relevant hydraulic hoses with the ground.

• Do not swing the turret or the undercarriage when the attachment boom is fully lowered. Under these conditions there is the danger that the boom collides with the track chains.

Do not use the traction force of the machine for digging Do not travel the machine to dig. In doing this, an excessive stress on the front attachment could results in damages to the structure. Use the undercarriage for traveling only.

2-13

2 - SAFETY INFORMATION

Do not use the upper structure swing for digging Do not use the upper structure swing for digging or moving rocks. An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system. Also, this inappropriate use of the machine could cause serious injuries or fatalities.

SP0035

11

SP0036

12

SP0037

13

NH0057

14

Do not use the bucket as a hammer The use of the bucket as a hammer or for piling operations could cause serious damages to the bucket itself and the components of the front attachment. Also, this inappropriate use of the machine could cause serious injuries or fatalities.

Avoid operating the cylinders to full stroke Do not extend repeatedly the bucket and the arm cylinders full stroke with the purpose of cleaning the bucket from residual materials. This could cause damages to the cylinders. To remove residues from the bucket, use water under pressure or remove them manually.

Transporting the machine under safe conditions During loading or unloading operations of the machine on a truck or trailer the danger for tipping over is always present.

• Use a truck or trailer appropriate for transporting the machine.

• Secure safely the machine to the trailer with appropriate chains or cables. Please refer to the chapter "TRANSPORT OPERATIONS" of this Manual for the safe loading and unloading procedures.

• Make sure that you comply with National and local regulations when transporting the machine on open roads.

2-14

2 - SAFETY INFORMATION

WARNING Avoid injury!

When towing, do not enter the area between the machine and towing vehicle. Do not apply a shock load to the wire rope. Keep the wire rope horizontal and perpendicular to the machine frame. Tow in low speed mode.

Failure to comply could result in death or serious injury.

W1193A

Towing the Machine It may be necessary to tow the machine if stuck in soft soil.

RAPH12CEX0458AA

• Attach a wire rope or chain to the lower frame (1).

• Attach other end of the wire rope or chain to the towing vehicle.

• Operate the travel lever in the same direction as the towing vehicle.

NOTICE: Do not pull machine using the brackets welded on the lower plates (2) of the undercarriage. These brackets are provided for pulling lightweight objects.

NOTICE: For towing the machine body, apply pads to the crawler frame corners to prevent damage to the wire rope and crawler frame.

Store attachments safely Stored attachments such as buckets, hydraulic breakers and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling.

• Keep bystanders away from storage areas.

SP0054

2-15

16

15

2 - SAFETY INFORMATION

Use appropriate tools Use tools appropriate for the job to be performed.

• Inappropriate tools, parts and procedures might generate dangerous conditions.

• Use tools of correct size to tighten or loosening securing elements, in order to avoid injuries caused by a wrench getting out of control.

• Do not use U.S. Standard or British Standard tools on metric fasteners and vice versa.

• Use only genuine spare parts (please refer to the Parts Catalog).

SP0063

17

SP0061

18

Evacuating in case of fire If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the starter key to the OFF position.

• Use a fire extinguisher if there is time.

• Exit the machine making use of hand rail and step.

2-16

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.

2-17

2 - SAFETY INFORMATION

Safety signs

RAPH12CEX1341GA

2-18

1

2 - SAFETY INFORMATION

RAPH12CEX1331GA

2-19

2

2 - SAFETY INFORMATION

1 - Do not use counterweight lifting DANGER Do not use counterweight lifting eyes to lift whole machine.

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

Refer to operators 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 righthand sides of the counterweight.

Part Number — YN20T01221P1 Quantity — 2 YN20T01221P1

3

YN20T01049P1

4

2 - Keep surface area clean 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 fuel tank (rear right-hand corner) Part number — YN20T01049P1 Quantity — 1

2-20

2 - SAFETY INFORMATION

3 - Pressurized hydraulic oil tank 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.

Prior to performing maintenance operations on the hydraulic oil tank, bleed the pressure by pressing the bleeding button located on the tank. The hydraulic oil, at operating temperature, can cause burns in case of contact with the skin.

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

5

PW20T01007P1

4 - Do not step on WARNING There is a danger of falling when work on areas above ground. Do not step on the area where this safety sign is attached. Failure to comply could result in death or serious injury.

• Do not approach edges • Use the appropriate equipment, such as ladders or platform when working above ground. In addition, strap yourself to the proper equipment accordingly.

• Do not leave any tools around the working area.

• Use extreme caution to avoid slipping while walking.

• Do not jump on or from the machine. Use the steps and handrails and securely maintain a three point contact while mounting or dismounting at all times.

This warning safety sign is located on top of the battery cover.

Part Number —ZL11N02704 Quantity —1

ZL11N02704

2-21

6

2 - SAFETY INFORMATION

5 - Counterweight operating range 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

7

YN20T01015P2

8

YN20TO1338P1

9

6 - Prevent battery explosion – Booster cable 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 - Battery cable 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

2-22

2 - SAFETY INFORMATION

8 - Hot coolant 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 safety sign is located on top of engine fan shroud.

Part Number — YN20T01010P1 Quantity — 1

YN20T01010P1

10

PA20T01131P1

11

YN20T01012P1

12

9 - Engine stop WARNING Rotating parts can cause personal injury.

Keep away from fan and belt when engine is running.

Stop engine before servicing. Failure to comply could result in death or serious injury.

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

Part Number — PA20T01131P1 Quantity — 1

10 - Rotating & hot parts 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

2-23

2 - SAFETY INFORMATION

11 - Hot parts 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

2-24

13

2 - SAFETY INFORMATION

12 - Adjusting track tension The grease in the track adjust valve is under extreme pressure and can penetrate the skin causing severe injury. Carefully read the relevant maintenance section prior to performing the track adjusting procedure.

This safety sign is located on the crawler frame.

Part Number — YN20T01813P1 Quantity — 2

YN20T01813P1B

2-25

14

2 - SAFETY INFORMATION

13- Do not step on WARNING There is a danger of falling when work on areas above ground. Do not step on the area where this safety sign is attached. Failure to comply could result in death or serious injury.

• Do not approach edges • Use the appropriate equipment, such as ladders or platform when working above ground. In addition, strap yourself to the proper equipment accordingly.

• Do not leave any tools around the working area.

• Use extreme caution to avoid slipping while walking.

• Do not jump on or from the machine. Use the steps and handrails and securely maintain a three point contact while mounting or dismounting at all times.

This warning safety sign is located on top of pump cover.

Part Number — YY20T01387P1 Quantity — 1

YY20T01387P1

15

YN20T01017P1

16

14 - Handling battery 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

2-26

2 - SAFETY INFORMATION

15 - Prevent battery explosion 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.

LS20T01202P1

17

YN20T01495P1

18

YN20T01339P1

19

• 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 - California proposition 65 WARNING CALIFORNIA Proposition 65 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals know to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Failure to comply could result in minor or moderate injury.

This WARNING safety sign in located on top of the battery cover.

Part Number — YN20T01495P1 Quantity — 1

17 - Do not insert hand into moving part 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

2-27

2 - SAFETY INFORMATION

18 - Lock front window at the housed position Risk of injury deriving from the front window not being locked or being improperly locked in the open position.

Always make sure the front window is locked.

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

Part Number — LC20T01331P1 Quantity — 1

LC20T01331P1

20

YY20T01273P1

21

19 - Operate safety lock lever carefully CAUTION When pulling up the safety lock lever to the “LOCKED” position operate it carefully. Depending on the seat position, 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 located on the bottom of the left controller.

Part number — YY20T01273P1 Quantity — 1

2-28

2 - SAFETY INFORMATION

20 - Dozer interference WARNING Dozer wings should be folded for transport only. Do not load or off load with wings in folded position. Don no 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 inside the cab on the right-hand side and on the dozer blade.

Part number — 2432P4143

2-29

2432P4143

22

2 - SAFETY INFORMATION

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

Part Number — LC20T01338P1 Quantity — 1

LC20T01338P1

1.

WARNING 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 could result in death or serious injury.

VOLTAGE (Volts) 50 V or LESS 50 - 200 V 200 - 350 V 350 - 500 V 500 - 750 V 750 V or over

2.

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

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

23

position before exiting the cab. Failure to comply could result in death or serious injury.

3.

WARNING 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.

4.

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.

Failure to comply could result in death or serious injury.

5.

CAUTION

2-30

2 - SAFETY INFORMATION

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.

6.

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.

7.

NOTICE 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 turbo charger to gradually cool down.

8.

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.

9.

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.

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.

11. 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.

12. WARNING Automatic two speed travel system changes travel speed automatically and can adversely affect machine control when descending a slope and loading or unlading 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.

22- Keep clear working area DANGER KEEP CLEAR OF MACHINE Failure to comply will result in death or serious injury.

Make sure the area is clear of obstacles and persons before beginning the operation of the machine. Always look around before you start the swing operation. Make sure everyone is cleared in your work site. Sound horn before beginning swing operation.

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

2-31

YN20T01337P1A

24

2 - SAFETY INFORMATION

23 - Attachment mode select switch (option) CAUTION Before starting work, select and switch the attachment mode appropriately.

If the machine is operated with mode other than breaker mode, hydraulic component such as an oil cooler, and breaker are damaged.

When “H”, “S” or “E” of the work mode is flickering, this shows that the selection of attachment mode is improper.

Set the attachment select switch to the proper position.

Failure to comply could result in minor or moderate injury.

Before starting work, be sure to set the attachment select switch to the proper position.

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

Part Number — LC20T01334P1 Quantity — 1

LC20T01334P1

25

PY20T01062P1

26

YN20T01039P1

27

24 - Operation by foot pedal (option) 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

25 - Confirm the movement of the attachment before operating the attachment (option) 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 on the right-hand side window of the cab.

Part number — YN20T01039P1 Quantity — 1

2-32

2 - SAFETY INFORMATION

26 - Stop the engine before changeover (option) DANGER Rotary multi control Read operator manual ISO BHL lever lock position and control pattern.

DANGER stop the engine without fail at time of change over.

This DANGER safety sign is located on the guard support of the right deck. Failure to comply will result in death or serious injury.

Part number — YY20T01384P1 Quantity — 1

YY20T01384P1

2-33

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.

2-34

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.

2-35

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.

2-36

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.

2-37

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).

2-38

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.

2-39

2 - SAFETY INFORMATION

2-40

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

SP0008

1

NHC0055

2

• 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.

Opening the door from the outside NOTE: the key supplied is used 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.

If unlocked, pull the opening lever (1) outwards.

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

NHC0057

5

Releasing the door from the inside To keep the door wide 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 To open the front windshield proceed as follows: • Move locking device lever (5) rightward.

• Hold and push up the handles (6) located on the upper and lower side of the windshield. After the windshield reaches the rear side of the roof, it locks automatically.

To close the front windshield proceed as follows: • Unlock the windshield moving locking device lever (5) leftward.

• Slide the windshield using handles (6) to stroke end.

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 by hands and remove it from the window frame.

• Store the lower window in the holders located on the left rear side of the cab securely.

NHC0059A

6

NHC0060

7

NHC0054

8

Opening and closing the door window Release the locks (7) and slide the window panels inward.

Close the window panels by moving them back to their previous position until the locks engage.

Inside Cab light The inside cab light switch (8) has two positions: • Down: light OFF • Up: light ON

Emergency exit If the cab door cannot be opened in an emergency, escape from the cab following the procedures described below: • Open the front windshield and escape through the opening. .

• Should opening of the front windshield be impossible, use the life hammer located on the left rear side of the cab to break the front windshield.

• If the front windshield is unavailable to escape, use the life hammer to break the rear window.

3-3

3 - CONTROLS/INSTRUMENTS

OPERATOR'S SEAT

Operator's seat WARNING Loss of control hazard!

Do not make seat adjustments while the machine is in motion. All seat adjustments should be made with the machine stationary and the safety lever in the LOCK position.

Failure to comply could result in death or serious injury.

W0393A

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

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

Forward and backward adjustment It is possible to obtain a double longitudinal adjustment: • by actuating lever (2) the distance of the seat from the pedals is adjusted; • by actuating lever (3) the distance of the seat and control levers from the pedals is adjusted;

Height and tilt adjustment Press down the lever (4) and adjust seat angle and height for maximum comfort by moving your body back and forth.

Release the lever to lock the seat.

Backrest angle adjustment The backrest angle relative to seat cushion is adjusted by pulling the lever (5).

Armrest angle adjustment The armrest angle relative to the backrest is adjusted by turning the armrest controls (6) (one per armrest).

Headrest The headrest can be adjusted in height and can be moved at an angle. Lift the headrest upwards to remove.

3-4

NHC0362

1

3 - CONTROLS/INSTRUMENTS

AIR SUSPENSION SEAT NOTE: The adjustment procedures of the air suspension seat are the same of the mechanical seat, except for the suspension adjustment.

Suspension adjustment • turn the starter key to ON position.

• push the manual air valve (2) to increase the suspension.

• pull the manual air valve (2) to decrease the suspension.

Cushion heater • turn the starter key to ON position.

• press the switch (1), located on the rear side of the backrest, to I position.

NOTICE: In order to preserve the charging of the batteries, it is recommended that the cushion heater is activated with the engine is running.

NH0191

2

NHC0247

3

ARMREST HEIGHT ADJUSTMENT The height of the right and left armrests is adjustable in four positions: • Open the clamp (3).

• Push the pin (4).

• Slide the armrest up or down to the desired height until the pin locks.

• Close the clamp (3).

3-5

3 - CONTROLS/INSTRUMENTS

FORWARD CONTROLS

Front console

RAPH12CEX1349GA

1. Left travel pedal 2. Left travel lever 3. Right travel lever 4. Right travel pedal

1

5. Gauge cluster 6. Right hand operator control lever 7. Left hand operator control lever 8. Safety lock lever

3-6

3 - CONTROLS/INSTRUMENTS

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

•

LOCK: with the machine stationary and the engine running or stopped, it prevents the possibility of machine unexpected movements if the control levers/pedals are accidentally moved UNLOCK: the safety lever enables the operation of all controls. Therefore, to control and operate the machine, the lever should be moved to this position

NH0002

2

NH0003

3

NHC0201A

4

Left control lever The left control lever activates the following operations: 1. Swing Right 2. Swing Left 3. Arm Roll-Out 4. Arm Roll-In 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 Roll-In 8. Bucket Roll-Out NOTE: When the control lever is released, it returns automatically to the neutral position and the associated work function stops.

RAPH12CEX0137AA

3-7

5

3 - CONTROLS/INSTRUMENTS

Travel control pedals and levers NOTE: The words right, left, front, back, clockwise and counter-clockwise are to be referred to the operator position properly sitting in the driver’s seat.

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

Neutral Machine moves forward Machine moves backward Opposite simultaneous rotation of the tracks with consequent counter-clockwise 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

RAPH12CEX0138GA

1

1.

Engine coolant temperature meter

10. Auto Idle button

2.

Fuel level meter

11. Travel speed button

3.

Screen change button

12. Windshield washer button

4.

Menu button

13. Windshield wiper button

5.

Buzzer stop button

14. BACK button

6.

Digging mode button

15. UP button

7.

Nibbler mode button

16. NEXT button

8.

Breaker mode button

17. DOWN button

9.

Work mode button

3-9

3 - CONTROLS/INSTRUMENTS

Engine coolant temperature meter Meter (1) 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 water cools down 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: overheated NOTICE: If the indicator enters the red range, the relevant warning icon is displayed and the buzzer sounds at the same time. In this case, stop temporarily the operations and let the engine low idle. In the event the overheating continues, stop the engine, wait for a few minutes, then check the coolant level.

RAPH12CEX0187BA

2

RAPH12CEX0188BA

3

Fuel level meter Meter (2) 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.

3-10

3 - CONTROLS/INSTRUMENTS

Screen change button With the starter key in position ON or the engine running, each time the screen change button (3) is pressed, the display shows the following screens in sequence: 1. Rear view camera 2. Consumption graph: it shows the fuel consumption at 5 min intervals. The average consumption is shown below the graph. To reset the consumption graph, press DOWN button.

3. KOBELCO logo NOTE: when starting the engine, rear view camera screen is always displayed.

RAPH12CEX0189BA

4

RAPH12CEX0141BA

5

Menu button Menu button (4) provides the entry to the modification screen of the following parameters • MAINTENANCE • SWITCH STATUS • OPTION SETTING • CONSUMPTION • SCREEN SETTING • CLOCK SETTING

MAINTENANCE • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

3-11

3 - CONTROLS/INSTRUMENTS

• MAINTENANCE item of the menu is displayed with a blue background. Press NEXT button to enter the maintenance information screen. The screen shows the recommended replacement interval, the remaining time prior to the next change and the date of the previous change of engine oil, fuel filter, hydraulic filter and hydraulic oil.

• Pressing buttons UP or DOWN, move cursor to the desired maintenance item to be changed. Press NEXT button to move cursor in the REMAINING TIME column. The value is displayed with a blue background.

• Modify the maintenance interval pressing UP or DOWN button (10 hours interval) or press the Menu button (4) to reset the interval prescribed by the manufacturer. Save the maintenance interval by pressing NEXT button.

• Press the screen change button (3) to return to the main display.

RAPH12CEX0190EA

3-12

6

3 - CONTROLS/INSTRUMENTS

SWITCH STATUS (Auto Warm-Up) • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select SWITCH STATUS item of the menu. Press NEXT button to enter the switch status screen.

• Press DOWN button and select AUTO WARM-UP. Press NEXT button to enter the modification mode. The state of the function is displayed with a blue background.

• Activate or deactivate the automatic warming up function pressing button UP or DOWN. Press Menu button to set the status.

• Turn the starter key OFF to store the status.

• Press the screen change button (3) to return to the main display.

In case of very low ambient temperatures and AUTO WARM-UP function activated, when the engine is started the automatic warm up is performed as indicated by the relevant icon WARM on the display. At the end of the warming-up, the buzzer sounds for about 5 seconds and icon WARM disappears.

NOTE: The automatic warming-up is cut-off when the control levers or the travel controls are actuated. It is automatically activated once the control levers and the travel controls return to neutral position after about 10 seconds.

RAPH12CEX0201EA

3-13

7

3 - CONTROLS/INSTRUMENTS

OPTION SETTING (Nibbler) Depending upon the nibbler mounted, it is possible to select one of the ten pre-set flow rate and pressure settings.

• With the starter key in ON position or the engine running, keep pressed Nibbler mode button (7) until the flow rate and pressure screen appears.

• Press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select OPTION SETTING. Press NEXT button to enter the nibbler setting screen.

• Select the desired set pressing button UP or DOWN. Press Menu button to confirm the selection.

• Press the screen change button (3) to return to the main display.

RAPH12CEX0193EA

8

OPTION SETTING (Breaker) Depending upon the breaker mounted, it is possible to select one of the ten pre-set flow rate and pressure settings.

• With the starter key in ON position or the engine running, keep pressed Breaker mode button (8). The flow rate and pressure screen appears.

• Press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select OPTION SETTING. Press NEXT button to enter the breaker setting screen.

• Select the desired set pressing button UP or DOWN. Press Menu button to confirm the selection.

• Press the screen change button (3) to return to the main display.

RAPH12CEX0202EA

3-14

9

3 - CONTROLS/INSTRUMENTS

CONSUMPTION • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select CONSUMPTION. Press NEXT button to enter the consumption screen.

The consumption graph shows the fuel consumption of the last 12 h. The engine work time, total consumption and average consumption are shown below the graph. To reset the consumption graph, press DOWN button.

RAPH12CEX0196EA

10

SCREEN SETTING (Contrast) • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select SCREEN SETTING. Press NEXT button to enter the screen setting display. CONTRAST item of the menu is displayed with a blue background.

• Press NEXT button to enter the modification mode. The contrast value is displayed with a blue background.

• Modify the value pressing UP or DOWN button. Step of adjustable range is from 1 to 10. Press Menu button (4) to confirm the selection.

• Press the screen change button (3) to return to the main display.

RAPH12CEX0203EA

3-15

11

3 - CONTROLS/INSTRUMENTS

SCREEN SETTING (Brightness - day) • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select SCREEN SETTING. Press NEXT button to enter the screen setting display.

• Press DOWN button and select Brightness (day). Press NEXT button to enter the modification mode. The brightness value is displayed with a blue background.

• Modify the value pressing UP or DOWN button. Step of adjustable range is from 1 to 100. Press Menu button (4) to confirm the selection.

• Press the screen change button (4) to return to the main display.

NOTE: Perform the same procedure to modify the value of the item Brightness (night).

RAPH12CEX0204EA

12

CLOCK SETTING • With the starter key in ON position or the engine running, press Menu button (4) to enter into USER MENU screen.

• Press DOWN button and select CLOCK SETTING. Press NEXT button to enter the clock setting display.

• Press UP or DOWN button and select the item to be modified. Press NEXT button to enter the modification mode.

The value is displayed with a blue background.

• Modify the value pressing UP or DOWN button. Press Menu button (4) to confirm the selection.

• Press the screen change button (3) to return to the main display.

RAPH12CEX0194EA

3-16

13

3 - CONTROLS/INSTRUMENTS

Buzzer stop button Buzzer stop button (4) cuts off the warning sound signal in case of malfunctions, indicated on the display of the monitor by the relevant icons. The table here below indicates the warning icons coupled with the buzzer sound that could be manually stopped.

RAPH12CEX0197BA

14

Buzzer characteristics Priority

A

B

Level

Icon

Description

Auto stop

Manual stop

Key Type ON

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

1

Overload alarm

no

yes

2

no

yes

3

Engine oil low pressure

no

yes

2

no

yes

3

Excessive engine coolant temperature

no

yes

3

yes

yes

3

Engine coolant low level

no

yes

3

yes

yes

3

Clogged air filter

no

yes

3

yes

yes

Error codes

no

yes

3

yes

yes

3-17

3 - CONTROLS/INSTRUMENTS

Attachment mode buttons NOTICE: Before starting operation, make sure to select the proper attachment mode.

The attachment mode buttons enables to select three operating modes, depending on the attachment which has been installed.

Digging mode: press the button (6) for standard digging operations.

Nibbler mode: press the button (7) when using a nibbler.

The flow rate and pressure screen appears and the icon changes to nibbler.

Breaker mode: press the button (8) when using a breaker.

The flow rate and pressure screen appears and the icon changes to breaker.

RAPH12CEX0198BA

15

RAPH12CEX0199BA

16

Work mode button Work mode button (9) provides the selection of one of the three operational modes of the machine as a function of the work to be performed. By pressing the work mode button the display on the monitor shows in sequence icons S, E and H. NOTE: When starting the engine, work mode S is automatically selected.

Mode S: select work mode S for standard work conditions.

Work mode S provides optimized conditions in terms of performance/fuel consumption ratio.

Mode H: select work mode H for heavy-duty work conditions.

Mode E: ECO mode for lower fuel consumption digging work.

3-18

3 - CONTROLS/INSTRUMENTS

Auto Idle button 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

With the engine running, press Auto Idle button (10) to bring the engine to the automatic idle speed, providing a reduction of the noise and fuel consumption. This speed is achieved after about 5 s, providing that no control levers are actuated. The activation of the Auto Idle function is indicated on the monitor by the relevant indicator light coming on.

NOTE: When a control lever is actuated or the Auto-Idle function is deactivated, the engine speed returns to the speed established by the position of the engine speed throttle.

To deactivate the Auto-Idle function, press again button (10). The relevant indicator light goes off.

RAPH12CEX0195BA

17

RAPH12CEX0205BA

18

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 (11) it is possible to select two travel speeds: 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.

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 by the relevant icon.

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

3-19

3 - CONTROLS/INSTRUMENTS

Windshield washer button By pressing windshield washer button (12) 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 (13) 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 (13) once.

Continuous. Press button (13) twice.

To deactivate the wiper, press button (13) until the icon on the monitor disappears.

RAPH12CEX0206BA

3-20

19

3 - CONTROLS/INSTRUMENTS

Warning icons The table here below lists all the warning icons in sequence by priority and level.

Icons (priority A) Icon

Level 1

1

1

1

Description

Solution

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

Swing brake disengaged icon: this icon appears when the parking brake release Put the machine in safe conditions and contact the dealer. switch is moved into position RELEASE LOCK. Overload alarm icon: this icon appears when the load momentum function is Reduce the load of the attachment. activated and a load value exceeding the prescribed limits is monitored.

Engine cut-off icon: this icon appears a few seconds after the engine oil low pressure Contact the dealer. icon. The engine is automatically cut-off.

Icons (priority B) 1

2 2

2

2

2

2

Wrong work mode icon: this icon appears when the work mode selected results inadequate with respect to the attachment mounted.

Power Boost icon: this icon appears when pressing the power boost button located on the right control lever.

Select the correct work mode.

-

Wait for the icon to go off prior to starting work operations.

Place the safety lever in LOCK soot is deposited in the exhaust gas position. Push the manual post-cleaning device and this device needs regeneration switch. Regeneration to regenerate starts.

If displayed as a result of manual regeneration (operator selects the manual regeneration switch) : Place the safety lever in LOCK position Do not operate machine. Wait for the icon to go off before starting The exhaust gas post-cleaning device is in operations or regeneration will be the regeneration process interrupted.

If displayed during autoregeneration: Operate machine normally.

Allow the auto-regeneration cycle to complete before shutting off engine.

Do not press the manual regeneration switch.

Soot is deposited in the exhaust gas Place safety lever in LOCK position. post-cleaning device. Regeneration has Push the manual regeneration not been performed Exhaust gas after switch. Regeneration starts. treatment, equipment will be damaged Soot is deposited in the exhaust gas post-cleaning device. Regeneration is needed. Regeneration has not been Contact the dealer performed and the device cannot be regenerated Automatic warm up completed

3-21

3 - CONTROLS/INSTRUMENTS

2

2

3

3

3

3

3

3

4 4 4

5

5

5

Engine oil low pressure icon: this icon appears when the engine oil pressure results lower than the prescribed values or there is a malfunction in the engine pressure switch line.

Heavy Lift icon: this icon appears when the Heavy Lift switch is pressed to activate the relevant function.

Contact the dealer

-

Reduce the engine speed to low Engine coolant temperature icon: this icon idle and stop operating until the appears in case of excessive temperature temperature of the coolant drops to of the engine coolant. normal operating values.

Stop the engine, wait for the Engine coolant level icon: this icon appears machine to cool off and top up the when the level of the engine coolant is engine coolant level. insufficient.

Presence of water in the fuel prefilter icon: Purge the water from the fuel this icon appears when there is a significant prefilter. quantity of water in the fuel prefilter.

Preheating failure icon: this icon appears Stop immediately the engine and when a problem occurs in the preheating contact the dealer. system.

Engine air filter icon: this icon appears when the elements of the air filter are too dirty Stop the engine and clean or to provide an adequate supply of air to the replace the elements of the air filter. engine.

Error codes icon: the error codes appear when the controller monitors malfunctions Contact the dealer. relative to solenoid valves, pressure switches etc.

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.

Stop the engine, wait for the Engine oil level icon: this icon appears when machine to cool off and top up the the engine oil level is insufficient. engine oil level.

Engine preheating icon: this icon appears when the starter key is moved into position Wait for the icon to go off prior to ON and the controller monitors that the starting the engine. coolant is such that the engine preheating is required.

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.

Safety lever icon: appears when the safety Place the safety lever in LOCK lever is in unlock position and the starter switch is turned to START or ON position. position before starting the engine.

The engine does not start.

3-22

3 - CONTROLS/INSTRUMENTS

Rear view camera

RAPH12CEX0100FA

1

NOTICE: Do not disassemble and modify the rear view camera. Do not wash the rear view camera with high pressure water.

In order to avoid collisions with other workers or neighboring equipment not visible from the operator's seat, a rear-view camera is installed on the counterweight. The rear view appears on the lower area of the instrument cluster screen.

VIEW ANGLES: • Horizontal view angle: 116 °.

• Vertical view angle: 85 °.

The operator cannot monitor the entire area of the machine rear side with the rear view camera. There is a blind area due to the angle view of the camera.

VIEWING DIMENSIONS OF BLIND AREA ED160–3 • (A) 1095 mm (43.1 in) • (B) 404.2 mm (15.9 in) • (X) 6.0 °

3-23

3 - CONTROLS/INSTRUMENTS

RIGHT-HAND SIDE CONTROLS

Right-hand console - operating

RAPH12CEX1343FA

1. Starter switch 2. Engine speed throttle 3. Blade control lever 4. Radio 5. Climate control 6. Work light switch (boom, deck)

1

7. Independent travel select switch 8. Work light switch (cab) 9. Not used (optional switch) 10. DPF regeneration switch 11. Not used (optional switch) 12. Pressure release switch 13. Blade control switch

3-24

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 to the 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 counter-clockwise (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 The independent travel select switch provides fine metering resulting in smooth simultaneous travel and attachment operations. Travel control levers/pedals must be in the neutral position before activating this switch.

RAPH12CEX0215AA

3-25

5

3 - CONTROLS/INSTRUMENTS

Cab work lights switch The cab work lights switch activates the work lights located on the top of the cab. The switch has the following positions: OFF (side without symbol pressed): the three lights are inactive.

ON (side with symbol pressed): the three lights are on.

NHC0004

6

DPF regeneration switch Automatic regeneration will occur every 10 hours. Manual regeneration is required when auto-regeneration has failed or did not run to completion.

When the warning icon appears on the instrument cluster display commanding manual regeneration: 1. Move the machine to a safe place, operate the attachment and take the parking position.

2. Place the safety lever in the LOCK position.

3. Push the regeneration switch. Regeneration icon will display on the instrument cluster. Engine speed is set to idling speed and pump relief operation starts.

RAPH12CEX0500AA

4. Regeneration icon will disappear and the engine speed returns to the last speed set before the regeneration process started.

Pressure release switch The pressure release switch allows to release the pressure inside the hydraulic system.

NOTE: The pressure release operation must be performed with the engine running.

To release the pressure proceed as follows: • Keep pressed the pressure release switch for a period between 5 s and 10 s.

• Release the switch and wait for a period between 1 s and 5 s.

NHC0009

• Keep pressed again the switch for a period between 5 s and 10 s.

The display shows the PR icon and the buzzer sounds.

The engine automatically sets to low idle RPM and the pressure inside the hydraulic system is released at the same time. Then actuate the control levers to release the residual pressure inside the hydraulic cylinders.

NOTE: If monitor displays FAIL DRAIN HYD PRES, the pressure release operation is not correctly occurred. Repeat the operation and should the trouble persist, see an authorized dealer.

3-26

8

7

3 - CONTROLS/INSTRUMENTS

Dozer blade control switch To operate the dozer, press the dozer switch to activate the dozer circuit. The dozer switch is located on the operator’s right-hand side console.

RAPH12CEX1200AA

9

RAPH12CEX1199BA

10

RAPH12CEX1344AA

11

WARNING Crushing hazard!

If you touch the dozer blade lever, it may cause unexpected dozer blade motion. Turn OFF the dozer switch when the dozer blade is not in use.

Failure to comply could result in death or serious injury.

W1234A

Dozer control lever The dozer control lever is located on the operator’s righthand side console.

NOTICE: For operation of the dozer blade control lever refer to 6-5

Angle blade control switch The angle blade control switch is located in front of the dozer control lever.

• Press the angle blade control switch on its left corner (1) to angle the blade toward the left.

• Press the angle blade control switch on its right corner (2) to angle the blade toward the right.

3-27

3 - CONTROLS/INSTRUMENTS

WARNING Crushing hazard!

If the dozer blade is suspended in the air and you depress the float control switch, the dozer blade will fall freely to the ground. Turn OFF the dozer switch when the dozer blade is not in use.

Failure to comply could result in death or serious injury.

W1235A

Dozer blade float control switch The dozer blade float control switch is located on the left side of the dozer control lever.

• Press the dozer blade float control switch to make the blade float.

• Pull back the dozer control lever to disengage the float function.

3-28

RAPH12CEX1335AA

12

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.

3-29

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.

3-30

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.

3-31

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.

RAPH12CEX0128AA

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

3-32

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

Fundamental use

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

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). To operate the air conditioner system in automatic mode, proceed as follows: • Press the Auto control button (2). The display shows the wording AUTO. The fan speed and the air distribution are automatically regulated.

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

NOTE: Pay special attention to prevent the spillage of liquids in the zone marked by decal (A). Also, avoid using detergent liquids or steam to clean the same zones.

Never use alcohol or alcohol based products.

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

3-33

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, this is deactivated.

Buttons (3) provide the regulation of the quantity of air flowing from the ducts. The quantity of air flowing out the ducts is indicated by the display.

NHC0018

2

NHC0019

3

NHC0020

4

NHC0021

5

Temperature setting buttons Buttons (4) provide the setting of the desired temperature 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, it is possible to increase/ decrease the temperatures by 0.5 °C ( 0.9 °F) steps.

Air distribution selection button NOTE: If the air distribution selection button (5) is pressed while the air conditioner system is in AUTO mode, this 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 setting of the recirculation of the air inside the cab or the inlet of fresh air from the outside.

3-34

3 - CONTROLS/INSTRUMENTS

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

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

NHC0022

6

NHC0023

7

Air conditioner activation button To activate the air conditioner, press button (8).

3-35

3 - CONTROLS/INSTRUMENTS

REARWARD CONTROLS

Rearward controls

RAPH12CEX0502GA

1. Parking brake release switch 2. 12 V socket

3-36

1

3 - CONTROLS/INSTRUMENTS

Parking brake release switch Switch (1) releases the swing parking brake, in case it does not occur normally during the swing and arm retracting operations. To release the parking brake, operate as follows: • Move switch (1) into RELEASE LOCK position. The monitor shows the relevant icon (b) and the alarm buzzer is activated. It is now possible to swing the upper structure by actuating the relevant control lever.

Contact your authorized dealer.

RAPH12CEX0503BA

2

RAPH12CEX0504AA

3

12 V socket A 12 V socket (2) is located on the right side of the rear panel. The socket can be used to power small electrical equipment.

NOTE: Do not connect equipment that requires more than 60 W of power.

3-37

3 - CONTROLS/INSTRUMENTS

3-38

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS COMMISSIONING THE UNIT

Hydraulic oil level Before operating the machine confirm the hydraulic oil is at an acceptable level, perform the following: 1. Park the machine on a level surface with the attachment in the hydraulic oil level check position.

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 hydraulic oil level is low, top off referring to page 7-43.

NOTICE: Do not top off using oil with different specifications from the oil already in the hydraulic oil tank.

If the machine was filled with biodegradable hydraulic oil MOBIL EAL Envirosyn 46H , do not top off with mineral hydraulic oil, as they cannot be mixed.

RAPH12CEX0505AA

1

RAPH12CEX0506AA

2

NOTICE: Avoid overfilling. 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)

4-1

4 - OPERATING INSTRUCTIONS

Fuel level 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

1. Turn the ignition key to the ON position and check the fuel level on the relevant instrument cluster meter (1).

2. If the level indicator is close to the E range or the fuel level warning icon displays on the instrument cluster, turn the ignition key to the OFF position.

3. Remove the fuel tank cap (2).

4. Fill the fuel tank with the appropriate fuel.

5. Reinstall the fuel tank cap (2).

4-2

RAPH12CEX0508AA

1

4 - OPERATING INSTRUCTIONS

Engine oil level NOTICE: Prior to checking the engine oil level, check that the machine is positioned on a flat surface.

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

2. Extract the dipstick (1), clean with a dry rag, and then reinsert the dipstick (1).

3. Extract the dipstick (1) and check the oil level. The oil level should be between the H and the L range located at the end of the dipstick (1).

NOTE: Insert the dipstick slowly to avoid pressure altering the oil level check.

NOTICE: If engine oil level is low, remove filler cap (2) and top-off the oil level, through the filler neck.

NOTICE: Do not use oil with different characteristics from the oil already in the engine (see "Fluids and lubricants" at the end of chapter MAINTENANCE).

NOTICE: If the level exceeds the mark H on the dipstick drain excess oil through the draining plug (3). Recheck the oil level.

RAPH12CEX0499CA

4-3

1

4 - OPERATING INSTRUCTIONS

Engine coolant level 1. Open the left hand side door and check the coolant level of the reserve tank (1).

2. Open the side door of radiator with ignition key and check coolant level on expansion tank (1). Level must be checked with cold engine and it must be between the FULL (A) and LOW (B) reference marks.

3. In the case the level is insufficient, remove the filler cap (2) and top off the level, through the filler neck, until it reaches the FULL mark.

4. Install the filler cap (2) and close the side door.

NOTICE: When topping off, keep the water and antifreeze percentage existing in the system. Use clean water and free from chlorinated compounds whenever possible (see "Fluids and lubricants" at the end of chapter MAINTENANCE).

4-4

RAPH12CEX0498AA

1

RAPH12CEX0497AA

2

4 - OPERATING INSTRUCTIONS

Windshield washer fluid level This operation should be carried out consistently with how frequently the windshield washer is used. Washer fluid reservoir (1) is located under the floor plate in the cab.

1. Remove the floor mat.

2. Check the level of the washer fluid reservoir (1) Remove the cap from the windshield washer tank and top off the level adding water and detergent liquid of the prescribed type.

3. Reinstall floor mat to the original position.

RAPH12CEX0496AA

4-5

1

4 - OPERATING INSTRUCTIONS

Draining the fuel filter water separator The fuel pre-filter (2) is located in front of the counterweight on the right rear of the machine.

When icon (1) appears on the instrument cluster display, drain the water trapped inside the prefilter (3) as follows: 1. Open the side door on the right rear of the machine.

2. Place a suitable container under the drain hose (4) of the fuel prefilter.

3. Loosen the drain plug (3) 1/2 to 1 turn and drain water and sediment until only fuel flows.

4. Tighten the drain plug (3).

RAPH12CEX0494AA

1

RAPH12CEX0493AA

2

NOTE: When sediment remains in the case (6) after draining, clean the case (6) and the drain plug (3) as follows: 1. Open the drain plug (3) and completely drain fuel and water from the fuel prefilter (2).

2. Clean the drain plug (3) and the O-ring (5). Replace the O-ring (5) if damaged.

3. Remove and clean the case (6). Replace O-ring (5) if damaged.

4. Install the case (6) . Tighten the pre-filter (2) to the case (6) by 1/2 turn by hand when the O-ring (5) makes contact with the bottom surface of the fuel pre-filter (2).

4-6

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.

NH0002

1

NHC0245A

2

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

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

4-7

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 relevant icon (3) on the instrument cluster display.

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

NOTICE: If during the pre heating phase the warning icon (4) should appear on the instrument cluster display, turn starker key to OFF position and contact the dealer.

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

4-8

RAPH12CEX0492AA

3

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

4-9

4

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.

NH0002

1

2. Operate travel control levers. Confirm machine does not travel.

RAPH12CEX0491AA

4-10

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 guarantee turbocharger progressive slow down and cooling.

5. Turn starter key (1) to OFF position.

6. Remove starter key from the starter switch.

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

4-11

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

4-12

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 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.

• Investigate beforehand the conditions of the road to be traveled, 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. Put blocks to the tires of trailer to prevent machine from moving.

• Accurately clean the machine undercarriage and tracks to prevent mud or debris from 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

W0390A

1. From the instrument cluster, turn the Auto Idle function off and select the slow travel speed.

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

Slowly travel on the trailer ramp.

5-1

1

5 - TRANSPORT OPERATIONS

3. Slowly travel forward to the required position giving particular attention to the attachment so as not to touch the bed of trailer.

NOTICE: The point connecting the ramp with the trailer shows a bump. Proceed with extreme care once reaching this point since the machine has the tendency to drop suddenly. In arranging the attachment when loading, avoid to fully extend the arm and bucket cylinders to prevent damaging them due to accidental impacts of the attachment with the trailer bed.

NH0058

2

NH0060

3

NHC0324

4

NH0065A

5

4. After arriving to the required 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.

Loading machine without front attachment If loading the machine when the front attachment is removed, direct counterweight upward direction on the ramp.

Securing the machine After the machine is loaded and positioned, secure the machine as follows: 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 blocked.

1. Position the trailer on firm and level ground. Put blocks to the tires of trailer to prevent machine from moving.

2. Remove chains or wire ropes used to secure the machine.

3. Start engine and move the safety lever to the unlock position.

4. From the instrument cluster, verify that the Auto Idle function is deactivated and the travel speed is set to SLOW.

NHC0325

6

NHC0326

7

5. Raise attachment and travel slowly. Stop the machine horizontally on the rear end of trailer.

6. Set arm and boom to angle (B) between 90 - 110 ° and travel down slowly from trailer to ramps.

NOTICE: The point connecting the ramp with the trailer shows a bump. Proceed with extreme care once reaching this point since the machine has the tendency to drop suddenly. In arranging the attachment when unloading, avoid to fully extend the arm and bucket cylinders to prevent damaging them due to accidental impacts of the attachment with the ground.

7. Travel down on ramps slowly while operating boom and arm softly until the machine passes through the ramps completely.

5-3

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.

A

RAPH12CEX1195EA

1

RAPH12CEX1196FA

2

Expander

NOTE: This lifting up 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 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.

W0256A

Lift the machine from firm level ground as follows: 1. Stop the engine and move safety lock lever to the locked position. Remove starter key and get off the machine. Check the operator's seat and area for any loose item, tools, etc. that could fall or cause a problem or injury during the procedure. Remove or secure them.

2. Use wire rope and expander of sufficient length to prevent interference with the machine body when lifting 5-4

5 - TRANSPORT OPERATIONS

up machine. Cover wire rope with cloth to protect machine from damage if necessary.

4. Lift up machine with an angle of two wire ropes adjusted within the range of 12 ° to 30 ° slowly.

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

5-5

5 - TRANSPORT OPERATIONS

5-6

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

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.

6-2

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.

6-3

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

6-4

1

6 - WORKING OPERATIONS

Dozer blade control Dozer blade operation The dozer control lever is multi-functional.

A. Forward Variable speed for blade lowering.

B. Backward Variable speed for blade raising.

C. Center Hold position.

D. Left Variable speed for blade right tilt.

E. Right Variable speed for blade left tilt.

RAPH12CEX1337BA

NOTICE: See 3-24 for angle blade switch operation, and dozer blade float switch operation. These switches are located on the dozer blade control lever.

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 & 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 center 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

Emergency boom lowering In the event the engine stops and it cannot be restarted, lower the boom and rest it on the ground, referring to the procedures listed here:

Machine without anti-drop valves 1. Open engine hood and lock in open position.

2. Remove securing screws (1), located in correspondence with the control valve by using a 19 mm locknut wrench. Remove guard (2).

3. On the control valve, loosen locknut (3) and loosen discharge screw (4) to stroke end.

Locknut wrench: 19 mm Discharge screw wrench: 10 mm 4. Enter cab and slowly lower attachment to the ground, moving the right control lever forward. Reinstall guard (2) and contact an authorized dealer.

NHC0336

1

NHC0337

2

NHC0338

3

NOTE: The position of the starter key or the safety lever does not influence the procedure.

Machine with anti-drop valves 1. Make a reference mark between the valve body, locknut (5) and setting screw (6).

2. Loosen locknut (5) then afterward, loosen slowly (3 to 3.5 turns) setting screw (6). It is sufficient to perform the procedure on one anti-drop valve only.

Locknut wrench: 13 mm Setting screw wrench: 4 mm 3. Perform the operations previously described for the " Machine without anti-drop valves".

4. Lower attachment to the ground, return locknut (5) and setting screw (6) in their initial positions then contact the Dealer.

6-8

6 - WORKING OPERATIONS

Machine operation in adverse weather conditions Operation in extreme cold • Follow procedures on page 4-7 (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.

• 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.

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 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.

• 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.

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

• 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.

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

6-9

6 - WORKING OPERATIONS

6-10

7 - MAINTENANCE

7 - MAINTENANCE GENERAL INFORMATION

Preparing machine for maintenance NOTICE: While any company can perform necessary maintenance or repairs on your equipment, KOBELCO strongly recommends that you use only authorized KOBELCO dealers and products that meet the given specifications. Improperly or incorrectly performed maintenance and repair voids the equipment warranty and may affect service intervals

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

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 the machine on a level surface.

2. Lower the 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 the LOCK position.

2

YN20T01320P2

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.

NHC0272

7-1

3

7 - MAINTENANCE

Biodiesel fuel - Biodiesel fuels Biodiesel usage in KOBELCO products

Biodiesel blends are covered by:

Introduction to Fatty Acid Methyl Ester (FAME) biodiesel

• European Diesel Fuel Specification EN 590 allows up to 7 % biodiesel since 2009. European fuel suppliers are allowed to use up to 7 % biodiesel fuel (B7) to supply the network.

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.

NOTICE: Your Selective Catalytic Reduction (SCR) system is compatible with up to 7 % biodiesel fuel (B7). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine and fuel system of your machine. The use of non-approved fuels may void KOBELCO Warranty coverage.

Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: • B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels. Do not use.

• 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.

• United States Diesel Fuel Specification ASTM D6751-09A allows up to 7 % biodiesel since 2009.

United States fuel suppliers are allowed to use up to 7 % biodiesel fuel (B7) to supply the network.

• United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B6 to B20.

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 byproduct 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 European Standard EN14214 or 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 EN14214 or 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 EN14214 for Europe, or ASTM D6751 for the United States) will no longer be covered for Warranty by KOBELCO.

Biodiesel fuel usage conditions

• Biodiesel is fully biodegradable and non-toxic.

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to both the engine and the fuel injection equipment.

Diesel and biodiesel fuel specifications Tier 4a diesel fuel specifications are covered by the following: • Europe: EN 590 - Specification of Diesel fuel. (10 ppm sulfur maximum.)

The main concerns related to operation with biodiesel fuels are:

• United States: ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

• Filters and injector blockage caused by poor fuel quality.

7-2

7 - MAINTENANCE

• 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 conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by KOBELCO. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality.

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 machine using the FPT NEF and Cursor 9 Common Rail Engines, no change to maintenance intervals is required when using biodiesel blends up to B7.

7-3

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.

7-4

7 - MAINTENANCE

MAINTENANCE CHART

Maintenance Chart

Interval

Page no.

7-7 7-9 7-10 7-12 Every 120 hours 7-13 7-14 Every 250 hours 7-15 7-17 7-18 7-19 7-20 7-21 7-22 Every 500 hours 7-24 7-25 7-27 7-29 7-31 7-32 7-33 7-34 Every 1000 hours 7-35 7-36 7-37 Every 2000 hours 7-38 7-39 7-40 7-41 Every 5000 hours 7-43

Every 50 hours of operation or weekly

Maintenance action

Battery Fuel tank Track tension Dozer blade lubrication Swing reduction unit oil Travel reduction unit oil Engine air filter: outer element Checking the radiator hoses Hydraulic return filter (Breaker use only) Hydraulic oil tank Bucket grease fittings Outside fresh air filter Fan, alternator, and air conditioner belts Cab air recirculation filter Engine oil and filter Fuel filter Fuel pre-filter Fuel tank filter Swing bearing Control lever lubrication Boom lift - Lubricate Engine air filters Hydraulic oil return filters Hydraulic reservoir breather Pilot line filter Swing reduction unit oil Travel reduction unit oil Engine coolant Hydraulic oil

7-5

Filling Storing Adjust Change fluid Grease Replace Cleaning Lubricate Drain fluid Check No. of pts.

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

7 - MAINTENANCE

Interval

As required

Page no.

7-46 7-48 7-50 7-52 7-54 7-55

Fluids and lubricants

7-56 7-57 7-58 7-59

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

Fuses and relays X Removing and installing the bucket X Removing and installing the dozer blade in the X field Bucket teeth and side cutters X Moving a disabled machine X Lowering bucket attachment on a disabled X machine X Preparing for storage Every 30 days X X Starting up after storage Fluids and lubricants X

7-6

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, 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.

7-7

7 - MAINTENANCE

Checking battery fluid level 1.

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

2.

Remove the battery cell caps (2) and visually inspect the 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.

7-8

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, 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 To drain the condensation inside the fuel tank, proceed as follows: 1.

Locate drain valve on bottom of fuel tank.

Place an empty container below the drain valve.

2.

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

3.

Close the drain valve (1).

NOTE: When the temperature is above 0 °C (32 °F), draining can be done before engine startup. When working with temperatures below 0 °C (32 °F), the tank should be drained at the end of work, after engine stop, as water might freeze and not drain properly.

A. B.

Open Closed

7-9

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, 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).

7-10

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.

7-11

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, 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

7-12

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, 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 To check the swing reduction unit oil level, proceed as follows: 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 the oil level is low.

3.

Reinstall the oil level dipstick (1).

RCPH11EXC002AAQ

7-13

1

7 - MAINTENANCE

Travel reduction unit oil Level check 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

WARNING Pressurized system!

System is still under pressure. Release pressure according to instructions in this manual.

Failure to comply could result in death or serious injury.

W1044A

To check the travel reduction unit oil level, proceed as follows: 1.

Park the machine on a level surface.

2.

Position the reduction units as to have the plugs (1), (2) as shown. Observance of this position is essential for proper servicing.

3.

Lower the bucket to the ground.

4.

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

5.

Slowly release the threaded plug (1) gradually relieving pressure from inside the reduction unit. After relieving pressure, fully remove the plug (1) from its seat.

6.

Check oil level inside the travel reduction unit through the plug (1). If oil just seeps from the port, oil level is correct. If oil is low, add oil through the hole of plug (2) until oil comes out of the hole of plug (1).

7.

Reinstall plug (1).

NOTICE: The above operation should be carried out on both travel motors.

7-14

RAPH12CEX0985AA

1

RAPH12CEX1348AA

2

7 - MAINTENANCE

Every 250 hours

Engine air filter: outer element CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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 To clean the outer element of the engine air filters, proceed as follows: 1.

Open air filters compartment panel and lock in the open position.

2.

Release hooks (1) and remove the filters cover.

3.

Extract outer element (2)

4.

Clean the inside of air cleaner housing

5.

Clean the outer element using compressed air (less than 0.2 MPa (29.0 psi)). Direct the air jet from the inside to the outside of the filter.

6.

Install outer element (2) making sure it is properly positioned.

7.

Install the filters cover securing it with the hooks (1).

8.

Close air cleaner compartment panel.

7-15

RAPH12CEX0474AA

1

NHC0349

2

7 - MAINTENANCE

NOTE: The inner element (3) must be replaced when the outer element (2) is replaced.

NOTE: Do not remove inner element (3) while cleaning the outer element (2) to prevent dust from entering the engine air intake.

RAPH12CEX0472AA

7-16

3

7 - MAINTENANCE

Checking the radiator hoses 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

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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 the engine 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 (1) and clamp if leaks, cracks, or fatigue is found. See next procedure for hose replacement.

RAPH12CEX0455AA

1

RAPH12CEX0456AA

2

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.

Loosen clamp (3) and remove drain plug (4).

Drain coolant into a suitable container. Coolant level should be below the damaged hose (2).

4.

Install drain plug (4).

5.

Loosen clamp (1) and remove damaged hose (2) .

6.

Install new hose and tighten clamp.

7.

Fill radiator and reserve tank using the prescribed coolant liquid. (see page 7-59)

8.

Install radiator cap.

9.

Reinstall lower radiator cover.

10.

Close engine hood.

7-17

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, 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.

7-18

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RAIL12CEX0987AA

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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 the LO position, stop the engine, extract the starter key and place the safety lever in the 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.

7-19

NHC0266

1

RCPH11EXC001BAD

2

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 or mud.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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.

NOTICE: Every 8 hours for the first 50 hours, it is necessary to perform the lubrication operations listed on page 7-59 (Break-in period).

RAPH12CEX0452BA

7-20

1

7 - MAINTENANCE

Outside fresh air filter CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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 To clean the fresh air filter, proceed as follows: 1.

Move operator's seat fully forward and lower the backrest (see page 3-4).

2.

Remove lower panel (1).

3.

Lift fresh air filter (2) vertically and check its condition. Clean if dirty.

4.

Reposition fresh air filter (2) in its seat.

5.

Reinstall lower panel (1).

6.

Reposition operator's seat.

NOTICE: Clean the outside air filter exclusively with compressed air. Replace it every 10 cleaning operations or every 2 years.

RAPH12CEX0454AA

1

RAPH12CEX0462AA

2

NOTICE: The normal maintenance interval requires the inspection every 250 hours. Under particular ambient conditions (very dusty area) it is recommended to reduce the interval.

7-21

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

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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 9 - 11 mm (0.35 - 0.43 in) 3 - 4 mm (0.12 - 0.16 in)

RAPH12CEX0535AA

1

Tension — belt inspection Force 11 - 13 mm (0.43 - 0.51 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.

RAPH12CEX0316AA

7-22

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 idle 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.

RAPH12CEX0317AA

7-23

3

7 - MAINTENANCE

Every 500 hours

Cab air recirculation filter CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Clean the air recirculation filter exclusively with compressed air. Replace it every 10 cleaning operations or every 2 years. The normal maintenance interval requires the inspection every 500 hours. Under particular ambient conditions (very dusty area) it is recommended to reduce the interval.

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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.

To clean the air recirculation filter, proceed as follows: 1.

Lift up the floor mat.

2.

Extract the air recirculation filter (1) and check its condition. If dirty, clean filter.

3.

Reposition the air recirculation filter (1) in its seat.

4.

Reposition the floor mat.

RAPH12CEX0453BA

7-24

1

7 - MAINTENANCE

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, 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 filler cap. These operations provide a faster draining of the oil.

4.

Loosen drain valve (2) manually. Drain oil into a suitable container.

8.

Tighten drain valve (2) securely.

7-25

RAPH12CEX0470AA

1

RAPH12CEX0469AA

2

7 - MAINTENANCE

6.

Clean contact area and around the filter (3).

7.

Place a drip pan under the filter (3).

8.

Remove oil filter (3) using a filter wrench.

Filter wrench part number: YW01T01014P1

9.

Wipe oil off oil filter mounting surface with a cloth.

10.

Check gasket for proper placement on the new oil filter. Lubricate the gasket of the new filter with new engine oil.

11.

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.

RAPH12CEX0451AA

3

RAPH12CEX0470AA

4

NOTICE: Tighten new oil filter by hand. Do not use a filter wrench to avoid possible damage to the filter.

12.

Pour oil into the engine through filler neck until the maximum level indicated on dipstick (1) is reached, then tighten the filler cap (4) and insert the dipstick.

Refer to 7-59 for specified oil type.

13.

Start the engine, let it run a few minutes then stop it. Use dipstick (1) to check again the level and top off in the event the level has changed with respect to the previous check.

NOTE: Handle and dispose the exhausted engine oil and filters in accordance with current regulations. Use only authorized disposal procedures and, in case of doubts, contact the appropriate authorities.

7-26

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, 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 (3) and loosen air bleed plug (4).

4.

Drain water from the fuel filter (1) into a suitable container.

5.

Remove the case (5).

6.

Remove the fuel filter element (6) using a filter wrench.

Filter wrench part number: YW01T01014P1.

7.

Completely wipe off any adhered fuel from the mounting surface of the filter bracket (4).

8.

Apply a thin film of clean fuel to the filter element (6).

9.

Turn the fuel filter element (6) until the seal comes into contact with the mounting surface of the filter bracket (4). Turn an additional 3/4 turn.

10.

Apply a thin film of oil to the O-ring (7) of the case (5).

11.

Turn the case (5) until the O-ring (7) comes into contact with the mounting surface of the bottom of the fuel filter element (6). Tighten an additional half turn by hand.

12.

Tighten the air bleed plug (3).

13.

Open the fuel shut off valve.

14.

Bleed air from the fuel filter.

7-27

RAPH12CEX0468AA

1

RAPH12CEX1345AA

2

7 - MAINTENANCE

Bleeding air from the system Bleed the air in the fuel system operating as follows: 1.

Open fuel shut off valve (3).

2.

Loosen bleed air plugs (4), (5) on fuel filter (1) and fuel pre-filter (2).

3.

Repeatedly actuate the priming pump (6) until a small quantity of fuel, free of air bubbles, drains from the loosened connection plug (5).

4.

Tighten air bleed plugs (4), (5).

7-28

RAPH12CEX0304AA

3

RAPH12CEX0305AA

4

7 - MAINTENANCE

Fuel pre-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

Prior operation: Keep all unauthorized personnel clear of the area. Park the machine on level ground, 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.

To replace fuel prefilter, proceed as follows: 1.

Open right rear door and lock the door in the open position.

2.

Clean the area around the fuel prefilter (1).

3.

Close the fuel shut off valve (2) and loosen the air bleed plug (3).

4.

Drain water from the fuel prefilter (1) into a suitable container.

5.

Remove case (5).

6.

Remove fuel prefilter (1) using a filter wrench.

Filter wrench part number: YW01T01014P1

7.

Wipe off excess fuel filter element (6) and filter bracket (4).

8.

Install the new fuel filter element (6) into the filter bracket (4)

9.

Install new O-ring (7).

10.

Install case (5).

11.

Fill the new filter with clean fuel and hand tighten until the gasket contacts the support body. Turn filter an additional half turn by hand.

7-29

RAPH12CEX0468AA

1

RAPH12CEX0324AA

2

7 - MAINTENANCE

Bleeding air from the system Bleed the air in the fuel system operating as follows: 1.

Open fuel shut off valve (3).

2.

Loosen bleed air plugs (4), (5) on fuel filter (1) and fuel pre-filter (2).

3.

Repeatedly actuate the priming pump (6) until a small quantity of fuel, free of air bubbles, drains from the loosened connection plug (5)

4.

Tighten air bleed plugs (4), (5).

7-30

RAPH12CEX0304AA

3

RAPH12CEX0305AA

4

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

7-31

1

7 - MAINTENANCE

Swing bearing To grease the slewing ring, proceed as follows: 1.

Park machine on a level surface.

2.

Lower bucket to the ground.

3.

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

4.

Inject grease of the specified type (See "Fluids and lubricants" on page 7-59) through the grease fitting (1). Rotate the upper structure 90 ° and repeat step 4.

5.

Continue to rotate the upper structure at 90 ° increments and inject grease until the entire slewing ring is greased.

6.

Do not inject excess grease. Grease should be injected until it is seen coming out of the seals.

7-32

NHC0292

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.

2.

3.

Turn the boot (1) up and use a Phillips screw driver to loosen the bolts (2).

RAPH12CEX1346AA

1

RAPH12CEX1346AA

2

RAPH12CEX1347AA

3

While holding the boot up, release the hooks (3) to remove the rubber boot from the control lever.

Apply a small amount of grease to the push rod (4) and top end (5) of the rotation of the control lever.

7-33

7 - MAINTENANCE

Boom lift - Lubricate 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.

Use a grease gun to pump the specified type of grease into the lubrication stations indicated in the figures.

Monoblock version: 7 grease fittings located between the boom cylinders.

1A: Right boom cylinder bottom 2A: Right boom foot boss 3A: Left boom foot boss 4A: Arm cylinder bottom 5A: Right boom cylinder rod 6A: Left boom cylinder rod 7A: Left boom cylinder bottom RAPH12CEX0461AA

1

NHC0521

2

NOTICE: Within the first 500 hours it is necessary to perform the lubrication operations listed on page 7-59 (Break-in period).

7-34

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 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.

Replacement To change the engine air filters, proceed as follows: 1.

Open the air filters compartment panel and lock in the open position.

2.

Release the hooks (1) and remove the filters cover.

3.

Remove the outer element (2) and the inner element (3).

4.

Clean inside the filters housing.

5.

Install a new inner element and a new outer element making sure that they are properly seated.

6.

Reinstall the filters cover securing it with the hooks (1).

7.

RAPH12CEX0474AA

1

RAPH12CEX0472AA

2

Close the air filters compartment panel.

NOTE: Cover air outlet when replacing inner and outer elements to prevent dust from entering the system.

NOTE: The inner element (3) must be replaced when the outer element (2) is replaced.

7-35

7 - MAINTENANCE

Hydraulic oil return filters 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.

Replacement To change the hydraulic oil return filters, proceed as follows: 1.

Remove the breather cap (1). Release the pressure from hydraulic tank by pressing valve (2) several times.

2.

Loosen the mounting bolts (3) and remove the cover (4) of the upper tank.

3.

Remove the spring (5) and the filter kit assembly (6) from the tank.

4.

Remove the O-ring (7)

5.

Disassemble the elements of filter kit assembly (6) as indicated in the figure.

6.

Reinstall the filter kit assembly (6), replacing: the O-ring (9) on valve (8), the filter elements (10) on valve (8) and the seal (12) on the plate (11).

7.

Insert a new O-ring (7).

8.

Insert filter kit assembly (6) in the tank, install spring (5) and cover (3) in its seat.

9.

Tighten bolts (3). Torque to 41.9 - 51.1 N·m (30.9 - 37.7 lb ft) 50 N·m (37 lb ft).

7-36

RAPH12CEX0307AA

1

RAPH12CEX0308BA

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.

To replace the hydraulic tank breather, proceed as follows: 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) using a 19 mm wrench.

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

7-37

1

7 - MAINTENANCE

Every 2000 hours

Pilot line filter To clean the pilot line filter, proceed as follows: 1.

Park the machine on a level surface.

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 several times to bleed the pressure inside the hydraulic tank.

5.

Open the hydraulic pump compartment panel and lock it in open position.

6.

Remove hose (2).

7.

Remove connector (3).

8.

Remove pilot line filter (4) and clean with light oil.

9.

Reinstall pilot filter (4), connector (3) and hose (2).

7-38

NHC0266

1

RCPH11EXC004AAQ

2

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.

Oil replacement To replace the swing reduction unit oil, proceed as follows: 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.

4.

Remove fill plug (2) Pour new oil through the filler neck until reaching the specified level.

5.

Use the dipstick (3) to confirm oil level is in the specified range.

6.

Clean fill plug (2) with light oil, dry and tape plug.

7.

Reinstall fill plug (2) and tighten securely.

RCPH11EXC003AAQ

1

RCPH11EXC002AAQ

2

NOTE: See “Fluids and lubricants” at the end of this chapter for specifications and capacities.

7-39

7 - MAINTENANCE

Travel 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

WARNING Pressurized system!

System is still under pressure. Release pressure according to instructions in this manual.

Failure to comply could result in death or serious injury.

W1044A

Replacement To replace the travel reduction unit oil, proceed as follows: 1.

Park the machine on a level surface.

2.

Position the reduction units as to have the plugs (1), (2) as shown. Observance of this position is essential for proper servicing.

3.

Lower the bucket to the ground.

4.

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

5.

Slowly release the threaded plug (1) gradually relieving pressure from inside the reduction unit. After relieving pressure, fully remove the plug (1).

6.

Loosen and remove plug (2) . Allow oil to drain in a suitable container.

7.

Clean and reinstall plug (2).

8.

Tighten plug (2) securely.

9.

Add new oil through the fill level port (A) until the oil starts flowing out of the fill/level port.

10.

Clean and reinstall plug (1).

11.

Tighten plug (1) securely.

NOTE: see "Fluids and lubricants" at the end of this chapter for specifications and capacities.

NOTICE: The above operation should be carried out on both travel motors.

7-40

RAPH12CEX0985AA

1

RAPH12CEX1348AA

2

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.

Draining of coolant Drain the engine coolant operating as follows: 1.

Position the machine on a flat surface with the upper structure swung 90 ° to facilitate the access.

2.

Wait for the machine to cool off then open the engine hood and the radiator and filter compartment doors, locking them in the open position.

3.

Loosen radiator cap (1) slowly to completely bleed the pressure inside the radiator, then remove the cap (1).

4.

Remove the panel under the radiator.

6.

Open drain valve (2), and drain plug (3) and let the coolant drain into containers of appropriate capacity. Once the operation is over, close the drain valve (2) and drain plug (3).

7.

Inspect carefully the sleeves checking that they are trouble free (replace them if required) and tighten the clamps if slacken. Check the there are no leakages from the radiator, damages or accumulation of dirt.

7-41

RAPH12CEX0318AA

1

RAPH12CEX0319AA

2

RAPH12CEX0320AA

3

7 - MAINTENANCE

Flushing and filling the cooling system 1.

Fill through radiator filler neck, clean water and a cleaning flushing agent until the radiator is fully filled, then tighten radiator cap (1).

2.

Start the engine at let it run at a speed slightly over idle, until the coolant temperature meter located on the instrument cluster, reaches the white range. Then let the engine operate for about 10 min.

3.

Stop the engine and let it cool-off.

4.

Drain the water and detergent following the procedure described above 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 and fill the system using the prescribed coolant liquid (see "Fluids and lubricants" at the end of this chapter) through the radiator filler neck until it is fully filled.

7.

Install radiator cap (1) and complete the filling of expansion tank (4).

8.

Close the engine hood. Reinstall the panel located under the upper structure, securing it with its relevant screws.

9.

Start the engine and let it operate several minutes.

10.

Stop the engine, let it cool-off and 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.

7-42

RAPH12CEX0321AA

4

7 - MAINTENANCE

Every 5000 hours

Hydraulic oil 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.

Replacement To change the hydraulic oil, proceed as follows: 1.

Position the machine on a flat surface with the upper structure swung 90 ° to facilitate access.

2.

Position the front attachment as indicated in the figure.

3.

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

4.

Wait for the machine to cool off.

5.

Clean the upper side of the hydraulic oil tank to prevent contamination of the hydraulic system.

6.

Press the button (1) located on the tank several times to bleed the pressure inside the hydraulic tank.

7.

Loosen securing bolts (2) using a wrench and remove cover (3).

8.

Remove the hydraulic oil return filters cover (6)..

7-43

NHC0259

1

NHC0260

2

NHC0261B

3

7 - MAINTENANCE

9.

Locate and remove drain plug (7) to allow the residual oil to drain into a suitable container.

10.

Clean, install and tighten drain plug (7). Tightening torque: 108 N·m (80 lb ft).

11.

Replace the hydraulic oil return filters as described on page 7-36.

12.

Clean suction filter (4). In the event the filter must be replaced, install a new filter on the rod.

13.

Install a new O-ring (5) and suction filter assembly (4).

14.

Pour specified oil through the suction filter. (see "Fluids and lubricants” for specifications and capacities) until the level is included between the marks MIN and MAX on level gauge (8) located inside the hydraulic pumps compartment.

15.

Install cover (3) ensuring that the suction filter assembly is correctly seated. Tighten the bolts (2). Tightening torque: 41.9 - 51.1 N·m (30.9 37.7 lb ft)..

7-44

NHC0355

4

NHC0261B

5

NHC0356

6

7 - MAINTENANCE

16.

Start and run the engine at low idle for several minutes.

17.

Operate each cylinder and swing movement.

18.

Return the machine to the hydraulic level checking position and stop the engine.

19.

Check the hydraulic oil level.

20.

If the hydraulic oil level is low, add oil.

7-45

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 Windshield wiper and washer Optional Flasher relay Air conditioner (main) Air conditioner (compressor) Option (Hand Control) Hour meter 12 volt power supply Horn, horn relay Radio Starter key switch Cab room lamp Optional Optional Bucket dump cut solenoid Air conditioner Work light DC-DC converter DC-DC camera Optional Travel alarm Safety lever Mechatro controller Mechatro controller Engine controller (ECU) Engine controller (ECU) IT controller Fuel transfer pump 7-46

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.

7-47

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.

7-48

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

7-49

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.

7-50

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.

7-51

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.

7-52

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

7-53

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)

7-54

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.

7-55

RAIL12CEX1031AA

1

RAIL12CEX1032AA

2

7 - MAINTENANCE

Preparing 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.

7-56

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.

7-57

7 - MAINTENANCE

Starting up after storage 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.

7-58

7 - MAINTENANCE

Fluids and lubricants

Fluids and lubricants ED160-3 COMPONENT TO BE FILLED

Engine

Swing reduction unit Travel reduction units (each)

Cooling system (1)

Fuel tank Hydraulic oil tank (2) Hydraulic system (2) Swing grease bath

Pressure grease fittings

QUANTITY

SPECIFICATIONS

11.5 l (3.0 US gal) total volume.

TUTELA UNITEK CJ-4 10.5 l (2.8 US ENGINE OIL SAE gal) H level.

15W-40 7.5 l (2.0 US gal) L level.

1.65 l (0.4 US gal) NEW HOLLAND AMBRA HYPOIDE 90 5.9 l (1.6 US gal) X 2 10.7 l (2.8 US CNH XHD HEAVY gal), 13 l (3.4 DUTY COOLANT / US gal) Total ANTI-FREEZE volume 200 l (52.8 US gal) 85.2 l (22.5 NEW HOLLAND US gal) AMBRA HYDROSYSTEM 126.7 l (33.5 46 HV US gal) NEW HOLLAND 8.6 l (2.3 US AMBRA HI-TEMP EP gal) GREASE NEW HOLLAND AMBRA HI-TEMP EP GREASE

INTERNATIONAL SPECIFICATIONS

API CJ-4

APLI GL 5 MIL-L-2105 D

ASTM D 3306

EN 590

MAT—3509

NOTE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 24 l (6.3 US gal) .

NOTICE: (2) If the machine was filled with biodegradable hydraulic oil NEW HOLLAND AMBRA HYDROSYSTEM 46 BIO-S (option), take note that this oil cannot be mixed with mineral hydraulic oil.

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

7-59

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

7-60

8 - SPECIFICATIONS

8 - SPECIFICATIONS General specifications ED160–3 ENGINE Make Model Type Rated output power at 2000 RPM ( ISO 14396 ) Number of cylinders Total displacement Bore x Stroke

MITSUBISHI D04EG-TAA Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger.

74 kW (101 Hp) 4 3.331 l (203.3 in³) 94 mm (3.7 in) x 130 mm (5.1 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 Maximum displacement Maximum flow rate Maximum input horsepower

2 x 65.2 cm³ 2 x 130 l/min (34.3 US gpm) 64.9 kW (88.2 Hp)

MAXIMUM OPERATING PRESSURE Attachment Travel Swing Power Boost

34.3 MPa (4975 psi) 34.3 MPa (4975 psi) 28 MPa (4061.4 psi) 37.8 MPa (5483 psi)

CYLINDERS (Bore x Stroke) Boom Arm Bucket

100 mm (3.9 in) x 1092 mm (43.0 in) x 1320 mm (52 in) 115 mm (4.5 in) x 1120 mm (44.1 in) x 1588 mm (62.5 in) 95 mm (3.7 in) x 120 mm (4.7 in) x 1080 mm (42.5 in)

TRAVEL Hydraulic motors Parking brake Reduction unit Maximum climbable gradient TRAVEL SPEED Low High

3.2 km/h (2.0 mph) 6.5 km/h (4.0 mph)

SWING Hydraulic motor Parking brake Reduction unit Bullgear SWING SPEED

Axial piston type Oil disk brake 2 stage planetary gear unit Grease-bath 11.0 RPM

Axial piston type Oil disk brake 2 stage planetary gear unit 70 %

8-1

8 - SPECIFICATIONS

Dozer specifications

RAPH12CEX1334GA

Dozer overall width (A) Dozer overall width without RH/LH dozer blade (B) Height (C) Maximum depth (D) Digging depth (E) Maximum tilt height (F) 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)

8-2

8 - SPECIFICATIONS

Dimensions and weights ED160–3

RAPH12CEX1333FA

VERSIONS ED160–3

D C

A

B

F H I G 455 mm 1490 mm 3600 mm 2800 mm 8530 mm 2700 mm 2590 mm 600 mm 3030 mm (17.9 in) (59 in) (142 in) (110 in) (336 in) (106 in) (102 in) (24 in) (119 in) * C

D

1

E

ED160–3 500 mm (19.7 in) 600 mm (23.6 in) 2490 mm (98 in) 2590 mm (102 in) 15700 kg (34613 lb) 16200 kg (35715 lb) 50 kPa (7.3 psi) 43 kPa (6.2 psi)

Track shoe width Gauge, Overall width of crawler Working weight Specific ground pressure

Measurements are based on standard machine configuration with a 2.38 m (7.8 ft) arm length and a bucket SAE heaped of 0.50 m³ (0.65 yd³). Marked * dimensions do not include height of shoe lug.

8-3

8 - SPECIFICATIONS

Digging data ED160–3

RAPH12CEX1332GA

1

2090 mm (82.3 in)

2360 mm (92.9 in)

2840 mm (111.8 in)

Maximum digging reach 8040 mm (316.5 in) Maximum digging reach at ground 7860 mm (309.4 in) A' level Maximum digging depth 5070 mm (199.6 in) *B Maximum digging height 9070 mm (357.1 in) *C Maximum dumping clearance 6620 mm (260.6 in) *D Minimum dumping clearance 3060 mm (120.5 in) *E Maximum vertical wall digging *F 4520 mm (178 in) depth Minimum swing radius G 2070 mm (81.5 in) Height at minimum swing radius *H 7010 mm (276.0 in) *J 2440 mm (96.1 in) level digging 4810 mm (189.4 in) depth K Horizontal digging stroke at ground 3610 mm (142.1 in) level: Stroke L Horizontal digging stroke at ground 2410 mm (94.9 in) level: Minimum Marked * dimensions do not include height of shoe lug.

8340 mm (328.3 in)

8780 mm (345.7 in)

8160 mm (321.3 in)

6610 mm (260.2 in)

5360 mm (211.0 in) 9340 mm (367.7 in) 6900 mm (272 in) 2740 mm (107.9 in) 4730 mm (186.2 in)

5820 mm (229.1 in) 9710 mm (382.3 in) 7260 mm (285.8 in) 2380 mm (93.7 in) 5290 mm (208.3 in)

2000 mm (78.7 in) 6990 mm (275.2 in) 5130 mm (202.0 in)

2400 mm (94.5 in) 7010 mm (276.0 in) 5630 mm (221.7 in)

4230 mm (166.5 in)

4720 mm (185.8 in)

2100 mm (82.7 in)

2040 mm (80.3 in)

Arm A

8-4

8 - SPECIFICATIONS

RAPH12CEX1204GA

2

Face shovel attachment Arm Maximum digging reach A Maximum digging reach at ground level A' Maximum digging depth *B Maximum digging height *C Maximum dumping clearance *D *D’ Maximum dumping clearance 45 ° Minimum dumping clearance *E Minimum swing radius G Height at minimum swing radius *H *J 2440 mm (96.1 in) level digging depth K Horizontal digging stroke at ground level: Stroke L Horizontal digging stroke at ground level: Minimum Marked * dimensions do not include height of shoe lug.

8-5

2870 mm (113.0 in) 9820 mm (386.6 in) 9650 mm (379.9 in) 6700 mm (263.8 in) 10700 mm (421.3 in) 7790 mm (306.7 in) 6650 mm (261.8 in) 2860 mm (112.6 in) 2340 mm (92.1 in) 8150 mm (320.9 in) 6500 mm (255.9 in) 3790 mm (149.2 in) 5660 mm (222.8 in)

8 - SPECIFICATIONS

Buckets application as a function of the arm ED160–3 Type

Bucket

Outside width of bucket Without With side side cutters cutters

Can be turned over Arm Number Weight 2.38 2.84 of teeth m arm m arm 2.38 2.84 m m

SAE SAE (Heaped) (Struck) Hoe 0.24 m³ (0.3 0.20 m³ (0.3 bucket yd³) yd³) 590 mm 500 mm 3 Yes Yes 280 O 0.31 m³ (0.4 0.23 m³ (0.3 yd³) yd³) 700 mm 600 mm 3 Yes Yes 300 O 0.38 m³ (0.5 0.28 m³ (0.4 yd³) yd³) 800 mm 700 mm 4 Yes Yes 340 O 0.45 m³ (0.6 0.35 m³ (0.5 yd³) yd³) 915 mm 815 mm 4 Yes Yes 360 O 0.50 m³ (0.7 0.38 m³ (0.5 yd³) yd³) 1000 mm 900 mm 5 Yes Yes 380 S 0.57 m³ (0.7 0.43 m³ (0.6 yd³) yd³) 1100 mm 1000 mm 5 Yes Yes 400 L 0.7 m³ (0.9 0.5 m³ (0.7 yd³) yd³) — 1150 mm 5 Yes Yes 410 L Breaker O Nibbler O Standard Combination S General Excavation or loading of sand, gravel, and clay Operation O Light Cultivation or Loading of loose gravel or sand. operation L Prohibited KOBELCO’s warranty does not cover damage resulting from using these X combination combinations. Not recommended.

8-6

O O S L X X X O O

8 - SPECIFICATIONS

Lift capacities - Model ED160–3 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

Carefully read and comply with the following: • Do not lift or hold any load greater than listed lift capacities specifications.

Note: Weight of all accessories must be deducted from listed 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 % of hydraulic lift capacity or 57 % of tipping load.

Note: Lifting capacity specifications limited by hydraulic capacity versus tipping load are noted in tables by shaded gray appearance.

• Listed lift capacity specifications apply only to machines as originally manufactured and normally equipped by Kobelco.

8-7

8 - SPECIFICATIONS

YY11Z00591P1

1

Part number — YY11Z00591P1

YY11Z00592P1

2

Part number — YY11Z00592P1

8-8

8 - SPECIFICATIONS

YY11Z00588P1

3

Part number — YY11Z00588P1

YY11Z00589P1

4

Part number — YY11Z00589P1

8-9

8 - SPECIFICATIONS

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. Do not allow the machine weight to be supported by prying with the crusher and cylinders fully extended or retracted. Doing so may damage the front attachment.

In particular, avoid doing so with the crusher cylinder fully extended as the front attachment will be more easily damaged.

NH0212A

1

NH0213A

2

NH0214

3

2. Do not perform crushing on either side of the machine, always do so at front or rear, parallel with tracks. Otherwise, the machine may overturn.

3. When operating the crusher up high with the boom fully raised, be careful of falling objects.

9-1

9 - ACCESSORIES

4. When operating the crusher on a floor in a building, first confirm 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 the excavator with the bucket cylinder fully extended. This made damage the attachment due to high travel vibrations.

9-2

4

9 - ACCESSORIES

Monoblock (proportional switch version) NOTICE: Always make sure to press the nibbler mode button (2) located on the instrument cluster before using the nibbler.

1. To operate the nibbler, proceed as follows: 2. Verify that valves (1) located on the arm are open (mark on the valve parallel with the arm). In case the valves are not open, use 24 mm wrench to turn them.

3. Start the engine and press the nibbler mode button (2). The flow rate and pressure screen appears and the icon changes to nibbler.

NHC0313

5

NHC0296

6

NHC0297

7

NOTE: depending upon the type of nibbler mounted, it is possible to select on of the ten preset flow/pressure settings Operate the nibbler using the proportional switch (3) located on the right control lever: 1. Slide right the proportional switch (3) to open the nibbler.

2. Slide left the proportional switch (3) to close the nibbler.

NOTE: the opening or closing speed is determined by the stroke of the proportional switch (3).

9-3

9 - ACCESSORIES

Monoblock (pedal version) NOTICE: Always make sure to press the nibbler mode button (2) located on the instrument cluster before using the crusher.

To operate the crusher, proceed as follows: 1. Verify that valves (1) located on the arm are open (mark on the valve parallel with the arm). In case the valves are not open, use 24 mm wrench to turn them.

2. Start the engine and press the nibbler mode button (2). The flow rate and pressure screen appears and the icon changes to nibbler.

NHC0313

8

NHC0296

9

NHC0304

10

NOTE: depending upon the type of nibbler mounted, it is possible to select on of the ten preset flow/pressure settings Operate the nibbler using the right pedal (3) : 1. Unlock the nibbler pedal (3) moving locking device (4) outward.

2. Actuate pedal (3) to open or close the nibbler. When releasing the pedal in neutral position, the operation is stopped.

9-4

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. Avoid hitting objects with breaker. The breaker is heavier than the bucket and lowers faster. This may cause damages to the breaker, attachment, and upper structure. 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

2. Do not use the hydraulic breaker and/or swing function to push objects as damages to the attachment may result.

3. Do not operate the breaker with the excavator cylinders fully extended or retracted to avoid attachment and/or cylinder damage.

9-5

9 - ACCESSORIES

4. Stop working if hydraulic hoses look abnormally bent.

Contact your authorized Dealer.

NH0197

4

NH0199

5

NH0200

6

NH0201

7

5. Do not operate the hydraulic breaker in water. Doing so will cause rust and seal damage, resulting in damage to the hydraulic system components.

6. Do not use the hydraulic breaker to move objects. The excavator might overturn and/or the hydraulic breaker may be damaged.

7. Do not operate the breaker to the side of the machine. The machine may become unstable and undercarriage components life may be reduced

9-6

9 - ACCESSORIES

8. Operate the excavator carefully to avoid hitting the boom with the hydraulic breaker.

NH0202

8

NH0203

9

NH0204

10

NH0205

11

9. Do not operate the breaker with the arm positioned vertically. Excessive vibration to the arm cylinder may cause oil leakage.

10. Press the breaker so that the chisel point thrust is square (perpendicular) to the object to be broken.

11. 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.

9-7

9 - ACCESSORIES

Monoblock (switch version) NOTICE: Always make sure to press the breaker mode button (2) located on the instrument cluster before using the breaker.

To operate the breaker, proceed as follows: 1. Verify that valves (1) located on the arm are open (mark on the valve parallel with the arm). In case the valves are not open, use 24 mm wrench to turn them.

2. Start the engine and press the breaker mode button (2). The flow rate and pressure screen appears and the icon changes to breaker.

NHC0313

12

NHC0307

13

NHC0306

14

NOTE: depending upon the type of breaker mounted, it is possible to select on of the ten preset flow/pressure settings.

3. Operate the breaker pressing the button (3) located on the right control lever.

9-8

9 - ACCESSORIES

Monoblock (pedal version) NOTICE: Always make sure to press the breaker mode button (2) located on the instrument cluster before using the breaker.

To operate the breaker, proceed as follows: 1. Verify that valves (1) located on the arm are open (mark on the valve parallel with the arm). In case the valves are not open, use 24 mm wrench to turn them.

2. Start the engine and press the breaker mode button (2). The flow rate and pressure screen appears and the icon changes to breaker.

NHC0313

15

NHC0307

16

NHC0304

17

NOTE: depending upon the type of breaker mounted, it is possible to select on of the ten preset flow/pressure settings.

Operate the nibbler using the right pedal (3): 3. Unlock the breaker pedal (3) moving locking device (4) outward.

4. Actuate pedal (3) to operate the breaker. When releasing the pedal in neutral position, the operation is stopped.

9-9

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 (*)

NOTICE: (*) 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

NOTICE: (**) 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. Hydraulic oil change interval

9-10

9 - ACCESSORIES

Hammer and rotating bucket hydraulic system - Operating This system is a must when equipment requiring a rotation, such as nibbler, grabbing bucket etc. is going to be used. The choice of a rotating equipment must be made in agreement with the Dealer. This is because the equipment one intends to use must ensure, in any case, the stability of the excavator and the compatibility with its hydraulic systems.

When a rotating attachment is installed, operate as follows: 1. Swing the excavator slowly.

2. Rotate the attachment when the equipment is inoperative. This is in order to avoid dangerous swings which could endanger the stability.

NHC0308

1

NHC0309

2

3. When lowering the boom, make sure that the rotating attachment is in vertical position.

4. Never use a rotating attachment for piling jobs or removing poles.

5. Before leaving the operator's compartment, lower the boom until the rotating attachment rests on the ground.

Rotate the attachment using the proportional switch (1) located on the left control lever as follows: 1. Slide right the proportional switch (1) to rotate clockwise.

2. Slide left the proportional switch (1) to rotate anticlockwise.

9-11

9 - ACCESSORIES

Biodegradable hydraulic oil PANOLIN HLP SINTH 46 NOTICE: If the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 , take note that this oil cannot be mixed with mineral hydraulic oil.

BIODEGRADABLE OIL SAMPLING • The sampling of oil for analysis must occur every 500 hours, using the kit and the relevant instructions provided by the Dealer. The sample must be shipped by the Customer to PANOLIN AG., that shall provide the required tests. It is the Dealer’s responsibility to inform the Customer in the event the oil lacks the required characteristics for continuing its use.

NOTICE: In case special attachments are used (hydraulic breaker etc.) the oil analysis must be performed every 250 hours.

NOTICE: Oil should be changed if the Dealer informs the Customer that oil is outside operating limits. Failure to observe this measure will invalidate the warranty and may cause damages to the machine.

BIODEGRADABLE OIL CHANGE • The biodegradable oil change must be performed every 2000 hours. To change the biodegradable hydraulic oil, refer to the procedure described on page 7-43..

NOTICE: If the machine was bought filled with mineral hydraulic oil and you what to change to biodegradable hydraulic oil, this operation must be carried out by the Dealer personnel. In fact, it is necessary to thoroughly drain mineral oil and flush the entire hydraulic system.

Remember that mineral hydraulic oil must not be mixed with biodegradable hydraulic oil.

9-12

Index ACCESS TO OPERATOR'S PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Biodegradable hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Hammer and rotating bucket hydraulic system - Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Hydraulic oil - breaker/nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Preparing for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Starting up after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

COMMISSIONING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Draining the fuel filter water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Windshield washer fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

CONTROLS/INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Rearward controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Right-hand console - operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Every 1000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Every 120 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Every 2000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Pilot line filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Checking the radiator hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Engine air filter: outer element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Outside fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Every 50 hours of operation or weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Boom lift - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Cab air recirculation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Every 5000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

FORWARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Fluids and lubricants ED160-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Diesel particulate filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, left, front and rear of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Dozer blade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Emergency boom lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Biodiesel fuel - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Biodiesel fuel - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Boom lift - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Bucket grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Bucket teeth and side cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Cab air recirculation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Checking the radiator hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Control lever lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Dozer blade lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Engine air filter: outer element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Every 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Fan, alternator, and air conditioner belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Fluids and lubricants ED160-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Hydraulic oil return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Hydraulic reservoir breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Hydraulic return filter (Breaker use only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Lowering bucket attachment on a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Moving a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Outside fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Pilot line filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Preparing for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Preparing machine for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Removing and installing the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Removing and installing the dozer blade in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Starting up after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Swing reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Track tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Travel reduction unit oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Draining the fuel filter water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Windshield washer fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PARKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

REARWARD CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Rearward controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

RIGHT-HAND SIDE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Climate control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Right-hand console - operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

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

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Buckets application as a function of the arm ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Digging data ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Dimensions and weights ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Dozer specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 General specifications ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Lift capacities - Model ED160–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

STARTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Inspection after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

TRANSPORT OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Preparing for road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

WORKING OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Dozer blade control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Emergency boom lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Machine operation in adverse weather conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Operating the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Practices to improve efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Swing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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.