Kobelco MD240B Hydraulic Excavator Operator's Manual PDF

MDI-YUTANI I

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Book , ode No .

IS2LLI00 2 EI

Operators Manual

IID24DBk

Applicable Machines LL-1488 '"'Printed in Japan 1988.07

PREFACE We extend our thanks to you for purchasing our hydraulic excavator.

This hydraulic excavator has been manufadured using years of experience and high technology. It is our firm belief that you will be fully satisfied with this hydraulic excavator.

MDI-YUTANI is well aware that safety begins with a properly designed and manufactured machine_

However, as the manufacturer has no direct control over the inspection, maintenance, lubrication or operation of the machine, safety in the field must ultimately remain the responsibility of the user and operator. Since a majority of machine accidents occur because the basic safety rules or precautions were not observed, you, the operator, should be thoroughly familiar with and understand all safety considerations in this manual before operating the machine and be aware that misoperation of the power in this machine can result in destructive and/or lethal situations.

Likewise the care and lubtication that is given to the machine everyday together with the operating practices and skill determines how effectively it operates.

This manual provides operating instructions and vital information concerning safety, lubrication and maintenance. A separate manual is furnished for the engines of this machine. Be familiar with the instructions in both manuals before attempting to operate this excavator.

LL

0-1

INTRODUCTION • This machine is guaranteed under the terms of the warranty and any mechani cal trouble for which it is recognized to be our responsibility shall be repaired free of charge in accordance with the provisions of this warranty. It should be cautioned however. that this warranty will be voided if the machine is operated contrary to the procedures described in this manual.

• After delivery of the machine, in accordance with the specified period of time and frequency, a periodical service check shall be performed free of charge. Also, should there be any problems or questions concerning maintenance of the machine .. please do not hesitate to contact your representative or our distributors.

• Information regarding the engine on this machine is not included in this manual. A separate manual has been provided and it is vital that this engine manual also be read before operating the machine.

• Safety notices are used in this manual to increase operator awareness of the dangers involved when using the machine. These notices are not all inclusive since every possible hazard can not be anticipated. Therefore, the operator must also be satisfied that the operating techniques and the machine conditions are safe.

In this manual :

&1

WARNING

1_

is used to indicate that injury to personnel could occur if this notice is not observed. is used to indicate that damage to the machine could occur if this notice is not observed.

NOTE

is used to give detailed additional information that may be useful for the operator.

• The machine serial number is found on the lower left side outside the operator's cab .

When ordering parts or asking for repairs and/or maintenance, please indicate the machine serial number.

• It should be noted that continuing improvement of product design may cause changes to your

machine which may not be included in this publication.

Whenever a question arises regarding the content of this manual, please contact your representa · tive or our distributor.

0-2

LL

TABLE OF CONTENTS Page

SECTION I I.

Directions for Sa fet y

2.

Safety- Precautions

.. . . . . . . . . . . . . . . .. . . ... . ... . . . . . . . . . .... . ..... 1-1 ... . . .. .... . . . . . . . . . . . . . . . . . ... 1·2

3.

Safety Precautiuns for Preventive Maintenance

4.

Outline of Safety Devices

SECTION II

.. .. . .. . ...... . ... . ... .. . . ... 1-5

... .. . . . .............. . . . .. .. . . 1-6

SPECIFICATION

I.

Name of Components ..... . . .. . . .. . . ... .. . ... . .... . ..... '.. . . . . . . . . . 2-1

2.

General Dimensiuns . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . .... . .. . . . . . . . . . 2-2

3.

Specifications and Performance

2-3

4.

Type of Shoes . . . . . . . . . . . . .

2-4

5.

Type and Combination uf Attachments

2-5

6.

Working Range of Attachments

2-7

SECTION III 1.

OPERATION

Operation of the Machine ... . .. .. . . .. . . . . . . : ... . ... . . . . . . .. . . . . . ..... 3-1

2. Selection of the Modes

3-6

3.

Pre-operation Checks

3-7

4.

New Machinel'recautions ... ... ..... . . . . ... ... .. . . . . . . . . . . . .. .. . . . . . 3- 7

5.

Starting and Stopping the Engine

6.

Warm-up Operation

7.

Operation . . . . . . . . . . . . . ..... ..... . .. . . . . . . . . . . . . . . . . . . . . . . .. .... 3-8

. . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . ... . 3-7

.... . .. .. .... . ..... . . . .. . . . . . . . . . . . . . . . . . . . . . . . 3-8

8.

Operating Precautions . . . . . . . . . . . . . . . . . . ... .... . . . ..... . ..... ... .... 3-11

9.

Operation Under Unusual Conditions . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. ... 3-14

SECTION IV

LL

FOR SAFE OPERATION

PREVENTIVE MAINTENANCE

I.

Introduction..... . . . . . . . . . . . . . . ...... . .... . . . . . . . . . . . . . . . . . . .... 4-1

2.

Periodical Maintenance Check . . . . . . . . . . . . . . . . .. .... .. . . . . . . . . . . . . . . . .. 4·1

3.

Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.

Filter Element Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4·5

5.

8 Hour/Daily Maintenance .... . . . . . . . . . . . . .. . . . . . . . . . . . . .. ..... . ..... 4-6

6.

50 Hour/Weekly Maintenance

... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 4-7

7.

120 Hour/Monthly Maintenance ... ... .. . .. .... .. . . . . . . . . . . . . . . . . . . . . .. 4-7

8.

250 Hour Maintenance

4-8

9.

500 Hour Maintenance

4-8

10.

1,000 Hour Maintenance

4-9

11 .

2,000 Hour Maintenance

4-9

12.

Maintenance Procedure

4-10

0-3

Page

13.

Air Cleaner Check and Cleaning Replacement of Element ...... ... ....... ... ....................... . .... 4-16

14.

Maintenance of Hydraulic Oil System . ... .... ... . ..... . ... ..... ....................... ... ... ... ..... ... .. .. .. 4-17

15.

Cleaning of Water Separator ......... ... ........... ........ .. ... ...... .. ........... .... ................. .. ..... 4- 19

16.

Hydraulic Oil Care'" ... ............. . ... .............. .... ....... .. . .. . ..... ... .... .. ......... . .......... .. .... .. 4-20

17.

Change Oil of Swing Reduction Unit ..................... .... ............... ..... ........... .. .......... . .... 4-22

18.

Change Oil of Travel Reduction Unit .. .... . ..... . .. .... .. ...... .... .... ...... .......... .... ...... ..... . .. .. .. 4-22

19.

Adjustment of Track Tension ............................. .... ........ .. ..... .... .. .. ....... .... ............... 4-23

20.

Tightening Torque of Capscrews and Nuts .. ............ ......... .. .. .. ................. . .. .. ........ .. .... 4- 24

21.

Replacement of Bucket Tooth Points .............................................. . .......................... 4-25

22.

Removeal and Installation of Attachm ents ........... ... .. .. .............. .. .... .. .. .... .. .. .. .. .... .. .. .. .. 4-26

23.

Converting to Face Shovel ....................... .. ................................... .. .......... . ......... . ... 4- 27

24.

Replacement of Bucket Pin SeaJ(O-Ring) .......... .. .......... . .. .. ............ .. ..... .. .... .. ....... ... ... 4-27

25.

Periodical Replacement of Important Preventive Maintenance Parts ... .... ....... .... ......... ... ... 4-28

26.

Storage of Machine ... ..... ..... ..... .. ...... .... ........ ...... . ... . .. . .. ...... ...... ............. ... ...... . .. ..... 4- 29

SECTION V l.

TRANSPORTATION

Preparation .... . ...... .. ........................................................

5·1 5 ·1

2.

Self·Travelling ... .. .. . .. .. . . ... . . . .. ... .. .. . .. . . .. . . .. .. . . .... ..... .. . ..... .. . . ..

3.

4.

Transportation by Trailer or Truck .......... . ............ .. ...... . ...... . . . .... . ...

5·1

Weight of Components ... . ..... . ... . ... . ...... . ..... . .. . ......... . ... . ... . .. . .. . . .

5.

Transportation Weight

5·3 5·4

SECTION VI

.. ... ... . . . ...... . ....... . ..... .. . .. ..... . .............. . ..

GENERAL INFORMATION

I. . Hydraulic System

6·1

2.

Electrical System

6·3

3.

Air System

6·8

SECTION VII TROUBLESHOOTING . . ... . .. .. ..................... ... . 7·)

0-4

LL

SECTION I 1.

FOR SAFE OPERATION

DIRECTIONS FOR SAFETY

I) Safe operation is one of the most important responsibilities of the op.erator.

Before starting operation think about the work to be done and make sure there is nothing at the work site that may endanger safe operation .

Consult with the person in charge of the project and always use proper preventive measures to ensure safety.

2) Stop the machine immediately whenever you have

5) Always wear a safety helmet and safety shoes on the job site . Depending on the site, also wear safety glasses and a protective mask.

found a symptom threatening safe operation.

U553

L-1540

3) For safe operation, the operator must always be physically and mentally fit with good eyesight, hearing and a good sense of judgment.

4) Likewise, daily care and lubrication of the machine together with the operating practices as explained in this manual determine how effectively the machine operates. So before operating the machine, always carry out the pre-operation checks as described in this manual.

6) Never let people near the working range of the machine and remove all obstacles before starting operation . In order to prevent ob~ervers from coming close to the job site, especially on city streets, appoint an experienced groundman and operate the machine according to his hand signals.

L·1542

7) Check and ascertain beforehand, the location of buried gas pipes and electric power lines.

L·1534

LL

1-1

2.

SAFETY PRECAUTIONS

I) Never touch the control levers when getting on and off the machine-use the hand rails.

4) Before travelling the machine, check to see if the travel motors are at the rear or front of the lower frame and then operate the travel control pedals accordingly. Also, be sure to engage the swing lock when travelling.

L-1538

2) Blow the alarm horn before starting the engine, travelling, swinging or operating the boom and check the job site to make sure there is nothing which may endanger safe operation. Pay particular attention to areas that may become blind spots for the operator .

L-1535

5) When travelling uphill or downhill; lower the attachment close to the ground so that the bucket can be lowered to the ground to stop the machine in case of an emergency.

L-1541

3) Always pay attention to .the surroundings during operation and make sure there are no people or materials inside the working range of the machine_ Do not allow a person to ride on the machine except in the

L-1552

6) When travelling downhill or in tight quarters, reduce the engine speed and work slowly_ You may tend to misjudge distance if the speed is high_ The travel brakes automatically engage when the travel control pedals are returned to neutral.

cab.

L-1543

L-1549

1-2

LL

7) When beginning work, position the machine on firm and level ground.

The machine may turn over if

11) When the operation is stopped or finished , lower the bucket slowly to the ground and then stop the engine .

it swings on a slope .

L-1544 L-1660

12) Make sure the machine is parked safely . When leav-

8) On loose and soft ground, instead of digging up close

ing it on a slope , use blocks to secure the machine

to the machine, back off the machine a little , in order

and lower the bucket to the ground to act as a brake.

to provide extra room for the machine .

L-1546

9) Wear cab guards on job sites where there may be a danger of falling rocks or cave-ins.

13) When the operator is leaving the machine, place the control levers in neutral , engage the swing lock, remove the engine key and keep it safe so that no other person can operate the machine without permission.

L-1662 L-1547

10) Never jump on or off the machine when travelling or 14) If circumstances do not permit the lowering of the

during operation.

bucket to the ground, the operator should remain in his seat ready to operate the control levers.

L-1659

LL

L-1545

1-3

15) Be sure to engage swing lock during transportation or when travelling.

17) In case the machine comes into contact with live power lines, the operator should remain in his seat until the power is cut off.

If he must leave the machine, he should jump off, not climb down .

Also, do not let anybody on the ground touch the machine. While any part of it is in contact with a live power line.

L-1663

16) Ascertain the exact location of buried gas pipes, water pipes and telephone lines before starting the job and appoint an experienced groundman in a good position to give signals. The operator should take instructions from this appointed groundman only.

L-l664

WARNING

18) Since this machine is an excavator, please use extreme

1. Never operate any part of machine closer

caution when handling heavy loads.

than 10 ft (3 m) to any live power lines.

(Check local power company codes and reg· ulations, and conform to them if different from above) 2. The design and construction of this machine does not incorporate any electrical in-sulating members in any part of the front attachement components, that would afford protection against electrical shock and/or possible electrocution from contact with live power lines, not to mention possible machine damage that could occur under these circumstances.

....W.A.R.N.I.N.GIIIIII' . (Option) Heavy Lift Caution!

Operator must Never turn heavy lift switch to off position while supporting load.

Boom could lower unexpectedly with extreme heavy loods.

WARNING' Do not exceed the machine's capacity charts.

Use only approued slings and shackles (clevises).

Never lift a load from the bucket teeth.

1-4

LL

3.

SAFETY PRECAUTIONS FOR PREVENTIVE MAINTENANCE

1) Stop the engine during inspection and maintenance, remove the key and place a sign on the cab clearly indicating that the machine is being serviced.

5) Use extreme caution when removing the radiator cap. If the engine is still hot. boiling water may spray out. If possible. wait until the engine has cooled.

L-1665 L-l020

2) Never work under a machine that is supported only by the boom and bucket. Use heavy duty wooden blocks under the crawlers when working under the machine.

6) Gas generated from· battery electrolyte is flammable so do not smoke or expose open flames when servicing the batteries. Also, make sure to keep this electrolyte off clothing. skin and out of eyes. Never use a match to check battery levels.

L-1554

L-1551

3) When working on the boom, arm or bucket , lower the bucket to the ground.

7) Stop the engine when filling the fuel tank and be sure there are no open flames or heated surfaces that could ignite the fuel.

L-1555

4) If necessary to inspect. service. or repair the machine with its boom and arm uP. apply safety blocks and

L-1550

struts.

LL

1-5

4.

OUTLINE OF SAFETY DEVICES

The following safety devices are installed on this machine:

(1 ) Swing lock This device locks the upper and lower frames during transportation, travelling, parking on slopes or after operation is finished.

(2) Travel brakes This machin brakes automatically when the travel control pedals are returned to neutral or when the

WARNING A seat belt is standard eguipment. For safety purposes it is recommended to use the seat belt for heavy work, working on slopes, or at sites where seat belts are necessary. Be sure to replace the seat belts evey 3 years, or as necessary due to deterioration, which ever occurs first.

engine is stopped. safe operation.

(3) Horn The horn sounds if the switch on the knob of the control lever is pressed. Make full use of this for safe operation. To signal danger or instructions to jobsite personnel.

(4) Head lights For safe operation, use head lights when working with poor visibility.

(5) Cab guards Cab guards are available as an option for operation on sites where there is a danger of falling rocks.

(6) Back up alarm This is audible alarm that will activate any time. The machine's lower crawlers are travelling in the reverse direction.

NOTE

"Reverse direction" is defined as; The direction of rotation of the crawler belts, that allows the travel reduction gear boxes to be positioned in the direction of travel. Recommended working posi· tion is with the travel reduction gear-boxes positioned under the machine's counter weight in the normal working position.

(7) Control lever lock This safety lever is located adjacent to the left-hand work control lever. Lowering this lever provides pilot oil flow to front attachment controls for normal operation. Raising this lever prevents pilot oil flow to front attachment controls only for safety lock.

NOTE

Travel pedals cannot be safty·locked on this model.

1-6

LL

SECTION II 1.

SPECIFICATION

NAME OF COMPONENTS FUEL TANK

HYDRAULIC OILTANK

ENGINE

SWING MOTOR

SHOE

BOOM

CAB

COUNTERWEIGHT MUFFLER

ARM CYLINDER

BUCKET LINK IDLER LINK

TRACK GUIDE

LOWER ROLLER

CRAWLER ADJSTER

BUCKET CYLINDER

LL

2-1

2. GENERAL DIMENSIONS MD240BLC g ft-g in (2 .98 m) ARM (STD)

32'8" (9.955)

"

9'1" (2 .770)

. -- ~ . - ;.

32" (800) 15'2" (4.630)

11'1" (3.390)

MD240BLC ? ft-? in (2,32 m) ARM 33'1" (10.075)

MD240BLC 11 ft-11 in (3,63 m) ARM

32' 8" (9,965)

2-2

LL

3.

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY MD240BLC Swing speed

10.5 r.p.m

Travel speed

3.412.5 MPH (5.5 / 4 km/hr)

Gradeability

35° (70%)

ENGINE MD240BLC Model

Mitsubishi

Type

4·cyc\e. water cooled. direct injection type diesel with turbo charger

Number of cylinder X Bore X Stroke

6X4.4 inX4.5 in (6X113 mm X 115 mm)

Total displacement

1,828 cuin (6.92 t )

Rated output power / revolution

Maximum torque/

6D15T

JIS D 1005

Net

155 PS/2150 r.p.m

SAEJ1349

Net

114 kW/2150 r.p.m

DIN 6270

Net

155 PS/2150 r.p.m

JIS 0 1005

Net

58 kg 'm/1600 r.p.m

SAE J 1349

Net

570 N ' m/1600 r.p.m

DIN 6270

Net

58 kg'm/1600 r.p.m

revolution

HYDRUALIC COMPONENTS MD240BLC Hydraulic pump

Double variable displacement pump+Gear pump

Hydraulic motor (swing)

Axial piston motor

Hydraulic motor (travel)

Axial piston motor

Control valve

5 ·section multiple control valve+ l ·section control valve (swing)

Cylinder (Boom, Arm, Bucket)

Double acting cylinders

Return filter

Filter paper with safety valve

Oil cooler

Air·cooled type

WEIGHT MD240BLC Fully equipped weight

Approx. 52204 Ibs (Approx. 23,680 kg)

Upper machinery

Approx. 21053 Ibs (Approx. 9,550 kg)

Lower machinery (with 32" (800 mm) grouser shoes)

Approx. 21274 Ibs (Approx. 9,650 kg)

Attachment (with boom +9 ft·9 in (2.98 m) arm + 1.18 cu yd (0.9 m') bucket)

Approx. 9876 Ibs (Approx. 4,480 kg)

LL

2-3

4.

TYPE OF SHOES

Shape

Model

Width of Track Shoe . ft- in (mm)

Overall Width of Crawler ft- in (mm)

Ground Pressure psi (kg/cn!)

24" (600)

10'5" (3,190)

6 .68 (0.47)

28" (700)

10'9" (3,296)

5.83 (0.41)

32" (800)

11'1" (3,390)

5.12 (0.36)

Grouser (Equal height)

Number of links: 51

28" (700 mm) and 32" (800 mm)shoes are for use in general construction work at earth, sand sites . . Do not use in gravel pits or rocky areas.

2-4

LL

5.

TYPE AND COMBINATION OF ATTACHMENTS

TYPE OF BUCKET Hoe bucket

Outer Width ft· in (mm) Number Heaped Possibilitv• !I Side !

Capacity of of With Without cu yd (m' ) Side Cutters Side Cutters Tooth Cutters Fac e Sh ovel

0.92 (0.7)

3'5" (1 ,050)

3'1 " (960)

4

Yes

,

Yes

i

Weight Ibs (kg)

1.455 (660)

--+--

118 (0.9) *118 (0.9)

4'2" (1 ,270) 3'10" (1.180) -

-

4

Yes

Yes

5

No

Yes

1.31 (1.0)

4'6" 0,380) 4'2" 0 ,290)

5

Yes

Yes

1.57 (1.2)

5'3" (1,600) 4' 11" (1.510)

5

Yes

Yes

! 1.610 (730) i2.226 (1.010

_+

-<------

1.741 (790) 1.895 (860)

'mark shows for heav y dut y digging.

Rippel

Weight: 1.366 Ibs (620 KY)

Side slope finishing bucket

Capacity: 0.98 cu yd (0.76 m') Weight: 2.314 Ibs (1050 KY)

Ripper bucket

Capacity: 0.78 cu yd (0.6 m' ) Weight: 2.226 Ibs (1 .010 KY)

LL

2-5

COMBINATION OF ATTACHMENTS

Applicable Arm

Bucket Type

Hoe bucket

Side slope finishing bucket Ripper Ripper bucket

JIS heaped capacity cu yd (m')

SAE heaped capacity cu yd (m')

With With With JIS.SAE struck 9 It·9 in (2.98 m) 7 ft·7 in (2.32 m) 11 It·1O in (3.36 m) capacity cu yd (m') arm arm ext.arm

0.92 (0.7)

1.05 (0.8)

0.78 (0.6)

1.18 (09)

1.36 (1.04)

0.99 (0.76)

1.18 ("0.9) ' . (For heavy duty digging)

1.36 (1.04)

0 ©

0 0

<0 .c.

0

X

1.31 (1.0)

1.52 (1.16)

1.10 (0.84)

0 .c.

1.83 (1.40)

1.31 (1.0)

X

© .c.

X

1.57 (1.2) 0.99 (0.76)

-

-

0

0

.c.

-

-

0.78 (0.6)

-

-

0 0

0 0

X

(~

)

0.99 (0.76)

©

Standard combination

.c.

Light duty :

\York mainly loading loose gray!'1 or clayey soil

X

Not usabil':

Not warranted

X

X

o Gl'Ill'ral USl': Digging and loading of graYeI. sand and clayey soil

If a bucket other than the hoe bucket is turned over fo'r operation, the arm and the bucket may be broken.

2-6

LL

6.

WORKING RANGE OF ATTACHMENTS

BACKHOE ATTACHMENT A'

/

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/

\

17

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~ ,~~

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-.-+------+++--I~--+--+--+--------=t-----r------/ ~ ~ Q ~

wrw~~~~~i-t-ri~~O~~~H~ca~~~·~=~I~~~~:11 VI/ /1

K

L

"

/// /

\

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~~\~~~o~~~~~ ~ ~-+--~--4---+-~~~~~--+-~~-+--~ 3

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5

/

6

/'

11M 10

9

8

7

6

5

4

3

7M

2

Unit: ft-in (m) 9 ft- 9 in (2.98 ARM 7 ft-7 in (2.32 ARM ~nt Item [With 1.31cu yd (1.0 m') bucketl [With 1.18 cu yd (0.9 bucket) m)

(STD)

m)

m')

11 !t-ll in (3_63 m) ARM [With 0_92 cu yd (0.7 m') bucketl

A Maximum digging reach

31'10" (9.72)

33'10" (10.31)

35'10" (10.92)

A' Maximum reach at ground level

31'3" (9.53)

33'3" (10.14)

35'3" (10.75)

B Maximum digging depth

20'6" (6.25)

22'8" (6.91)

24'9" (7.56)

C

Maximum digging height

30'8" (9.37)

31 '7" (9.63)

32'5" (9.90)

D

Maximum dumping clearance

21'2" (6.47)

22'1" (6.72)

22'11" (6.98)

E Minimum dumping clearance

10'4" (3.15)

8'2" (2.49)

6'0" (1.84)

Vertical digging depth

17' 4" (5.29)

19'9" (6.04)

21 '1 0" (6.67)

G Minimum swing radius

13'7" (4.16)

13'4" (4.08)

13'1" (4.00)

H Height at minimum swing radius

26' 4" (8.04)

25'11" (7.92)

25'10" (7.89)

F

I

Digging depth 8' flat floor

19'9" (6.03)

21'11" (6.70)

24'4" (7.42)

K

Horizontal

Stroke

12'3" (3.75)

17'2" (5.25)

21'2" (6.45)

L

digging distance

Minimum

11'6" (3 .52)

8'6" (2.61)

6'7" (2.01)

-

LL

2-7

FACE SHOVEL ATTACHMENT A A'

u

I

II I

I.. = K

(II II L

11

\

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\ 0

/// /

IV

1\ ,4AV ~~\~~~~-.~~~~~£

r-T-+\\~--r-+-*\rH--r-+-+-,~ \ 1 15 ~

~\

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~~~~---+--~~-r--~~~--+---r-~~~6

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~F==F==~==F==F==~~F=~--~--r--+~7

11M 10

9

8

7

6

5

4

3

2 Unit: m (ft·in)

~t

Item

7 ft·7 in (2.32 m) ARM 9 ft·9 in (2.98 m) ARM (STD) 11 ft·ll in (3.63 m) ARM (With 1.31 cu yd (l.Om') bucket) (With 1.18 cu yd(0.9 m')bucket) (With 0.92 cu yd (0.7 m') bucket)

A Maximum digging reach

32'5" (9.89)

34'5" (10.49)

36'4" (11.09)

A' Maximum reach at ground level

31'10" (9.71)

33'10" (10.31)

35'10" (10.92)

B Maximum digging depth

21'1" (6.42)

23'2" (7.08)

25' 4" (7.73)

C Maximum digging height

31'9" (9.70)

32'7" (9.95)

33'6" (10.22) 22'7" (6.89)

D Maximum dumping clearance

20'9" (6.34)

21'9" (6.63)

D'Maximumdumpingclearance(45')

20'1" (6.14)

19'10" (6.06)

20'7" (6.29)

E Minimum dumping clearance

9'9" (2.99)

7'7" (2.32)

5'5" (1.67)

F Minimum swing radius

13'7" (4.16)

13'4" (4.08)

13'0" (4.00)

G Height at minimum swing radius

26'4" (8.04)

25'11" (7.92)

25'10" (7.89)

K

Stroke

10'2" (3.12)

13'11" (4.26)

17'6" (5.35)

L

Minimum

20'11" (6.38)

19'2" (5.84)

17'6" (5.35)

Horizontal --- digging distance

2-8

II

SECTION III 1.

OPERATION

OPERATION OF THE MACHINE

The machine is divided in two halves- the upper and the lower. The operator's cab is mounted on the upper at the left. The attachment side is called the front and

the engine is at the rear. On the lower the travel motors are installed at the rear and the idler at the front.

INSTRUMENT PANEL [STD.]

The instrument panel is of monitor type. If tro uble should occur during operation , the lamps in the cluster gauge light and the buzzer blows concurrently to caution the operator.

14 16

7 1. ENGINE THROTILE LEVER

9. DECELERATION SELECT SWITCH

17. CONTROL LEVER SET KNOB 18. CLUSTER GAUGE

2. STARTER SWITCH

10. HORN SWITCH

3. WIPER WINDOW WASHER SWITCH

11. CAP

19. D.M.S.S RELEASE SWITCH

4. BUZZER STOP SWITCH

12. HEAD LIGHT SWITCH

20. HEAVY LIFT SWITCH 21. POWER BOOST SWITCH

5. MODE CHANGEOVER SWITCH

13. BLIND PLUG

6. DECEL OPERATION SWITCH

14. CAR RADIO

7. HEATER SWITCH

15. CIGARETIE LIGHTER

8. TWO-SPEED TRAVEL SWITCH

16. FUSE BOX

LL

3-1

(I) Engine throttle lever This lever regulates the revolution (output) of the

( 4) Buzzer stop swi tch In case any fault has occurred on the engine oil

engine and acts as the stop lever.

pr~ssur e _ air

cleaner . engine oil filter or engine

water temperature, the lamps in the cluster gauge light which causes the buzzer to blow concurrently .

The bUlzer ceases to blow if the switch is turned "OFF."

ENGINE

Always turn the switch "ON" after cor-

recting a fault.

LOW IDLING - -......-"'...

(5) Mode Changeover switch HIGH IDLING _ _--'''k~.

This is the three-step switch that controls the pump horsepower.

1) Engine stop Push the lever fully forward from the low idling position.

NOTE Do not release the lever till the engine comes to a complete stop. If the lever is let free. it automatically returns close to the low idling position.

NOTE

2) Low idling Pull the lever a little toward yourself. push it forward

dard for Selecting the Mode Changeover Switch" (on pages 3-6).

again till it comes to the detent position.

3) High idling Fully pull the lever toward yourself from the low

(6) Decel Release Switch

For mode changeover standards. refer to "Stan-

This is used to release the decel function.

idling position.

RELEASE

(2) Starter switch

~'SCH"G'

This is the engine start switch. For starting the engine. refer to "Starting and Stopping the Engine".

(3) Wiper Window Washer Switch 1) To actuate the wiper. turn the switch about 30

0

(7)

Heater Switch

clockwise from the "OFF" position.

2) When operating the window washer. depress the (8) 2-speed Travel Switch

switch.

The switch that changes the travel speed.

INTERMITTENT WIPER

Maximum travel speed: 3.4 MPH(5.5 km/hr) Maximum travel speed: 2.5 MPH (4 km/hr)

O f & CONnNUOU, W",'"

High and low speeds can be selected with the travel changeover switch.

C!D

When running on bumpy roads. use the low speed shift.

When running the machine to change work sites. advance i~ with the travel motor in the rear.

3-2

LL

(9) Decel operation switch

1) Position of control stand when getting on and off the

Use it when waiting for a dump truck. If the decel

machine.

select switch is depressed. the engine revolution falls

Position the lefthand stand in getting on and off the

to low speed .

machine. as shown below. This applies a safety lock to the lever to insure safety against unexpected contact

(10) Horn switch

when the operator gets on and off the machine.

Consequently. all steering systems except the travel system are deactuated. (when the control lever is

(11) Cap

(12) Head light switch

locked.)

PositiQn for getting on and off the machine

When I k

Head lights light.

(13) Blind Plug

(14) Car radio

One pressing of the ·ON" switch causes the radio to be turned on. and another pressing causes it to be turned off.

(When the control lever is locked.)

2) Position of the control stand during operation (15) Cigarette lighter

Since the lever is always freed from a locked condition

Use it when firing a cigarette.

at the start of operation. bring the control stand to its

If the lighter is pushed in. it returns to its original

operating position.

position several seconds later.

The operating position can be varied steplessly within

Pull it off and fire a cigarette with its red hot tip.

10

0.

Choose an optimum position according to the

types work.

AT NORMAL CONOITION

(16) Fuse box LEVER SET KNOB

Control lever set knob

(When the control lever is unlocked)

(18) Cluster gauge If the set knob is pressed. the contro( stand moves

Cluster gauge check lamp

back and forth freely.

If the starter switch is turned "ON "before running. all

If the pressure on the set knob is let free. the control

lamps in the cluster gauge light for three seconds. If

stand is set in.

any of the lamps does not light. it means that it is blown. For lamp lighting timings. refer to Cluster Gauge Display on page.

LL

3-3

5

4

6

3

7 8 9 10

2

In case the lamp does not go out within 15 seconds after starting the "engine, the buzzer will sound.

Stop the engine immediately, refer to the Engine Manual and inspect the lubrication oil system.

;==tc=:;;::;;:;r+--r--- 18 19 *--,il,--I-l------I-c-ll

7) Engine oil filter lamp When the engine oil filter has clogged up, the lamp

12

lights whereupon the buzzer sounds.

14

engine immediately and replace the engine oil filter.

13

Stop "the

For th~ replacing procedure, refer to the Engine Manual.

15

16

17

I) Hour meter The hour meter indicates a cumulative operating hours of the engine .

8) Overheat alarm lamp This lamp lights when the engine cooling water is overheated, whereupon the buzzer sounds.

Bring

the engine to an idling condition and refer to the Engine Manual.

2) Fuel level gauge In addition to one on the side face of thefuel tank, this electric-operated fuel gauge is provided .

G""~, ~'""

0

r

WHITE--UE /

3) Water temperature gauge It indicates the temperature of the engine cooling water. The green zone is the normal range .

G,,,.)J5,m., RED

This lamp lights when the air cleaner has clogged up, whereupon the buzzer sounds . In that case stop the engine immediately and clean the element.

FULL FUEL

EMPTY

9) Air cleaner lamp

8

For the procedures of cleaning and replacing the elements, refer to the Engine Manual.

10) CPU trouble lamp

The lamp lights when the controller is faulty. Turn "OFF" the decel select switch and at the same time. turn the release mode to "OFF".

(The above action makes operation possible. but contact a designated shop without delay.)

Use the level warning lamp (green) for checking before starting operation. Namely. three green lamps lights when the engine is still with the engine key "ON" and within 10 seconds after start of the engine.

11) Fuel level lamp This lamp lights when the fuel in the fuel tank has

WHITE

4) Battery charge a"iarm lamp "

fall en to a low level. About 14.5 gal (55 f)

12) Engine oil level lamp

This lamp lights if the starter switch is in "ON"

The green lamp does not light when the engine oil is

position before starting and after stopping the

short. (When the engine is still with the key "ON ".)

It also lights when any fault is present in

13) Engine cooling water level lamp The green lamp does not light when the cooling water is short. (When the engine is still with the key "ON".)

14) Hydraulic oil level lamp

engine.

the charge circuit .

5) Preheat alarm lamp If the starter switch is turned from the OFF to HEAT. the glow lamp lights about 25 seconds later. After the glow lamp lights. bring the starter switch to "START".

6) Engine oil pressure alarm lamp

It lights if the ignition switch is brought to ."ON" position. The lamp goes out within 15 seconds after start of the engine.

3-4

The green lamp does not light when the hydraulic oil short.

However. the above condition is when the machine is in an oil operating level checking position and also when the engine is still with the key "ON".

LL

15) Decel lamp

(21)

The lamp lights when the decel lamp is operating.

16) Travel 2-speed lamp

Power boost switch

Only. use POWER BOOST SWITCH on right hand control lever to increase break Qut force during

The rabbit mark lamp lights if the travel 2-speed

digging.

switch· is depressed.

17) Travel I-speed lamp

WARNING'

The tortoise lamp lights if the travel I-speed switch (tortoise mark) is depressed.

Never use power boost switch during lifting

Pull the lever (1) the front side upwards to make

operations. Unexpected implement speed changes

front/rear adjustment.

could result in injury to personnel.

18) Air pressure alarm lamp The lamp lights when the inner pressure of the hydraulic oil tank falls below 3.5 psi (0.25 kgflcn1).

19) Heavy lift lamp (spare lamp)

Do not use this switch for original Manufactur-

The lamp lights when the heavy lift function is working. (option)

er's l.3cuyd (l.Om3 ) & l.6cuyd (l.2m3 ) BUCKET and local BUCKET which have less strength than original manufacturer's l.2cuyd (0.9m3) BUCKET (STD).

(19) D.M.S.S release switch

~

!

.M,S.S

If the I.T.C.S should be out of order. For operation,

ADJUSTMENT OF OPERATOR'S SEAT The operator's seat is of reclining type. Adjust it so you can operate the machine in acomfortable position .

pull out plug and turn the toggle switch to "RELEASE".

(20) Heavy Lift Switch Only select the 'ON" positIOn of HEAVY LIFT SWITCH (located at rear end of control con sol) for precision heavy lifting operations. To resumu normal digging operations, move HEAVY LIFT SWITCH to 'OFF' position.

WARNING' Never turn HEAVY LIFT SWITCH to 'OFF' positio.n while lifting or supporting 10ad.Unex pected lowering or raising of load could result in injury to personnel.

LL

(I) Front / rear adjustment Pull th('

\e\"l'r

(I) th(' front side upwards to make

front ! rI'~r ~djllstmenl.

Adjusting stroke: 80 mm (3.1")

3-5

(~)

Height adjustment Vertical adjustment is possible if the ratchet (2) is turned.

Adjusting stroke : Height riser .

100 mm (3.9") (STD)

Suspension.

50 mm (2.0") (Option)

(3) Reclining adjustment

I.ifting the adjust len'r (:!) upwards permits front rear adjustment. The reclining adjustment is possi·

\· 1)

hk in fou rteen stl'llS. Ih'adrest adjustment Thl' hl'ad rl'st ( I) can hl' adjuslt-c1 hy pulling it up · wards ...\djustment can hl' mad" in two stl'ps. :Li mm (I .:r;- in) for thl' I st step and :1O mm (I I X in) for thl' 2nd skp.

(5) Rotary angle of arm rest The arm rest (5) can be jumped up. Adju~tment can be make to 20 0 forward downward by means of an ajust bolt.

(Locked Condition of the Front Window When Rested in the Upper Position) (2) Right window On the right side of the cab is a sliding window which

WARNING

can be opened and closed to the up and down.

A seat belt is available as an option. For safety

(3) Left door The window in the door at the left can be wound up

purposes it is recommended to use a seat belt for

and down

heavy work. working on slope (s. or at sites where

with the handle . When operating the

machine with the left door open. be sure to engage the

seat belts are necessary. Be sure to replace the

door lock.

seat belts every 3 years.

(4) Ceiling window The ceiling window is of full open type. Lift it up and turn it back.

OPERATOR'S CAB WINDOWS (1) Front window

WARNING

The front window can be moved in overhead.

The can be done from inside of the operator's cab as

Exercise care so as not to pinch your fingers in

follows.

the window when operating it. Lock the window

1) Place the machine on flat level ground.

positively after opening/closing.

2) Disconnect wiring of the wiper.

3) Remove the upper and lower locks of the front window.

4) Lift and move the front window upward until the window is seated in .the ceiling.

5) After lifting the window to the ceiling. be sure to lock it at the rear of the cab.

WARNING'

2.

SELECTION OF THE MODES

MODE CHANGEOVER SYSTEM The mode changeover switch (H. S. F.C) changes the op· eration modes according to working conditions and pur· poses. in order to achieve efficient operation.

(1) Three modes signify: H mode

The engine output can be used to 100%.

(Heavy duty mode)

The mode is used when speed and power are required.

1. Do not open or close windows on a slope.

2. When closing the front window. draw it down slowly and be careful not to place your

S mode

fingers between the window.

(Energy saving mode)

Fe mode

Is used to save fuel when work is light.

Is used to work on a slope or perform

(Fine operation mode) finish work slowly when work is light.

3-6

LL

. Type of work

(2) How to read the table and select the mode

I:

In each type of operation, select the most effective

For large volume uf work tu be dune in a short time

mode suitable for the type uf operatiun ' and the nature of soil to be handled.

II:

General mode selections are given in the below

III: For such operations which are not urgent but

For general uperation require fuel savings in particular.

table.

~ .

1'.1'/l{' ur

Nature of 50il

Digging Operation

"')r,. i

II

III

Loading Operation

Ground Reclamation and Correcting Levelling Work Work

Crushing Work

Transfer Work

I

I

I

j II j ill

I j ll j ill

II

III

II

III

I

II

III

50ft viscous soil

H

5

F.C H

5 F.C F.C F.C F.C H

5

F.C

Loose sandy soil

H

5 F.C H

5 F.C F.C F.e F.e H

5

F.e

Well tight sandy soil

H

5 F.C H

5

-

-

F.e

5

F.e F.e

-

Flatland : 5.

H

Gravels and raw ores

H

H

S

H

H

S

5

5

F.C

-

-

-

Well tight soil mixed with tiles and pebbles

H

H

S

H

H

S

H

H

S

-

-

-

50ft rocks

H

H

H

H

H

H

H

H

H

-

-

-

510pe & Longdistance travelling: H. F.e

INLET CONNECTOA

3.

PRE·OPERATION CHECKS

To prevent accidents frum uccurring and to increase the efficiency of the machine. the operator should carry out the recommended maintenance and lubric:!tiun checks before starting operation.

For procedures of carrying oUI these checks. refcr 10 the "Preventive Maintenance" section of this manuaL

INLET OIL PIPE

1) How to start the engine a) Check the machine before starting. The "OFF" is the positio'il where the key is inserted and pulled out.

4.

OFF

NEW MACHINE PRECAUTIONS

~.

For the first SO hours. do not engage the machine in heavy duty operation or run the en~ine at more than 1,500 r.p.lll.

Excessively hard work during this running-

in period can result in damage to the whole machine.

Check lamp lighting by turning the key to the "ON" position.

And a reduction in total life of unit.

5.

STARTING AND STOPPING THE ENGINE

For operation of the engine, refer to the Engine Manual.

b) When starting the engine after a long period of non·operation, execute engine cracking; i.e. T~rn the starter switch to "START" with the engine throttle lever at "STOP", and perform cracking for 15 seconds.

Since the turbo charger rotates at high speed, it is particularly necessary to notice how the engille oil is circulating (quantity and pressure).

c) At low engine temperature. bring the throttle lever to "LOW IDLING", turn the key to "HEAr. and when the preheat warning lamp lights again, turn it to "START".

LL

3-7

for about 5 - 10 minutes. Warm up each component equally circulating hydraulic oil to the swing and 1. If the preheat warning lamp (5) is kept

travel motors.

lighted, the intake heater will be burnt out.

2 . For starting in cold condition, refer to "HANDLING IN COLD CLIMATE" which will be described later.

1. Operate the levers slowly if the hydraulic oil temperature is low. Do not operate the levers suddenly.

d) As soon as starting is over, let your hand off the

2. The optimum operating temperature range of the hydraulic oil is between 122 -1 76 OF

key. Then the key will return to "ON" by itself.

(50

0

-

80 't:.) but before starting operation

be sure to raise the temperature to at least 68 OF (20 't:.)

7.

OPERATION

BACKHOE ATTACHMENT OPERATION

Avoid holding the key in the "START" position for more than 15 seconds.

In case the engine does not start, return the key after confirming that the engine has been stopped completely, Restart the engine a little while later and if it does not start by four trials, check for fault by referring to the troubleshooting section of the Engine Service Manual.

2) Stopping the Engine After operation and before stopping the engine, always idle it for about five minutes, bring the throttle lever to "STOP" to stop it completely.

Turn the starter switch to "OFF", pull out the key and keep it.

Extending and retracting of the cylinders-boom. arm and bucket - and swing direction are determined by the

WARM-UP OPERATION

6.

If the engine is heavily loaded while it is still cold, it may cause damage to the hydraulic pump and cause early wear to the engine which will be bad for the machine.

Before starting operation, be sure to warm up the engine as follows and start work only after the temperature of the engine has risen.

I) Idle the engine for 5 minutes without load.

2) Next, increase the engine speed to about half speed and warm up the hydraulic oil for about 5 minutes while the bucket control lever is in extended or retracted position.

3) Increase the engine speed to its maximum speed and operate the bucket or arm control lever in relief state

3-8

control levers. The amount they are shifted determines the speed of each actuator.

When the levers are released, all motion of the actuators will stop. Combination operations can also be done.

When the swing control lever is in neutral. the swing control valve will act to stop the swing .

However. this mechanism is designed to operate gradually in order to avoid shocks to the machine and operator. Therefore , when stopping the swing motion, remember to allow for this slight extra swing that occurs after the control lever is put in neutral.

LL

There are several different control lever layout patterns.

These layouts are shown on pages 3-12 and 3- 13.

When you receive your machine , check which layout you have by checking what lever operates what actuator.

Never alter the original control pattern without changing the control layout decal.

FACE SHOVEL OPERATION

Note that operation of the control lever of face shovel is opposite to that of backhoe attachment.

(See page 4-26) TRAVEL OPERATION

The travelling operation of this machine can be performed with foot-operated pedals. Forward and reverse speeds can be controlled by the extent to which the pedals are pressed.

[Pivot Turn) (I) Forward or reverse travelling on flat ground Depressing the front ends of the two foot-operated pedals at the same time causes the machine to travel forward .

For reverse travelling_ depress the rear

ends of the foot -operated pedals at the same time .

WARNING The above operation must be reversed when the lower machinery and the upper machinery are turned through 180 degrees (i.e. the travel motor in the front)_ (2) Pivot turn This is a method of changing the machine direction by driving the one-side crawler only. Operate one of the travel control pedals by turns.

[Spin Turn)

(4) Climbing up and down slopes I) The maximum gradeability of the machine is 35° (70%). Due to engine lubcication requirements.

2) Operate the pedals slowly when climbing down a slope. The brake works if the pedals are put to the neutral position.

SWING LOCK

When swinging is not necessary , such as in travelling and transportation, secure the upper and the lower carrier with the swing lock pin _ Two locking positions are provided-front and reat.

When the swing lock has been engaged , get out of the cab and make sure that it is properly engaged. Before beginning the swinging motion, be sure to disengage the swing lock.

(3) Spin turn This is a method of changing the machine direction

WARNING'

by driving the right and left crawlers in opposite directions.

Operate one of the two travel control

pedals in a forward direction and the other in a reverse direction at the same time.

LL

The swing lock must be securel positioned into the "lock-up" detent or it could fall into place in the locked position.

3-9

[Left Swing Left/Right Lever System (ISO Type)(Std.)J - _

ARM & SWING LEVER

TRAVEL PEDAL

BOOM & BUCKET LEVER

L-1689

[Right Swing Left/Right Lever System j - - -

BOOM & BUCKET LEVER

TRAVEL PEDAL

ARM & SWING LEVER

L-1556

[Left Swing Forward/Backward Lever S y s t e m j - - - - - - ,

ARM & SWING LEVER

TRAVEL PEDAl.

BOOM & BUCKET LEVER

L-1557

3-10

LL

[Right Swing Left/Right Lever System (M T y p e ) ] - - - - - - - - - - - - - - - - - - ,

BOOM

& BUCKET LEVER

TRAVEL PEDAL

ARM & SWING LEVER

L-1931

8.

OPERATING PRECAUTIONS

The precautionary notices listed in this section will all

I

come under :~~u:~!??] (in other words, if these notices are not observed, damage to the machine could occur)_ I) Reduce speed of each cylinder as it nears its stroke end_ 2) Always ensure that the crawlers are in good contact with the ground and that the machine is in safe and stable condition, especially when ground conditions are poor, such as in muddy areas.

3) Do not use the bucket to break hard objects like concrete or rocks _ This may result in broken teeth, pins, cracked booms or other damage .

L-1060

5) Do not use the bucket to stop swinging. Do not try to stop machine swing suddenly as this can result in damage to the machine. Therefore . when deciding the final swing position, allow for the extra swing that occurs after the swing control lever is released .

6) Do not sweep the ground with the bucket like a broom. Move the arm in and out when levelling out ground .

L-1059

4) Do not use the falling (gravitational) force of the attachment to dig. This shock can cause damage to many parts of the machine.

L-1062

LL

3-11

7) Do not dig while travelling. boom, arm and bucket.

This can damage the

and then speeds up again. This is characteristic of hydraulic excavators and is not a malfunction. This will be particularly evident in combination operation.

The same phenomenon will be seen with the bucket.

This is because the speed with which the cylinder extends, assisted by the weight of the arm and bucket (gravity), is faster than the speed of the oil entering the cylinder from rhe pump . At point A, the cylinder temporarily stops moving while pressure is being built up and then the arm will start moving again. For the same reason , sometimes the arm rattles if the lever is shifted with the arm at point A. The longer the arm

8) When operating with the attachment close to the side of the. machine, take the following precautions.

is, the more noticeable this phenomenon is.

a) For backhoe operation, moving in the armand bucket fully can cause the bucket teeth to hit the crawler tracks. b) Lowering the boom to its maximum digging depth may cause the boom to hit the crawler tracks.

L-1564

b) A continuous hissing sound may be heard when the boom is being lowered . This is the sound of the oil that flows through the valves . c) An unusual sound may be heard when an overload was occurred during work. This is the sound of the relief valves in operation to protect the hydraulic system. d) A sound will be heard near the swing motor when starting or stopping the swing motion . This is the 9) When changing from combination operation (for example , boom and bucket operation) to a single operation (bucket operation only), the cylinder movement speed will accelerate and this should always be taken into account when judging operation of the machine.

10) Repeatedly extending the arm and bucket cylinders

sound of the brake valve in relief action.

12) When climbing uphill, be sure to observe the following: a) Determine whether the drive sprocket is in the front or back of the crawlers and be sure the travel pedals are pushed in the correct direction. b) Extend the arm and bucket out as far as possible , but have the bucket ready for braking at any time.

to their stroke ends to shake out earth stuck in the bucket put a strain on the attachment which may eventually cause excessive wear and other problems.

II) The following are characteristics of this hydraulic excavator which occur during normal operation and are not signs of machine malfunction: a) When engine revolutions are below medium speed , arm cylinder extension (moving in the arm and

L-I561

bucket) slows down at point A as in the figure below

3-12

LL

c) When parking the machine on a slope. lower the bucket on to the ground as a brack and put chocks at the rear of the crawlers.

I. Avoid towing the machine by just placing a wire rope in the hook on the machine: This may damage the hook.

2. Be sure that a side force is not be exerted to the hook.

3 . When hooking up a wire rope. be sure to put some padding in between the frame.

L-l035

d) For going downhill, point the upper machinery down. hill, and drive down the slope slowly.

L·1562

13) Precautions on travelling If travelling (moving by self·travelling) is continued for many hours, the oil temperature in the reduction unit will rise abnormally, leading to a failure of the reduction unit.

Because this tends to occur in the

summer time, avoid self·travelling as much as possible when moving a long distance.

15) Cleaning crawlers The crawlers are designed to be operable even with some soil and gravel fouling them. but this constitutes an unduly ' heavy load to the travel system. and may result in damage.

The crawlers. therefore should be

cleaned occaSionally as follows :

Swing the upper

frame till the operator's seat comes above the crawler to be cleaned . push the bucket down against the ground by retracting the boom cylinders until the crawler comes off the ground .

Then operate that

crawler back and forth repea tedly until the foreign matters have worked its way off the crawler. Repeal this operation for the other crawler.

14) Travelling on soft ground a) Proceed as far as the machine can travel. b) When the machine can not travel any further, lower the bucket to the ground and use the arm to drag the machine body along, travelling at the same time. c) When towing the machine which has sunk into soft ground and is not able to pull itself out by its own power , or when towing heavy objects with the towing power of the excavator. use the method illustrated as following.

LL

3-13

4) In low temperatures. low viscosity fuel must be used.

Select a suitable fuel from the " Lubrication" chart When jacking up the machine by using boom and arm. push the bottom of bucket to the ground. At this time. the angle between boom and arm is to be 90°-

in this manual.

5) Use hydraulic oil suitable to the climate in accordance with the "Lubrication" chart.

110°. lacking up the machine when arm cylinder and bucket cylinders are fully extended, can cause damage of boom, arm and cylinders.

BOOM

When hydraulic oil is cold, move all the control levers slowly.

6) When there is a sudden drop in temperature in winter or in cold areas. the cooling water can freeze and result in damage to the radiator , cylinder block or cylinder head.

In order to prevent this, use a permanent type antifreeze for year-round. protection.

To fill anti-freeze, proceed as follows.

WARNING' Use extreme caution when removing the radiator cap, as hot water may gush out when the engine is hot.

9.

OPERATION UNDER UNUSUAL CONDITIONS

OPERATION IN COLD WEATHER

I) In cold areas. the starting of the engine is especially difficult because of an increase in the engine oil viscosity and reduced battery performance.

Try to start the engine in one try if possible, following the instructions given in the Engine Manual.

2) Starting operation of low engine temperature may cause the engine to wear quickly and damage the

a) Open the drain plugs of the radiator and the engine block to completely drain the cooling water in the system. b) Then, tighten each drain plug sufficiently and fill in a fifth of the volume of the cooling water. c) Add the required quantity of anti·freeze specified in the mixing table and fill it to the level directly below the overflow pipe of the radiator. Thereafter, open the lid of the sub-tank and fill it in to the "FULL" line.

hydraulic pumps, resulting in poor machine performance.

NOTE

Always go through warm-up operation before

starting actual work.

Extend the warm-up time as

necessary till the oil temperautre rises.

NOTE

I. The anti-freeze mixture to be refilled should be of the same concentration as that originally filled.

2. Decide the concentration of the anti-freeze so that its

Covering the entire radiator is also a method to aid

freezing point is 41 °F ( 5"C) lower than the lowest

If necessary. especially in cold areas ,

anticipated temperature of the area in which your

warm-up.

cover part of the radiator to maintain sufficient wannth during operation.

machine is working.

3. Take in to consideration the wind chill factor when deciding protection temperature. Also, keep in mind

3) In accordance with the Engine Manual , use engine oil with a suitahlc viscosity.

3-14

that trans portation of unit by truck in winter can subject it to much lower wind chill tempera-tures !

LL

4. Take in to consideration the wind chill factor when

OPERATION IN EXTREME HEAT

deciding protection temperature. Also. keep in mind that transportation of unit by truck in winter can subject it to much lower wind chill tempera·tures 1

I) Refer to the Engine Manual and use engine oil of suitable viscosity according to the temperature.

2) Always maintain the correct level of coolant and check the cooling system for leaks. Use of a permanent type antifreeze and coolant is recommended for year·round

If coolant in the radiator become discolored due to

rust and other matter. clean the cooling system thoroughly and pressure test cooling system and radiator to check for possible problems causing rust to form .

protection.

3) Clean the radiator cooling l1ns. particularly the air passages . of insects. leaves. dirt or wooden chips that will restrict air flow or cause damage to the fins. It is important you don 't allow debris to accumulate be· tween radiator and oil cooler.

7) When using the heater in cold weather, always open the heater cock.

4) Keep the water pump fan belt properly tensioned.

5) If the engine becomes overheated, stop the engine after

8) Keep the battery fully charged at all times. A dis· charged battery will freeze before a fully charged battery.

idling and check the cooling system.

If the engine still overheats after adding coolant. stop

the engine and allow it to cool off. Drain the cooling system by opening the drain plugs on the radiator and engine block and flush out the system. Refill the cooling

I. Keep the battery terminal connections clean and free from snow and ice.

Otherwise the

system with fresh coolant.

Do not usc a salt or

mineral water solution in the cooling system.

If the cable con·

6) Make frequent checks of the battery electrolyte level

nector and battery terminals are corroded, use

and add distilled water as necessary to keep the

terminals may short circuit.

proper level.

a soda solution to remove the corrosion.

2. When leaving the machine out-of-doors over-

7) Notice in particular the water temperature gauge and

night or for an extended period of time in cold

the engine oil pressure lamp during operation. Avoid

weather. it is advisable to remove the batteries

unnecessarily low speed running of the engine for

and store them in a warm area.

operation.' During a lull in operation, keep the engine running at low idle.

9) After completion of work, clean the crawlers and drive the machine onto wooden planks to prevent crawlers from being frozen to the ground.

Extend

the boom, arm and bucket as much as possible so as to reduce the exposed areas of the cylinder rods.

Also, wipe off any water on the exposed part of the

OPERATION AT HIGH ALTITUDES

I) The output power of the engine will decrease due to low atmospheric pressure at high altitudes.

This should be taken into account when applyillg a working load to the machine .

cylinder rods.

10) Cold region specifications are also available for those areas where the ambient temperature at the time of

2) Since the atmospheric pressure is low, the engine should be checked frequently for overheating.

starting the engine is at 5 OF (-15 "C) or less. As compared to the standard specification machines, larger capacity starter and batteries are used.

1~1 Avoid starting the engine at 5 OF (- 15 "C} or less

OPERATION IN DUSTY, SANDY AREAS

1) Check the element of air cleaner when the air cleaner lamp lights and buzzer souds. clean or replace the element and/or dust cap. regardless of the inspection period.

with standard specification machines, since this might cause starter burnout.

LL

3-15

NOTE As an optIOn. a double element type air dean e l is available.

2) Make a frequent LheLk of the radiator and keep th~ Looling tins dean.

3) Keep the filler Lap of the fuel tank tight to prevent sand or dust from enterIng the fuel tank. ServiLe fuel filters frequently to keep them free from sand and dust.

4) Keep the breather cap of hydraulic oil tank tight to prevent sand and dust from entering the hydraulic system . Also. service hydraulic oil filters frequently.

5) Always keep the pins and bushings clean and clean all grease fittings before lubrication.

OPERATION IN HIGH HUMIDITY OR SOFT GROUND I) Moisture and muddy water will cause deterioration and corrosion of pain t. wiring and metallic parts.

Keep parts dry and well lubricated when working in such areas.

2) If any part of the machine is rusted or corroded, dry the· part thoroughly and paint the exposed surfaces.

Apply a film of lubricant or grease on all machined surfaces which can not be painted .

3) After work. wash the machine and inspect all parts and perform lubrication as soon as possible .

If the swing bearing has been immersed in water or

mud for any length of time, grease the bearing until the old grease oozes out, and the fresh grease becomes visible!

OPERATION AT SEASHORES I) Check whether all plugs, cocks and bolts on the machine are tightened properly so as to prevent entry of salt water.

2) After work, clean the machine thoroughly washing off salt water and take adequate measures to prevent corrosion to the electrical components and the hydraulic cylinders.

3-16

LL

SECTION IV PREVENTIVE MAINTENANCE 1.

INTRODUCTION

PREVENTIVE MAINTENANCE SCHEDULE

Safety in operation and the performance and life of the

3) Drain oil from the gear case when it is still warm after operation.

machine are determined by the inspection. care and

4) Disassembly and assembly of the machine or replace-

lubrication given to the machine everyday.

For the purpose of performing more positive periodical

ment of parts should always be performed under the supervision of a well-experienced serviceman.

inspections and maintenance. has provided necessary

5) The engine key should be kept in the supervisors custody when the machine is not operating_

procedures and instructions in this manual. The time intervals of inspection. maintenance and lubrication de-

6) Engage the swing lock pin.

scribed in this manual are based on an avaerage 8

7) Open the engine cover only after the engine has

hours/day. 50 hours/week. and 120 hours/month of work.

stopped and be sure to support the cover with the stays.

Therefore. working hours exceeding these hours or the type of work being done. size of loads. and ground and

8) Always check the hydraulic piping. When replacing Make sure re-

weather conditions are all factors which must be consi-

hydraulic hoses. use genuine parts.

dered when establishing a maintenance schedule for your

placed hoses are not twisted after installation.

machine.

For inspection and maintenance of the engine, refer to

9) When jacking up for maintenance, make sure that the supports are firmly secured and stable.

Never

work under the machine that is jacked up by the

the Engine Manual.

attachment only.

GENERAL PRECAUTIONS FOR MAINTENANCE

I) Use genuine parts for replacement.

10) Points not considered to be normal wear points (levers, linkages, pins, etc.) should be lubricated with

Also use desig-

gear oil once a week_

nated lubricants for lubrication.

2) Before lubrication, be sure to clean off dirt from oil inlets, grease fittings and relief fittings.

2. PERIODICAL MAINTENANCE CHECK The check sheet shows the periodical inspection, main-

The codes used on this sheet are defined as follows:

tenance, lubrication and the time intervals for each

o Inspection, maintenance of the function and

component. To carry out each of these checks, refer to "Preventive Maintenance" items.

check for damage of that item • Parts replacement of fIlters and elements /':, Check and supply of lubricants •

Oil and hydraulic oil change

* First replacement only NOTE The numbers in parentheses of each item show the check location No. Refer to the figure of page 4-5.

LL

4-1

~ Item

8

hr

Check w~ter level of radiator and (E-I) supply.

0

Check engine oil and supply.

(1--2)

0

Ch~nge engin"

oil filter.

(1-3 )

*.

'"

Check wa ter separator.

(1 ·-4 )

0

~

Check ~nd elea n radiator and oil cooler.

(E-S)

" .g .,u

Change radiator water.

(E-l)

.5

Check and clean (or ch~nge) air cleaner clemen t.

(E-6)

Change fuel filter.

(1'-7)

Check engine .

(F-8)

Change engine oil.

(E-9)

Check electrical wiring and instruments.

(U-l)

u

t: t:

~

'-' Z U.l

" E ;:; ::0

a-

.,!.. ~

",-

...le

.,u t:

~

" .5 '" ::0

250 hr

500 hr

1,000 2.000 hr hr

Remarks

• 0 0

• 0

•

0

• 0

0

0

*.

J:

0

.D .-

120 hr

(Before (Week- (Monthop cr~ Iy) Iy) tion)

C)

U.l

50 hr

0

0

Refer to Engine Manual.

0

•

0

Check car heater and heater hose. (U-2)

0

Check fuel level and drain water of fu el tank.

(U-3)

0

Check poss ible damage of swing lock.

(U-4)

Check control pedal.

(U-S)

Clean fuel supply port strainer.

(U-II)

0

Check battery electrolyte level.

(U-6)

0

Check. possible damage of upper frame deck.

(U-7)

Check possible damage of ca b.

(U-8)

0 0

~

~

U.l

8:

;:J

" "a-

.2 '0

.5

0 0

Check damage and wear of swivel (U-9) boots. . .!.. c ~ 0 .D.-

0

Check. supply and chang e oil of (U-lO) swing reduction unit.

6

Check and lubric~te control pedal (U-S) joints.

6

*•

•

",-

...le

~

I-IJ ~

~" u

Adjust track tension.

~E

Check wear and damage of

.-"0'"""

(L-l)

(L-2) "".-. sprockct. idler and roller. :3 .5::0 Check wear and damage of track

0 0

~

links and shoes.

4-2

(L-3)

0

LL

~ Item

Check po ssible damage of Illwcr frame ..

~" <> t: :::

.52 ~

-gt;" Cl., ,_

~ '" .5::;;

cr::

"'-l

~

9

8

hr

50 hr

(Before (Weck- (Mon thopera· Iy) Iy) tion)

250 hr

Drain water of swing grease bath. (L-5)

0

Check damage and wear of swing (L-6.8) gear and pinion .

0

Change oil of travel reduction unit.

(L-7)

Lubricate swing bearing.

(L-S)

-l'"

*.

l::,

::E

"'-l

f-<

en

>Vl U

"uc ::: '"

;:" .;;; ::;; ~

(L-5,6)

Check and supply hydraulic oil tank level.

(H-I)

Check function and unusual sounds of hydraulic components.

0

Change drain filter.

(H-3)

::s::l

.9

Check damage and oil leak s of hydraulic components.

0

.5

"Q.

Drain water of hydraulic oil tank . (H-4)

« cr::

>::z:

c

u

0 0

(H-Z)

*. *.

•

• 0

0

0

Clean hydraulic oil tank.

(H-4)

0

Clean or change suction strainer.

(H-5)

0

Change or clean pilot line filter.

(H-6)

0

Change hydraulic oil.

(H-4)

•

.,!. C M

0

.0 .o~

-lrl ..J ..J

-<

f-<

Z

"'-l

::E

::z: U

« « f-< f-<

~" u c c 0'" .c ~c Q. .-

-"

0

0

Retighten all capscrews.

~ '" .5::;;

~" u c c .-0'" c

~~ Q. . -

.5::;;'" ~

..!. c: MO .0 .",-

-lrl

LL

•• • •

Check damage and oil leaks of hydraulic hoses, pipes and couplings.

Change return filter.

Remarks

l::,

Change oil of idlers, upper rollers (L-Z) and lower rollers.

Change grease of swing grea se bath .

1,000 2,000 hr hr

0

c

.g u '" :§

500 hr

0

(L-4)

Check oil leak from idlers. upper (L-2) rollers and lower roller s.

120 hr

Check wear of pins and bushings. (A-I)

0

Check possible damage to boom , arm and links.

(A-Z)

0

Check damage or wear of bucket, (A-3) tedh and side cutters.

0

Lubricate attachment pins.

(A-I)

l::,

4-3

3. LUBRICATION CHART Lubricant

Recommended Lubricant (Initial Factory Fill)

Quantity (NO. of) POints

Location

Lubricating Interval (hr)

First Replacement Cleaning Replacement Interval Interval Interval (hr) (hr) (hr) (Cleaning)

Hl'draulic oil with anti·wear. anti o~idant an anti · harmful foaming 59' F B6' F 131' F 1104' F - -13' F --22' F - 23' F -41 ' F HydruuliL' (551: (151: (401: t301: -- 5t:) --251::) - -301::) - 51:) Oil ISO YG46

ISO YG68

ISO YG32

(190 I)

Swin/! reduction unit (tHO)

4.25 gal (161 1 )

Travel reduction unit (L-7)

1.9 gal X (2) ( 7.5 I X (2)J

Control lever Joint (U-5)

A few drops

8/120

Attachment pins (A-I)

(15 )

8 or as necessary as

Swing bearing (L-8)

(4)

250 or as necessary if unit becomes submereged in water or mud

'Crawler adjuster (L-I)

(2)

50

Swing gear (L-6)

21 lbs (9.5 kg)

500 or as necessary if unit becomes submereged in water or mud

50 gal

Grade G L-4 by API c1assifiea tion

120

2.000

2.000

MUltipurpose grease NLGI No.2 lithium base grease EP type

NLGI No.1 lithium base with MoS2 grease

500

2.000

conditions dictate

Extreme pressure.

Grease

8

ISO YG22

Extreme pressure gear oil #90 Gear Oil

Hydraulic oil tank (H-4)

2,000

API classification for service CD

Engine Oil YJ (/)j')

!~

:/. ;")

104'F Above (401::)

SAE40

104' F-41 ' F (401::-51::)

SAl:: 30

50'F--22'F (101::- - 301::)

SAE IOW-30

23'F

23'F-5'F

Above (-5t:) (-51::--151::)

Fuel

Cooling Water

5'F--13'F (-1St: --251::)

Jl5 #2

JlS #3

Jl5 #3 special

Light oil

Light oil

Light oil

Soft water (Mixed with anti-freeze in winter)

Engine oil pan (1--9)

Fuel tank (U-3)

Radiator (E-I)

Total: 5.3 gal (20 I) Oil pan: 4.2 gal (16 I )

8

82 gal (310 t)

8

Water vol.: 8 gal (30 t )

8

50

250

500

500

NOTE I . Overall tank capacity including hydraulic oil in circuit is 84.5 gal (320 i l.

2. Regarding the engine, refer to the Engine Manual.

4-4

LL

4. ·FILTER ELEMENT CHART Inspection and Replacement Points

Parts

Q'ty

(H-2)

Element

I

Suction strainer (H-S)

Strainer

I

Drain filter

(H-3)

Cartridge

I

Pilot line filter

(H-6)

Element

I

Air cleaner

(H-5)

Element

I

Engine oil filter (H-3)

Element

I

(E-6)

Element

I

Gauze filter

I

Return filter

Unit : hour Checking Interval

Cleaning Interval

First placement

Replacement Interval

50

250

50

500

2,000

2,000 Every 1.000 hrs or pinhole on element

Every 250 hrs or when the air cleaner lamp lights and the buzzer sounds

8

or as necessary as conditions dictate

50

500 500

Fuel filter Fuel feed pump gauze filter

or as ne.c~ssary as conditions . dictate

500 or as necessary as conditions dictate

NOTE For details regarding the engine, refer to the Engine Manual.

-S.9 -3

u-S

A -2

LL

A-I

L -2

L -I

L -3

L-6.8

L -4

U - 7 L -2 L-7

4-5

5.

8 HOUR (DAilY) MAINTENANCE

MAINTENANCE BEFORE WORK

Contents

Item (Location Code)

No. I

Radiator

(E-!)

Check water level and check for leakage. refill.

2

Engine oil level

(E-2)

Check oil level and refill.

3

Engine

(E-8)

4

Fuel tank

S

Check for water leak. damage and unusual

Remarks Water level should be more than 0.4" - 0.8" ( 1- 2cm) above radiator cor e.

Before starting engine, refer to page 4-10.

noise.

Refer to Engine Manual.

(U-3)

Check fuel level and drain water.

Refill after work.

Hydraulic oil tank

(HA)

Check hydraulic oil level.

Refill if oil is low and check for leaks.

6

Control lever

(U-S)

Check functions.

Check if levers are working normally.

7

Instrument panel

(U-l)

Check for proper operation.

Refer to page 3-1 .

8

Electrical wiring

(U-I)

Check for loosening and tears.

Loose terminals, tear of covers, etc.

9

Hydraulic components

Functional check and unusual noises.

Refer to page 4-14.

10

Hydraulic hoses and piping

Check for loosening and leakage.

Torn hoses, disfigured pipes, loose bands.

II

Heater and heater hoses

(U-2)

Check for water leaks.

12

Swing lock

(UA)

Check for function and damage.

13

Idlers, ufJper rollers and lower ro lers

(L-2)

Check for oil leaks.

Refer to page 4-12.

MAINTENANCE AFTER WORK

No.

Item (Location Code)

I

All parts of machine body

2

Fuel tank

3

4-6

Cooling water

Contents Clean, check water and/or oil leakage, loosening and damage.

(U-3) (E-!)

Remarks Clean clogyed dirt and dirty water.

Repair fau ty parts.

Add fuel.

Measure consumption.

Drain.

If antifreeze has not been provided in cooling system and freezing wheather approaches.

LL

6.

50 HOUR (WEEKLY) MAINTENANCE

In addition to "8 hour maintenance," perform the following.

Contents

Item (Location Code)

No .

Remarks

I

Engine oil filter

(E·3 )

First replacement

2

Fuel water separator

(E-4)

Check.

3

Engine

(E·8)

Check .

Refer to Engine Manual.

4

Engine oil

(E·9)

First replacement

Loosen the drain plug and change engine oil.

5

Crawlers.

(L·I)

Adjust tension.

Refer to page 4·23 .

6

Return filter

(H·2)

First replacement

Refer to page 4·17, 18.

7

Drain filter

(H·3)

First replacement

Refer to page 4·17, 18.

8

All capscrews and nuts

Check and retighten.

Refer to page 4·24 .

9

Attachment pins

Grease thoroughly .

Refer to page 4·15.

7.

(A·I)

"

Refer to Engine Manual.

Refer to page 4·19 .

120 HOUR (MONTHLY) MAINTENANCE

In addition to "8 hour and 50 hour maintenance," perform the following.

Item (Location Code)

No.

Contents

Remarks Refer to Engine Manual.

1

Engine

(E·8)

Check and adjust.

2

Fuel tank filter strainer

(U·11)

Clean.

3

Battery

(U·6)

Check electrolyte level and specific gravity. Clean .

4

Upper frame

(U·7)

Check for damage .

5

Control lever joint

(U·S)

Check and lubricate.

Refer to page 4·12.

6

Swing reduction unit

(U·10)

Check oil level and supply.

Refer to page 4·22 .

7

Travel reduction unit

(L·7)

Check oil level and supply.

Refer to page 4·22.

8

Hydraulic components

Check for oil leakage and damage.

Refer to page 4·14.

9

Lower frame

(LA)

Check for damage .

10

Cab

(U·8)

Check for damage.

11

Attachment pins and bushings (A·I)

Check for wear and seizuere.

Refer to page 4·15.

12

Boom , arm and links

Check for damage.

Refer to page 4·15 .

13

Bucket. teeth and side cutters (A·3)

Check for wear and damage.

Refer to page 4·15.

14

Track links and shoes

Check for wear and damage.

LL

(A·2)

(L·3)

Refer to page 4·12 and 6·3.

.-

4-7

8.

250 HOUR MAINTENANCE

In addition to "S hour, 50 hour and 120 hour maintenance," perform the following.

Contents

Item (Location Code)

No.

Remarks

I

Air cleaner

(E-6)

Clean element.

Refer to page 4-16.

2

Retu rn filter

(H-2)

Replace element.

Refer to page 4-17.

3

Engine oil pan

(E-2)

Change engine oil.

Refer to Engine Manual.

4

Engine

(E-S)

Check.

Refer to Engine Manual.

5

Swing bearing

(L-S)

Lubricate.

Refer to page 4-13 .

6

Capscrews and nuts

Check and retighten.

Refer to page 4-24.

9.

500 HOUR MAINTENANCE

In addition to "S - 250 hour. maintenances," perform the following.

Contents

Item (Location Code)

No.

Remarks

I

Radiator and oil cooler

(E-5)

Check and clean.

Refer to page 4-11 .

2

Radiator

(E-I)

Change cooling water .

Refer to page 4-11.

3

Engine oil filter

(E-3)

Replace element.

Replace the element if the engine oil filter lamp lights within 500 hours.

4

Fuel filter

(E-4)

Replace element.

Refer to Engine Manual.

5

Engine

(E-8)

Check.

Refer to Engine Manual.

6

Swivel boots

(V-9)

Check for wear and damage .

Refer to page 4-12.

7

Swing grease bath

(L-5)

Drain water.

Refer to page 4-13.

S

Swing gear and swing pinion

(L-6)

Check for wear and damage.

Refer to page 4-13 .

9

Swing reduction unit

(V-IO)

Change oil (First).

Refer to page 4-22.

10

Travel reduction unit

(L-7)

Change oil (first).

Refer to page 4-22.

11

Drain filter

(H-3)

Replace cartridge.

Refer to page 4-18.

12

Hydraulic oil tank

(H-4)

Drain water.

Refer to page 4:17.

4-8

LL

10.

1,000 HOUR MAINTENANCE

In addition to "8 - 500 hour maintenances," perform the following.

Contents

Item (Location Code)

No.

Remarks

I

Air cleaner

(E·6)

Replace element.

Clean inside. Refer to page 4-16.

2

Engine

(E-8)

Check.

Refer to Engine Manual.

3

Water separator

(E-4)

Clean.

11.

2,000 HOUR MAINTENANCE

In addition to "8 - 1,000 hour maintenances," perform the following.

No.

Item (Location Code)

Contents

Remarks

1

Swing reduction unit

(U-IO)

Change oil.

Refer to page 4-22.

2

Travel reduction unit

(L-7)

Change oil.

Refer to page 4-22.

3

Idlers, ufJper rollers and lower ro lers

(L-2)

Change oil .

Refer to page 4-4 .

4

Swing grease bath

(L-5)

Change grease.

Refer to page 4-13.

5

Hydraulic oil tank

(H-4)

Clean and change hydraulic oil.

Refer to page 4-17.

6

Suction strainer

(H-5)

Clean or replace .

Refer to page 4-17.

7

Pilot line filter

(H-4)

Clean or replace .

Refer to page 4-1 8.

LL

4-9

12.

MAINTENANCE PROCEDURE

ENGINE Never uperate the engine with the oil level below the low mark nr above the upper mark on the

WARNING'

dipstick.

Stop the engine before carrying out any inspecti()n and maintenance checks.

(I) Check water level in radiator. (E-I) Check the level of the cooling water and add water if necessary. The water level should be more than 0.39" -0.78" ( 1- 2 em) above the radiator core. Use the

type and amount of anti -freeze as recommended by the engine manufacturer.

WARNING' Use

[Engine Oil Dipstick]

extreme care when removing the radiator

cap when the engine is hot as boiling water may gush out. If possible. wait until the engine has cooled down.

IProper Oil Level of Engine Oil Dipstick) (3) Change engine (iii filter. (E-3) Change the engine oil filter at the first 50 hours of operation. After this. change every 500 hours (before. if the engine oil filter lamp in cluster gauge lights and the buzzer sounds.) Refer to the Engine Manual.

[Radiator]

(2) Check and fill engine oil. (E-2) Check the engine oil level before starting operation.

For accurate readings. check the oil level approximately 15 minutes after stopping the engine.

Remove the oil dipstick. wipe it with a clean cloth. reinsert and withdraw it again. Check that the oil level is between the upper and lower marks and if the oil Jevel is low. fill and maintain the oil level between the upper and lower marks. The appearance of the oil should also be noted t() see if it is dirty or too thin

4-10

YN-Ol13

[Engine Oil Filter) (4) Check fuel water separator and drain water. (E·4) Check the float and the marked level. Before float reaches the level. loosen the drain plug and drain out water.

LL

(5) Clean front grill of the oil cooler. (E5)

OI) Change engine oil. (1'-9) Change the engine oil at the first 50 hours of operation. Refer to the Engine Manual. After this_ change the oil every 250 hours .

OIL COOLER

UPPER MACHINERY FRONT GRILL

(I) Check electrical wiring and instruments . (U-I) Before starting the engine, turn the ignition switch and monitor check switch "ON" and check all monitor lamps. Next starting the engine, also check horn, lamps and gauges in the instrument panel.

(6) Check and clean radiator and oil cooler. (E-5) Check the outside of the radiaior and oil cooler_ clean if necessary and then dry . When the machine is operated in a very dirty or dusty site_ it is neces-

gauges in the instrument panel.

(2) Check car heater and heater hoses_ (U-2) Check the car heater , connections and heater hoses for water leaks_

sary to clean th e radiator more frequentl y. It is important you don't allow debris to accumulate between the radiator and oil cooler.

(7) Change water in radiator. (E-I)

Change th e water in the radiator. Add anti-freeze as necessary _ (8) Clean or change air cleaner element. (E-6)

Clean the element every ~50 hours or when the air cleaner lamp lights and the buzzer sounds.

For

details , refer to "Air Cleaner Check and Cleaning , Replacement of Element. " [Car Heater 1

(3) Fill fuel tank. (U-3) Place the machine horizontally and check the fuel level by means of fuel level gauge in the instrument panel.

If fuel level is low , remove the tank filler

cap and fill the tank with fuel through the strainer.

Fill up the tank after operation. Before operation, open the drain cock and drain water from the tank hottom .

I Air Ckaner Elem ent I (9) Change fuel filter. ([--7) Change the fuel filter element. with reference to the Engine Manual. (]O) Che<.:k engine. ( c-li)

Check the engine for water leaks. damage and abnormal noises with

referen<.:e to the Engine

Manual. Make sure of other adjustment and inspection items.

LL

4-11

FULL FUEL

:~~::?a}3L EMPTY

/

[Fuel Level Gauge I

[Batteries)

(9)

Check upper frame deck for damage_ (U-7)

( 10) (,hec k cab for damage. (U-8)

( I I ) Check swivel hoots_ (U-9) (4) Clean fuel tank filter strainer. (U-ll)

(,h~ck for wear a'nd damage to the swivel boots

(5) Check function of control lever. (U-S)

:IfIll/nd the swivelioint.

(6) Check control lever joints_ (U-5)

(I:!) Check oil level of swing redudion unit. (U-JO)

Check levers, rods and ball joints for damage _ (7) Lubricate the control lever joints with a few drops of gear oiL (U-S)

Check the oil level of the swing reduction unit using the oil level gauge and add oil if the level is low.

Refer to "Oil Change of Swing Reduction

Unit" for details.

LOWER MACHINERY

(I) Adjustment of track tension (l.-I) If the crawlers are too tight, it will put excessive strain on various parts of the machine and can result in damage to the machine.

On the other

hand. if the crawlers are too loose , they may ride off the rollers or sprocket during travel. To prevent [Travel Control Lever Joints)

L-1720

(8) Check battery electrolyte level. (U-6)

this, check the crawler and ments.

m~ke

proper adjust-

Refer to section "Adjustment of Track

Tension" fin the adjustment procedure.

Check the battery water level and add distilled wa ter as necessary to maintain the water level at 10 mm (O_39") above the plates_ Clean any corrosion or dirt

from battery teminals_

WARNING Gas generated from the battery electrolyte is flammable, so never smoke or expose open flames to it when servicing the batteries_ Also, be sure to keep this acidic electrolyte off clothing, skin and out of eyes.

4-12

LL

(9) Lubrication of swing bearing (L-B) Check and lubricate the swing bearing every 250 Reduce the track tension slightly at sites where stones could be easily caught in the crawlers.

(2)' Check sprockets, idlers, upper rollers and lower

hours. When it has been immersed in water or mud, lubricate imm ediately. Until the old grease oozes out, and the fresh grease becomes visible.

rollers for leaks, wear and damage. (L- 2)

(3) Check track links and shoes for wear and damage.

(L-3) (4) Check lower frame for damage. (LA) (5) Check idlers, upper roilers Jnd lower rollers for oil leaks_ (L-2) (6) Drain water from swing grease bath. (L-S ) Remove the cover for draining water from upper frame and drain water from the swing gr ease bath.

(7) Check swing gear and pinion_ (L-6,8) Remove the swing gear covers and check the condition of the lubricant.

L-1727

[Lubrication of Swing Bearing]

Also check for damage or

wear to the gear and pinion through these covers. (l 0) Change oil in idlers, upper rollers and lower rollers.

(L-2) Consult with your nearest service station for oil . change.

I II) Change grease in the swing grease bath. (L-5 , 6) Remove and change grease in the swing grease bath using the drain coVer underneath the upper frame and the swing gear inspection port at the top of the upper frame.

(Swing Grease Bath)

(8) Check oil level of travel reduct ion units. (L-7) A small amount of water may sometimes accumulate at the hottom of the travel reduction unit case.

Drain this water to prevent emulsification due to the water mixing with oil. Rotate the travel motor so that the drain plug is at the lowest pOSition as shown in the picture and then remove the filler plug

HYDRAULIC SYSTEM

(I) Check hydraulic oil level. (H-I) To check the hydraulic oil leveL place the machine horizontally, fully retracting the ,!rm and bucket cylinders.

With the bucket put onto the ground,

the hydraulic oil level should be slightly below the (enter of the level gauge.

and check the oil level. Oil up to the level of the filler·plug is the correct level. Refer to "Oil Change of Travel Reduction Unit" for details.

LEVEL GAUGE

(HydrJulic Oil Level) [Travel Reduction Unit]

LL

4-13

(2) Check hydraulic hoses and piping.

Check hydraulic hoses and piping for damage and leaks.

For leaks that can not be stopped by tightening the fittings, install new parts.

(3) Check the hydraulic pumps, control valve, swivel joint, swing motor, travel motors and hydraulic cylinders to see that they function properly and [Swing Motor I

that there are no abnormal noises.

[Travel Motor I

YN-Ol19

[Hydraulic Pump I

L-1708

(4) Check hydraulic pump, control valve, swivel joint, swing motor, travel motors and hydraulic cylinders for oil leaks and damage .

(5) Change return filter element. (H-2) For replacement procedures, refer to "Replacement of Return

Filter" in section "Maintenance of

Hydraulic Oil Tank and Filter."

NOTE It is especially important to always keep the hydraulic oil clean . Be extremely careful in the maintenance of the return filter. It is also neces[Control Valve I

sary to change the return filter at every 250 hours in normal weather and normal operating conditions.

However , if the atmosphere at the

work site is excessively dirty, it is recommended that filter change interval be lowered to around 120 hours.

(6) Change drain filter. (H-3) At the first 50 hours, change the drain filter at the side of the hydraulic oil tank with the special tool in the tool box. Refer to "Replacement of Drain Filter" in section "Maintenance of Hydraulic Oil [Swivel loint J

4-14

Tank and Filter" for details regarding the replacement procedure.

LL

(7) Drain hydraulic oil tank. (H-4) Loosen the drain plug at the bottom of the hydraulic oil tank and drain water and deposits.

[Lubrication of Bucket Pins) [Draining Hydraulic Oil Tank) (8) Clean hydraulic oil tank and change oil. (H-4) Drain out all the oil in the hydraulic oil tank and remove the cover at the top of the tank. and then clean the inside of the tank.

Flush the hydraulic

system if metallic particles are found , since they can cause malfunction of the machine. Fill with fre sh hydraulic oil. Refer to section "Maintenance of Hyd · raulic Oil Tank and Filter."

YN-0123

WARNING'

[Lubrication of Boom Cylinder Pins)

Before removing the nange at the top of the hydraulic oil tank , loosen the breather cap slowly and release any remaining air pressure in the tank.

(9) Change or clean suction strainer. (H-5) Change or clean the suct ion st rainer by referring to "Replacement of Suction Strainer" in "Maintenance of Hydraulic Oil Tank and Filter ."

(10) Change or clean pilot line filter. (H-6)

CAPSCREWS AND NUTS After the first 50 hours of operation, retighten capscrews

[Boom Remote Lubrication Points)

and nuts in accordance with the table "Tightening Torque of Capscrews and Nuts."

Also check every

250 hours and retorque .

ATT ACHMENTS (I) Check attachment pins and bushing for wear and seizure . (A-I) (2) Check boom, arm and links for damage . (A':!)

(3) Check bucket. teeth and side cutters for wear and damage. (A-3) (4) Lubricate attachment pins. (A-I)

LL

4-15

13.

AIR CLEANER CHECK AND CLEANING, REPLACEMENT OF ELEMENT

When the air cleaner element is clogged, air intake and engine output will decrease, and fuel consumption will increase.

AIR CLEANER LAMP

If the air cleaner element is clogged, the air cleaner lamp lights and at the same time the buzzer sounds. This indicates the interval for cleaning or replacement of the element.

3) To clean the element, spray with clean compressed air below 97.5 psi (7 kg/en!) uniformly along the crease inside the element and clean off the dust.

4) When the element is excessively soiled with dirt, carbon or grease, wash the element clean using element detergent (ND-ISOO type supplied by Japan Donaldson).

It will be more effective if warm water of about 104°F (40"C) is used.

5) For drying, place the element in the shade or when in a hurry, use an electric fan . Never dry with heat.

NOTE Since drying takes some time, a spare element should be prepared.

6) Clean the inside of the air cleaner body and the dust cup thoroughly. Be careful not to allow foreign particles to enter during disassembly.

7) To install, secure the element firmly with the wing screw and the arrow mark of the dust cup positioned to the top .

[Air Cleaner Lamp]

CLEANING AND REPLACEMENT OF AIR CLEANER ELEMENT

CLAMP

o RING

WING SCREW DUST CUP ELEMENT

L·1739

YN·0125

1) Loosen the clamp and remove the dust cup. Next, loosen the wing screw fitting the element and remove

[Air Cleaner Element]

the element.

2) Clean the element when the air cleaner lamp lights and the buzzer sounds or every 250 hours, but do not fail to change the element every 1,000 hours or when there are pinholes in the filter paper. Do not blow holes in the element while cleaning.

4-16

LL

14. MAINTENANCE OF HYDRAULIC OIL SYSTEM The figure below shows the construction of the hydraulic oil tank.

REPLACEMENT OF RETURN FILTERS

I) Remove capscrews (3) fi~ting filter cover (2).

2) Remove cover (2), 0 ring (4 ) and remove bypass

9~

valve (5), spring (6) and return filter (7) from the tank.

3) Install bypass valve (5) to new filter (7) and insert this into the tank.

4) Install new 0 ring (4) to the tank flange. Next, being careful not to damage the 0 ring, install spring (6) 1f-- --

l--l0

and cover (2) and then install capscrews (3).

I. Be careful not to let foreign matters, such as water or sand get into the hydraulic oil tank .

2. Make sure there are no metallic particles on the old removed filter which can be the sign 16

of faultyhydraulic components.

WARNING' Before removing the tank cover and flange, be sure to slowly turn the air cock to release any remaining pressure in the tank. Then, do not forget to return air cock to operate position. after servicing hyd. tank.

1. HYDRAULIC OIL TANK

10. SUCTION STRAINER

2. FILTER COVER

11. o RING

3. CAPSCREW

12. DRAIN FILTER

4. o RING 5. BYPASS VALVE

13. ELBOW 14. TEE

6. SPRING 7. RETURN FILTER

16. LEVEL GAUGE

8. FLANGE

17. LEVEL SWITCH

15. PLUG

9. CAPSCREW

LL

4-17<D

REMOVAL AND INSTALLATION OF SUCTION STRAINER

I) Remove capscrews (9) installing suction strainer flange (8) and remove the flange .

2) Remove suction strainer ass'y {I 0) from the tank.

3) Disassemble the suction strainer ass'y.

4) Reassemble the suciton strainer ass'y following the reverse procedure of disassembly and insert this into the tank.

S) Install new 0 ring (II) and then install flange (8).

1

22 .8 in (580

g

m "')~f

REMOVAL AND INSTALLATION OF PILOT LINE FILTER

YN-0127

[Drain Filter J OIL LEVEL OF HYDRAULIC OIL TANK

Refer to "Check Hydraulic Oil Level" in "Pre-operation /8 Hour Maintenance" for the hydraulic oil tank level.

Always maintain the proper level.

CHANGE OF HYDRAULIC OIL

I) Remove the drain plug and drain the oil into a suitable container. Allow sufficient time for all the oil to drain from the walls of the tank.

WARNING' Before opening the tank release all air pressure from {he tank.

5

L-1892

I) Remove case (S) with a wrench.

2) Pull out filter element (2).

3) After cleaning or replacing the element, install new o ring (3) and back·up ring (4) on to case (5). then screw it into head (1).

REPLACEMENT OF DRAIN FILTER

Remove the cartridge turning it counterclockwise with the provided tool, clean the dirt accumulated at the bottom of the filter rest and install a new cartridge element . To install the cartridge, turn it about 2/3 of a turn after the packing of the cartridge contacts the seal surface of the filter rest.

Be sure to tighten this with

your hands only.

I~q] Be careful not to overtighten at the time of installation.

4-18

2) Remove the cover from the top of the tank and clean the inside of the tank manually.

3) Install the drain plug. Fill the tank with hydraulic oil.

4) Cycle the machine through all excavator functions including travelling several times in both directions.

S) Release air pressure and remove the drain plug and drain the flushing hydraulic oil from the tank.

6) Disconnect the hoses attached to the retract side of the boom cylinders, and raise the boom to its maximum elevation slowly. This will force the flushing oil from the cylinders.

WARNING This operation must be done slowly to avoid flushing oil gushing out of the hoses. This applies to 9 and 10 below also.

7) Reconnect the hoses to the boom cylinders, and lower the boom to a horizontal position. Add clean oil to the tank as required to maintain the proper oil level.

LL

8) Disconnect the hoses attached to the retract side of the arm cylinder. Extend the arm cylinder to force

II) Reconnect the hose to the retract side of the bucket cylinder.

the flushing oil from the arm cylinder.

9) Reconnect the arm cylinder retract hose and retract 'the arm cylinder.

Add oil, as required, to maintain the

proper level.

12) Swing the upper of the machine in both directions

Add oil to the tank, as required,

to force the flushing oil in the swing mutor back to the tank.

to maintain the p'roper level.

10) Disconnect the hose attached to the retract side of

13) Replace the return filter.

Cycle the machine through

the bucket cylinder, and extend the cylinder. This

all excavator functions induding travelling in both

will force the flushing oil from the cylinder.

directions to filter out any remaining contaminant.

15. CLEANING OF WATER SEPARATOR The water separator separates and removes the water in the fuel.

A collection of water in the fuel system

causes a decrease in engine output and can damage the fuel system components. Perform inspection and cleaning posi·

REMOVING AIR FROM FUEL SYSTEM After assembling the water separator, bleed air in the

following procedure: I) Turning the priming pump of the fuel feed pump counterclockwise causes it tu rise JutlJmJlicaliy .

tively.

2) Luosen the air plug at the top of the fuel filter and the air plug at the top of the water. separator and

5

move the priming pump up and down to feed fuel.

Pump fuel till air bubbles in the flowing fuel cease

4

10 come out.

2

When air bubbles cease to come out ,

tighten t he air plugs.

3

1. CASE

2. RING NUT 3. BAFFLE PLATE 4 . SCREEN 5.

AIR PLUG

6.

FLOAT

7.

DRAIN PLUG

3) Bleed air from the air bleeder of the fuel injection pump [Water Separator)

in th e same way as with the fuel filter. Before tightening the air bleeder push down and turn the

CLEANING SCREEN

I) Remove ring nut (2) attached to case (I) of the water separator and take out the case .

priming pump clockwise to secure it.

4) Wipe off fu el leaked on and around the fuel filter, start the engine and inspect for fuel leakage_

.2) Remove baffle plate (3) and take out screen (4).

WARNING'

3) Wash screen (4) with cleaning solvent and dry with compressed air.

4) After washing screen (4), assemble the water separator in the reverse urder uf disassembly.

LL

Correct fuel leakage if found, as it may bring about a fire .

4-19

16. HYDRAULIC OIL CARE 2) Use clean hydraulic oil of the designated quality and always maintain the proper level in the hydraulic oil tank.

3) Keep the connecting parts firmly tight so air will not enter the hydraulic system .

Also, relief valves are provided to control and limit the pressure for safe operation of the hydraulic system. The settings of these relief valves must never be changed.

POINTS IN HYDRAULIC OIL CARE

All the digging, travelling and swinging motions of the hydraulic ·excavator are operated by the pressure and flow rate of the hydraulic oil generated by the hydraulic pumps moving the hydraulic motors and cylinders.

Therefore, for the maintenance of the hydraulic excavator, care of the hydraulic oil system is vitally important.

Flow rate is the amount of oil that a pump will force through the system in a given amount of time and 'determines the speed of operation . The greater the flow rate, the faster a cylinder is filled with hydraulic oil and the faster its rod moves. A large volume of hydraulic oil entering into the hydraulic motor will rotate it faster, increasing the swinging or travelling

EXAMINATION AND CARE OF HYDRAULIC OIL

(1) Examination of hydraulic oil I) When draining oil from the hydraulic oil tank, check if there is any foreign matter, such as metallic particles in the strainer. If metallic particles are found, this is a sign of damage in the hydraulic components.

2) Sample about 0.52 gal (2 f ) of hydraulic oil while it is still warm every 6 months and have the sample analyzed by a Qualified specialist. If the hydraulic oil is dirty or has deteriorated, change the oil in the entire system immediately regardless of the change interval.

3) Although an accurate analysis of hydraulic oil can not be made unless proper equipment is used, the following simple method can be used to inspect the oil condition locally: a) Examination of external appearance Compare the oil from the tank with new oil and check if there is any sludge , dirt , metallic particles, vinegary or burnt smell or if the oil has changed to a milky or dark brown color.

Check and compare with the chart of next page.

speed .

Pressure is the amount of force of the hydraulic oil delivered from the pumps; acting as the operating force of the actuators.

When the level of hydraulic oil is low or when there is air, water, dirt, metallic particles or sludge in the hydraulic oil, not only can it cause cavitation, change in viscosity, drop in lubricancy, rise in oil temperature , internal leakage and corrosion inside the pipes, but it can also be the cause of faulty operation of the whole system.

Therefore, the following three points are most effective in order to maintain the performance and life of the hydraulic system and the machine : I) Change filters and hydraulic oil periodically.

Serviceability of Hydraulic Oil COMPARE

External Appearance

~

OIL DRAINED FROM TANK

NEW OIL

Transparent and not discolored Transparent but washy color Milky color

Smell Good

Condition Good

Serviceable for further use.

Good

Foreign oil in fluid

Good

Air and/or water in fluid

Serviceable for further use, if viscosity is good .

Separate water by oil manufacturer's instruction.

Inferior fluid

Change fluid.

Foreign particles in fluid

Filter fluid by oil manufacturer's instruction .

Grease in fluid

Change fluid .

Dark brown color

Bad smell

Transparent but with dark spots

Good

Contains bubbles

-

L-1137

4-20

Serviceability

LL

b) Examination in a still condition Check if there is water or foreign particles in the oil by using a magnifying glass.

'OR"GN

~ PARTICLES

! o j ,,,,a

c) Examination using a hot metal plate Put a drop of oil on a heated metal plate , if the oil contains water, a hissing sound of the water evaporating can be heard.

I) Containers used for storing hydraulic oil must be completely clean . Use a funnel with a 200 mesh screen to supply oil to the hydraulic oil tank and supply oil through the filler port only.

MAGNIFYING GLASS

~

(2) Handling hydraulic oil

Oil containing no water will

Avoid using cloth to filter hydraulic oil as pieces of cloth may get into the system .

2) When removing hydraulic components, be sure to plug the hydraulic lines and attach tags to facilitate reassembly later. Also, be sure to plug the ports of the removed component.

3) Be sure the connections of the hydraulic oil pipes are properly tightened.

If the connections of the pressure lines are loose, this can cause oil leaks and aeration.

If air stays in the hydraulic ocmponents, it will lead to cavitation damage and abnormal sounds.

ignite.

(L~~~/)

,

.-i..--------.

O~.\I;., METAL ,_ ,_ J PLATE 'l

f=.==;;==.

L·1139

LL

4-21

17. OIL CHANGE OF SWING REDUCTION UNIT I) Before carrying out oil change, swing the machine to warm the oil and then stop the machine on level ground.

2) Remove lubrication port plug (2) at the top of the

3

1. DRAIN PLUG

reduction unit.

3) Remove drain plug (I) of the reduction unit from

2. LUBRICATION PORT PLUG

under the upper frame and drain the oil into a suit·

3. LEVEL GAUGE

able container.

4. UPPER FRAME

4) Wind sealing tape around drain plug (I) and install this to the reduction unit.

5) Supply fresh oil through lubrication port plug (2) and check the oil level using level gauge (3).

4

YN.()12B

6) Wind sealing tape around lubrication port plug (2) and install this to the reduction unit.

7) Swing slowly and check to make sure there is no oil leakage.

I. Use proper oil for the reduction unit by refer·

ring to the "Lubrication" chart.

2. Check and see that there is no foreign matter such as metallic particles or chips in the drained oil.

YW-0036

[Drain Plug of Swing Reduction Unit)

18. OIL CHANGE OF TRAVEL REDUCTION UNIT I) Before changing the oil, travel the machine to warm the oil and then rotate the reduction unit so drain

2

OIL LEVEL

plug (I) comes at the lowermost position as in the right figure . Then stop the machine .

1. DRAIN PLUG

2) Remove plug (2) and then drain plug (I). Drain the

2.

gear oil.

3) Wind sealing tape around drain plug (I) and install

LEVEL PLUG (SUPPLY PLUG)

this to the reduction unit.

4) Pour fresh oil up to the bottom of the hole of plug (2).

5) Wind sealing tape around level plug (2) and install this to the reduction unit.

6) Travel slowly and check to make sure there is no oil leakage.

L . . - - - - - f - - - - - - - -- - - ' L·1560

1:rc!~~1

I . Use proper oil for the travel reduction unit by

referring to the "Lubrication" chart.

2. Check and see that there is no foreign matter

such as metallic particles or chips in the drained oil.

4-22

LL

19. ADJUSTMENT OF TRACK TENSION T-o adjust the track tension, swing the upper frame so

When the track tension is not correct, adju~t as follows:

that the crawler to be adjusted comes in front of the

WHEN TENSIONING THE CRAWLER

operator's seat, push the bucket against the ground by

1) To tension the crawler, inject grease throu!!, diusting

retracting the boom cylinder and lift up the machine

window into gr ease nipple (L) at the side of the track frame until the correct ten~ioi1 is obtained.

body.

Adjust at the center of the crawler frame so the gap between the crawler frame bottom and the 'top surface of the track shoe is 11.4' - 12.6' (290 - 320 mm).

The

gap between the roller and the track link contact surface

2) Next move the machine forw ard ana backward 6'6"-

9'10" (2-3m) 3) Check the crawler tension once again, 1nd inject grease until the correct te nsion is obtained.

at this time is 3.5'-4 .7'(90-120 mm).

WHEN SLACKENING CRAWLER TENSION

1) To slacken the crawler tension due to overtensioning or for disassembly, loosen the grease nipple holder (H).

Then the grease inside is discharged and the crawler will slacken.

2) When the crawler slackens to the correct tension tighten the grease nipple.

WARNING'

11.4' -12.6' (290-320 mm) YN-0051

1_ If the grease nipple holder (H) is loosened suddenly, grease will jet out. So loosen the joint gradually without bringing your face close to the grease nipple.

2, Do not loosen the grease nipple holder (H) beyond the stopper. If loosened more than allowed, the grease nipple holder (H) will

L

shoot out by the high pressure insid e. Move the machine back and forth if the grease does not come out s moothly.

[Adjustment of Track Tension)

LL

4-23

20. TIGHTENING TORQUE OF CAPSCREWS AND NUTS MAIN CAPSCREWS AND NUTS (Wet) Tightening Torque ft·Jbs (kgf'm)

Location

Size

Fuel tank level gauge Hydraulic oil tank level gauge

Size

8.7±0.7 (1.2±0.1)

Swing motor Swing reduction unit -

* *

Engine fitting bracket MIO

Gear pump ._--- --- _.-- -

-

~ ----.--

Swing brake valve port Pump delivery port

Travel reduction unit

* *

396.9±39.7 (55±5)

Upper roller

---M24

Sprocket

*

Counterweight

*

642.2±36.1 J8_9*~

865.9± 14.4 (l20±2)

Side cutter

50.5±5.0 (7±07) 57.8 ±5.7 (8±0.8)

Swing control valve Travel brake valve

M12

M20

28.9±2.9 (4±0.4)

46.9±0.7 (6.5±1)

Tightening Torque ft·Jbs (kgf'm)

Location

Pump suction port

The capscrews marked

Cab

Loctite #242 or #271 (locking compound). For

79.4±10.8 (11 ± 1.5)

Control valve

* are tightened with

retightening, therefore, apply Loctite #242 or #271 to the thread part.

5/818UNF

43.3±7.2 (6±1)

Track tension grease fitting Pump coupling boss

of<

Radiator

*

Floor plate Fuel tank

>I<

Hydraulic oil tank Pump coupling insert

*

M16 Bucket pin bolt

Track tension bracket

MI8

Engine mount rubber

'" *

Shoe bolt Main pump

137.1±7.2 (l9±1) 140.7 (19.5) 151.5±14.4 (21±2) 158.8±7.2 (22± 1) 198.4±28.9 (27.5±4)

Cab

Lower roller

86.6±7.2 (12± 1)

*

205.7±21.6 (285±3) 216.5±21.6 (30±3) 166.0± 14.4 (23±2) 433.0±43.3 (60±6) 317.5±28.9 (44±4)

4T CAPSCREWS

(Dry)

Size

Location

Tightening Torque ft'lbs (kgf'm)

M6

Instrument panel

2.9-3.6 (0.4-0.5)

M8

Cable clamp

7.2-8.7 (1.0-1.2)

MIO

Cover

14.4-17.3 (2.0-2.4)

MI2

Cover

23.8-29.6 (3.3-41)

MI6

Cab

58.4-71.4 (8.1-9.9)

NOTE 1. 4T capscrews have the letter M marked at their head.

2. The tightening torques in the above table are under dry condition. If oil is applied to the thread part, reduce the figures in the table by about 20%.

--~ ~ ~ --

M20

(U pper )

Swing bearing

*

274.2±21.6 (38±3) (Lower)

396.9±39.7 155±51

4-24

LL

21.

REPLACEMENT OF BUCKET TOOTH POINTS Broken Rubber

3

~

[Badl

Lock Pi n too Short

[Bad]

a

(4)

5

YW-0040

'''go m. Bonom

[Tooth Point) 1. RUBBER LOCK

4 . ADAPTER

2.

LOCK PIN

5. TOOTH POINT

3.

ADAPTER

L

Steel rolier will slip in I when pressed with hand.; I

[Bad]

L-1300

[Wear Limit of Rubber Lock and Lock Pin) The wear limit is as shown in the figure below.

The

appearance of small holes in the tooth points indicate the limit of use.

4) Install rubber lock (J) into the hol~ of the tooth nose.

j I/13--/if!

(2-3mm)

/ L-1298

L-1299

(This condition shows) th e Wl·ar limit.

Do nol usc to

(this condition)

·To replace the tooth points. proceed as follows: ) It is not necessary to remove the bucket from the

machine to replace the tooth points.

[Good)

[Bad) YW-0041

5) Place new tooth point (5) over tooth nose (4) and tap it into place, using a soft mallet.

Lower the

4

bucket onto wooden blocks and position it in such a manner as to allow easy access to the teeth.

2) Using a drift pin and hammer, remove the lock pin from the tooth point being removed .

3) Remove the tooth point from the tooth.

YW-0042

NOTE Do not use worn lock pins or rubber locks. Re-

place them with new ones.

[Good)

YW-0043

[Bad)

6) Align the hole of the tooth point with the hole of the nose and install lock pin (2).

2

2

WARNING

Wear suitable eye Protection While changing teeth.

YW-0044

[Good)

LL

YW-Q045

[Bad)

4-25

22. REMOVAL AND INSTALLATION OF ATTACHMENTS 1) Operate the control lever and bring the bur~et down

Reverse the . removing procedure. noticing the following

to the ground so no load may be laid on .he pin that

cautions and steps:

links the bucket with the arm .

I) Clean the welds on each structure and inspect for

2) To remove the pin (A) in the embossed part of the

cracks.

bucket. remove ring (18) and pin (19) by means of

2) Inspect the bushings in the bucket bosses according

a flat ·bladed screwdriber a~d draw out the pin (A).

to the - Maintenance Standards' and replace them as required.

3) Inspect rubber and seals to check for damage and replace faulty ones.

4) When inserting pins. coat grease over the sbalt sections.

NOTE 1. If the pin is hard to come out. it indicates that the pin is loaded.

Then operate the

control lever to remove the load.

2 . Use care so as not to damage 0 ring be· tw~n the arm and the bucket boss.

3) Operate the· control lever so pin ( B ) between the bucket link and the bucket may not be loaded.

4) Remove ring (18) and pin (19) that fasten the pin of the embossed part of the bucket by means of a flat· bladed screwdrever. Then draw out pin (B).

NOTE Bucket installing will be facilitated if the bucket links are attached initially.

WARNING' When matching pin holes. never put your finter into them. Align them visually.

A8

4-26

lQ

23. CONVERTING TO FACE SHOVEL Face shovel operation can be performed by facing the hoe bucket in the opposite directiun.

To cunvert the hoe bucket for face shuvel uperatiun. proceed as fullows: I) Place the back of the bucket parallel with the gruund and remuve pins (a) (b).

[Backhoe Operation]

2) Lift the arm slightly and turn the bucket I RO°.

Lower the arm , and the pusition of the hules is reversed.

3) Align the hole of the arm end with bucket hole (a) and insert the pin. Then align the hule of the bucket link with hucket hule (b) and install the pin .

WARNING

1. Before starting face shovel operation, prac · [Face Shovel Operation]

tice is needed .

2. If bucket is equipped with a weld on lifting hook. check for contact betwean hook and dipper stick hook removal may be necessary.

3. An 0 ring is used at the bucket fitting part, therefore at the time of disassembly or reassembly, place the 0 ring on the boss at the bucket side as shown below.

4) After completing the above. face shovel work can be

24.

periormed, but note that operation uf the control

If a bucket other than the hoe bucket is turned

levers uf the bucket (digging and dumping) is now

over fur operation. the arm and the bucket may

upposite to that for backhoe operation.

be bruken.

ADJUSTMENT OF BUCKET MOUNTING

This machine uses a bucket with adjustable clearance.

To adjust the clearance, loosen three bolts, remove the

ADJUST BUSHING

BUSHING WITH COLLAR

flange, remove the amount of shims equal to the gap SHIM

caused, and retighten the bolts.

Tightening torque: 86.7±14.4 ft'lbs(l2±2 kgf'm)

Tightening Torque

Capscrews

l.

LL

BUCKET

4-27

25.

PERIODICAL REPLACEMENT OF IMPORTANT PREVENTIVE MAINTENANCE PARTS

The parts listed below may cause lethal or destructive

designated as important preventive maintenance parts

accidents due to deterioration over time.

for periodical replacement. every 2 years.

Since it is difficult to determine the life of these parts by

Be sure to replace them

visual examination and operating hours, they have been

No.

Designation and Location

2

Hose between bottom side of boom cylinder and control valve

2

3

2

4

Hose between bottom side of arm cylinder and control valve Hose between rod side of arm cylinder and control valve

5

Hose between rod side of bucket cylinder and control valve

6

Hose between bottom side of bucket cylinder and control valve

2 2

Hose between car heater and engine

7

Fuel hose between fuel tank and engine

8

Suction hose between hydraulic oil tank and pump

Q'ty 2

2

2

7,8

3·4

4-28

II

26. STORAGE OF MACHINE It is very important to . store the machine with the

DURING STORAGE

greatest care after the machine has been .removed from

I) Run the engine once a month for a short while to

service for an extended period of time to keep the ma-

allow oil to circulate throughout the engine.

chine in good condition_ Store the machine' indoors in a dry atmosphere.

rods and check the cooling water before starting the

Be sure to wipe off grease from the hydraulic cylinder If

circumstances do not permit the machine to be stored inside, place the machine on dry, solid and level ground and cover it with tarps.

engine.

2) Check the charged condition of the battery once a month and if necessary, charge the battery.

PREPARATION FOR STORAGE

BEFORE RE-USE

I) Clean the entire machine_ 2) Check the machine for loose or lost parts_ If neces-

2) Check the condition of the air cleaner element.

sary, retighten or replace.

3) Lubricate the machine in accordance with the "Lubrica-

I) Clean all dirt accumulated during storage.

3) Drain water from the fuel tank, engine oil pan and hydraulic oil tank.

tion" chart. Be sure to flush swing bearing thoroughly

4) Open the drain plugs of the various gear cases and

until old grease oozes out.

4) Fully extend the bucket. 'Fully extend the arm and

clean out water deposits and dirt, and then refill with

lower the boom. Coat the exposed portions of the

5) Wash off anti-rust grease coated over the exposed

cylinder piston rods with anti-rust grease.

5) Fill the fuel tank_ 6) Remove the battery, clean it thoroughly and store it in a cool, dry location where the temperature will not fall below 32 OF (0 t).

7) If there is a possibility of freezing weather, either add anti freeze to the cooling water or drain the water

the prescribed amount of oil to the gear cases. parts with light oil.

6) Install a fully charged battery and connect the terminals_ 7) Before performing the first run after being removed from storage, make a thorough visual inspection of the machine. Check particularly for damage and/or deterioration of the hydraulic hoses.

out completely. Be sure to place a "No Water" sign on the machine_ 8) Check and service all tools for proper storage.

CAUTION TO BE EXERCISED WHEN WASHING THE MACHINE

Exercise care so jet steam and water do not splash directly over I.T.C.S. parts. connectors and electrical fittings.

LL

4-29

SECTION V 1.

TRANSPORT ATION

PREPARATION

I) Before making preparation for transportation , refer

2) Investigate the road width, bridges. road and traffic

to the preceding section on "Specification" and

conditions of the scheduled route beforehand as well

ascertain the weight , overall height, width and length,

as the governing laws and regulations. Also, obtain

travelling speed, ground pressure , etc . of the machine.

required

permits and/or authorization from

the

appropriate agencies.

2. SELF-TRAVELLING I) Before travelling the machine , inspect the underframe

3) When travelling on a paved road. use wooden boards or somethjng so as not to damage the road surfac.e.

once again, and service and lubricate it.

2) Assign a flagman as required and have him control traffic for safety.

3.

TRANSPORTATION BY TRAILER OR TRUCK

1) Use a vehicle suitable for the weight and general dimensions of the machine to be transported .

2) Loading or unloading should be performed on firm, level ground.

1. TRUCK DECK 2.

WALKING PLATE

3.

SECURING THE DECK AND WALKING PLATE

4.

WOODEN BLOCKS

3) Prepare a walking plate which is strong enough to support the machine weight and wide enough to travel up or down.

The machine can go up and down easily if the angle of the walking plate is within 15° - 16°. Determine this angle from the relation between the height of the truck deck and the length of the walking plate,

L·1255

as shown above.

Unit: ft ·in (m) A meter 3'3" (1.0) 3'5" (105) 3'7" (11) 3'9" (115) 3'11"(12)

4'1" (125) 4' 3" (1.3) 4'5" (135) 4'7"(14) 4'11 ' (15)

B meter 12'0" -12'S" (365- 3.S5) 12'6" -13'3" (3.S-4.05) 13'1'-14'0" (4.0-425) 13'9"-14'5" (4.2-4.4) 14'3"-15'1" (4 .3 5-46) 14'11"-15'9" (455-4.S)

5) Engage the swing lock.

6) Travel the machine to just the top of the walking plate. then lower the bucket onto the trailer deck . travel forward it slowly and lower the machine onto the trailer deck by slowly raising the boom.

7) Unloading should be done with the attachment facing the direction of travel.

Move the machine

slowly and carefully on the walking plate.

15'7"-16'5" (4.75-5 .0) 16'1'-17'1" (4.9-5.2) 16'9"-17'9" (51-54) . IST-lS' 10" (55-575)

Relation between Height of ITruck Deck and Walking Plate l

4) Engage the brake of the trailer or truck and place wooden blocks around the wheels.

LL

5-1

WARNING I . The center-of-gravity changes abruptly between the footboard and the bed. Travel slowly. keeping the attachment at a height from which it may be brought down to the ground at any moment.

2. Swinging on a sloped footboard is very dangerous. Lock the swinging motion by inserting the swing lock pin.

3. If the front attachment is off, the machine has its center-of-gravity on the counterweight side and is extremely unstable. Always climb up and down a slope, directing the counter~eight toward the top of the slope, and do not swing the machine in a tilted position.

(Shoe plate attachment and fixing of wire rope)

10) When transporting the machine. fully embrace the bucket and the arm and secure the top end of the bucket with wire slings.

8) When using· a platform, bring the end of the truck or trailer to the platform and unload or load the machine.

21}g J~m/ffa

~

lATFORM

/'/,

l·1257

9) For transporting the machined, embrace the bucket and the arm to the full and secure the top end of the boom firmly.

1. If the arm is fully retracted on the arm ·equip ped machine. the boom and the bucket tooth may hit each other. Therefore. when fully retracting

(Fixing of bucket tip)

the arm. bring the bucket to a fully raked ·in position.

2. When the bucket is attached in a reversed position (face shovel), adjust the bucket position so the clearance between the boom and the bucket tooth is more than 1.96" (50 mm). In that case the overall

transporting

height is a little

higher than the standard height.

5-2<D

LL

4.

WEIGHT OF COMPONENTS

_______ MO: ~ *

Unit: Ibs ( kg f) MD240BLC

Item

I.

Complete Machine (Std. Std. Export (32 in (800 mm) Shoe)

52200 (23.680)

Upper Frame Assy (Inc. 1.1-1.9)

20500 (9.300)

1.1 Counter Weight 1.2 Cab Assy

9700 (4.400) 530 (240)

1.3 Boom Cylinder

485X2 (220X2)

1.4 Engine

~<l160

1.5 Pump Assy 1.6 Control Valve

(*525)

250 (115) 330 (150)

1.7 Fuel Tank

*200 (*90)

1.8 Hydraulic Tank

*550 (*250)

1.9 Swing Motor & Reduction Gear 2.

Lower Frame Assy (Inc. 2.1- 2.9)

2.1 Swing Bearing 2.2 Travel Motor & Reduction Gear

790 (3.60) 19995 (9.070) 730 (330) 900X2 (410X2)

2.3 Idler Assy

595X2 (270X2)

2.4 Lower RoIler Assy

1300X2 (590XI4)

2.5 Upper RoIler Assy

130X2 (58X4)

2.6 Tracktention Assy

330X2 (150X2)

2.7 Sprocket

300X2 (135X2)

2.8 Swivel Joint

60 (26)

2.9 Track Link (24 in (600 mm) Shoe)

3490X2 (l.585X2)

2.9.1 Track Link (28 in (700 mm) Shoe)

3825X2 (l.735X2)

2 . 9.2 Track Link (32 in (800 mm) Shoe)

2050X2 (1.875X2)

2.9.3 Track Link

1480X2 (670X2)

3.

Attachment (Inc. 3.1-3.3)

9880 (4.480)

3.1 Bucket Assy (1.18 cuyd (0.9 M3) STD.)

1610 (730)

3.2 Arm Assy (9 ft6 in (2.9 M) STD) (Inc. FoIlowing)

2535 (1.150)

3.2.1 Arm

1590 (720)

3.2.2 Bucket Cylinder

400 (180)

3.2.3 Idler Link

70 (30)

3.2.4 Bucket Link

200 (90)

3.2.5 Pin (For Arm Cylinder & BucketX2)

190 (85)

3.3 Boom Assy (Inc. FoIlowing)

5730 (2.600)

3.3.1 Boom

3600 (l.635)

3.3.2 Arm Cylinder

705 (320)

3.3.3 Pin (Install Arm)

33 (l5) *Mark Dry Weight

LL

5-3

5.

TRANSPORTATION WEIGHT

5. 1 COMPLETE MACHINE ON TRAILER DECK Unit· ft-in (mm) MD240BLC Width

10'5" (3,190 mm)

Weight

52200 Ibs (23.68 ton)

Unit: I\·in (~"')

32'S' (9,955)

6

'"

6 .... eo

\i

\i ::0

'"

0

N

6

'" '"

N ~

5.2 COMPLETE MACHINE LIFTING

5.3 BASIC MACHINE LIFTING Unit- It ·in (mm)

lInit- ftin (mm)

MD240BLC

MD240BLC Width

10'5" (3,190 mm)

Width

10'5" (3 ,190 mm)

Weight

52200 Ibs (23.68 ton)

Weight

43610 Ibs (19.78 ton)

Unit: I\·in("",,)

NOTE 22'10' (6,955)

Above weights include the boom cy lin der's weight.

Unit: I\·in(mm)

_

5-4

_

. c::::=:=::l

,

~_

LL

5.4 ARM & BUCKET Unit" It ·in (mm)

MD240BLC Width

4'2" (1 ,270 mm)

Weight

3968 Ibs (l.8 ton)

Unit: It-in (mm)

.'"

'"

18'1" (5,490)

5.5 BOOM ( Init· It ·in (mm)

MD240BLC Width

2'5" (750 mm)

Weight

4410 (2 ton)

Unit: It-in (m.)

20'5" (6,235)

5.7 BUCKET

5.6 ARM Unit · It·in (mm)

l lnit · !tin (mm)

MD240BLC

MD240BLC

Arm length

9'9" (2,980 mm)

Width

4'2" (1,273 mm)

Width

1'5" (433 mm)

Weight

1543 Ibs (0.7 ton)

Weight

2425 Ibs (1.1 ton)

Unit: II-in (m.)

Bucket capacity

l.18 cu yd (0,9 m' )

Unit: II-in (mm)

13'3" (4,055)

LL

5-5

SECTION VI GENERAL INFORMATION 1.

HYDRAU Lie SYSTEM

The hydraulic circuits of this machine differ greatly from

(Attachment circuit)

convetional ones the The following functions have been

A parallel confluent circuit with two pumps IS provided for

added:

the arm raising motion. whereas a fixed regeneration circuit

0) An accumulator added to· the pilot circuit

is provicd for th e boom lowering motion.

(2) 2·speed variable motor semployed as the trav el motor

A circuit is so designed as to control the boom action if the

(3) An automatic swing brake incorporated

mode changeover switch is turn ed tmode Fe.

(4) An automatic confluent circuit for arm digging added

A tandem confluent circuit with two pumps is set up for the ar m extrusion motion. whereas a variable regeneration

(Construction of component) This machine comprises

circuit. an automatic confluent circuit with a sequence valve two

variable -displacement

pumps (for travel and operation). one gear pump (for pilot). one main control valve. swing control valve. swing motor. swivel joint. an oil cooler. a hydraulic tank. two travel motors. pilot valves. different cylinders and filters.

and a swing preferential circuit are set up for the arm contracting motion.

Use of a controllability changeov er switch in addition to such circuits permits control of the arm action.

The bucket is actuated by a single pump. Its parallel connection insures smooth action of the bucket according to

(Fuel consumption reduction system) The combined output of two pumps is always controlled

lever strokes even when the bucket is operated simul·

by two regulators not to exceed a certain level and the

taneously with other attachment.

engine output can be utilized effectively in all circumstances. The fuel consumption during operation is reo

(Hydraulic oil control)

duced to a large extent by having a negative control sys·

The hydraulic tank has in its interior a return filter and

tern a controllability changeover switch and also a mode

a suction strainer. and also has. in its side face a drain

changeover switch. and an engine with direct injection

filter to protect hydraulic components and to prevent

exhaust turbo supercharger.

hydraulic oil from being contaminated.

The hydraulic

tank of selfclosed type is pressurized naturally by fluc(Travel circuit) The oil discharged from the hydraulic pumps is delivered

the self· suction ability of the pumps and prevent entry of

to the control valve and is regulated as to its direction

dust.

and flow to ultimately actuate the hydraulic motor and

The cooling of the hydraulic oil is executed by passing

tuations of the oil level in the tank. in order to promote

the hydraulic cylinders.

the return oil from the control valve through the oil cool-

The travel circuit is of tandem configuration in which the

er at the front of the radiator.

travel section is arranged in the uppermost stream of the

cooler piping a bypass line with a check valve is pro-

travel

veded in order to decrease the oil flow to the oil cool~r at

straight even during the simultaneous operation of travel

low atmospheric temperature and to reduce the time re-

and other. attachment. without halving the travel speed.

quired for warming·up.

control

valve.

This

allows

the

machine

to

On its way of the oil

This circuit is called Travel Preferential Circuit.

The

travel boost pressure circuit works during travel operation to provide powerful travel force.

(Filot circuit) This machine adopts a pilot control method to obtain light and delicate operation.

The pilot control line is

(Swing circuit) In the swing circuit. the conventional brake valve (with a

supplied with pressure oil from a single gear pump that

counterbalance valve) has been deleted and a method of

the control valve spool is actuated by pilot pressure

controlling the swing brake with the swing control valve

variations brought from operating lever strokes.

has been adopted instead.

is connected to two variable displacement pumps. Thus

This increases the braking

force according to the lever stroke and realizes shock· less. smooth swing action.

The system operates as a

swing preferential circuit when swing and arm retracting motions are performed simultaneously.

LL

6-1

BACKHOE HYDRAULIC CIRCUIT DIAGRAM ARM CYL YNDER SWING CONTROL VALVE

SWING MOTOR

- - - -, BOOM CYL YNDER

'n I

.

I I I

I I I I I I I I

_...J

SWING BEARING

r" I

- - - - - - - ' '-- J

_ _

-, ~

I

RETURN FILTER

(

VA VE

I

(

I I I

SUCTION STRAINER

I

(

...J

I

>-

UJ

I

~

o§1 «

I

a:

1 w'---'

ZUJ w(/)

> « a:

I--

:I: ...J

...J

UJ

I!!I ~'"

> « a:

I--

:I: II:

I-~

UJ

w

::;)

0 0

"

()

w

IJ

--'

AIR BREEZER HYDRAULIC OIL TANK

ZUJ UJ(/)

DRAIN FILTER

_ _ _ _ _ .---.J BRAKE VALVE

CENTER JOINT

SPROCKET ~---------+---------, , I

:

I

o--J

L

- -- - MAIN LINE ===~ SUCTION AND RETURN

EXCLUSIVE LINE TRAVEL REDUCTION UNIT

-----DRAIN LINE TRAVEL MOTOR TRAVEL MOTOR

6-2

TRAVEL REDUCTION UNIT

- - . - - PILOT LINE

----41-- FLOW DIRECTION

LL

2.

ELECTRICAL SYSTEM

HANDLING ELECTRICAL COMPONENTS

The electrical system that includes a starter motor, alternator, regulator, hour meter, lighting and their wir·

ing operate on 24 volts. Two 12·volt batteries housed at the front right of fhe machine serve as a power source.

Exercise care of the following in handling these components,

NOTE I . When making a quick charge to the batteries ,

L·1366

always disconnect lead wires between the bat· teries and the alternator. Otherwise, the diodes may be blown.

2, Rotary equipment like the alternator/cell motor

and the control equipment such as the regulator have been adjusted by a special instrument and require skills to handle them. Therefore, ask a nearby service shop when inspection and repair become necessary, 3. Short-circuited wiring and loose terminals not only disable electric components but also cause damage to them. Always use care to see if such faults are not present.

4. When replacing electric components or repairing wiring, do not forget to take out the ignition switch key. Exercise care not to place a wrench on the batteries.

5, When wires have been disconnected, identify them by, for example, attaching tags to them, so as to avoid wrong connections.

HANDLING BATTERIES

If the batteries are abused or left unused for a long period to the extent that their charged level decreases too much, the inside plates are damaged and require repair. In that case, measure the specific gravity of the electrolyte and confirm it in the following table to check the charge level (represented by the charging rate).

Always keep the charging rate at 70 per cent or over.

Keep the charging rate well controlled as the starting performance in a frigid district depends on it.

~ lcnlp

;'II:~!~IIl ~

100% 90% 80% 75%

68°F (20"(;)

32°F

14°F

(O·C)

(-IO·C)

1.,26 1.24

1.27 1.25

1.22

1.23

1.28 1.26 1.24

1.21

1.22

1.23

[Specific Gravity of Electrolyte 1

NOTE The specific gravity of the battery for cold service differs from that of the machine of standard specification.

Atmospheric temp.

Specific gravIty

68°F, (20"(; )

(-IO'C)

14°F

-4 °F (- 20"(;)

1.28

1.30

1.31

[Specific Gravity of Battery for Cold Service) (When 100% charging) Even though the batteries are sufficiently charged, electric current may not run in some cases because of poor contact of terminals. In such a case, shine the contact faces of the battery and cable terminals by means of emery paper and retighten the terminals. Greas·

ing the terminals after tightening is effective for rust prevention, but do not grease them before tightening.

In case the batteries are not used for a long time, charge them to full capacity, tighten up the caps, place them in a cool dry room and inspect the charge level every month.

If the datteries are to be left unused for a very long time,

consult a battery shop.

LL

6-3

ELECTRICAL CIRCUIT DIAGRAM

1-

S1AR~H

,~ \HEAm --

J ~

UHERY RELAY

~

:~ ;!

-< ....

1

BAHERY ~ CON. ROLLER TO E

TERMINAL

~

STARTER RELAY r:;="\

!

All;IMATO~

~ i

I~

S

AP

CONTROllERt BY

S,

SO

S2

l

I

:;

> <

ClUSHR GAUGE

I ",..

R

'"~

N

I

~

., •

SAFETY AEUY

AV~

~HEATER RElAY

~

1

BUTERY ~

.

-

BW

5

::s lEY SWITCH

~

B

I

Bl

r.. r.,

I "R

C

I :~f~~:

n ...,

OFF

-

.J1~"

BUZZER

un

AV2WRL AV 2WG 4-AV2V

1

'V' RB GR

1.!..

00

S7

I

or.

r-

r-

p- L3J...

-r. ....

vo YlL

,e

VI

IS

VBI

.

S

22

2

STOP

GR

ACC

:;

0

, 5

20

W lY!;R

VW

,.

16

.'

vo

~y

00

3

'6

4

7

5

e f.-:L-

0"

WB O.~ll

Rl A 0 Ava ,v,ow

- ~ 'tv>- fA

V2Y

AV 1. 25L fUSE lOX

....

....

....

LI GHT SW ITCH

IE 5 JSl!R

OF F

>I~I·

ON

::s;

.$

= "'"

l~

lot<

••

0•ro:

• I,

INT

CONT

........

~ .

~~

I L

OFF

'"

~

HOII IELAY

WI PER SWITCH

'"

,m"'T IILAV

~>

(}

n .

.1 B

... . ....

•

lS

....D<'"

1 IS

....~~..,.

HAVEL

HORN SWITCH

~

znRU ~L <p

IJ !JIJ !JIJ~

'"co

....

.

CONDE~

Ii~

rJl1

..

..

~ ~

~

HEAD lIGH.

CI GAlEnE II GHHR

WI PER

WASHH

BACK BUZZER (OPT. )

HORN

RADIO

Color tabl e of wiring WIRING COLOR SAMPLE

W

L

I I

LINE COLOR (BLUE LINE)

Symbol

Co lor

Symbol

Col or

B

Bla ck

W

White

G

Gr een

y

Yellow

L

Blue

P

Pink

Red

0

Orange

GROUND COLOR fWHITE GROUND)

R

6-4

LL

CONlROL L ER 1HROI1l£ P01£1110

R

• ,. _8 2

62i E9

e

+ +

-o-~

THERMO

SENDING UNIT

FUEL

LEVEL

DUST

INDICATOR

S'III TCH

OIL

---r"~

01 L

-r"--:--+

EIG

THERMO S'III TCH

SUB

TANK

EIG

OIL

OIL

LEVEL

---~

---0

~

+

'--

'II

'---

SEALED

TURN METE

-----.

-o-~

ME1£.!-Q,. ..r-- p>

~

yeTFS O. 'U-3C

PRESSURE F I L TER

"

S'IIITCH

12

ALARIo!

LEVEL LEVEL

~

vcns •. 76-2C

B

+

R

-

SEALED

S'IIITCH

:Ic~ 0

D. II. S. S DISCHARBE SWITCH

SWITCH

SWITCH

BA11ERV~

TO CHAMBER

E ,$

APPLIED AIR PRESSURE

1T

..

... Ie

OQ

~~.

SV

f I I ! eo 111 0 I IUtllO-,UElIllt YAL

REttr

l-1 ~

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a

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Symbol

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Symbol

Color

ROOW LAMP

Table of classified wirIng AV60

Br

Brown

Lg

Leave green

AV8 . 5

Or

Gray

AV2 . 1.25

Sb

Lead

AVO.85

V

Violet

AV20

6-5

INDICATION BY CLUSTER GAUGE LAMP The table below shows the lighting and un lighting conditions of the cluster gauge lamps. (At engine stop and engine rorating).

The numbers in the table match those in the instructions on the cluster gauge on pages 3-4 .

-p- Lighted. Unlighted

Indication by Cluster Gauge Lamps e:

Normal Display

.g

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Hydraulic oil level lamp

Hydraulic oil volume

Battery charge lamp

Charge amount

Engine oil pressure lamp

Engine oil pressure

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Travel 2-speed function at work

Travel I-speed lamp

Travel I-speed function at work

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Remarks

ON for ON after HEAT START Engine after for 10 under 3 sec.

3 seconds 25 sec. sec. rotation

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Engine rotating

Engine stop

Indicating item

1 Hour meter

Cumulative operating hours of the machine

• • • • -'0"

LL

I.T.C.S. (INTELlGENT TOTAL CONTROL SYSTEM) Model MD240BLC employs a inteligent total control system.

The main feature of this system is that it can display a larger horsepower than a conventional system even with a same engine capacity, which means that the machine can give more output than a conventional machine with an engine of the same output.

Given hereinunder is a description of how an engine of the same output can turn out a higher workload.

Hydraulic excavators currently produced convert the mechanical horsepower of the engine to a hydraulic force with a hydraulic pump, so that the hydraulic force is set lower than the engin's horsepower to prevent an engine stop.

The I. T. C. S enables more high ·performance control with its microcomputer. Theref@re, the engine horsepower is set higher than the force of the hydraulic pump (cross sensing power), so that when a load to the pump has increased during operation, the pump's horsepower is lowered according to the degree of engine speed sensing to match it to the engine output. It also serves to prevent an engine stop as the pump's output is reduced according to the fall in the engine output. Hereinafter is given all the functions of the I. T. C. S:

1)

Mode H (heavy·duty control) :

This is effective for high speed powerful digging. Turn the mode changeover switch to "W for operation.

2)

Mode S (standard control) :

This is effective for light·duty work that requires energy saving. For operation, turn the mode changeover switch to

"S".

3)

Mode FC (fine control) :

This is effective for accurate work at low speed. For operation, turn the mode changeover switch to "Fe".

Mode

4) Release mode:

The machine turns out the same workload as a coventional one if the I. T. C. S should be out of order. For operation, turn the release switch to "RELEASE".

5) Finger·tip control decel:

This is effective to bring the engine revolution to low speed repeatedly when the machine is at rest during a work shift to wait for a dump truck or something.

For actual operation, turn on the decel release switch and switch the decel select switch. At the beginning of work , bring the engine to high speed by depressing the decel select switch again.

(Hereinafter O. P. T .)

6) I. T. C. S. automatic warmup: 7) Semi·auto bucket control:

LL

6-7

3.

AIR SYSTEM

The pressurized air is built up by the engine mount

raulic oil tank. When the inner pressure of the hydraulic

compressor and used to pressurize the hydraulic oil tank.

oil tank is abnormal. the air pressure lamp on the cluster

The compressor runs continuously while the engine is

gauge lights.

running. but actual compression of air is controlled

Two safety valves are equipped. The safety valve for the

between 91 psi(6.4 kg / en!) and 104 psi (7.3 kg / en!) by the

air reservoir is set 128 psi (9.0 kg / en!) and another safety

governor.

valve for the hydraulic oil tank is set at 17 psi (1.2 kg / cn!).

The reduction valve reduces the pressure in the air

Do not change the set pressure.

breather to 4.3 psi (O.3kg/ en!) and delivers it to the hyd -

10

7

6

5

2

/

( 12)

11

1 ___ _

=

( 1. COMPRESSOR

A

8. SAFETY VALVE

2. COMPRESSOR GOVERNOR

9. AIR COCK

3. AIR RESERVOIR

10. HYDRAULIC OIL TANK

4. REDUCTION VALVE (WITH AIR FILTER)

11. DRAIN COCK

5. CHECK VALVE

12. DRAIN COCK)

6. AIR PRESSURE SENDING UNIT

13. UNLOATER VALVE

7. SAFETY VALVE

6-8

LL

SECTION VII TROUBLESHOOTING Never neglect any small malfunctions.

Continuing to

lowing chart contains a list of possible troubles which

work with malfunctions may lead to fatal accidents and

may be experienced with this machine .

cause expensive and time consuming repairs.

relating to the engine. refer to the Engine Manual.

Cause

Trouble I . All motions slow Lack of hydraulic power

function of some cylinders

\) Supply hydraulic oil.

2} Aeration in suction pipe

2) Tighten

3) Hydraulic

3)

Repair or replace .

4)

Readjust or· replace unit.

pump trouble

Maladjustment of main relief valves

5) Readjust

or replace unit.

6)

Maladjustment of pilot relief valve

6) Readjust

or replace unit.

7)

Drop in engine speed

7) Refer

to Engine Manual.

8} Drop in engine power

8) Refer

to Engine Manual.

1) Damage

1) Repair

or replace.

2) Directional control

2) Repair

or replace .

3) Cavitation in the cylinder

3)

4) Pilot

4) Repair

to cylinder packing

valve or overload valve functioning improperly

valve functioning improperly

Loose pilot piping

Bleed air from the cylinder.

1) Repair

2) Control valve or overload valve trouble

2)

Too heavy load in bucket has caused the overlo ad valve to function.

or replace.

5) Retighten.

\) Damage to cylinder packing

3)

4. Swing impossible

pump trouble

hose clamp or replace hose.

5)

5)

3. Cylinders do not hold position with control levers in neutral.

Remedy

1) Lack of hydraulic oil

4) Pilot

2. Lack of power or poor

The fol -

or replace.

Repair or replace.

3) Decrease

load to bucket (dump).

4) Pilot valve functioning improperly

4)

\) Brake valve t rou ble

\ ) Repair or replace.

Repair or replace .

2)

Control valve trouble

2) Repair or replace.

3)

Swing motor trouble

3)

Repair or replace .

4)

Damage to swing gears

4)

Repair or replace.

5)

Repair or replace.

5) Damage

to swing bearings

6) Pilot valve functioning improperly

7)

Damage to swing reduction unit

For matters

6) Repair or 7)

replace .

Repair or replace.

(Contmued)

LL

7-1

Cause

Trouble 5. Swinging speed too slow

6. Abnormal sound while swinging

7. Difficult to control swing when braking 8. Travel not smooth

I) Brake valve

functioning improperly

3) Swing motor trouble

3) Repair or replace.

4)

Hydraulic pump trouble

4) Repair

I)

Insufficient greasing to swing gear and bearing

I) Lubricate .

2) Insufficient oil in swing reduction unit

2) Lubricate .

I) Brake

I) Repair

valve functioning improperly

or replace.

2) Readjust

I) Crawlers too

I) Adjust

tight

trapped in links

valve functioning improperly

I) Hydraulic

pump troubl~

tension .

2) Clean.

3) Repair or replace.

4) Repair

I)

or replace.

Repair or replace .

2) Reduced engine output

2) Repair or replace.

3) Maladjustment of main relief valves

3) Readjust

4) Low hydraulic oil level

4) Supply

5) Travel motor trouble

5)

Repair or replace .

6) Brake valve

6)

Repair or replace .

functioning improperly

7) Damage

to 0 ring or seals in the swivel joint

I) Unbalanced

tension between the two

hydraulic oil.

7) Repair

or replace.

I) Adjust

tensio n .

crawlers

machine does not go straight.

2)

Unbalanced pressures of main relief valves

3) Travel motor trouble

2)

Readjust .

3) Repair or replace.

1)

Oil cooler core clogged

I) Clean.

2)

Engine V-belts slipping

2) Readjust or replace .

3) Lack of hydraulic oil

7-2

or replace.

2) Maladjustment of brake valve setting

4) Damaged travel reduction unit

II. Abnormal rise of hydraulic oil temperature

or replace .

2) Repair or replace.

3) Brake

10. While travelling,

I) Repair

2) Control valve functioning improperly

2) Something

9 . Lack of tractive force

Remedy

3) Supply

hydraulic oil.

4)

Hydraulic oil contaminated

4)

Change hydraulic oil.

5)

Hydraulic pump trouble

5)

Repair or replace .

LL