Kobelco SK030SR-2 SK035SR-2 Operator's Manual PDF

OPERATOR'S MANUAL HYDRAULIC EXCAVATOR

SK030SR-2 SK035SR-2

Applicable: SK030SR-2 PW08-20001~ Applicable: SK035SR-2 PX09-08001~ S2PW00003ZE-01

APPLICABLE NO.

SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

READ, UNDERSTAND AND FOLLOW ALL SAFETY "~ PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS

MANUAL BEFORE OPERATINGTHE MACHINE.

BOOK CODE NO. S2PW00003ZE01

J

Any use of editorial or pictorial content is strictly prohibited without express written permission from Kobelco Construction Machinery America, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 Kobelco Construction Machinery America, LLC. All Rights Reserved.

FOR

EWORD

GENERAL ¯Thismanualcontains procedures to aid theoperator gainpeakperformance througheffective, economical machineoperation and maintenance for the KOBELCOHydraulicExcavators. ¯ Beforeoperating the machine, operators mustthoroughly readand understand all Safety,Operation and Maintenance instructions foundinthismanual.

Failure to follow theinstructions givenin thismanual maylead to serious injury to persons andor equipment failure. ¯ Operators andpersons working withthismachine shouldcontinually studythismanualuntilproperSafety, Operation and Maintenance procedures are completely understood. ¯Thismanualdescribes thebasicoperating techniques.

Skillis gainedas theoperator utilizes thesetechniquesandperfects themwithan actualmachine. ¯ Someillustrated pictures maybe different fromyourmachine, as technical improvement is continuous, manuals areperiodically updated to reflect thesechanges. ¯ Thismanualmaynot containattachments and optional equipment thatare available in yourarea.Please contactan authorized KOBELCODistributor forany optional attachments required. ¯It is expressly notedthatthismanualis described on thepresupposition thattheKOBELCO genuine partsare to be used,notincluding casesthatthepartslocally procured wereusedand/orthemachine wasarbitrarily modified by theuserinlocal. ¯ Materials andspecifications aresubject to change without notice.

PERIODIC INSPECTIONS ¯Afterdelivery of a machine, theAuthorized KOBELCODistributor willmakeperiodic serviceinspections.

Theseinspections willbe freeof chargeto theownerof themachine and willbe at timeintervals set by KOBELCO. Contactan authorized KOBELCODistributor for any Servicerelatedquestions not explained in thismanual.

NOTICE ¯ Thecontents of thismanualmaynotreflect thespecifications of themachine delivered.

Contact an authorizedKOBELCODistributor to obtainassistance in specifications formachines equipped withoptionsnot contained in thismanual. ¯ Owing to the policy of continualimprovement,changes may be made by KOBELCO CONSTRUCTION MACHINERYCO.,LTD.to any of its productswithoutany obligation on the partof KOBELCOCONSTRUCTION MACHINERY CO.,LTD.

All rightsreserved.

Any use of editorial or pictorialcontentis stdctlyprohibited withoutexpresswrittenpermission from KOBELCOCONSTRUCTION MACHINERY CO.,LTD.

O-1

FOR

ORDERING

For orderingpartsand service,informan authorizedKOBELCODistributor of your machine’sSerialNumberand Engine SerialNumber stampedin the locations,and Hour Meter read, shown on the illustrationsbelow.For futurereference, recordtheseSerialNumbersin the spacesprovidedbelow:

MACHINE No. ENGINE No. MACHINE

NO.

Manufacturer :KOBELCO CONSTRUCTION MACHINERY CO.,LTD (JAPAN)

Mo~el :I

I

Serial Number :[ Manufacturing Year:1

¯ ENGINE NO.

NOTE¯ Thenumbers intheillustrations areforexplanation onlyanddiffer from actual numbers

/ I

; I/Q

¯ HOUR

METER

HOUR METER 1/10H

0-2

NOTES

TABLE OF CONTENTS

Safety Precautions

Machine Familiarization

Basic Machine Operation

Maintenance

Transportation

Specifications

Troubleshooting

Optional Equipment

Specifications(EPA Engine) 0-3

SAFETY

Table

PRECAUTIONS

of Contents Page No.

1.1GENERAL SAFETY INFORMATION ......................................................................

1-2 1.2SAFETY PRECAUIONS ..............................................................................

1-2 1.3PRE-START SAFETY ...............................................................................

1-5 1.4SAFETY DURING OPERATION .........................................................................

1-11 1.5INSPECTION & MAINTENANCE SAFETY..................................................................

1-19 1.6BATTERY SAFETY .................................................................................

1-26 1.7WARNING LABELS & DECALS .........................................................................

1-27 1.8PROHIBITED MACHINE OPERATION .....................................................................

1-34 1.9ENDOFWORKSHIFTSAFETY .........................................................................

1-36 1.10PRECAUTIONS FOR TRANSPORTATION .................................................................

1-37 1.11 TOWING illililiimi THE iili iilllllliilillillllilaiilliilliliiiIillwliillliliii.l...lliiliill.ilii MACHINE ..... ¯ 1-38

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATFEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS OPERATION. KOBELCO CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT ARE THEREFORE NOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECHNIQUE NOT SPECIFICALLY RECOMMENDED BY KOBELCO IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

1-1

SAFETY 1.1 GENERAL

SAFETY

PRECAUTIONS

INFORMATION

WARN I N G Do Notoperate or perform anymaintenance on this machine untilallinstructions foundin thismanual havebeenthoroughly readand understood.

Improper operation or maintenance of thismachine may causeaccidents and couldresultin serious injury or death.

Alwayskeep thismanualin the operatorsseat pocket.

If it is missing or damaged, placean orderwithan authorized KOBELCO Distributor fora replacement.

If youhaveany questions, pleaseconsultan authorizedKOBELCODistributor.

c. CAUTION-Indicatesa potentially hazardous situation which, if notavoided, mayresult inminoror moderate injury.

It mayalsobe usedto alertagainstpossible damageto the machine anditscomponents andis represented as follows:

4.It isverydifficult to forecast everydanger that may occurduringoperation.

However, safetycan be ensuredby fullyunderstanding properoperatingprocedures forthismachine according to methods recommended by KOBELCO. 5. Whileoperating the machine, be sureto performworkwithgreatcare,so as notto damage the machine, or allowaccidents to occur.

whichoccurduringoperation, are 1. Mostaccidents, due to neglectof precautionary measuresand safety rules.

Sufficient careshould betaken toavoid 6. Continue studying thismanualuntilallSafety, theseaccidents.

Erroneous operation, lubrication Operationand Maintenance procedures are comor maintenance servicesare verydangerous and pletely understood by allpersons working withthe maycauseinjuryor deathof personnel.

Therefore machine. all precautionary measures,NOTES,DANGERS, WARNINGS and CAUTIONS contained in this manualand on the machineshouldbe readand understood by all personnel beforestarting any workwithor on themachine.

1.2 SAFETY PRECAUTIONS 2.Operation, inspection, and maintenance shouldbe carefully carried out,andsafety mustbe giventhe firstpriority.

Messages of safety areindicated with marks.The safetyinformation contained in this manualis intendedonly to supplementsafety codes,insurance requirements, locallaws,rules andregulations. of safetyappearin thismanualand on 3. Messages themachine.

Allmessages of safetyareidentified by the words "DANGER","WARNING"and "CAUTION". a. DANGER-Indicatesan imminently hazardous situation which, ifnotavoided, willresult indeath or serious injury andis represented as follows:

DANGER b. WARNING-Indicatesa potentially hazardous situation which, if notavoided, couldresult in deathor seriousinjuryandis represented as follows:

WARNING 1-2

WARN I NG

,"i

Theproperand safelubrication and maintenance for this machine,recommendedby KOBELCO,is outlined in thisMANUALforthemachine.

Improper performance of lubrication or maintenance procedures aredangerous and couldresultin injuryor death.Readand understand thisMANUAL beforeperforming anylubrication or maintenance.

The serviceman or mechanicmay be unfamiliar with manyof the systemson thismachine.

Thismakesit important to use cautionwhenperforming service work.A knowledge of the systemand or components is important beforetheremoval or disassembly of any component.

Becauseof the sizeof someof the machinecomponents,the serviceman or mechanic shouldcheckthe weights notedin thismanual.

Useproper lifting procedureswhen removingany components.

Weightof componentstable is shown in Sec.6 SPECIFICATIONS.

SAFETY

PRECAUTIONS

Thefollowing is a listof basicprecautions thatmust alwaysbe observed.

.

1.Readand understand all Warningplatesand decalon themachine beforeOperating, Maintaining or Repairing thismachine.

2. Alwayswearprotective glassesand protective shoeswhenworkingaroundmachines.

In particular,wearprotective glasseswhenusinghammers, punchesor driftson anypartof themachineor attachments.

Use weldersgloves,hood/goggles, apronandtheprotective clothing appropriate to the weldingjob beingperformed.

Do not wearloose fitting ortornclothing.

Remove allringsfromfingers,loosejewelry, confine longhairandloose clothing beforeworking on thismachinery.

3.Disconnect the batteryand hanga "DoNot Operate"tag in the Operators Compartment.

Remove ignition keys.

4.Ifpossible, makeallrepairs withthemachine parked on a level,hardsurface.

Blockthemachine so it doesnotrollwhileworkingon or underthe machine.Hanga "Do NotOperate" tagin theOperatorsCompartment.

5.Do notworkon anymachine thatis supported only by lift,jacksora hoist.

Always useblocks or jack stands, capable of supporting themachine, before performing any disassembly.

:\

WARNING

Do not operatethismachineunlessyou haveread and understand the instructions in thisMANUAL. Improper machine operation is dangerous andcould result ininjury ordeath.

allpressure in air,oilor water systems be6. Relieve foreanylines, fittings orrelated itemsaredisconnectedor removed.Alwaysmakesureall raised components areblocked correctly andbe alertfor possible pressure whendisconnecting anydevice froma systemthatutilizes pressure.

7.Lowerthebucket, blade,or otherattachments to thegroundbeforeperforming anyworkon themachine.

If thiscannot be done,makesurethebucket, blade,ripperor otherattachment is blocked correctly to prevent it fromdropping unexpectedly.

1-3

g,

Use stepsand grab handleswhen mountingor dismounting a machine.Cleanany mud or debrisfromsteps,walkways or workplatforms beforeusing.Alwaysfacethemachinewhenusing steps,ladders andwalkways.

Whenit is notpossibleto usethedesigned accesssystem, provide ladders, scaffolds, or workplatforms to perform saferepair operations.

Referto itemL on Ipage1-71.

Toavoidbackinjury, usea hoistwhenlifting componentswhichweigh20kg(451bs)or more.Make sureallchains, hooks, slings, etc.,arein good condition andare thecorrect capacity.

Be sure hooksarepositioned correctly.

Lifting eyesare nottobe sideloaded during a lifting operation.

be alertforhotpartson machines 10.Toavoidburns, whichhavejustbeenstoppedandhot fluidsin lines,tubesandcompartments.

11.Be carefulwhenremovingcoverplates.Graduallybackoffthelasttwocapscrews or nutslocatedat opposite endsof thecoveror deviceand carefully prycoverlooseto relieve anyspring or otherpressure,beforeremovingthe lasttwo capscrews or nutscompletely.

12.Be careful whenremoving fillercaps,breathers and plugson the machine.Holda rag overthe capor plugto prevent beingsprayed or splashed by liquidsunderpressure.

Thedangeris even greater if themachine hasjustbeenstopped becausefluids canbe hot.

13.Alwaysusetheproper toolsthatarein goodcondition andthataresuited forthejobathand.Be sureyouunderstand howto usethembeforeperforming anyservicework. allfasteners withthesamepartnumber.

14.Reinstall Do notusea lesserquality fastener if replacementsarenecessary.

15.Repairswhichrequireweldingshouldbe performedonlywiththebenefit of theappropriate referenceinformationand by personneladequately trainedand knowledgeable in welding procedures.Determinetype of metal being weldedandselectcorrect weldingprocedure and electrodes, rodsor wireto provide a weldmetal strength equivalent at leastto thatof theparent metal.Makesureto disconnect batterybefore anyweldingprocedures areattempted.

SAFETY

PRECAUTIONS

16.Do notdamagewiringduringremoval operations.

Reinstall thewiring so itis notdamaged norwill be damagedin operation of themachineby contacting sharpcorners, or by rubbing against some object or hotsurface.

Do notconnect wiringto a linecontaining fluid.

17.Be sureall protective devicesincluding guards andshields areproperly installed andfunctioningcorrectly before starting a repair.

Ifa guardor shieldmustbe removedto performthe repair work,useextracaution andreplace theguardor shield afterrepair iscomplete.

18.The maintenance and repairworkwhileholding thebucketraisedis dangerous dueto thepossibility ofa falling attachment.

Don’tfailtolower theattachment andplacethebucketto theground before starting thework.

19.Looseor damagedfuel,lubricant and hydraulic lines,tubesand hosescancausefires.Do not bendorstrike highpressure linesor install ones whichhavebeenbentor damaged.

Inspect lines, tubesandhosescarefully.

Do notcheckforleaks withyourhands.Verysmall(pinhole) leakscan result ina highvelocity oilstream thatwillbeinvisible closeto thehose.Thisoilcanpenetrate the skinand causepersonalinjury.Use cardboardor paperto locatepinhole leaks.

20.Tighten connections to thecorrecttorque.

Make surethatallheatshields, clamps andguards are installed correctly to avoidexcessive heat,vibrationor rubbing against otherpartsduring operation.Shields thatprotect against oilsprayonto hotexhaustcomponents in eventof a line,tube orsealfailure mustbeinstalled correctly.

21.Do notoperate a machine if anyrotating partis damagedor contacts any otherpartduringoperation.

Any highspeedrotating component that has beendamagedor alteredshouldbe checked forbalance beforereusing.

1.4

22.Be careful whenservicing or separating thetracks (crawlers).

Chipscanfly whenremoving or installing a track(crawlers) pin.Wearsafety glasses andlongsleeve protective clothing.

Tracks (crawlers)canunroll veryquickly whenseparated.

Keep awayfromfrontand rearof machine.The machinecan moveunexpectedly whenboth tracks (crawlers) are disengaged fromthe sprockets.

Blockthemachine to prevent it frommoving.

SAFETY

PRECAUTIONS

1.3 PRE-START SAFETY Manyfailures thatoccurduringmachine operation or servicing resultfromneglecting fundamental safetyprecautions.

The following safetyprecautionsaregivento prevent suchfailures, butthey areonlya partof whatyoumustfollow.

Read,understand andfollowallsafety precautions foundin thismanualand on the machine thoroughly before operating themachine.

A. OBSERVE SAFETY PRECAUTIONS Follow allsafetyrules, precautions, andoperatingprocedures.

If thereareotherpersonnel and flagmenworkingin the area,havethem observe thespecified signs.

OBSERVE ALL SAFETY PRECAUTIONS

B. WEAR PROTECTIVE CLOTHING Wearwellfitting safetyshoes,hardhat,and working clothes, andputon protective glasses, faceshield,earprotection and gloves.When necessary, wearreflective vest.

Do notweartheworkingclotheswithadheredoil, since itiseasytocatch fire.

PMJ-I-1

WEAR PROTECTIVE

CLOTHING

C. READ and UNDERSTAND THE OPERATION & MAINTENANCE MANUAL Beforeoperating themachine, readandunderstand this OPERATION & MAINTENANCE MANUALthoroughly in orderto usethemachine effectively andsafely.

KEEP OPERATION & MAINTENANCE MANUAL IN STORAGE KeepthisMANUALin thespecified storage locatedbehind theoperators seatforquickreference. Should the OPERATION & MAINTENANCE MANUAL become lost or damaged, contactan authorized KOBELCODistributor to order the OPERATION & MAINTENANCE MANUAL.

1-5

READ MANUAL / KEEP IN STORAGE

SAFETY

PRECAUTIONS

E. DO NOT OPERATE MACHINE EXCESSIVELY TIRED OR UNDER THE INFLUENCE OF DRUGS Yourpoorphysical condition causesimproper reactions.

Voluntarily refrain fromoperating the machinewhenfeelingexcessively tired,and neveroperate themachineundertheinfluence of drugs.

PL-I-1

REFRAIN POOR PHYSICAL CONDITION F. PREPARE FOR EMERGENCIES Havea fireextinguisher andfirstaidkitready for emergencies.

Knowhowto operate thefire extinguisher andknowwheretheFirstAidKitis located foreasyaccessin caseof emergency.

Preparebeforehand the communication means in caseofanyemergency, andtakenoteof telephonenumbersfor emergencycontact.

PR-1-5

PREPARE FOR EMERGENCIES G. ENSURE SAFETY AT THE WORK SITE Knowthe workarea!Beforeoperating the machine, carefully survey andrecord thelandand worksite features to prevent the machine from falling orthesoilfromcaving in.

LOCK LEVER BEH. ENGAGE SAFETY FORE LEAVING MACHINE Beforeleavingthe operator’s seat,movethe safetylockleverto the"LOCKED" (Up)position.

Thiswillnotallow operation ofanyhydraulic controls shouldtheybe accidentally moved.If theleveris notsetto the"LOCKED" position andhydraulic controls aretouched accidentally, the machinemay move suddenlyresultingin serious injury.

Alsobeforeleavingthe machine,lowerthe bucket to theground, placethesafety locklever in the "LOCKED"(Up)position, stopthe engineandremovethestarter switchkey.

PMJ-1-3

WORK SITE SAFETY-KNOW THE AREA

LOCK(UP)POSITION

¢2 PAE-1-2

SAFETY LOCK LEVER 1-6

SAFETY

PRECAUTIONS

I. SIGNS, SIGNALS & FLAGMEN Install signson softshoulders andgroundareas,andhavea flagmandirecttheoperation if necessary.

Theoperator shouldnotemarks andfollowsignals fromtheflagman.

Allpersonnelshouldknowthemeaning of thesigns, marks,and signals.

Onlyoneflagmanshould givethesignsandsignals.

I

" . . ¯ ..- . . .

,

¯

PMJ-1-5 i

SIGNS, SIGNALS & FLAGMEN J. KEEP FIRE AWAY FROM FUEL AND OIL Oil,antifreeze, andespecially fuelarehighly flammable.

Neverusefirenearthe machine.

Securely tighten allfuelandoilcaps.

Keepfuel and oil in the designatedstorageareas.

Promptly cleanup anyoilspillsanddispose of wasteproperly.

PAE-1-3

KEEP FIRE AWAY FROM FUEL AND OIL K. SURELY INSTALL SAFEGUARD Confirm thatallguards andcovers aresecurely and properly installed.

If damaged, immediatelyrestore themto propercondition.

Do notoperate themachinewithout guardsor covers.

Makesureto maintain themin normal condition.

PMJ-1-6

SURELY INSTALL SAFEGUARD L. MOUNTING & DISMOUNTING MACHINE Whengettingon and offthe machine, always maintain threepointcontact by usingthehandrailsandstep.Inspect andcleanhandrails, step,and mountingparts.Removeslippery materials, suchas lubricants, andmud.Always placethecabentrance parallel to thetracks (crawlers) before stopping theengine fordismounting.

CANOPY !111

.

MOUNTING & DISMOUNTING

1-7

MACHINE

SAFETY M.

PRECAUTIONS

PAY ATTENTION TO WORKING MACHINE Do not approach a workingmachine.

Makesure to makevisual contact withtheoperator before approaching a workingmachine.

PA-1-5

PAY ATTENTION TO WORKING MACHINE N. USE THE PROPER OPTIONAL AI"FACHMENT Useonlyoptional attachments designed forand approvedby KOBELCO.Read,understandand followallinstructions in themanualaccompanyingtheoptional attachment.

Useof anyoptionalattachmentnot approvedby KOBELCO in writing, cancauseserious injuryto personnel,damageto themachine andits components andshorten thelifeof themachine.

Contact an authorized KOBELCODistributor for optional attachments available forthemachine.

©

) PR-1-14

USE PROPER ATTACHMENT O. PREVENT FIRES Leaking orspilled fuel,lubricants andhydraulic oilarefirehazards.

Cleanandproperly dispose ofspills astheyoccur.

Repair orreplace allleakingcomponents to prevent fire.Also,cleanthe machine regularly removing alldebristo help prevent fires, payparticular attention to removal of leaves, sticks, paperetc.Keepfireextinguisherin an accessible areaandknowhowto usethefireextinguisher should a fireoccur.

PMJ-1-48

PREVENT FIRES-CLEAN UP SPILLS P.CONFIRM OPERATING CONTROL PATTERNS Slowly operate thecontrol levers to confirm the operating patterns in advance.

Thefigureshowsthe standard operating systernforLHoperating lever, specified in ISO. Referto page2-9 formoredetailsregarding thedifferent operating control functions.

LEFTCONTROLLEVER

P~I~

CONFIRM OPERATING 1-8

PATTERNS

SAFETY Q.

PRECAUTIONS

KEEP CLEAN CAB FLOOR AND DRIVER’S SEAT Do notplaceanypartsandtoolsin thedriver’s cabintoprevent injury duetoslippage andstumbling.Removeanydebrisfromthecab floor, control levers, handrails, etc..Makesuretokeep alloperating controls cleanatalltimes.

El

PR-I~I

KEEP CLEAN AROUND DRIVER’S SEAT R. HOW TO HANDLE LIFE HAMMER-CAB only A lifehammeris provided on therightsideof cab.In caseof emergency, takethelifehammer,breakthecabglass,andescapefromthe cab.In addition, thelifehammeris equipped witha cutteron theleversideto cuttheseat belt, etc.

LIFE HAMMER--~

PAE-1-6

HOW TO HANDLE LIFE HAMMER-CAB only S. PERFORM PRE-START INSPECTION Walkaroundthe machinebeforestartingthe machine,performa PRESTARTinspectionof the machineand make noteof any abnormality.If anyproblems arefound, repair or replace defectivecomponentsimmediately.DO NOT OPERATETHE MACHINEuntilall problemareas are properlyrepaired.Alwayskeepthe windshield, workinglamps,and mirrorsclean forgoodvisibility.

PV-I-IO

PERFORM PRE-START INSPECTION T. TAG OUT MACHINE DURING MAINTENANCE Beforeperforming any inspection or maintenanceprocedures to themachine, filloutand postto the operators controls a "DO NOTOPERATE"tag to warnpersonsnot to startthe machine.Ordertag Part No. YN20T01320Pl. Makesureto informthesupervisor andalloperators thatthemachine is underinspection or maintenance and theywill be informedwhen themachine is readyfornormaloperation.

£

PAE-1-7

"TAG-OUT" MACHINE

1-9

SAFETY

PRECAUTIONS

U. USE CAUTION NEAR NOISE If noiseis highduring operation, hearing loss mayresult.

Approved hearing protection should be usedif personnel willbe exposedto high noiselevels fora longperiod oftime.

SK32001010

USE CAUTION NEAR NOISE

V. AVOID HOT SURFACES & AREAS Immediately afterthemachine is operated, the temperature and pressure of the enginecoolant,engine oil,andhydraulic oilareveryhigh.

Burnsmay resultif capsareremoved, or oil, water,or filters arechanged undertheseconditions.

Waituntilthetemperature goesdown, before attempting tocheckfluids or change illters.

SK32001012

AVOID HOT SURFACES & AREAS

1-10

SAFETY

PRECAUTIONS

1.4 SAFETY DURING OPERATION A. PASSENGERS Thisequipment is notintended or designed for thetransportation of persons.

Neverallowpersonsto rideon themachine.

Serious injuryor deathcan resultfromallowing passengers on or in themachine.

PR-1-17

NO PASSENGERS B. STARTING ENGINE Startenginefromtheoperator’s seat.Do not short circuit thestarter circuit orbattery tostart theengine.Thismay causeseriousinjuryor causedamageto theelectrical system.

PAJ-1-8

DO NOT SHORT CIRCUIT C. HORN BEFORE STARTING ENGINE Soundthe hornbeforestarting the engineto alertpeoplethatthemachine is beingstarted.

Makesureno one is nearthe machine.

HORN SWITCH

Do not startthe engineif the machinehas been taggedout.

PAE-1-9

SOUND HORN BEFORE STARTING CHECK AFTER STARTING ENGINE Makesureto checkmachinefor properfunctioning afterstarting theengine.

Slowlycycle attachments, swing,andtravelfunctions in an areawithsufficient space,without obstacles, andpersonnel.

Failure to do so couldresultin injuryor machinedamage.Makenote of any abnormalities andrepairas needed.

PMJ-1-21

CHECK AFTER STARTING ENGINE

1-11

SAFETY

PRECAUTIONS

E. WARM UP MACHINE BEFORE OPERATION Takea sufficient timeto warmup themachine, especially at coldseason,otherwise the responseof machineagainstthe operationof operating leveris delayed whichmaycauseinjuryand/ormachinedamage.

RED

~

PM-1-24

WARMING

UP OPERATION

F.CONFIRM OPERATING CONTROL PATTERN Slowly operate thecontrol levers to confirm the operating patterns in advance.

Makesurethe operation control pattern isaccording to theindication plate.

PA-1-11

CONFIRM OPERATING PATTERN G. CONFIRM TRAVEL DIRECTION Makecertain of thelocation of thetravelmotorsbefore operating travel.

Payattention thatin thecasewherethetravel motors areinthefrontside,thetravel function isreversed.

Soundhornbeforemovingthe machineto informany personnelaroundthe machinethat themachine is nowin operation.

CONDITION WHERE THE TRAVEL DIRECTION IS REVERSED

T

:::::::::::::::::::::

..:.:~

KNOW TRAVEL MOTOR POSITION H. DO NOT HIT CAB WITH ATTACHMENT Checkclearencebetweenbucketand cab beforeoperation.

Slowlycyclebucket, checkfor interference witharmandcab,particularly if a lifting eyeis weldedon bucketbottom.Exercisecarewhenoperating thebucketnearthe cab.

~

CAUTION FOR ’INTERFERENCE

) PAE1- 13

DO NOT HIT CAB

1-12

SAFETY

PRECAUTIONS

I. SWINGING FUNCTION Makecertain theswingareaof machine is clear of all personsand obstacles beforeoperating swingcontrols.Soundhorn beforeswinging machine.If necessary, havea flagmansignal operator duringoperation to helpprevent injury to personsor damageto obstacles and equipment.

E1

PA-1-14

SLEW / SWING / TRAVEL SAFETY J. TRAVELING ON SLOPE Useextremecaution whentraveling on slopes, machine couldturnover or slidecausing injury or machinedamage.

Keep the bucketat the heightof 30-40cm (12-16inch) abovethe groundlevel,andwear thesafety beltatalltimes.

Nevermakea changeof direction on theslope or crossovertheslope.

PMJ-1-11

K. FROZEN & SNOW COVERED WORK SITES Use extremecautionwhen operating the machineon frozenor snowcoveredworksites.

Operateallcontrols slowlyandcautiously to preventsuddenmovements suchas start/stop/ turn,thatmay causethemachineto unexpectedlyshift, slideor move.Evenon theslightest slope,whensnowis presentor workareais frozen, it canallowa machine to unexpectedly move.Snowon shoulders or snowdriftscan be much deeperthan expected.The machine can easilybecomeburiedundersuch conditions.Useextreme caution whileoperating the machinearoundor in snow.

Be careful forfrozengroundthatbecomes soft alongwiththeincrease of ambient temperature.

L. TRAVEL Position theattachment as showninillustration beforebeginning travel.

On roughterrain move the machineat slowspeeds,and do not turn suddenly.

Avoidtravelling overobstacles.

Shouldit becomenecessary to traveloveran obstacle, keeptheattachment lowto theground andtravelat extremely slowspeed.

PAY ATTENTION ON SLOPE

.2_ PMJ-1-12

USE EXTREME CAUTION ON FROZEN OR SNOW

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PAE-1-15

TRAVEL POSTURE

1-13

SAFETY

PRECAUTIONS

M. GROUND STABILITY Becertain thecondition oftheworksiteisstable and capableof supporting themachineweight duringoperation.

Do notoperate attachment too closeto themachine.

Operation of themachine on shoulders or filled areascouldcausethemachineto becomeunstablepresenting a work hazard.

Position thecrawler at rightangleto shoulder and thetravelmotorsto therearof themachine, allowing forquickreversal, should the workareabecomeunstable.

PMJ-1-14

WORK ON STABLE

GROUND

N. LIFTING Thismachine is an excavator.

Useextreme cautionwhenliftingor movingheavyloads.Use properlifting equipment ratedat a capacity to handle the load. NEVER USE BUCKET TEETH TO LIFT OR MOVE HEAVY LOADS.

OPERATING ON INCLINES OR SLOPES Operation of thismachine onan incline or slope may causethe machineto becomeunstableor unbalanced.Work up and down inclinesor slopes, neveracross.NeverSwingor turnmachinearoundon slopes.

Builda levelareafor themachine to operate.

Operate controls carefullyto preventsuddenmovements whichmay causethemachine to slideor tipover.

P. WORKING AROUND ELECTRIC POWER LINE Ifitissuspected thatutility lines suchasphone or electrical powerarein theworkarea,contactthelocal utility authority forlinelocation BEFOREbeginning work in the area.Use extremecautionaroundelectrical powerlines.

Keepa sufficient distance awayfromelectrical linesduring operation.

Seechartbelowforminimum distances.

LINE VOLTAGE MINIMUMDISTANCE-M(FEET) 0-50,000 3.0M (10) OR MORE 50,000-200,000 4.5M (15) OR MORE 200,000-350,000 6.0M (20) OR MORE 350,000-500,000 7.5M (25) OR MORE 500,000-750,000 10.5M (35) OR MORE 750,000-1,000,000 13.5M (45) OR MORE 1-14

PV-1-13

USE PROPER LIFTING DEVICES

X

0

PMJ-1-15

BUILD BANKING FOR SLOPE OPERATION

D PAE-1-16

KEEP A SAFE DISTANCE FROM UTILITIES

SAFETY

PRECAUTIONS

Q. WORKING AROUND UTILITY LINES UNDERGROUND At theworkaroundpresumable placeof laying power,wateror gaslineundertheground, ask theactual location of themto theorganization concerned, givea trialdigging, andproceed the workwithcareafterconfirmation fornonexistenceof themor location of them.

PMJ-l-17

CHECK LOCATION OF UTILITIES R. PARKING THE MACHINE Alwaysparkthemachineon a firm,levelsurface.

If nofirmlevelsurface isavailable, block thecrawlerand lowerbucketanddozerblade to the groundto helppreventmachinemovement.

Shouldthe machinebe parkedon a roadway, movethemachine to theshoulder to allowpassingoftraffic.

Alsopostreflective warning signs and markers at a distance fromthe machine to safelywarnmotorists.

Referto localcodeand regulations regarding theposting of workarea warningsand markers.

~

OCK

PAE-1-17

PARKING SAFETY

S. RESTRICTED WORK AREAS In worksiteswithlimited height andSwingareassuchas tunnels, bridges, aroundelectrical power lines, other utilities, orinside structures, useextreme caution in keeping themachine and itsattachment ata safedistance toprevent personalinjury and/orequipment or structure damage.

Usea flagmanto guidetheoperator.

PMJ-1-9

USE EXTREME CAUTION AT RESTRICTED AREA T. DO NOT WORK UNDER PRECIPICES Don’tdigunderprecipices.

It causesfalling rocksor loosening of theprecipice resulting in injuryand/ormachinedamage.

"M J-I-20

DO NOT DIG UNDER PRECIPICE 1-15

SAFETY

PRECAUTIONS

U. WORK WITH SUFFICIENT LIGHTING Whenworking in darkplaces, turnon theworkinglight.

Andifrequired, provide additional lightingfacilities toensure thevisual field.

Stopworkingwhenit is impossible to ensure thevisual field clueto fog,snoworrain.

PMJ-1-22

WORK WITH SUFFICIENT LIGHTING P. SET LIMITS TO WORKING AREA Setlimits around theworking areatoavoidcollision orpersonal injury.

Makesureto checkfor obstacles and personnel whileswinging.

Usea flagmanto guidethe operatorwhenevernecessary.

PMJ-1-23

SET LIMITS TO WORKING AREA W. CAUTION FOR WORK IN URBAN AREAS It is dangerous to allowotherpersonnel to enterintotheworking area.

Maketheworking areaoff-limits to otherpeople providing caution plates.

Makesureto providea flagman in working areaswithheavytraffic to avoidaccidents.

P - -18

USE A FLAGMAN WHEN NECESSARY X. PROHIBITION TO USE NON-SERVICED MACHINE The use of non-serviced machinemay cause an unexpected accidentor breakdown.

Stopoperation of a faultymachine.

Makesure to repairany abnormalities beforeresuming operation.

PMJ-1-25

DO NOT USE NON-SERVICED MACHINE 1-16

SAFETY

PRECAUTIONS

Y. SLIPPERY GROUND SURFACE Usecautionwhenoperating machineon boards or steelplates.

Boards andsteelplates become veryslippery whenwet.

Payspecial attention whenworking on inclined areas.

Provide a deviceto prevent skidding, andproceedto workwithextremecare.Piledup tree leavesor branches alsomaycauseskidding.

I

PMJ-1-26

PAY ATTENTION AT SLIPPERY SLOPE Z. STRENGTHEN SOFT GROUND Whenworking on a softgroundor marshyarea, the machinemay sink.

Provide logsor lumberto pavehorizontally to preventthemachine fromsinking.

Frozengroundbecomes softalongwiththeincreaseof ambienttemperature.

~1_27

STRENGTHEN

SOFT GROUND

AA. LOOSENED GROUND AFTER RAIN After raining, there isa possibility ofgetting into dangerof tumbling downor falling downof the machinewithvibration and weightof the machinedueto loosened shoulder of road.

Payattention to loosened precipice or shoulder of road,and do notaccessto suchplace without care.

PMJ-1-28

PAY ATTENTION TO LOOSENED GROUND BB. LOOSENED GROUND AFTER EARTHQUAKE OR DYNAMITING Payattention totheloosened precipice orshoulderof road,andfalling rocks.Alsopayattentionto theunexploded dynamite.

PMJ-1-29

PAY ATTENTION TO LOOSENED GROUND 1-17

SAFETY

PRECAUTIONS

CC. BOOM, ARM & ATTACHMENTS Givetheworkyouaredoingyourundivided attention.

Makecertain theattachment beingused is suitedforthejobat hand.Makecertain of obstaclesin the work areaand operatethe machine withinthoselimits.

If necessary have a flagman signaltheoperator to prevent injury to personsor damageto the machineor obstacles in theworkarea.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

7’’’V~ln’

PAE-1-19

SLEW / SWING SAFETY DD. STABILIZE ATTACHMENTS Stabilize allattachments removed fromthemachineto prevent theattachment falling over.

SK32001025

STABILIZE ATTACHMENTS

1-18

SAFETY

PRECAUTIONS

1.5 INSPECTION & MAINTENANCE SAFETY A. UNDERSTAND INSPECTION/MAINTENANCE PROCEDURES Incorrect maintenance maycausenotonlydamageson themachine, butalsoinjury.

Make sureto readand fullyunderstand the maintenance proceduresand safetyprecautionsdescribed in the Operation and Maintenancemanualbeforeperforming any maintenancein thismachine.

\

/

PL-1-15

UNDERSTAND

PROCEDURES

B. MEETING PRIOR TO WORK To prevent any accidents or injurydueto errors,havea meeting before startworking.

When a flagman is provided, makesurethatallsignalsareunderstood accordingly.

i PL-1-16

MEETING PRIOR TO WORK C. ORGANIZE AND CLEAN UP WORKING AREA Organizeand cleanup the workingarea.Remove any obstaclesand also remove any grease, oil,paint, broken pieces, etc.,fromthe working areatoavoidinjury.

PMJ-1-30

CLEANING UP WORKING AREA

1-19

SAFETY

PRECAUTIONS

D. "TAG-OUT" MACHINE Beforeperforming any inspection or maintenanceprocedures to themachine, filloutand postto the operators controls a "DONOT OPERATE"tag to warnpersonsnot to startthe machine.Ordertag Part No. YN20T01320P1.

Alsoinform thesupervisor andalloperators that themachine is underinspection or maintenance andtheywillbe informed whenthemachineis readyfornormaloperation.

O

PAE-1-7

"rAG-OUT" MACHINE E. TOOLS & EQUIPMENT Usetheproper toolsandequipment forthetask at handKnowtheproperuse of the toolsand equipment beforestartingany inspection or maintenance procedures.

PR-1-32

USE PROPER TOOLS F. SET THE ATTACHMENT Alwaysset the machinein the hydraulic oil checkposition on firmlevelgroundbeforeattemptingany inspection or maintenance procedures to themachine.

If it isnotpossible to put themachinein thisposition, securethe boom,armandattachment to helpprevent sudden movement. ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB.

HYDRAULICOIL LEVEL CHECK POSITION

BUCKET

~

~

DLOAZDEER

:::::::::::::::::::::::::::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: .:~,: ::: :,’:.

1: PAE-1-22

HYDRAULIC OIL LEVEL CHECK POSITION G. CLEAN THE MACHINE Keepthemachine cleanandfreeof debris, excessor spilled lubricants, fuelandfluids.

Use approvedsolvents,detergents and waterto cleanthe machineand its components on a regular basis.

Be careful notto allowwaterto reachelectrical components.

Seriousdamage canoccurto theelectrical systemby allowing waterto reachtheelectrical components.

Never cleaninsideof cab,or electrical components withpressurized wateror steam.

PR-1-33

KEEP MACHINE CLEAN 1-20

SAFETY

PRECAUTIONS

H. STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE "LOCKED" (UP) POSITION beforeattempting anyinspection or maintenance procedures to themachine.

Failure to stopenginecould result inserious bodily injury ordeath.

STOP

STOP

I~A.1.20

STOP ENGINE / ENGAGE SAFETY LOCK LEVER I. REFUELING Movethemachine to a wellventilated areafor refueling.

Useonlyspecified fuelas described in the MAINTENANCE sectionof thisMANUAL. Immediately cleanup allspilled fuelanddisposeof properly.

Afterrefueling is complete, securely tighten fuelcap.

Neverusethefuelforcleaning.

FUEL

¯

PAE-1-3

REFUELING J. SUPPORT THE MACHINE If it becomesnecessary to raisethe machine forinspection or maintenance, alwayssupport the machineby positioning the machineas shownin theillustration andusesafety supports orblocks, witha sufficient capacity rating tosupport the machine,underthe crawler/frame.

NEVER INSPECT OR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTL Y SUPPORTED. PMJ-1-31

SUPPORT THE MACHINE K. HYDRAULIC PRESSURE Undernormal conditions, allcircuits of thehydraulicsystemare underextremepressure.

Wheninspecting forleaks, usea smallpieceof cardboard,wood or metalto locateleaks.

SMALL (PINHOLE) LEAKS CAN DANGEROUS IF CONTACT WITH SKIN OR EYES IS MADE. Wear approved safety glasses or faceshield, gloves, hardhat,safety shoesandworkclothes during allinspection and maintenance procedures.

Seekforimmediate medical assistance if injury occurs

1-21

PR-1-37

CHECKING FOR HIGH PRESSURE LEAKS

SAFETY

PRECAUTIONS

L. PRESSURIZED FLUIDS & LUBRICANTS Alwaysrelease pressure fromhydraulic reservoir,enginecoolant, fuelsystemandallsystemscontaining pressure beforeremoving any caps or components¯ BE CAUTIOUS OF HOT FLUIDS AND GASSES FROM SYSTEMS ON MA CHINES THA T HA VE JUST BEEN STOPPED. ALLOW SUFFICIENT TIME FOR SYSTEMS TO COOL BEFORE PERFORMING ANY INSPECTION OR MAINTENANCE PROCEDURES.

,

~

PA-1-21

RELEASE HYDRAULIC TANK PRESSURE M. CARE ABOUT VENTILATION Maintenance forthe machineindooror in the place with poor ventilation may cause poisonning by gas.

Payspecial attention to ventilate anyexhaust gas,fuel, cleaning oil,paint orsimilar articles.

Ensureproperventilation to theworkingarea whenthe machineis operatedindoors.Providea ventilating fan,ifrequired¯

¯.~....

-.. :-......"

D e ---.-. ¯°

PMJ-1-51

CARE ABOUT VENTILATION N. PREVENTION AGAINST FIRE It is unavoidable to handleflammable materialssuchasbattery, fuel, lubricating oil,etc.ina maintenance area;therefore, follow thegeneral guidelines to prevent fire: ¯ Usea nonflammable cleaning oil to cleanthe parts, etc. ¯ Extinguish anybarefirepossible toinflame. ¯ Provide an appropiate firefighting equipment suchasfireextinguisher. ¯Refrainfromsmoking duringmaintenance work. ¯ Putawayanyflammable materials whengrindingworkor welding work.

PL-1-19

PREVENTIVE MEASURE AGAINST FIRE

O. USE APPROVED WORK LIGHTS Use onlyapprovedworklightswhenperforming inspection and maintenance procedures to prevent possible fireor explosion.

Certain types of worklightsshouldnot be useddue to the possibility of ignition of certain flammable gassesandfluidsfromthemachine.

PR-1-40

USE APPROVED WORK LIGHTS 1-22

SAFETY

PRECAUTIONS

R DO NOT HEAT HYDRAULIC EQUIPMENT OR PIPING Neverapplyheatto hydraulic equipment or piping,suchas welding, soldering, heating with torch, etc.

Heating of hydraulic components or pipingwill causegas expansion, whichcan easilycatch fireand/or explode.

Q.

WORKING ABOVE GROUND Thereexistsdangerof falling whenworking on areasaboveground.

Be careful notto approach edges. * Makesureto use the appropiate equipment, such as laddersor a maniiftwhen working aboveground.

Inaddition, strapyourself to the properequipment accordingly. ¯Avoidspillage ofanyoilor grease. ¯Do notleaveanytoolsaround theworking area. ¯ Use extremecautionto avoidslipping while walking. * Neverjumpintoor fromclimbing equipment.

Use a step-ladder or handrailand securely maintain a threepointcontact whilemounting or dismounting atalltimes. * Make sure to read the manliftequipment operator’s manualbeforeusing. * Complywithclimbingequipment weightratings.

PL-1-21

DO NOT HEAT HYDRAULIC PIPING

"

’

PA-1-23

TAKE CARE AT ELEVATED SPOT

R. DO NOT DROP TOOLS AND PARTS Dropping of anytoolsandpartsin theworking areamaycauseinjuryor faultymachine operation.

Do notleaveanytoolsor articles in theworking area or componentcompartment.Make sure to storealltoolsproperly whentheworkis completed.

PMJ-1-34

DO NOT DROP OFF TOOLS AND PARTS S. ELECTRICAL SYSTEM Beforeperforming any inspection or maintenanceto theelectrical system,or performing any weldingprocedures, disconnect the negative(-) cablesfromthebattery terminals.

Not disconnecting thenegative(-) cablecouldcause extensive damageto theexcavator’s electrical system.

WHEN REMOVING. REMOVE A THE NEGATIVE TERMINAL FrRST4 ~

I i -

ELECTRICAL SYSTEM PRECAUTION 1-23

1

SAFETY

PRECAUTIONS

T. CAUTION TO MODIFICATION KOBELCOwillnot be liablefor anyinjuryor damagesdue to equipment modification withoutapproval.

Whenanymodification is intended, consult with an authorizedKOBELCODistributorin advance.

PMJ-1-35|

CAUTION TO MODIFICATION AFTER COMPLETION OF MAINTENANCE WORK Always,makesureto checkmachineforproper functioningwhen any maintenanceis completed: ¯Afteranymaintenance workis completed, operate theengine atlowidle,andcheck forleakagesandabnormalities. ¯Slowlyoperate eachmachinefunction to confirmproperoperation. ¯ Increasethe enginespeedgradually, and againcheckforleakages andabnormalities. ¯Operate eachoperating levernormally to confirmsmoothoperation.

PMJ-1-21

CONFIRM

SMOOTH OPERATION

P. DISPOSE OF WASTE PROPERLY Dispose of oils, fuel, coolant, solvents, filters, batteries etc.according to federal, stateand localcodesandregulations regarding hazardouswastedisposal.

ContactLocalauthorities forproperdisposal methods of suchmaterials.

PR-I~2

DISPOSE OF WASTE PROPERLY

1-24

SAFETY

PRECAUTIONS

W. GENERAL GUIDELINES FOR WELDING Welding workmustbe performed by a certified welder withsufficient experience.

In addition, safetypractices mustbe followed by anypersonnel involved in suchwork.Identify allcracks to be repaired or areasto be weldedby thoroughlycleaning thesuspected surface, remove paint,and checkwithdye penetrant or magneticparticle testing.

Thelifeexpectancy ofthe weldedareadependson the workqualityand theattention givento details during welding. ¯ Avoidwelding structures withsurface temperaturebelow16 °C (60°F).If needed, preheat surfaceto hand-touch.

In caseswherethe machine components areextremely cold,it is recommended that the components be broughtinsideandallowthemto warmto 16 °C- 20°C (60°F - 70°F)foratleast12hours prior towelding. ¯ Removepaintfromanysurfaceto be heated or welded.

Painted surfaces giveoffunhealthy gasseswhenheatedor welded.Use maskand properskinprotection whenremoving paint fromanysurface.

Whenremoving paintsanding,do not breaththegenerated dust.Make sureto useplenty soupandwaterto rinsethe surfaceto be welded,sincechemicals will generate unhealthy gasseswhenheatedand/ or welded.

CRAWLER SHOE TENSION Thegreaseusedto adjustthecrawler shoetension is underextreme pressure in thecylinder.

Useextremecaution whenadjusting crawler shoetension.

KEEP FACE, HANDS AND LEGS AWAY FROM THE GREASE NIPPLE AREA. Carefullyandslowly loosen thegreasenipple whenlesseningcrawlershoetension.

Neverloosengrease nipplemorethanonecomplete turn.

Referto page4-18fortheprocedures to adjust the tension on thecrawler shoe.

PA-1-24

USE CAUTION WHEN ADJUSTING

CRAWLER

¯ Provide a fireextinguisher reachable at alltimes Y. PAYING ATTENTION TO BROKEN PIECES whileperforming grinding, heating, or welding.

WHEN HAMMERING ¯ Makesureto cleanoiland/orflammable materiFlyingparticles may causeinjurywhenhammering alsfromanysurface to be cut. tempered parts,suchas pin,edge,tooth,bearing, ¯ Protectall flammable partsand surfaces from etc.. sparksand/orflames¯ Wearprotective clothes suchas protective glasses, ¯ Makesureto performworkin a wellventilated safetyhat,etc.during maintenance. area. ¯ Keepsparksand flamesawayfrompaintand/or solvent. ¯Keepsparksandflames fromcylinder rods,seals, electrical wires,and/or hydraulic hoses

~PL-1-24

USE CAUTION PL-1-20 R

PAY ATTENTION TO WELDING WORK

1-25

WHEN HAMMERING

SAFETY

PRECAUTIONS

1.6 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wearlongsleeveshirt,glovesand approved safetyglasses or faceshieldwhenworking with or aroundbatteries.

Battery electrolyte (acid) willcausesevere burnsif allowed to makecontactwithclothing, skinoreyes.Should electrolyte(acid) comein contact withclothes, skin eyes,immediately removeeffectedclothing, flushareawithcleanwaterfor15 minutes and getpromptmedical attention.

PR- 1-43

WEAR PROPER PROTECTIVE

CLOTHES

B. KEEP AWAY FROM FIRE OR FLAMES Neverallowbatteries in thevicinity of fireor flamesand do not smokewhen workingwith batteries.

Explosive hydrogen gasis produced bytheelectrolyte (acid) inthebatteries.

Always workwithbatteries in a wellventilated area.

Ci

CHARGING BATTERY Chargebatteryoff andawayfromthemachine in a wellventilated area.Whencharging battery,removecellcapsto allowgassesto escape.Avoidbreathing gassesfrombattery.

Q

0

PR-1-44

KEEP AWAY FROM FIRE OR FLAMES D. USING BOOSTER CABLES ¯ If usinganothermachine or vehicle to boost bateries, makecertain the machine or vehicle DOES NOT touchthe disabledmachine. ¯ Makecertain of thepositive (+)andnegative (-)terminals onthebooster battery andthedisabled machinebefore connectingbooster cables. ¯ Connect thepositive (+)cablefirst, thenconnectnegative (-). ¯ Whendisconnecting, disconnect the negative (-)cablefirst, thendisconnect thepositive (+) cable. ¯ Refer to BASIC MACHINE OPERATION Sectionof thismanualforproperprocedures for useof booster cables.

OTHER PRECAUTIONS Payattention todanger ofsparks triggered offby erroneous connection between thepositive (+) terminal of battery andthemachine bodywitha tool, etc. ¯ Makecertain of tightening thebattery caps. ¯Securely tighten up thebattery terminals. ¯ Leavethewastebatteryto a specialist for dispossal.

1-26

CABLE CONNECTING ORDER (~)-~-~)--*(~) CABLE

DISCONNECTING

ORDER

~(~)-~)-’~

I

f (RED) I I I I

NORMALBATTER DISCHARGED

(BLACK) I

TO THE ENGINE

BATTERY

® i

OF THE TROUBLED

MACHINE PRE-3-11

Improper boostercableconnections can causean explosion resulting inpersonal injury.

Connect booster cablesusingfollowing procedure.

1.Connect redbooster cableto positive (+)battery terminal ofdischarged battery.

Connect otherend ofbooster cable topositive battery terminal ofnormalbattery.

2.Connect blackbooster cableto negative (-)batteryterminal of normal battery.

Connect otherend ofbooster cabletotheengine oftroubled machine.

3.Start engine andremove booster cables inreverse order.

SAFETY

PRECAUTIONS

1.7 WARNING LABELS & DECALS NOTICE FOR WARNING LABELS & DECALS Warninglabelsand decalsareaffixedto the ma¯ Do nottakeawaytheattached warning labelsand chineto remindoperators andpersonnel specific decals. safety precautions in certain areasof themachine. ¯ Confirmwhetherlabelscan be easilyread.If Thefollowing areillustrated examples of allwarnwords orillustrations areillegible, clean offorreinglabels anddecals alongwiththeirlocations. placethelabels. ¯ Usea cloth, water,anddetergent to cleanthelabels.Neveruseorganic solvents or gasoline. ¯ Iflabels aredamaged, missing or illegible, replace themwithnewones.Contactan authorized KOBELCODistributor fornewlabels.

LOCATION

OF WARNING

LABELS

& DECALS

[CANOPY] 4

8

A

DETAIL

(A)

11

VIEW I

B ,1

1-27

SAFETY

PRECAUTIONS j13

I

14

r

SECTION A-A

DETAIL(B)

9

12

3

@

@ 10

16

6

23

DETAIL(C)

22

23

i,o, Ioi

, 1 1

l ! i- ............................

®i ............................ \

20 22

CAB SPEC. INSIDE CAB R.H.

ROPS CANOPY VlEW-II

1-28

SAFETY

PRECAUTIONS

1. SLEW I SWING-DANGER Located on radiator cover.

Part Number - PE20T01014P1

4. PRESSURIZED HOT OIL-WARNING Located on topof hydraulic tank.

Part Number - PW20T01007P1

n Pressurized hot oil can cause bums.

Depress stem or remove cap slowlywith engineoffto relieve HydraulicTankpressure.

PE20T01014P1

PW20T01007P1

2. CALIFORNIA PROPOSION 65-WARNING Located on battery boxcover.

Part Number - YN20T01495PI

WARN

5. SAFETY LOCK LEVER-WARNING Located on seatstand.

Part Number - PY20T01073P1

NG

WARN

CALIFORNIAProposition65 Batteryposts,terminals,and related accessories contain leadandleadcompounds, chemicals knownto theStateof California to causecancerand reproductive harm.

Washhandafterhandling YN20TO1495P1

NG

Machine may move suddenly and causeseriouspersonalinjuryif a control leveris accidentally touchedbe surethe safetylever is disengaged and in the locked position beforeexitingthecab.

PY20TO1073P1

3. CALIFORNIA PROPOSION 65-WARNING Located on seatstand.

Part Number- 2432T6457

WARN

6. FOOT PEDAL. CAUTION Locatedon seatstand.

Part Number - PY20T01062P1(OPT)

NG

CAUTION

CALIFORNIAProposition65 Dieselengineexhaustand some of its constituents are knownto the Stateof California to cause cancer, birth defects,and otherreproductive harm.

Attachment operation byfootpedal.

Alwayscheckthe footpedal controlpatternbefore operation.

Alwaysread operatorsmanual beforeoperatingmachine.

2432T6457

PY20T01062P1

1-29

SAFETY

PRECAUTIONS

7. BUCKET TO CAB CONTACT-CAUTION LocatedinsidecabR.H. Part Number- YN20T01013P1

Bucketcan contactand damage cab when CAUTION machineequippedwith RE some attachments.

~E

Check clearance between bucket and cab beforeoperation.

Exercisecare when operatinga bucketnear cab.

YN20T0101~ol

10. GENERAL PRECAUTIONS-WARNING Located on seatstand.

Part Number - YN20T01016P1

8. HOT COOLANT-WARNING Located on radiator cover.

Part Number- PE20T01013P1

WARN

WARNING Steamof hot coolantcan causeinjuryor blindness.

Neverloosenor open radiatorcap when coolantis hot and underpressure.

Beforeopeningradiatorcap: ¯ Cool down enginecompletely. ¯ Coverradiator withclothrag. ¯ Loosencap slowlyto relievepressure.

PE20T01013P1

9. SELECTOR VALVE -CAUTION Located on seatstand.

Part Number - PE20T01016P1(OPT)

CAUTION

NG

Read and understandthe operators manual before operatingor performingmaintenance on this machine.

Failure to followor payattention to instructions in operators manualcan resultin injuryor death.

It is yourresponsibility to be awareof and follow alllocallawsandregulations.

Before starting machine, make sure hydraulic controlleveris in lockoutposition and allcontrol leversarein neutral.

Soundhornto alertpeople.

Ensurebystandersand obstaclesare clearof machinebeforemovingmachineor its attachments.

Do not carryriderson machine.

Before leavingoperatorscompartment,park on level ground,lowerattachmentsto ground,make surehydraulic controlleveris in lockoutposition and stopengine.

YN20T01016P1

Procedureto change selectorvalve Mark SELECTION N Nibbler B Breaker EXTRA E Pleaseadjustsuitable notchto capscrew. (somemark may not be indicated) CAPSCREW

11. ROTATY MULTI-DANGER Located on rotary multicontrol valve.

Part Number - YN20T01214P1(OPT)

STOP THE ENGINE WITHOUT FAIL AT TIME OF CHANGEOVER. YN20T01214P1 Notc~

I PE20T01016P1

1-30

SAFETY

PRECAUTIONS

12. ELECTRICAL POWER LINES-WARNING Locatedon seatstand.

Part Number - YN20T01006P1

WARN

15. ADJUSTING TRACK TENSION-WARNING Located on crawlerframe.

Part Number- 2432T6110(2-REQ’D)

NG

WARN

NG

Contact withelectrical power lines willresult In severe Injury or death.

e

Keep machineand attachment a safe distance fromelectrical powerlinesas per foUowlng Instruction.

VOLTAGE(Volts) SAFETY DISTANCE 50K OR LESS 3.0M(10FT) 50K TO 200K 4.5M(15FT) 200KTO 350K 6.0M(2OFT) 350KTO 500K 7.5M(25FT) Extreme highpressure in trackadjustment cylin500KTO 750K 10.5M(35FT) 750K OR OVER dercancausepersonal injurywhenadjusting 13.5M(45FT) YN20T01006P1 crawler tension.

Loosen greasenipple withcareto relieve pressure gradually, 2~zr611o 13.STOP ENGINE-WARNING Located on engineradiator.

Part Number - YN20T01009P1

WARNING

16. CHECKING CONTROL FUNCTION-WARNING Located on seatstand.

Part Number - YN20T01039P1(OPT)

WARN Rotatingpartscan causepersonalinjury.

Keepawayfromfan and beltwhenengineis running.

Stopenginebeforeservicing. YN20T01009P1

14.BOOSTER CABLE-WARNING Located on batteryboxcover.

Part Number - YN20T01338P1

WARNING

NG

This machineequippedwith a rotarymulti-control valvewhichallowschangingof operatinglever controlpatterns.

Operatingthismachinebeforecheckingfunctionof each controllever can cause unexpectedmachine movement, whichcanresultin serious personal injury.

Make sure you checkand know functionof each control leverbeforeoperating.

YN20T01039P1

17. HANDLING BATTERY-DANGER Located on battery boxcover.

Part Number - PY20T01069P1 /]k, DANGER EXPLOSIVEGASES

/,e Ie=rich=ar ma cause 1 when mishandling the cable.

Read operatormanualfor safe and properhandling~20T01~=1

Cigarettes, flamesor sparkscouldcausebattery to explode.

Always shieldeyesandfacefrombattery.

Do notcharge or usebooster cables or adjust postconnections without proper instruction andtraining.

,~ KEEP VENT CAPS TIGHT AND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid.Avoidcontact withskin,eyesor clothing.

In eventof accident flushwithwaterandcalla physician immediately.

KEEP OUT OF REACH OF CHILDREN YN20T01039P 1/"

1-31

SAFETY

PRECAUTIONS

18. HOT PARTS-CAUTION Located on radiator cover.

Part Number - YN20T01220P1

21. KEEP CLEAR OF MACHINE-DANGER Located on bothsidesof thearm.

Part Number - PE20T01012P1(2-REQ’D)

CAUTION

Engine may be hot which could cause bums.

Do not touch engine untilit coolsdown.

PE20T01012P1

22. ROPS CANOPY-WARNING Locatedon ropscanopy& insidecab.

Part Number - PE20T01028P1

YN20T01220P1

WARN

NG

Do not operatethismachine if therollover protective structure (ROPS) is structurally damaged,showscracks, is notproperly securedas originally installed or hasbeenroiled.

Do not repair,modifyor add attachments to the ROPSunlessauthorized in writingby the manufacturer.

Do not add attachments to the machinethat intrudeintothe operator’s protective area,reduce visibility, restrict emergencyexitsor add weightexceeding certification weightof ROPS. Do not operatemachineunlessseat belt conformingto SAE and/orASAE standardsis fastened.

See operator’s manualor contact yourdealerfor completeinspection requirements and maintenance instructions.

19. HOT PARTS-CAUTION Locatedon enginecover.

Part Number - YN20T01012P1

CAUTION Rotating enginefan,hot enginepartsanddrivebelt cancausesevereinjury.

Do not open enginecover or serviceenginewith enginerunning.

YT20T01012P 1

PE20T01028P1 i

20. SEAT BELT-WARNING Locatedon ropscanopy& insidecab.

Part Number- PE20T01027P1

WARN

I

~AVOID

NG

¯ DO NOT JUMP IF MACHINE CRUSHING BUCKLE UP

23. DOZER BLADE-CAUTION Locatedon seatstand Part Number - PY20T01077P1

~J~ (~-~ TIPS~~ PE20T01027P1

1-32

SAFETY

PRECAUTIONS 26

[CAB]

25 24

Pl’l ..... .... _

©

c

SECTION B-B

FRONT 24. CAB DOOR-WARNING Located insidecabdoor.

Part Number - PV20T01008P1

WINDOW 26. FRONT WINDOW OPERATING PRECAUSIONS-WARNING LocatedinsidecabR.H. Part Number- 2432T6108

Open or closethe door keepingmachinehorizontally andlockit securely.

Unlockingin the condition of machineoperationmay causeinjuredby unexpected door movement.

PV20T01008P1

25. LIFTING FRONT WINDOW-CAUTION Located insidecabfrontwindow.

Part Number - PY20T01084P1

CAUTION Openor closethe frontwindow keeping the bodyhorizontally, andlockit securely.

Unlocking in thecondition of thebodyforwardinclination maycausea fallof thefrontwindow. PY20TOlO84P1

1-33

/~ WARNING Pullout the connectorwhen lifting thefrontwindow.

Lock securelywhen opening and shuttingthe frontwindow.

2432T6108

SAFETY

PRECAUTIONS

1.8 PROHIBITED MACHINE OPERATION Thefollowing examples of machine abuseandmisuse shouldneverbe attempted by eventhe most experienced operator.

Suchabuseand misuseof thismachine anditsattachments canresultin serlousbodilyinjury, death,severeequipment damage and shortened servicelifeof the machine.

Underno circumstance shouldany of theseoperationsbe attempted.Use commonsense and followproperoperation procedures foundin this MANUALwhileoperating thisequipment.

DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT. Doingso willexertexcessive forceon themachinestructure, frontendattachments andcould causesevereequipmentdamage.Use crawlersfornormal travel operations only.

DO NOT USE THE MACHINE’S SLEWING / SWINGING FORCE FOR OPERATIONS. Doingso willexertexcessive forces to themachinestructure, frontend attachments and shorten lifeof theslewing/swinging systemof themachine.

Also,serious injury ordeathcould resultfromsuchoperations.

C. DO NOT PERFORM "HAMMERING" OPERATIONS WITH THE BUCKET. Performing operations suchas hammering and pilingwillcauseextensive damageto themachineand itscomponents.

Thesetypesof operations canalsoresultin serious injuryor death.

X

PMJ-3-50

DO NOT USE TRACTIVE FORCE

PMJ-3-49

DO NOT USE SLEWING / SWINGING FORCE

X

f,

PMJ-3-52

DO NOT HAMMER WITH ATTACHMENT D.

DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDED PURPOSE. Thismachineis designed andmanufactured for digging, loading andgroundleveling operations only.Anyotheruse canexertexcessive force to themachine, itscomponents, itssystems and result inserious bodily injury ordeath totheoperators andotherpersonnel working in thevicinity ofor withthemachine.

I PV-1-13

USE ONLY FORINTENDED 1-34

PURPOSE

SAFETY

PRECAUTIONS

E. DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY. Extendingthe bucketand arm cylindersto stroke endto cleandebris fromthebucket, will causeimpactto the bucketcylindercausing cylinder damage.Use highpressurewateror manuallyremovestubbornmaterialfromthe bucket.

ALLOWANCES

0

E!

PME-3-51

DO NOT OPERATE CYLINDER TO STROKE END F. DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Knowthelimitations of themachine anditsattachmentsand operatethe machinewithin thosespecifications.

Do notexceed liftcharts.

Nevertipor raisethemachine to obtainpower to movematerial.

Thiscouldcauseextensive damageto the machineand its components as wellas result in serious bodily injury ordeath.

~::~"

i PMJ-3-53

DO NOT OVER EXERT THE MACHINE G. CAUTION FOR DOZER BLADE NOT TO HIT OBSTACLES. Payattention to thedozerbladenotto hitany obstacles suchas rocklump.

It may causedamagesto the dozerbladeand cylinder.

PMJ-3-54 !

DO NOT HIT ROCK, ETC. BY DOZER H. CAUTION FOR FOLDING UP ATTACHMENT. Whenthe attachment is foldedup to travelor transport, payattention to thebucket nottohit thedozerblade.

PMJ-3-55

DO NOT HIT DOZER BY BUCKET 1-35

SAFETY

PRECAUTIONS

I. DO NOT SUPPORT MACHINE WITH DOZER BLADE AT ONE END. Whenthedozerbladeis usedas an outrigger, do not supportthe machineat one endof the dozerblade,butsurely at bothends.

F PMJ-3-56

DO NOTSUPPORTMACHINE WITHDOZERBLADEAT ONE END J. CAUTION FOR DEEP EXCAVATION. Payattention duringdeepexcavation withthe dozerbladein front.Theboomcylinder could comein contact withthedozerblade.

Placethe dozerbladein the backof themachinefordeepexcavations, unlesstheworking areadoesnotpermit it.

1.9 END OF WORK SHIFT SAFETY Perform allof thefollowing procedures after eachshiftis complete to insure themachine it inoptimal operating condition forthenextshift orjobsite.

A. Movethemachine to a firm,levelsurface.

B. Lowerattachment to theground.

C. Refill fueltanktofullmarktoreduce airvolumeand condensation (moisture).

Thiswill decrease thepossibility offreezing inthefuel tank,rusting dueto moisture andotherproblemsassociated withstartup andoperation.

D. Closeandsecure allwindows in placeto preventwateror moisture reaching theelectrical components of themachine(CABonly). cleanand inspectthe machine.

E. Thoroughly Performlubrication maintenance and repair or replaceany problemareasfoundbefore restarting themachine.

F.If operating themachine in coldclimates, it may be necessary to removethe batteries fromthe machineandstorein a warmwell ventilated area.Install thebatteries in the machine beforenextstartup.Thiswillhelp prevent premature battery deterioration.

G. Removekey from key switchand lock all doorsandaccesspanels.

H. Install vandalism guards, if necessary.

1-36

PMJ-3-57

TAKE CARE FOR DEEP EXCAVATION

6

END OF WORK SHIFT SAFETY

SAFETY

PRECAUTIONS

1.10 PRECAUTIONS FOR TRANSPORTATION Usethefollowing general guidelines forloading or unloading themachine tothetransportation vehicle:

X

¯ Loadingand unloading of the machinemustbe carriedouton firmleveledareasawayfromthe roadshoulder.

Do notusetheattachments to load or unloadthemachine fromthetrailer. ¯Whenneeded,use a rampcapableof withstandingthemachine weight.

Checktheramp’swidth, length andthickness to secure theloading/unloading work.And when much warp appearson the rampstructure, supportthemwithsafetyblocks oralike.

8

TAKE CARE FOR LOADING / UNLOADING

¯Removeany mud,oilsandgreasefromthe ramp surface as wellas fromcrawler shoeson themachine, to prevent themachine fromsideskidding. ¯Do notchange thetraveling direction ontheramp.

Whenrequired,back down the machineto the ground, reposition andtryit again. ¯Alwaysuse lowtravelspeedforloadingor unloading fromthetrailer. ¯Afterloading themachine, shutofftheengine and setthesafety lockleverto "LOCK" up position. ¯Usecableor wireropewithsufficient capacity to

PMJ-1-3~

USE RAMP FOR LOADING AND UNLOADING

securefrontandrearof themachine to trailer.

Provide shuckblocksto themachine crawlers, to avoidany movementof the machine. ¯ Protect wireropeagainst edgesproviding pad.

1

¯Whiletransporting, observe legalregulations concerned, keeping thesafetyin mind. ¯ Select therouting taking overall height andlength

-/

PAD FOR ~’~ EDGE ~

PAD FOR

,,

of thetruckintoconsideration.

l"

~EDGE

¯ Referto Section5 "TRANSPORTATION" for the details ofloading, unloading andfixing procedures of themachine.

PAE-1-28

SECURE

FROM

MOVEMENT

OVERALL LENGTH m

PAE-1-27

OBSERVE LEGAL REGULATION 1-37

SAFETY

PRECAUTIONS

1.11 TOWING THE MACHINE 1. If themachine shouldbecomestuckin softsoilareasit maybe necessary to towthemachine.

Attach a wireropeor chain,withthecapacity to pullthe machine out,to thelowerframeaxles.

2. Attach otherendto thevehicle usedto pullthemachine.Operatethe Machine’s TravelLeverin the proper direction whilepulling withtheothervehicle.

PV-1-5

¯ Whiletowing,do not enterbetweenthe machine andtowingvehicle. ¯ Do notapplya shockloadontothetowingrope. ¯ Do not use eyeson machinelowerframeto tow machine. ¯ Keepthewireropehorizontally, and perpendicularlytothecrawler frame. ¯ Tow the machineslowlyat low speedmode. ¯ Forthetowingof the machine body,providepads to be applied tothecorner of crawler frameto preventthewireropeandcrawler framefromanydamages.

NOTE Do notpullmachine utilizing thebrackets weldedon thelowerplatesof thecarbody.

Thesebrackets are provided forpulling lightweight objects.

Seefigure forbetter reference.

1-38

TOW MACHINE

PROPERLY

MACHINE

Table

FAMILIARIZATION

of Contents Page No.

2.1FAMILIARIZATION ...............................................................................

2-2 2.2GENERAL MACHINE NOMENCLATURE ...................................................................

2-2 2.3OPERATOR CABNOMENCLATURE ......................................................................

2-3 2.4 COMPONENT & CONTROLSNOMENCLATURE ...........................................................

2-4 A. MONITOR PANEL(GAUGECLUSTER) .................................................................

2-4 A.1METERS ................................................................................

2-4 A.l.aCOOLANT TEMPERATURE METER..............................................................

2-4 A.l.b FUEL METER ............................................................................

2-4 A.l.c HOURMETER ............................................................................

2-4 A.2WARNING LAMPS ...........................................................................

2-5 A.2.aBATTERY CHARGELAMP(Red)...............................................................

2-5 A.2.bENGINEOILPRESSURE LAMP(Red)...........................................................

2-5 A.2.cCOOLANTTEMPERATURE LAMP(Red)..........................................................

2-5 A.2.dLOWFUELWARNING LAMP(Red)..............................................................

2-5 A.3INDICATOR LAMPS .........................................................................

2-5 A.3.aHIGH(2ND)TRAVELSPEEDLAMP(Yellow) ..................................................

2-5 B.SWITCHES ..................................................................................

2-6 B.1STARTER SWITCH ..........................................................................

2-6 B.2TRAVEL SPEEDSELECTSWITCH ................................................................

2-6 B.3HORNSWITCH ............................................................................

2-6 B.4 DECELERATION SELECTOR SWITCH(Option)..................................................

2-7 B.5WORKING LIGHTSWITCH .....................................................................

2-7 B.6HEATER SWITCH (CABspec.;Option) ...........................................................

2-7 B.7WIPER SWITCH ............................................................................

2-7 C.LEVERS ANDPEDALS ...........................................................................

2-8 C.1SAFETY LOCKLEVER ........................................................................

2-8 C.2 OPERATINGLEVERS(ISOOPERATINGPATTERN)...........................................

2-9 C.3TRAVEL CONTROL LEVERS ....................................................................

2-9 C.4THROTTLE LEVER ..........................................................................

2-10 C.5DOZEROPERATING LEVER....................................................................

2-10 C.6BOOMSWINGOPERATING PEDAL................................................................

2-11 C.7NIBBLER& BREAKEROPERATING PEDAL.....................................................

2-11 D. GUARDWITHLOCKINGDEVICE& COVERS.........................................................

2-12 E. SEATFRONTTO BACKADJUSTMENT ................................................................

2-12 F.ELECTRICAL EQUIPMENT .........................................................................

2-13 F.1WORKING LIGHT SWITCH .....................................................................

2-13 F.2FUSE BOX(Main) ..........................................................................

2-13 G.FUSIBLE LINK(forstarter) ......................................................................

2-13 2.5STORAGE & OTHERS ..............................................................................

2-14 A.STORING PLACEFORMANUAL .....................................................................

2-14 B.TOOLS ....................................................................................

2-14 C.GREASE GUN................................................................................

2-14 2.6SEATBELT ....................................................................................

2-15 2.7CAB.......................................................................................

2-16

2-1

MACHINE

FAMILIARIZATION

2.2 GENERAL MACHINE NOMENCLATURE 2.1 FAMILIARIZATION The Nomenclature drawing below pointsout locations All operators,servicemechanicsand personnelreof major components of the KOBELCO Hydraulic sponsiblefor operation, inspectionand maintenance Excavator(TYPICAL). of the machine should become thoroughlyfamiliar with the controlsand components and theirfunctions Study these areas and locate these componentson beforeworkingwith or on this equipment.

Studythe information in this sectionto becomefamiliarwith the controlsand components of this ma-

the machine.Specificinformationregardingthese componentsare explainedon the followingpages of thissection.

chine.

ARM CYLINDER BOOM ARM

RIGHT OPERATING LEVER SWING CYLINDER

BUCKET CYLINDER

CANOPY TRAVEL LEVER

IDLER LINK BUCKET LINK

FUEL TANK DOZERLEVER MONITOR PANEL HYDRAULIC TANK

BOOM CYLINDER

LEVER

LEFT OPERATING LEVER

RADIATOR

SAFETY LOCKLEVER

RVETANK CLEANER

DOZER CYLINDER

PFFLER

DOZER~I

RUBBER CRAWLER SHOE

IDLER

NGINE

CONTROL VALVE

BA]-rERY

IDLER ADJUSTER

SLEWING MOTOR

UPPER ROLLER HYDRAULIC PUMP LOWER ROLLER SWIVEL JOINT SLEWING BEARING TRAVEL MOTOR PWA-2-1

2-2

MACHINE

FAMILIARIZATION

2.3 OPERATOR CAB NOMENCLATURE The operatorcab nomenclature, see Figurebelow, pointsoutlocations of operator controls of theKOBELCOhydraulic excavator operator cab (Typical).

Studytheseareasand locatethesecomponents on the machine.

Specific information regarding these components areexplained on the following pagesof thissection.

SWING REMOTE CONTROLSWITCH

TRAVELSPEEDSELECTSWITCH

NIBBLER& BREAKER OPERATNGPEDAL

LEFT TRAVELLEVERRIGHT TRAVELLEVER )RN SWITCH

LEFT OPERATING LEVER

LEVER SAFETYLOCK LEVER (LEFT)

SAFETYLOCKLEVER(RIGHT)

)OZEROPERATINGLEVER WORKINGLIGHT SWITCH

MONITORPANEL (GAUGECLUSTER)

DECELSWITCH (Option) THROTTLELEVER

HEATER (CABspec.Option)

WIPER SWITCH (CABspec.Option)

/ STARTERSWITCH

OPERATORSEAT

PWA-2-2

* Front, rear, rightandleftdirection Inthismanual, thefront, rear, right andleftdirections arebasedon theconditions wherethetravelmotors arepositioned at therearandtheoperator is facing the direction in whichthe machineadvances (forward).

F

"--"3

~

GHT

’1 TRAVEL MOTOR PAM-2-2

2-3

MACHINE

FAMILIARIZATION

2.4 COMPONENT & CONTROLS NOMENCLATURE The following information provides a briefdescription andfunction of thecomponents andcontrols of the KOBELCOHydraulicExcavator.

All personnel associated withthismachineshouldreadandunderstand thisinformation BEFOREbeginning anyworkwithor on thisequipment.

A. MONITOR PANEL (GAUGE CLUSTER) Themonitor consists of thefollowing: A.1METERS A.2WARNING LAMPS A.3INDICATORS.

--(a) WATER TEMP

(A. 1) -- ~b) METERS

,bi,it NG Ifl (a)--(A.3) I n

FLEL

--(c)

(e)

INDICATORS (A.2) WARNING LAMPS

’,810t10110110110l HOUR METER 1/10H

t PWA-2-3

A.1 METERS A.l.a COOLANT TEMPERATURE METER ~’-RED.,~

~ This indicates the temperature of theengine coolant water,andop-

cator isapproaching tothe"E"point.

Refill thefueltank withdieselfuelonly.Normally thegaugetakestimeto moveup to theapropiate leveafterturningthekey switchto theON position.

turned to the"ON"position. temperature is normal in the I~,IIEE%1 eratesThe when the starter switch is . greenrange.If theindicator enters theredrange, lettheengine runin lowidleuntilthe temperature coolsdownandthe indicator movesback intothegreenrange.

A.l.c HOUR METER "~ Thehourmeterindicates thetotal timetheenginehasrun.

Evenif the machineis not movHOUR METER 1/10H| ing,the metercontinues to count as longas theengineis running, A.l.b FUEL METER PM2-10) regardless of theenginespeed.

Whiletheengineis running, theindicator flashes to ~WH,TE~’~ "~ This indicates the amount of fuel.

F " Fulltankisabout 15liters (4.0 showthatthehourmeteris active.

Usethehourmeteras reference formaintenance.

The gaugeindicates the residual volumeof fuelin the fueltank.

Makesureto refuelwhentheindi-

I

2-4

/ /

MACHINE

FAMILIARIZATION

Whenanyof warning lampis lightened, immediately stopthework.Theninvestigate thecauseforit,andcarry out appropriate inspection and maintenance referring to the Section"INSPECTION AND MAINTENANCE."

A.2 WARNING LAMPS A.2.a BATTERY CHARGE LAMP (Red) Thisis to warnan abnormality in the battery charging systemduringengine running.

Thisindicator willilluminate whenthestarter switch is turned to the"ON"position,andshould turnoffafterthe engine is started.

Checkthecharging systemif this indicator doesnotturnoffafter the engineis started.

See Section4 (Maintenance) fordetails.

A.2.b ENGINE OIL PRESSURE LAMP (Red) Thiswarning lampwillilluminate if theengineoilpressure drops abnormally whilethe engineis running.

Stop the engineand checkthe quantity of engineoil.(Refer to

The enginemay sufferseverdamageif the machineis operated withtheengine oilpressure lamp illuminated.

NOTES stopoperation 1. If the engineis overheating, immediately andlettheenginerunat idling to lowertheenginetemperature.

2. Once the coolanthas cooleddown,stop the engine.

3. Oncetheengine temperature lowers, inspect the coolant level, fanbelt,clogging ofradiator core, etc.RefertoSection 4 (Maintenance) fordetails.

Do not performany kind of maintenance on an enginethathasjuststopped working.

Fluidsand surfaces willbe extremely hot.Allowtheengine to coolbeforeproceeding to inspection and/ormaintenance.

A,2.d LOW FUEL WARNING LAMP (Red) If thefuelis low,a warning lamp lights.Stopthe engineimmediatelyandaddfuel.

A.2,e AIR CLEANER CLOGGING LAMP

I ed) (R k_~oqv

I

A.2.c COOLANT TEMPERATURE LAMP

This lamp comeson if the air cleaner filteris clogged.

If the lampcomeson,cleanor replace the element immediately.

2-12

I

O~

If thecoolant temperature rises abnormally, this warninglamp lights. ¯ The coolanttemperaturemay I (Red) riseabnormally if theengine is SF2-10 runwithan excessive load.

The enginemay sufferseverdamageif the machineis operated withtheenginetemperature lamp illuminated.

2-5

A.3 INDICATOR LAMPS Theselampsindicatethe workingconditions.

A,3.a HIGH (2ND) TRAVEL SPEED LAMP (Yellow), Thisindicator willbe illuminated whenthetravelspeedis switched to high(2nd)speed.

Thetravelspeedselector switch is located onthegripof theright travel lever.

Thespeedautomatically returns tolow(1st)speed whenthestarter switch issetto "OFF".

MACHINE

FAMILIARIZATION

B. SWITCHES B.2 TRAVEL SPEED SELECT SWITCH Use thisswitchto select travel speed, HIGH (2nd speed)or LOW(1 st speed).

Whenthe starterswitchis turned to the"OFF"position, thetravel speedis automaticallysetto LOW.Selectthe desired speedbefore starting travelling.

9

4

5\ 6

j8

WARN PMA-2-25

1 2 3 4 5 6 7 8 9

NG

i’

Travelthe machinein LOW speedon slopesand atloading/unloading themachine on a truck/trailer.

Suddenchangeof the machinetravelspeedmay causethemachine to rollover.

/ No.

I

Switch Starter switch Travelspeedselectswitch Swing/remote controlswitch Deceleration switch Working lightswitch Heaterswitch(CANOPYSOption) Wiperswitch(CABspec.)

Socketof 12V powersource Hornswitch

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

Select this speed when travellingon roughor softterLOW(lst)speed rains, slopes,in narrow places,whenpowerful tractiveforce isrequired, orloadingorunloading froma truck/ trailer.

See page6-8 for speed.

B.1 STARTER SWITCH Thisis usedto startor stopthe .,.~,~.,,~’a | engine.

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

SettoHIGH when travellin on HIGH (2nd)speed flat, hardground.

See page6-8 for speed.

PR-2-2,8~

HEAT ..........

Whenengine start upisdifficult dueto coldclimate, turnthekeytothisposition toactivatethepre-heating andtheglowlampindicatorwillilluminate.

Holdthekeyin thisposition foraround15 secondsandthenturnthekeyto the"START" position to starttheengine.

Release keyafterengine starts.

In thisposition, theelectrical system is OFF........... turnedoffandtheengineis stopped.

In thisposition, themachine’s electrical ON............. circuit isenergized.

Maintain thekeyinthisposition whilethemachine is inoperation.

START. .....Turnthekeytothisposition tostartthe engine andrelease it aftertheengine starts, the keywillautomatically returnto the"ON"position.

2-6

B.3 SWING/REMOTE CONTROL SWITCH Operatethe controllever rightandleftkeepingthe switch onthegripoftheleft control leverpressedand !~ PWA-2"41 the boomswingsrightand left.

Switch ..............................

Presed(ON) Operate lever right ...........

Rightswing Operate lever left .............

Leftswing

The swingoperation does not stopeven if the switch is offin theswingoperation.

To switch the swingandslewing motions, placetheleftcontrol levertotheneutral position once.

MACHINE

FAMILIARIZATION

B.4 DECELERATION SELECTOR SWITCH

B.8 SOCKET OF 12V POWER SOURCE r ~ ~ You can use it if you open cap and

ginerotation toshift theengine to thelow speed.

Pressthisswitch againtorelease I ~ ~ Press this switch during the enthe deceleration function.

When PM2-3oyOUarewaiting thedumping or the nextwork,fuelcostandnoisegeneration canbe reducedby thisrelease.

Turnthestarter switchfrom "ON"to "OFF"to automatically release thedecelerationfunction.

I I~

insertthesocket forthecaraccessories.

1

B.5 WORKING LIGHT SWITCH Thisisused fortheboomand frameworking lights.

OFF - ON

A-2

NOTE: It cannotbeusedforthecigarette lighter.

B.9 HORN SWITCH Depress thisswitch provided on thetopof rightoperating lever, to soundthehorn.

OFF

I~)@p~,M~N311

B.6 HEATER SWITCH (CANOPY Option) Soundhornbefore starting theengine, travelling, swinging or operating theattachments.

L ; Lowspeeddriveof fan I ~@pH~M21 IThis isused tOwarm upthecabOFF32 OFFinteri°r’; Stop H ; Highspeeddriveof fan

NOTE: Enginecoolant is utilized fortheheater, accordingly theheatergenerate warmair only whencoolant is hot.

B.7 WIPER SWITCH (CAB spec.) ,WASHwasher fluid.

OFF WASH(Left) Spraying washerfluid.

ON H I~~~!i 1This isOFF used for ’Stop the wiper and PM2-33,,/ ON ; Operating wiper WASH (Right); Operating wiperandsprayingwasher fluid.

NOTE: If washeris usedcontinuously for20 sec.or more,or if washeris operated without washer fluid,the motormountedon washertankmay havetrouble.

2-7

E!

MACHINE C. LEVERS 2

AND

FAMILIARIZATION

PEDALS 3

No.

Operating Leversand Pedals

1

Safety locklevers

2

Right/Left operating levers

3

Travellevers

4

Throttle lever

5

Dozerbladeoperating lever

6

Nibbler & breaker operating pedal

6

PMA-2-34

C.1 SAFETY LOCK LEVER Thesafetylockleveris provided to prevent anyunexpected operation dueto involuntary movement of theoperator’s control levers.

WARNING ¯ALWAYS PLACE THE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITION BEFORE LEAVING THE OPERATOR CAB. NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR LEVER IN THE DOWN POSITION. ¯ NOTE THAT EVEN WHEN THE SAFETY LOCK LEVER IS SET IN THE LOCKED (UP) POSITION, THE FUNCTIONS FOR DOZER AND BOOM SWING ARE STILLACTIVATED.

"k LOCKING HYDRAULIC SYSTEM Whenthesafetylockleveris setin the "LOCK(UP)Position" the hydraulic systemis shutdown,exceptthedozerblade andthe boomswingfunctions.

LOCK (UP)POSITION I~ ff /

UNLOCKING HYDRAULIC SYSTEM Whenthesafetyleveris setto the"UNLOCK (DOWN)Position"all hydraulic functions areactive.

~~~)

NOTE : Whenthe safetylockleveris set to the "LOCK"(DOWN)position,eachattachment and swing motor are lockedsimultaneusly even thougheachlevercan be moved,becausethey are of a hydraulic locksystem.However,the travel levers areseparately locked withtheirmechanicallockingmechanism to lockthe movementitself ofthelevers.

PWE-2-7

UNLOCK f (DOWN) POSITION

PWE-2-8

2-8

MACHINE

FAMILIARIZATION

C.2 OPERATING LEVERS (ISO OPERATING PATTERN) C.2.a STANDARD OPERATION Thesetwoleversactivate eachoperationasillustrated ontheright.

5

1

WARNING ¯ Confirmforsafetyaroundtheworkingarea.Also ensurethateachleveroperation is in accordance withtheoperating pattern indicated onthelabels. ¯ If labels do notmatchtheoperator’s control pattern,replace themimmediately to avoidaccidents and/or injury.

NOTES Theoperator’s control leversreturnto theoriginal neutral position whenreleased, andtheoperation of attachment is stopped.

Allfunctions canbe activated simultaneously.

C.2.b J/D MULTI CONTROL SHIFTING IntheJ/Dmulti control shifting theBoom and Armfunctions are opposite to the ISO system.

C.3 TRAVEL CONTROL LEVERS Thetravel leversarelocated in frontof operator seat.Theyareusedto movetheleftor righttrackof themachine eitherforward or backward.

Thesecontrolshave2 basicoperational functions:

BOOM

~

¯

PME-2-11 ISO OPERATING PATTERN LH OPERATING LEVER RH OPERATING LEVER 5 ARM OUT 1 BOOM DOWN 6 ARM IN 2 BOOM UP 7 SLEWING LEFT 3 BUCKET IN 8 SLEWING RIGHT 4 BUCKET OUT

(A) (A)

WARNING Use cautionto avoidcomingin contactwithother machine functions whiletravelling.

Makesureto knowthelocation of thetravelmotors before operating thetravel function

THE TRAVEL FUNCTIONS DESCRIBED BELOW ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. (A):Pushbothleversforward to travelForward.

(B):Pullbothlevers backtotravel inReverse.

(C):Neutral(Release leversin thecenter position tostopthetravel function) Referto Ipage3-171forchanging travel direction

FOR ARO (B) PME-2-14

2-9

MACHINE

FAMILIARIZATION

C.4 THROTTLE LEVER Thethrottle control lever islocated totheright sideof theoperator’s seatandit is usedto control theenginespeed.

(A): LO(Low Idling) .....

Pushtheleverfullyforward tosettheengineinlowidle.

(B): HI(High Idling) .......

Pulltheleverfullyforward tosettheengineinhighidle.

~

ROTTLE

LEVER

(A)

(B)

PAE-2-10

C.5 DOZER OPERATING LEVER Thisleveris to bringthedozerup or getit down.

/.i\

DOZER

OPERATION

WARN I N G

¯ Eventhough thesafety lockleveris setat lockposition, thislever isnotlocked. ¯ Whilethe adjusting crawlerframewidthor dozer operation isnotcarried out,donottouchthislever, otherwise it maycausea severe injury. * DOZER OPERATION Thisleveris to control thedozerup or downfunction.

(E): Dozerdown (Pushtheleverforward.)

(F): Dozerup (Pulltheleverback.)

2-10

f DOZER

/ f (F){ (E)~

~

,,nj PAE-2-12

MACHINE

FAMILIARIZATION

C.6NIBBLER & BREAKER OPERATING PEDAL Thispedal, located totheleftsideofthetravel control levers, is usedtooperate theoptional attachment suchas the Nibbler& Breaker.

Locktheoptional pedalwhilethisfunction isnotoperated, failure to do so maycauseserious accidents.

I

Referto Section8 OPTIONALEQUIPMENT, SEE page 8-2,fortheoperation of hydraulic nibbler & breaker.

The pedallockbecomes effective by meansof pushing thepedaldownforward as illustrated in Fig.PM2-47.

2-11

PWA-2-5

MACHINE D. GUARD COVERS

WITH

LOCKING

FAMILIARIZATION

DEVICE

&

UNLOCK

Makesureto stopthe enginewhentheengineguard or radiator coveris opened. ~(1) A lockingmechanism is provided for theengine guards.Use the key to openand closeengine guards.

See Fig.PM2-55forbetterreference.

~

Q

LOCK

RELEASE PRE-2-54

D.1 Opening [1]Insert thekey.

[2]Afterreleasing thelock,removethekey and openthecoverpushing the keycylinder. with [3]Lockthecoverin theopenposition therod.

D.2 Locking [1]Return therodtotheoriginal position, and fixitintotheholder.

[2]Closethecover.

[3]Insert thekey,andturnit C.C.W. direction to lockthecover.Thenremovethekey.

PM2-55

NOTE Makesureto insertthekey completely for proper operation; otherwise damagemay occurto the key or lockingmechanism

~r~

SIDE COVER (L/H) \ Always,makesureto usetheopendoorlockrodto securetheenginecoverswhenever theyarein the openposition.

SIDE COVER(R/H)

~~

PM2-56

E. SEAT FRONT TO BACK ADJUSTMENT a.Pulltheseatadjustment levertorightside. b. Movetheseatforward or backward to desired position. c.Release thelevertolocktheseatin position.

AOJUST \

POSITION ~ L.....~’,~._ v

’ooKI \LEVER-1PAE-2-31

2-12

MACH I N E FAM I LIARIZATION F.ELECTRICAL EQUIPMENT F.1 WORKING LIGHT SWITCH A working lightis provided on theboomto improvethevisual fieldduring poorlighting conditions.

To turnON or OFFtheworkinglight,use the switch provided on theleftoperating leverportion.

Referto page4-25forthereplacement of the light bulb.

PM2-58

F.2 FUSE BOX (Main)

Be surethestarter switchis in the"OFF"position whenreplacing fuses.

Thefusesprotect the electrical systemfrom excesscurrent.

If operation is notnormal, a fusemay be blown.Replaceblownor faulty fuseswiththesparefusesas follows.

Replaceanyfusegenerating whitepowderon it or in casethatsomelooseness existsbetweenthefuseandfuseholder.

Fuse.

No.capact[y NOTE: (a)Whenreplacing a fuse,replace it withone of thesamecapacity. (b)Thesparefusesarestored inthebackside of fuseboxcover.

NOTE : Referto Section4-MAINTENANCE, page 435,formoredetails onreplacing fuses.

1

30A

2

10A

3

30A

4

30A

Wire Color Withe Heater, Wiper(Option) Yellow Yellow Deceleration relaySolenoid Black Yellow Working lightDecelertion motor Green Red Horn,Roomlight(Option) Green

5

30A

Enginestopsolenoid

White

6

relay, Cluster gauge IOA Battery

!White Green

Circuits

PM2-61

FUSIBLELINK (RED)

G. FUSIBLE LINK (for stater) In casepowerdoesnotcomewhenthe starter switch isturned ON,a disconnection of thefusiblelinkis suspected.

Inspect andreplace thefusible link.

NOTE : Thefusible linkisofa fusewiring ofbigsize provided in theelectric wiring forlargecurrent.It protects theelectrical equipment and wiringfromabnormal current justlikeas an ordinary fuse.

\

G FILLERPORT CAP (ENGINEOIL) ..

2-13

MACHINE

FAMILIARIZATION

2.5 STORAGE & OTHERS A. STORING PLACE FOR MANUAL Storethe manualin thestorageboxprovided on thebackof seat.

PAE-2-30

B. TOOLS Usethestandard toolssupplied withthemachine for themaintenance work.

Referto ~ for the detailsof the tools.

PA-2-26

C. GREASE GUN Usethegreasegun supplied withthe machine for lubrication.

Afteruse,foldthegrease gunhandle, wipeoffthegrease adhered to thenozzle withcloth andstore itinplace. and Precaution for GreaseGun. NOTE ¯ Handling Always, facilitate airbleeding fromthegrease gunbyfullyopenning theleverandfillgrease tothesection lineportion, seeFig,PAE-2-28.

Always, operate theleverat fullopenor full closecondition, otherwise thegreasein the cartridge is notsuckedup.

Someair maymixintothecartridge fromthe fixing threadup to thenextuseof thegrease gun,causing difficulty to extrude grease.

When thishapens, removethecartridge, bleedthe airmixed in,andreset it.

PA-2-27

GREASE

CARTRIDGE PAE-2-28

2-14

MACHINE

FAMILIARIZATION

2.6 SEAT BELT * Fastening/Unfastening [1]Confirming notwisting ontheseatbelt, fullyinsert theothersideintothebuckleuntilengaging is heard.

[2]Adjustthebeltlengthso thatthereis no slackBess.

[3]Pushdowntheredbuttonon thebuckleto unfastentheseatbelt.

PV-2-2g

WARNING Inspect seatbeltsdaily.

Replace seatbeltif itshows deformation or damage.Always,makesuretheseat beltsupport capscrews areproperly tighten.

RELEASE

BY DEPRESSING RED BUTTON ~

J ~.~~’ /,I I//

PV-2-30

2-15

MACHINE

FAMILIARIZATION

2.7 CAB Thefollowing equipment areprovided forthecab toventilate ortofacilitate operation.

CATCH

WARNING When using the equipmentin the cab, set the safetylockleverto thelockedposition to avoid unexpectedmachinemovementif a work lever is accidentally contacted whichcouldcausepersonalinjury.

LOCK & UNLOCK CAB DOOR

PV2-31

A. Lockingcab door To lockthedoorin theopenposition, slidethe doorfullyuntillocks onthecatch located onthe rearof thecab.

B. Unlocking doorfrominside To unlock thedoor,pullthelever(1)backward.

PV2-32

C. Openingtheupperwindshield Theupperwindshield canbe stored in theceilingofthecabinterior. on a level/solid groundand 1.Parkthemachine stoptheengine.

2. Lockthemachine withthesafetylocklever.

3.Pullthelockpin(3)ontherightandleft thetopof theupperwindshield (2)inwards andunlock it.

4. Gripthelowerhandleby yourlefthandand theupperhandle by yourrighthandfrominsidethecab,drawthemup andlockthelock pin(3)atthebackoftheceiling.

i

PVK2-33

When parkingthe machine,be sure to lock the lockpin (3).Otherwise the upperwindshield may falldown.

PV2-34

2-16

MACHINE FAMILIARIZATION D. Closing theupperwindshield 1.Parkthemachine on a level/solid groundand stoptheengine.

2. Lockthemachine withthesafetylocklever.

3. Unlock thelockpin(1).

m

4. Gripthehandleat thebottomof the upper windshield by yourlefthandandthehandle at thetopof the upperwindshield by your righthand.Thenbringdowntheupperwindshield gently.

PV2-35

5. Be sureto locktheRH andLH lockpins(1).

6. Connect theconnector forthewipermotor.

Whenclosingor openingtheupperwindshield, be careful notto catchyourhandinthewindshield.

1

PV2-36

E. Lowerwindshield Afterstoring theupperwindshield, liftthelower windshield by usingbothyourhandsto remove it fromthewindowframe.

1.Removethe lowerwindshieldfrom window frame.

2. Position lowerwindshield on rearholder (1).

3. Secure thewindshield withplate(2).

PV2-37

F. Room lamp The lampturnsON. ON......

OFF....

The lamp remainsOFF.

PV2-38

2-17

MACHINE

FAMILIARIZATION

G.Open/close thewindowon the rightside 1.Release thelock(3)andmovetheslideglass. by returning theslideglass 2. Closethewindow tothenormal position andlockit.

\ PV2-39

H. Supplywasherliquid The washertankis installed on therightand frontsideof cab.

1.Checkthewasher tankforliquid level.

2.Whentheliquidquantity fallsshort,remove cap and supplythe automobile washerliquid.

PV240

2-18

BASIC

Table

MACHINE

OPERATION

of Contents

Page No. 3.1PRE-START CHECK ...............................................................................

3-2 A.BRIEF CHECK OF MACHINE ........................................................................

3-2 B.CHECK BEFORE OPERATION ........................................................................

3-3 C.CONFIRMATION BEFORESTARTINGMACHINEENGINE..........................................

3-8 3.2 STARTINGAND STOPPINGMACHINEENGINE.........................................................

3-9 A.START-UP UNDERNORMALCONDITIONS ...............................................................

3-9 B.START-UP UNDERCOLDCONDITIONS .................................................................

3-10 C.START-UP WITHBOOSTER CABLES ...................................................................

3-11 D.CONNECTING/DISCONNECTING BOOSTERCABLES................................................

3-12 3.3STOPPING MACHINE ENGINE .........................................................................

3-13 3.4 INSPECTION AFTERSTARTINGMACHINEENGINE.................................................

3-14 A.EXHAUSTGAS COLOR,ABNORMALSOUND & SMELL ...........................................

3-14 B.CHECK EACHSWITCH & LEVER......................................................................

3-15 C.CHECK MONITOR PANEL ...........................................................................

3-15 3.5MACHINE WARMUP................................................................................

3-16 A.WARMING UPENGINE .............................................................................

3-16 B.WARMING UP HYDRAULIC OIL.......................................................................

3-16 3.6 MACHINE OPERATION ............................................................................

3-17 A.MACHINE TRAVEL ...............................................................................

3-17 B.STOP TRAVELING ...............................................................................

3-18 C.TRAVEL PRECAUTIONS ............................................................................

3-18 D.CARE ONUP/DOWN SLOPE.........................................................................

3-19 E.MACHINEOPERATIONIN WATER/ONSOFT GROUND.............................................

3-20 F.GETTING OUTOFSOFTGROUND ....................................................................

3-21 G.SLEWlNG OPERATION ............................................................................

3-22 3.7PRACTICES TO IMPROVE EFFICIENCY. .................................................................

3-24 A.DIGGING ...................................................................................

3-24 B.LOADING ....................................................................................

3-26 C.WORKS INNARROW SPACE .........................................................................

3-26 D.MINIMUM SLEWING POSTURE ........................................................................

3-26 3.8MACHINE PARKING ...............................................................................

3-27 3.9 CHECK& CONFIRMATION AFTERWORK.................................................................

3-27 3.10 PRECAUTIONS AFTEROPERATION ....................................................................

3-28 3.11 MEASURES AFTEREMERGENCY STOP..................................................................

3-28 3.12 LOCKING UPWITHKEY...........................................................................

3-29 3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE .....................3-30 A.RELEASING LOCKFORTRAVELMOTOR................................................................

3-30 B.LOWERING BUCKET. ..............................................................................

3-34 C.LOWERING ARM& BOOM...........................................................................

3-35 D.SLEWlNG UPPERSLEWING STRUCTURE ................................................................

3-35 3.14 CAUTIONON USINGRUBBERCRAWLERSHOES....................................................

3-36 A.HOW TOUSEWELL..............................................................................

3-36 B.PROHIBITED WORK..............................................................................

3-36 C.CAUTION ONUSE...............................................................................

3-37 3.15 MACHINE OPERATIONIN ADVERSE WEATHER CONDITIONS ................................

3-39 A.OPERATION INEXTREME COLD......................................................................

3-39 B.OPERATION AT SEASHOREOR SALTYCLIMATE....................................................

3-40 C.CAREFORELECTRICAL EQUIPMENT. ..................................................................

3-40 D.OPERATION INDUSTYAREAS .......................................................................

3-40 3.16 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD ...................3-41

3-1

BASIC

MACHINE

OPERATION

3.1 PRE-START INSPECTION A. DAILY INSPECTION OF MACHINE Beforestarting theengine, walkaroundthemachine NOTE to checkforanyloosenutsandcapscrews, anyoil, Thedailyinspection mustbe carried outin accordance fuelor coolant leakage, andthecondition of attach-withtheinstructions provided in thisMANUAL. mentand hydraulicsystem.Checkfor any loosenessin theelectrical wiring andforanyaccumulated material(leaves, dirt,etc).

5

4

PM3-01

1.Checktheengine foranyoil,fuelorcoolant leakage.5.Checktheattachments, cylinders, linkages andhoses Repairas required. foranycracks, wearor looseness andrepairas re2. Checkthe areaaroundtheengineand radiator for quired. any accumulated materialand removeas required.6. Checkthe guards,stepsand handrails for damage, 3. Checkthehydraulic equipment, hydraulic oiltank, and thecapscrews forlooseness. hoses,andjointsforoilleakage, andrepairas reRepairandtightencapscrews as required. quired.

7.Verifythatthegaugesandthemonitor panel(gauge 4.Checkthetravel system, suchas thecrawler, idlers, cluster) function properly. andsprockets, foranydamageor wear,andthe cap screwsforlooseness.

3-2

BASIC

MACHINE

B. INSPECTION BEFORE OPERATION Thefollowing itemsshould be inspected beforestartingmachineoperation: 1. CHECK COOLANT LEVEL

OPERATION BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

NEVER REMOVE RADIATOR CAP WHEN ENGINE IS HOT. ALLOW ENGINE TO COOL DOWN BEFORE REMOVING RADIATOR CAP

/JAil IIAII

Theradiator expansion tankis provided on the right sideof theenginecompartment, seeFig.PAE-3-2.

[1]Checkthecoolant levelwithcoldengine.

[2]Openenginecoverto checkthecoolantlevelin the radiator expansion tank.Thecoolantlevel shouldbe betweenthe linesof FULLand LOW.

NOTE: Enginecoolantlevelis higherthannormal whentheengineis warm.Thecoolantlevel willlowerwithenginetemperature,

lF@rt ll]l ,^, t~ ~ ~

(B) ~_r RADIATOR " \--7~---.__

FUL Maintain coolant levelat thefullmarkwithengine cold.

Referto page4-7forengine coolant specifications.

[3]Openradiator expansion tankcap(A)to refill with propercoolant mixture.

Checktheradiatorcoolantlevelwhenthe coolant levelin theexpansion tankdropsbelowtheLOWlevel mark.Makesureto checktheenginecoolingsystem forleakages andrepairas needed, beforeresuming operation.

[4]SeeFig.PAE-3-2andZ2-303Pforreference.

Removetheradiator cap(B),andcheckforproper coolant level. radiator withproper coolant mixture.

[5]Refill radiator cap(B)andtighten securely.

[6]Install

3-3

3--1 EXPANSION PAE-3-2

Z2-303P

BASIC MACHINE OPERATION 2. CHECK COOLANT LEAKAGE Ifthecoolant levelintheradiator expansion tankdoes notlower, butthecoolant inside theradiator does, thereisa possibility ofairleakage inthecooling system.Makesurecoolant levelis to sepecifications and pressurize system to checkforleakages.

Consult with an authorized KOBELCODistributor for adviseand/ or repairs.

Makesureto repairleakages beforeresumingoperation.

3. CHECK ENGINE OIL LEVEL NOTE : ¯ Makesurethe machine is on firmlevelwhencheckingengine oillevel. ¯Alwaysmakesureto checkengineoil levelbefore starting theengine. ¯ Keeptheengineto a standstill forat least30 minutes,whenchecking engineoillevelafterworking, --1

key to unlockand openengine [1]Use the ignition covers.

[2]Pulloutengine oildipstick (G),cleanitandinsert it fullyintoitssleeve.

Remove dipstick to check oillevel.Oillevelshouldbe between themarks "H"and"L".

If theoilisheavily contaminated or deteriorated, change it regardless of periodical schedule.

Referto page4-7foroilspecifications.

[3]Ifneeded, remove thefiller cap(F)torefill.

Makesuretochecktheoillevelagainafterrefilling..

[4]Clean engine oilfiller cap(F),before installing.

Close the engine cover and secure it withkey.

[5]

3..4

(G)

PAE-3-3

BASIC

MACHINE

OPERATION

4. CHECK HYDRAULIC OIL LEVEL

WARNING

WARNING NEVER PERFORM MAINTENANCE OR INSPECTION ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW SUFFICIENT TIME TO THE MACHINE TO COOL OFF. RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. 4-1 Check to firmlevelgroundandsetit [1]Movethemachine in thehydraulic oillevelcheckposition, asshown in Fig.PAE-1-22.

[2]Checktheoillevelthrough sightlevelgaugeprovidedonthesideof thehydraulic tank.Hydraulic oillevelshouldbe between H andL. Oillevelvariesdepending on oiltemperature.

Checktheoillevelreferring tothefollowings.

Before starting : "L"level [oiltemp.10-30°C (50-86°F)] Normaloperation :"H"level [oiltemp.50-80°C (122-176°F)]

"!

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

[l@11

HYDRAULICOIL LEVEL CHECK POSITION

OCET i;iii:

iii

iiiii PAE-1-22

NOTE: Avoidoverfilling.

It causesdamageson hydraulic equipment or oilspouting.

4-2Refill withoilwhenthelevelisbelow"L." Referto page4-7fortherecommended oilto be used.

[1]Openthecoveronthetopof thehydraulic oiltank, andsupport it bythestay. theinternal pressure ofthetankaccording [2]Release to theitem"Releasing internal pressure of hydraulicoiltankandhydraulic system" in page4-13.

[3]Ensure thattheinternal pressure of thehydraulic oil tank is completelyreleased,loosenthe capscrews (1),removethecover(2),andreplenishthespecified hydraulic fluid fromtheoilsupply porttillthespecified level.

[4]ChecktheO-ring(3)of thecover,andif wear damageis recognized, exchange it. thecover(2)andfasten withthecapscrews [5]Install atthespecified torque.

Tightening torque:2.4+0.20 kgf.m(17.4+1.4 Ibf.ft) andperform operation lightly five [6]Starttheengine to tentimeswhilemoving eachcylinder uniformly.

Thenreturnthe machineto theposturefor hydraulic oillevelinspection.

[7]Stoptheengineandchecktheoillevel.If the amount ofoilisinsufficient, replenish theoil.

[8]Removethestayandreturnthecoverto thenor-

/ PW-3-07

PW-3-08

3-5

BASIC

MACHINE

OPERATION

5.CHECK FUEL LEVEL

¯Makesureto usedieselfuelonly,andstopengine before refilling. ¯Be careful nottooverflow fuelatrefilling.

Cleanup allspilled fueltoprevent fire. ¯ Disposeof hazardous wasteaccording to environmentallawsandregulations.

[1]Turnignition key(1)to "ON"position toilluminate themonitor panel.

[2]Checkthefuelgauge(2),andremovefillercap (3)torefuel if needed.

[3]Refertopage4-7forfuelspecifications.

Fueltankcapacity: 15liter (4.0gal) fueltankstrainer (4)forrefilling [4]Donotremove avoidcontamination. refueling, install fuelcap(3)andtighten se[5]After curely.

Closetheengine coverandusekeyto lockit properly.

PM3-09

We recommend to refuelat theendof theworkshift.

Refueling shouldbe doneto fullmarkto reduceair volume(condensation).

Failure to do so couldcreate problems suchas rusting andfuelfreezing, as well as otherassociated problems.

f

NOTE: If themachine runsoutof fuelduringoperation,airmaygetmixedin thefuellines.

Proceedto bleedtheairoutofthefuelsystem as indicated in page4-15.

PM3-10

6.CHECK FOR FUEL LEAKAGE Checkandrepairanyfuelleakage.

Do notoperate a machineleakingfuel.Fuelleakagemay be caused by faulty drainplug(A),crackon hosein fuelline, loosened hoseclip,etc.Makesureto stoptheengineimmediately if anyfuelleakage is found.

Repair fuelleakage beforeresuming operation.

(A)

PM3-1’

3-6

BASIC

MACHINE

OPERATION

7. CHECKING BELT

Rotatingpartscan causepersonal injury.Keep awayfromfanand beltwhenengineis running.

Makesureto stopenginebeforeservicing.

Checkthefanbeltforinsufficient tension, wear,and damage.Insufficient belttensionmay causebattery chargefailure, engineoverheating, or abnormal belt wear.Likewise, If toomuchtension is applied to the belt,thebearings or beltmaybe damaged prematurely.

Applya forceof10 Kg (22Ib)to thecenter of beltbetweenpulleies, and measurethebeltdeflection.

The tablebelowshowsnormalcondition.

STOP

STOP

10kg(221b)

GENERATOR

Beltdefelection FanBelt

8-10mm(0.31-0.39in)

See the section, MAINTENANCE (EVERY 250 HOURS),fordetailson theinspection andadjustment procedure forthebelt.

PULLEY PAE-3-10

3"7

BASIC C. CONFIRMATION BEFORE MACHINE ENGINE

MACHINE

OPERATION

STARTING

1. CHECK WARNING LAMPS

Carelessmovementof any operatingleversmay causesuddenmovementof the machine.Make sure to setthesafety lockleverto the"LOCK" (up)positionbefore leaving thecab.Remember thatthefunctionsfordozerandboomswingarestillactive, even withthesafetyleveron the"LOCK"(up)position.

Beforestarting the engine,checkthewarninglamps andindicator lampsaccording withthefollowing procedures: [1]Makesurethesafetyleveris in the"LOCK"(up) position.

Make sureallcontrol leversarein the"NEUTRAL" [2] position. keyandthetablebelow(asrefer[3]Usetheignition ence)to checkallwarninglampsandindicators forproper functioning.

[4]Do not operatethe machineunderfaultyconditions.

Consult withanauthorized Kobelco Distributorif necessary.

Referto page2-5andmakesure allwarning lights andindicators function properly.

Repairany malfunctioning beforeresuming operation.

[-----1RED :WARNINGLAMP ~--~ YELLOW :INDICATIONLAMP OFF

ON

PMA3-15

-~"----~ey Operation !OFF_~HEAT OFF--,ON START*ON Lamp ~~ Pre-HeatingBefore Start Just After Engine Oil 1 Pressure LightOFF LightON LightOFF Lamp 2 Battery Lamp Charge LightOFFLightON LightOFF EngineCoolant 3 Temp.Lamp LightOFFLightOFFLightOFF Fuel 4 Low WarningLamp

LightOFFLightOFF LightOFF

2ndSpeedTravel 5 Lamp LightOFFLightOFFLightOFF Aircleaner 6 clogging lamp

LightOFFLightOFF’LightOFF

NOTE"Makesureallwarning lampsandindicators functionproperly before operating themachine.

2. CHECK WORKING LIGHT Whilethekeyposition in thestarter switch is being "ON"position, turnon theworking light switch tocheck thelightening ofworking light.

If it doesnotlighten, presumably thelightbulbis burned outor electrical wireisbroken.

Repair it referring to page4-25.

3-8

WORKING LIGHT PAE-3-12

BASIC

MACHINE

3.2 STARTING AND STOPPING MACHINE ENGINE A. START-UP UNDER NORMAL CONDITIONS locklever(1)is setto the [1]Makesurethatsafety "LOCKED"(up)position. levers aresetto the"NEU[2]Makesureallcontrol TRAL"position. movethethrottle control lever(2)from [3]Slightly thelowidling position. key(3)to theSTARTposition [4]Turntheignition starttheengine andrelease afterstarting theengine.

Releasethe ignition key immediately afterthe engine starts.

Thekeywillreturn to the"ON"position by itself.

OPERATION

LOCKED(UP) POSITION I~l

/

PWE-2-7

Makecertain the swingareaof machine is clearof peopleand obstaclesbeforeoperating.

Knowthe position of thetravel motors before starting travellingandmakesureto soundhornbeforestarting the engine.

NOTE : (a)Do notincrease theengine speed(highidling) with coldengine. keyin theSTARTposition (b)Do notholdtheignition formorethan15 seconds.

If theenginedoesnot start, return thekeyswitch totheOFFposition, wait 30 seconds, andthentryagain.

r

PAE-3-13

OFF i H EAT \

~’~"~-

ON ~ / START

/

( 3 PAE-3-14

3-9

BASIC

MACHINE

B. START-UP UNDER COLD CONDITIONS In coldweather, dueto theincrease in oilviscosity anddecrease in batteryperformance, starting the enginemaybe difficult.

Usethepreheater to start theengineeasilyundertheseconditions.

[1]Performsteps[1] - [3] mentioned in START-UP UNDER NORMAL CONDITIONS shown on the previous page.

OPERATION THROTTLE LE~R

~ PAE-3-.15

andhold [2]Turnthekey (3) to theHEATposition position or 15 seconds to preheat before starting. to startthe [3]Turnswitchkeyto theSTARTposition engine.

HEAT START ~NE

Do notholdthekeyswitchin theSTARTposition for morethan15 seconds.

If theenginedoesnotstart, return thestarter switch totheOFFposition, wait30 seconds, andthentryitagain.

START

OFF H EAT

ON

~TART ~~I~

-- "(3) PAE-3-16

thekeyswitchimmediately afterstarting [4]Release theengine.

Thekeywillreturn to theON position byitself.

3-10

BASIC

MACHINE

OPERATION

C. START-UP WITH BOOSTER CABLES Observethe followingprecautionswhen using booster cables tojump-start thebattery.

¯ Flammable gas (hydrogen gas)is generated in the battery.

Do notallowsparksor flamesto comein contact withbatteries to avoidtriggering an explosion. ¯ Do notallowthevehicle or machine usedforboostingto touchmetalto metalwiththedisabled machine. ¯ Wearhardhat,approvedsafetyglassesor face shield,glovesand othersafetyequipment when working withbatteries. ¯Neverallowthebooster cableclipsto comein contactwitheachotheronceconnected to a battery. ¯The negative cable,whenconnected to the upper frameof disabled machine, mayarccausing sparks.

Makesureto connect thebooster cableto a ground surface in the enginecompartment as faras possiblefromthebattery. ¯Whenthebattery fluidis frozen, donotstartupthe enginewithanotherpowersource. ¯ Follow theorderindicated in thenextpageforconnecting or disconnecting thebooster cables.

PAE-3--17

CAPSCREW

NOTE: Select suitable sizeforthebooster cables and clipsaccording to battery size.

Usethebooster cablesandclipswithout any damagesor corrosion.

3-11

BA’FI’E RY

f- 7 -x

I

BASIC

MACHINE

OPERATION

D. CONNECTING/DISCONNECTING BOOSTER CABLES Makesurethekeyswitchis in theOFFposition beforeconnecting thebooster cables.

Proceed as followsto connect anddisconnect theboosting cables:

¯ Erroneous connection of boostercablesmaycause explosion of thebatteries.

Payspecial attention to connect and disconnect the booster cables. ¯ Theelectrical systemof thismachineworkswith 12V DC.

[1]Setthekeyswitchto "OFF"forbothnormalvehicleandtroubled machine.

Refer to page 2-11 and remove theleftsidecover.

[2] Thenopenthe coverundertheoperator’s seat.

[3] Removethecoverfromthebatteryterminals.

[4]Connect thebooster cable(red)clipto thepositive(+)terminal on thebattery of troubled machine. theclipfromtheotherendof theposi[5] Connect tive(+)booster cable(red)to thepositive terminal on thebattery of normal vehicle.

[6] Connectthe boostercable(black)clipto the negative (-)terminal on thebatteryof normal vehicle. connect theclipfromtheotherendofthe [7]Finally, negative (-)booster cable(black) to theengine body(hook,etc.)of troubled machine, awayfrom thebattery.

B ATTERY PM3-25

I PA3-2(

CABLE CONNECTING ORDER (~)-~(~)-~)-~(~) CABLE DISCONNECTING ORDER ~)--~,~-~I~)-~(:~)

DO NOT CONNECT THE NEGATIVE (-) BOOSTER CABLE TO THE MACHINE CARBODY (LOWER STRUCTURE) of normal vehicle, andoperate it [8]Starttheengine foraround 10 minutes at highidling. machine.

[9] Starttheengineof troubled [10]Afterstarting theengineof troubled machine, removethebooster cablesin thereverse order of theaboveconnection.

[11]Makesureto checkand repairthecauseof the problem of thecharging systemon thetroubled machine.

3-12

(RED)

NORMAL BATTERY

DISCHARGED BATTERY

® (BLACK) I TO THE

ENGINE

.

OF THE TROUBLED

MACHINE PRE-3-11

BASIC

MACHINE

OPERATION

3,3 STOPPING MACHINE ENGINE Makesureto idletheengineforat least5 minutes beforemachineshutdown.

When the machineis suddenlystoppedwhilehigh speedoperation of theengine,temperature of the engineis rapidly increased causing deterioration of engine oilandseizure of seals. placetheattachment on thegroundbe[1]Normally, forestopping theengine (except forspecial situations).

[2]Makesureto placethesafetylockleverin the "LOCK"(up)position beforeleaving thecab.

[3]Pushthethrottle leverallthewayforward tolow idleposition forabout5 minutes.

Operate theengineat idlingfora whileto lower thecoolant temperature.

Turn the starter keyto OFFto stoptheengine.

[4] [5]Removetheignition key.

THROTTLE LEVER //~

(~

PAE3-151

OFF

ON

\~I~;

HEAT %

START I

~~

/

STARTER

KEY

PA3-22

3-13

BASIC

MACHINE

3.4 INSPECTION AFTER STARTING MACHINE ENGINE Checkandensurethefollowing itemsafterstarting theengine: A.

EXHAUST GAS COLOR, ABNORMAL SOUND & SMELL Whileoperating theengine, checkthefollowing items.

[1]Checkforabnormal exhaust colorduringtheengineoperation.

Avoidcontinuous operation if theengineexhaust is black.

Blackexhaust is an indication of an excessive richfuel/air mixture.

Checkandservice theengine accordingly if thiscondition ispresent. when any abnormal [2]Stopoperationimmediately soundexistsduringthemachine operation.

Check the causeof the abnormal sound,andrepairas needed. at thespeedrangewithreso[3]Avoidtheoperation nance.Theremay be a certainrotatingspeed rangeat whichthe vibration suddenly becomes largedue to resonance.

Avoidthe operation at such speed range becausesome parts may be damageddueto vibration. smellor smokeis generated, immedi[4]If burning atelystoptheengine.Checkforany abnormalitiesand repairas neededbeforeresumingoperation.

OPERATION WARNING ¯ Careless contact withany operating leverwill cause unexpectedsuddenmachinemovement.

Standing or shiftbodyposition of theoperator aftersecurely settingthesafetylockleverat "LOCK"(up)position. ¯ Makecertain theswingareaof machineis clear of peopleand obstacles beforeoperating.

Know theposition of thetravel motors before starting travelling and makesureto soundhornbefore starting operation.

SOUND

SMOKE NOTE: Whenevernecessary, consultwithan authorizedKOBELCODistributor forapropiate repairs.

NOTE : ¯Do not applyany heavyloadon to the new engine forthefirst50hoursoperation. ¯ Confirmthe LIGHT-OFF for eachwarninglamp. ¯ Carefully listento anyabnormal sound. ¯ Checkleakages foroilandwateraroundtheengine. ¯ At thefirstenginestart-up of theday,operate the engineforaround5 minutes withno loadto warmup theengine andreachoilto everypartof theengine.

3-14

BASIC

MACHINE

OPERATION

B. CHECK EACH SWITCH 8, LEVER Afterwarmingup the engine,checkthe following items: NOTE: Appropriate operation temperature rangefor hydraulic oilis50to80°C(122to176°F).

Avoid machine operation whenthehydraulic oiltemperature is below20°C(68°F).

Failure to so willreduce thelifeof thehydraulic components.

* SAFETY LOCK LEVER [1]Withthe enginerunning, set thesafetycontrol leverto the"LOCK" (up)position. levers,exceptthe dozer/width [2]Moveallcontrol andboomswingcontrol lever. exceptthedozer/ [3]Makesurethatall functions, widthandboomswingfunctions, are not active whenthesafety control leveris inthe"LOCK" (up) position.

[4]Ensurethatthetravelleversare mechanically lockedanddo notmoveat all.

NOTE ¯ Whenany abnormalities are found,immediatelystop the engine,proceedwith the appropiate repairs,and requestassistance from an authorized KOBELCODistributor if necessary.

C. CHECK MONITOR PANEL (GAUGE CLUSTER) Checkallgugesandindicators on thegaugecluster, afterstarting theengine.

Confirm thatenginetemperature gaugeandfuellevelgaugeworkproperly.

3-15

WATER "]IEMP

FUEL

©

BASIC

MACHINE

OPERATION

3.5 MACHINE WARM-UP A. ENGINE WARM-UP

THROTTLE LEVER

¯Avoidrapidspeedincrease of enginespeedwitha coldengine. ¯ Do not idletheenginefor morethan20 minutes.

Extended periods ofidling reduce thelifeoftheengine.

I Setthethrottle leverinthemiddle position, between thelowidlingandhighidling(seeFig.PAE-3-26), andoperate theengineforaround5 minutes withno load.

PAE-3-26

RIGHTOPERATINGLEVER BUCKETIN~

BUCKET OUT

B. WARMING UP HYDRAULIC OIL Appropriate operation temperature rangefor hydraulic oilis 50 to 80°C(122to 176°F).

Avoidma¯ chineoperation whenthehydraulic oiltemperature is below20°C(68°F).

Failure to do so willreduce thelifeof thehydraulic components.

UNLOC~ [1] Set the throttleleverin the "MIDDLESPEED" position.

[2]Set the safetycontrolleverin the "UNLOCK" (down)position, seeFig.PAE-3-27. theboomcontrol leverto raiseit allthe [3]Operate way up. thebucketcontrol leverto retract it or [4]Operate extend it completely against relief, seeFig.PAE3-27.Holdthisposition foroneminute, thenreleaseleverandwaitforanother minutebefore repeating process.

Repeatthisprocedure at least 10 timesor untilthetemperature of thepilothydraulic oilis safeforsmoothattachment operation.

[5]Afterwarming up hydraulic oil,slowlyextendand retract eachcylinder several times,andactuate travelingand slewingmotorsto completethe warm-upoperation.

WARNING In extremely coldclimate it maybe necessary to increasethe warm-uptimeto ensureproperandsafe operation.

Whenoperatingthe machinewithcold hydraulic oil,the operator mayexperience slowor unexpected movementof functions.

Likewise, cold hydraulic oilwillnotprovide adecuate lubrication to hydraulic components; thus,reducing thelifeexpectancyof the machine.

3-16

-3-27

BASIC

MACHINE

OPERATION

3.6 MACHINE OPERATION Thefollowing instructions areaimedat providing an operator withthebasicfunction of eachhydraulic control.

Useof theseinstructions, andpractice with a machine, willallowa givenoperator to becomemore efficient intheoperation ofthisequipment.

Eachoperatormustreadthroughly, understand, and follow thesebasicinstructions alongwithallsafety precautionsfoundin thismanualand on themachinebeforeoperating thisequipment.

UNLOCK ............................................

A. MACHINE

PAE-3-28

TRAVEL

/ BACKWARDTRAVEL] Makecertain theswingareaof machine is clearo’ peopleand obstaclesbeforeoperating.

Know the position ofthetravel motors before starting thetravel J [FORWAR~ function andmakesureto soundhornbeforestartingtheengine.

If anyabnormality is foundduringthemachine operation, immediately stopworking.

Makesureto repairanyfaulty conditions before resuming operation.

NORMAL POSITIONING OF THE MACHINE FOR THE PURPOSE OF DETERMINING FRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED BEHIND THE OPERATOR’S CAB. [PIVOTTURN] 1. Forward/Reverse Travel leveris in the"UN[1]Makesurethesafetycontrol LOCK"downposition.

Operate theboom,arm,and bucket control levers toraisetheattachments from theground.

[2]Pullthedozeroperating leverto raisethedozer.

[3]To movethe machineforward,pushboth(right andleft)travel levers toward thefrontofmachine¯ To movethe machinein reverse, pullbackboth travel levers.

FORWARD Travelspeedchangesdepending on how far you pushorpullthelevers.

2.Pivot turn ¯ Pushthelefttravel levertoward frontofmachine to turnmachineLEFT(PAE-3-30). ¯ Pushtherighttravel levertoward frontof machine to turnmachineRIGHT. ¯ Pullthelefttravel leverbackto turnmachine LEFT in reverse. ¯ Pulltherighttravel leverbacktoturnmachine RIGHT inreverse.

3. CounterRotating Machine(PAE-3-31) To counter rotate machine to theleft,pulllefttravel leverbackandpushrighttravelleverforward.

Tocounter rotate machine totheright, pullright travel leverbackandpushlefttravel leverforward.

3-17

PAE-3-29

[COUNTER ROTATING MACHINEI (SPINTURN)

ACKWA PAE-3-31

BASIC

MACHINE

OPERATION

4. TravelSpeedShifting (lst/2nd) [1]For fasttravelspeed,depressand releasethe travelspeedselector switchoncebeforeoperatingthetravel controls.

Thefastlampindicator (A) willilluminate in thecluster gauge. travelby operating thetravel [2]Startthemachine levers. speed,stoptraveland [3]To returnto "SLOW"travel depressand releasethe travelspeedselector switchonce.

NOTE:The travelspeedis alwaysresetto "SLOW" speedeverytimethekeyswitchis turnedto the "OFF"position.

(A~..41

B. STOPPING TRAVELLING (PAE-3-21) [STOPTRAVELING] Whentheoperation fortheattachment or slewing is inevitable during traveling, payattention nottooperateitrapidly.

[1]Putthetravel levers of leftandrightat neutral position to stopthemachine travel.

Avoidto stopthemachinetravelsuddenly.

Stop themachine travelas slowlyas possible.

PAE-3-21

C. TRAVEL

PRECAUTIONS Condition wherethetravel direction isreversed

I

¯Usea flag-man whentraveling on theshoulder of a

,I

roador in confined areas. ¯ Neverallowpersons to rideon themachine. is known [1]Makecertainthetravelmotorlocation before performing anytravel operation.

Travel with travel motorsin thebackof themachine forlong distance travel. onflatandfirmground andinstraight lines [2]Travel (orlargeangles) as muchas possible.

Whenturningthe machine, moveforwardandbackward alternately as muchas possible insteadof making onesharp(pivot) turn.

[3]Checkthestrength of bridges androadshoulders, andreinforce themif necessary.

[4]Be careful notto comeintocontact withbridges orelectrical powerlines. on roughground,use low (1st) [5]Whentraveling speedto reducethe shockto themachine. tostrike travel [6]Donotallowlargeorheavyobjects motors.

Likewise, do nottravel overlargeobjects suchas boulders, rocks, etc.

3-18

r

) PMJ-1-9

BASIC

MACHINE

[7]On a snowyor icyroad,travelwithslowerspeed avoiding any suddenstart,suddenstopandsuddenslewing. at thetransport, remove any [8]Forloading/unloading mudcloggedin thecrawler shoesto preventthe machinefromsideskidding on the gangboard.

Referto page5-2 for the usageof gangboard, etc.

OPERATION

ILOW IDLINGPOSITION

II II

PAE-3-33

D. CARE ON UP/DOWN

SLOPE

¯ Nevertakesuchtraveling manneras changing direction on a slopeor crossing a slope.Onceget downto a flatground andtakea detour, keeping in mindthesafety traveling. ¯ Raisethebucket30 to 40 cm (15-16in) abovethe groundlevel, whiletraveling.

Anddo notgetdown theslopewithreverse traveling. ¯Whenthemachineis skidded, immediately getdown thebucketandtakebreaking. ¯ The slewingon a slopemay cause the machine turning overdueto losingbalance on themachine.

It is quitedangerous to slewto downsideof the slopewithfullof loading in thebucket.

Whensuch workis inevitable, makethegroundlevelon the slopeto secure theflatworking area. ¯ Nevertravelon theslopeof morethan30° gradient. ¯Whenparking on theslopeis inevitable, makesure to applyskidsto the crawlers and get downthe bucketto theground.

PMJ 3-34

X

O

""’:":"" PMJ-1-15

[1]Themaxgradeability of themachine is 58%(30°).

Whilegetting downslope, slowly operate thetravel [2] levers.

[3]Travel slopewithlowspeed(1 st speed). slope,keepthe bucketat 30-40 [4]Whiletraveling cm (15-16in) of heightabovethe groundlevel, andtravelwithlowspeed.

90o 110

¯....:,:.:.:.’~

(12~16in).......~...{.:..

30-40cm (12-16in) PAE-3-34

3-19

BASIC

MACHINE

OPERATION

on a slope,placethe [5]Whentheengineis stalled attachment on the ground,and makesure each operating leveris in theneutral position.

Then starttheengine again. toclimb a slope withthetravel motor [6]Ifitisdifficult dueto skidding crawlers, etc.,thepowerof the armcan be utilized to pullup themachine with the bucketengagedon the ground.

[7]Whenparking themachine on a slope,evenif it is a shorttimeof period, placeallattachments on theground, placeeachoperating leverin theneutralposition, setthesafetycontrol leverto the "LOCK"(up)position andblockthecrawlers.

NOTE: Whenthehydraulic oilis notwarmedup sufficiently, themachine maynotbe ableto displayitsfullperformance.

Makesurethemachineis sufficiently warmedup beforeclimbinga slope.

E. MACHINE OPERATION SOFT GROUND

PAE-l-17

IN WATER/ON

NOTE: Payattention notto immerse theslewing bearing,slewing pinionandswiveljointintothe wateror mud.

If themachineis operated in wateror mud, the slewingbearingand othersmay be worn abnormally.

Immediate replacement of grease or overhaul oftheslewing bearing, etc.isrequired.

SLEWING BEARING

RIVERBED

UPPER ROLLER PWJ-3-28

[1]Wherea riverbedis flatandwaterflowis slow, themachinemaybe operated in a water-depth to theupperrollers (A). themachine in thewaterwithcarecheck[2]Operate ing riverbedconditions withbucket,etc.And neverenterintothe waterof thedepthbeyond (A)(PWJ-3-28). themachine bodysinkslittle by [3]On a softground, little in somecases.

Therefore, payfullattention to themachine at alltimesduring operation.

[4]Aftertraveling in seawater, thoroughly washup themachineto removesalt. bucketpinsand bushing [5]Makesureto lubricate every4 hoursif working withmaterials inwetconditions, supplygreasewitha greasegununtil greasepurges.

3-20

GREASING POINT ~[~

~/~

PAE-3-36

BASIC

MACHINE

OPERATION

F. GETTING OUT OF SOFT GROUND If possible, avoidtraveling onsoftground.

Avoidgetting caught inthemud.Intheeventthatthe machine getscaught in themud,getoutof it as follows: (a) ONE CRAWLER SHOE GETS CAUGHT IN MUD Wheneithersideof crawler shoesgetscaughtin the mud,lay logsor boardson themud to forma base.

Operatethe boomand armto forman anglebetween boomand arm of about90 - 110° and pushon the groundwiththebottomof thebucketto liftthemachinebodyup to climbon thelogsor bords(PMJ-339).

i

PMJ-3-39

(b) BOTH CRAWLER SHOES GET CAUGHT IN MUD Whenbothsidesof crawler shoesgetcaughtin mud andthemachine doesnotmovedueto skidding, providelogsandboards, as described in theabovesection.Andfirmlycatchthehardgroundon whichthe machineshouldgetoutof mudwiththebucket,and pullup themachine towardthehardgroundwiththe sameoperation of digging(PMJ-3-40).

PMJ-3-40

In casethemachine is notableto travel because its crawler is stuckin mud,sandor gravelon thesoft ground, takeeachcrawler offthegroundby pushing theboomandarmagainst theground, scrapeoffmud, sandandgravelandthengetthemachine outof the trouble.

Graveland mudmay be clearedif yourotatetheraised crawler backandforth.

,ii iiiii’° i!i iilfiiiii li i!i i Operate themachineat theoperator’s seat.Do not allowany personto comenearthe machine.

3-21

PMJ-3-41

BASIC G. SLEWING

MACHINE

OPERATION

OPERATION SLEWINGPATTERN(ISO)

¯ Operation of thismachineon an inclineor slope may cause the machineto becomeunstableor unbalanced. ¯ Makecertain theswingareaof themachine is clear of peopleandobstacles beforeswinging. ¯Workup anddowninclines or slopes, neveracross. ¯ Neverswingor turnmachinearoundon slopes. ¯ Operate control levers carefully to prevent sudden movements whichmay causethe machineto slide ortipover. ¯ Builda levelareaforthemachine to operate. ¯ Usea flagman to guidetheoperator.

LEFT OPERATING

LEVER

Sere7

PWA-3-3f

X

3-22

O

BASIC 3.7 PRACTICES

TO IMPROVE

MACHINE

OPERATION

EFFICIENCY

¯ Swingingon a slopemay causethe machineto becomeunstableor unbalanced.Do not swing downsideof theslopewitha fullbucket.When working in slopes, builda levelareaforthemachineto operate safely. ¯Makecertain theswingareaof themachine is clear of peopleandobstacles beforeswinging.

A. DIGGING [1]UseArmIn Action Operate thebucketat shallow depth,usethearm mainly, andusethebucketas required, in action to fillthebucket.

Setting thebucket toodeepwill decrease themachine’s efficiency.

[2] MaximumDiggingForcePosition The attachmentwill providemaximumdigging forcewhenthe arm and boomare at 90°-110 ° of eachother.Operateslowlyto get maximumdiggingforce.

[3]BucketTeethDirection Always pointbucket teethin thedirection themachinewillbe digging, andoperate thebucketat shallow depth,to reducedigging resistance and thepossibility of bucketteethdamage.

[4] OperateBoomSmoothly Alwaysbeginand endboomoperation slowlywith smooth, careful movement of thecontrol lever.

Do not perform suddenstartsand stops,especially suddenstopsduringdropping, of theboomas this createsunnecessary stresson the machineand its components.

NOTE: Otherthanshowingin the belowsketches, widerrangeof the machineapplication is obtainable by meansof utilizing theoptional attachments.

Referto page4-29forchanging thebucket.

~~ °

90°-110

I)IGGI’NDIGREcT;OI~

~ ..

PME-3-4

PMJ-3-43 [5]Cleaning Sand& SoilfromBucket Operate armto a nearlevelposition andbringthe bucket to a dumping position.

If sandandsoildo notfallout,movethebucket leverrightandlefta fewtimes.

i 3-23

BASIC

MACHINE

OPERATION

1. TRENCH DIGGING The workingefficiency is muchimprovedby means of setting thebucketsuitable fortrench digging and setting themachine in parallel to thetrenchto be digged(PMJ-3-44).

Forwidetrenchdigging, digbothsidesportions at first, thendigthecenter portion.

2. USING THE DOZER [1]Thedozeris usedto pushthesoilbackto digged trench, or forground leveling. at itsupperor [2]Scrapethesoillaidon theground sidefacewiththedozer.

Adjust theheight ofdozer withthedozercontrol leverto avoidoverloading theengine.

¯.~. ) .... ¯ ".".’I PMJ-3-44i

S PMJ-3-45

3. SIDE DIGGING

Carefully operate theattachment payingattention to thesurrounding conditions, sincetheboomswine operating rangeis wide.

SWING / REMOTE CONTROL SWITCH (B)

(A)

Operate thecontrol leverrightandleftkeeping the switch on thegripof theleftcontrol leverpressed, andtheboomswingsrightandleft.

Switch ..............................

Pressed(ON) Operate lever right ...........

Rightswing Operate lever left.............

Leftswing

/

Theswingoperation doesnotstopevenif theswitch is offin theswingoperation.

To switchtheswing andslewing motions, placetheleftcontrol leverto theneutral position once.

!i

I I ] ] I I ] i i l i i i x i

I l

I I ] I J I i i i ! i

, I

l I

/

] I.

PWA-3-58

3-24

BASIC MACHINE OPERATION B. LOADING efficiency is improved, if the dump [1]The working truck issetattheposition sothattheslewing angle becomesminimumkeepinga goodvisualfieldof theoperator. thatloadingbe startedfrom [2]It is recommended thefrontsideof thedumptruckbody.Thiswill makeloadingeasierandmoresoilcanbe loaded thanloadingfromtheside(PMJ-3-47).

PMJ-3-47

C. WORKING IN NARROW SPACE The positionshownin (PR-1-44) is available for swinging in narrowspaces.

D. MINIMUM SWING POSITION andbucketcylinder to maxi[1]Extendarmcylinder mumlength,andfoldbucket.

[2]Extendboomcylinderto maximumlength. on theleftcontrol leverdepress[3]Keeptheswitch ingandoperate theleftcontrol lever left. leverto swingboom.

[4]Handleoperating NOTE¯ Usecareto protect attachment frominterference.

* MINIMUM

At swing

SLEWING

RADIUS

SK30SR-2 SK35SR-2 CANOPY CAB CANOPY CAB 1,480mrn1,790mm1,540mrn1,940mm (4’10.3") (5’10.5") (5’0.6")(6’4.4") Left80"Left70° Left80" Left70"

PR-1-44

ARM OUT

Not swing

1,870mm 2,140mm 1,980mm 2,310mm (6’1.6")(7’0.3")(6’6.0")(7’6.9") BOOM SWING LEFT

Theswingoperation doesnotstopevenif theswitch is offin theswingoperation.

To switchtheswing andslewing motions, placetheleftcontrol leverto theneutral position once.

~

/

BOOM SWING RIGHT

Jll~

ARM IN

L.H. CONTROLLEVER (ISOPATI-ERN) LFK-2-32

3-25

BASIC 3.8 MACHINE

MACHINE

OPERATION

PARKING

WARNING ¯ Alwayspartthemachine on a firm,levelsurface. ¯Avoidparking on a slope.Whenparking on a slope is inevitable, makesurebucket teetharedigged in theground,restthe dozerbladeon the ground, andblockthecrawlers. ¯ Makesureto set thesafetycontrolleverto the "LOCK"(up)position to avoidany unexpected machinemovementandstopthe enginebeforeleavingthecab.

[1]Placebothtravellevers(1)intthe "NEUTRAL" position.

[2]Setthethrottle lever(2)to "LOWIDLING" position.

[3]Placethebucketon the ground.

[4]Placethedozerbladeon theground.

[5]Blockthecrawlers. control lever(3)tothe"LOCK" (up) [6]Setthesafety position.

PMA-3-90

PME-3-23

3.9 CHECK & CONFIRMATION AFTER WORK Regularly checkthe monitorpanel(gaugecluster) forwarning lampsandindicators. fully refill thetankwith [1]Ifthefuelisinsufficient, fuel,afterstopping theengine. isindicated withthewarning lamps [2]If anytrouble forthe coolanttemperature and/orengineoil, movethe machineto a safeplace,immediately stopthe engine, andrepairas necessary before resuming operation.

Referto page4-21forthe "INSPECTION & MAINTENANCE CHART" for detailson preventive maintenance.

3-26

© WATERTIEMP

__

;

FUEL

PMA-3-91

BASIC

MACHINE

3.10 PRECAUTIONS AFTER OPERATION [1]Checkforany oilor coolant leakage.

Checkthe attachment, exterior, and travelsystemcomponents.Repairas neededbeforeresuming operation.

[2]Fully refill withfuel.However, do notoverfill (to thetopof thetank)to avoidoverflowing dueto fluidexpansion undernormaltemperature.

[3]Removemud,etc.,adheredto thetraveling components.

3.11 MEASURES AFTER EMERGENCY STOP ¯ Avoidemergencystopsof the engineas muchas possible.

It shouldbe keptin mindthatthe engineis to be operatedfor around5 minuteswith no load (to disipate heat), beforestopping theengine.

Themostimportant matter is to always payattention to safetyso thatthe emergency stopof theengine willnotbe required. ¯Whentheemergency stopof theengineis inevitable due to dangerous condition or troubleon the machine,takethethefollowing preventive measures to avoidanyinjuryor damages to themachine. ¯ Donotrestart theengine untilitstemperature is completely lowered.

Sudden stopof theengine justafteroperation inhigh speedcausesa suddenriseof enginetemperature resulting indeterioration ofoil,seizure ofsealing components, etc.

3-27

OPERATION

YN-3-52

BASIC

MACHINE

[1]Evenif theengine ceasesitsoperation, keepthe safety control leverinthe"LOCK" (up)position. stopis donewithoutplac[2]Whenthe emergency ingthebucket ontheground, support it withsafety blocksundertheattachment or the bucket,and blockthecrawlers.

[3] Whentheemergency stopis activated on a slope, blockbothcrawlers at theirlowersides. while [4]Makesureto setlimitsaroundthemachine itis downforrepairs andtagit properly.

Usetag P/N: YN20T01320P1.

KOBELCODistributor [5]Consultwithan authorized forrepairs if needed. stop,do notrestarttheen[6]Afteran emergency gineuntilthetemperature of theengineis completely lowered.

OPERATION

I ~~~OCK PAE-1-17

PAE-3-46

3,12 LOCKING UP WITH KEY Makesureto usetheignition keyto lockthefollowingitems: (a) Engineguard (b) Cabdoor (c)Tankcoverforhydraulic oil (d)Coverfortoolkeeping

3-28

BASIC

MACHINE

OPERATION

3.13 EMERGENCY MEASURES AGAINST SUDDEN FAILURE OF MACHINE A. RELEASING LOCK FOR TRAVEL MOTOR Whiletravel motors areat a standstill, theyarehydraulically locked by thecounter balance valve, and alsomechanically lockedby thebrakesystem.

When themachine becomes unableto traveldueto failure SUPPO ~RT~~L~ onthetravel motors, etc., itispossible to temporarily movethemachine by meansof releasing lockforthe "/’////2///////2///////////;~ travel motorwitheither of thefollowing methods: PEE-4-103

(6)

Avoidcontamination ofreduction unitswhiletheir cov-I ers are removed.

I

(1)

(3).~.....

A-l) REMOVING GEARS (5)....

*Thisis thepreferred method.

Makesureto applysafetyblocksto frontandback sidesof crawlershoesbeforeremoving~he gears fromthetravel reduction units.

Provide a support fortheattachment if necessary.

(4) PEE-4-102

1.Provide a container underthetravel motorto collectdrained oil,see(PEE-4-101).

Slowlyremove to plug(4),thenremovelowerplug todrain reduction unitoil.

Plug(4):8 mm hex.bore

Cleanupallspilled oil.Dispose ofallhazardous waste in accordance withlocalgovernment environmental regulations.

PEE-4-101

3-29

BASIC

MACHINE

OPERATION

2. Inserta (flat)screwdriver intogapbetween the body(1) and O-snapring(3),to removethe snapring(3).

(3)

(2)

3.Removethecover(2)together withtheslidering (5).

(1)

E-4-107

4. Removethecarrierassy(6)fromthereduction unitandprotect it fromcontamination and/or damage.

NOTE:the sprocketforthiscrawlerbecomesfree fromthetravel motor.

(6)

5.Temporarily install thecover(2). travel 6. Repeatsteps1 through5 on theopposite reduction unitto remove thecarrier assy(6).

Toe themachine to a safeplaceto proceedwith theapropiate repairs.

O6

waste in a~cal government ronmental regulations.

envi-

I I

NOTE: Afterallrepairs aremade,reinstall thecarrier assy(6)on bothtravel reduction unitsin reverseorderandmakesureto use freshgear oil.RefertoMaintenance Section (4)forproper oilandcapacities.

3-30

BASIC

MACHINE

OPERATION

A-2) REMOVING SPOOL AND BRAKE 1.Remove thetrackchainsaccording to theinstructions "REMOVAL OF RUBBER CRAWLER SHOE"in page4-16.

2. Makesureto usesafetyblocksunderthecrawler frames(travel motorside) 3.Remove thetravel motorcovers (1)frombothsides of lowerframeloosening threecapscrews (2).

4.Provide an emptycontainer to catchdrainoil,then disconnect thehoses,see (PAE-3-50).

Makesure to releasehydraulic systemand tankpressure, seepage4-13.Makesureto markall hydraulic linesconnecting on travelmotorsand remove them.

Neverallowa hydraulic lineor component to become contaminated.

Thiscouldcauseseveresystemdamage.Contactan authorized Kobelcorepresentative to obtainthe propercapsandplugsto be usedon thismachine.

SAFETY BLOCK CORK

5. Removethe socketcapscrews (3) to removethe travel motorfromthelower(crawler)frame.

Graduallyloosenthecapscrews payingattention notto dropoffthetravel motor.

8-Socketcapscrew(3): M10x20

)

PAE-3-50

(4)

6. Removetheplug(4).

Plug(4):27 mm of hex.size

~-,,.~~

3-31

PAE-3-51

BASIC

MACHINE

7. Removethe spool(5).Be carefulnotto damage the spoolduringremoval.Placespool(5) and looseparts(6)and(7)in a cleancontainer cleanoilto protect themfromrustandcontamination.

OPERATION

(10)

8.Install plugs(4)to prevent contamination.

9. Remove7-socketcapscrew(12),and separate thebodies(10)and(11)fromassembly, see(PEE2-104).

(10) (13) ¯ Makesureto contain oilspillage anddispose of allhazardous wastein accordance withlocalgovernmentregulations.

.}

/

10.Remove10-spring (13)forparkingbrake.

11.Temporarily reassemble bodies(10)and (11) without springs (13).

12.Install thetravel motortothelower(crawler) frame andreinstall hydraulic lines.

\ (11) PEE-3-104

13.Repeatsteps3 through12 on theopposite track sideto remove theothertravel motor.

14.Install trackchainsin accordance with"INSTALLATIONOF RUBBER CRAWLERSHOE" in page 417,andmovethemachine to a safeplaceto proceedwithrepairs.

By removing the spoolsandsprings, the travel motorsarereleased fromlockedcondition.

Movethemachine to a safeplaceandcalla service-man as mentioned in ItemA-l).

NOTE: Afterallrepairs aremade,reinstall thecounter balancespoolsand brakespringson both travel motors.

Makesurehydraulic oillevelis to specifications.

Referto Maintenance Section(4)forproper oilandcapacities.

3-32

Neverallowa hydraulic lineor component to becomecontaminated.

Thiscouldcauseseveresystem damage.Contactan authorized Kobelcorepresentative to obtain theproper capsandplugsto be usedon thismachine.

BASIC B. LOWERING

MACHINE

OPERATION

BUCKET

Thisprocedure is to be usedonlyas an emergency to lowertheposition of thebucket.

Extreme caution shouldbe excersized sincetheweightof thebucket willtendto movethebucket abruptly whenthelines aredisconnected.

Makesureto blocktheattachments to avoidsudden changesin theirposition.

Slowlyremovehydraulic linesuntiloilpressure is completely released.

Then controlthebucketmovement by slowlyremoving the block.

To lowerthebucketposition, proceed as follows: Whenthebucketis in diggingposition (A)(bucket cylinder completely extended, seePAE-3-53), disconnecthose(H)side,seePAE-3-54.

Conversely, when thebucketis in dumpposition (B)(bucket cylinder completely retracted, seePAE-3-53), disconnect the hose(R)side,see PAE-3-54.

(

(A) PAE-3-53

Neverallowa hydraulic lineor component to becomecontaminated.

Thiscouldcauseseveresystem damage.Contactan authorized Kobelcorepresentative to obtain theproper capsandplugsto be usedon thismachine.

IlllUlllltllllm/ I Clean up allspilled oil.Dispose ofallhazardous waste I in accordance withlocalgovernment environmental I regulations.

I

(R)

(H~

PAE-3-54

3-33

BASIC C. LOWERING

ARM

MACHINE

OPERATION

& BOOM

¯ Thisprocedure is to be usedonlyas an emergencyto lowertheposition of attachment.

Extreme caution shouldbe excersized sincetheweightof theattachments willtendto dropthemabruptly whenthelinesaredisconnected. ¯ Makesureto blockthe attachments to avoid suddenchangesin theirposition.

Slowlyremove hydraulic lines untiloilpressure is completely released.Then controlthe attachment movement by slowlyremoving theblockage. ¯ Do notenterintothe areaunderattachments, whilelowering them.

STEPI~~

PAE-3-55

RM(R 1. Lowering Arm (Step1) Gradually loosenthehoseof rodsideconnected to thearmcylinder.

2. LoweringBoom(Step2) Gradually loosenthe hoseof headsideconnectedto theboomcylinder.

BOOM(H PAE-3-56 ~e of all I in ac~nment regulations.

.

hazardous waste environmental

I I

Keep the attachment at 30-40cm (12-16in) aboveground level,takingtheoccasion of movingthemachine intoconsideration.

.

Securely retighten the hosesnotto lowerthe attachment anymore.

.

Aftermovingthe machine to a safeplace,get touchtheattachment withthe ground.

,

Callup a serviceman to havethemachineinvestigated.

D. SLEWING UPPER SLEWING STRUCTURE The upperslewingstructure has no brakingsystem.Therefore, it is possible to slewthe upper slewing structure by meansof pushing theattachmentwitha fewpersons.

3-34

NOTE: If necessary, contactan authorized KOBELCODistributor for adviseand/orrepairs.

BASIC

MACHINE

3.14 CAUTION ON USING RUBBER CRAWLER SHOES A. PROPER USAGE The rubbercrawlershoeoffersexcellent features whicha steelcrawler shoedoesnot possess.

However, if it is usedin thesamewayas thesteel crawler shoe,thenitsadvantages cannotbe fully taken.Operation of the machinevariesuponsite andworking conditions.

OPERATION Althoughthe rubbercrawlershoedisplaysmany advantages because of itsmaterial properties, it hasdisadvantages intermsofstrength.

Itis thereforenecessary to getfullyfamiliar withthecharacteristics of the rubbercrawlershoeand observe whatareprohibited andcautioned against, in ordertoextend theservice lifeof therubber crawler shoeandhaveit fulfill itsadvantages to a maximum possibleextent.Read throughly"CAUTIONS ON USING RUBBER SHOES" before use.

Comparison betweenrubberand steelcrawlershoes: Rubbersho{ Steelshoe Lessvibration Smoothrun Low noise Harmless for pavedroad Easyhandling Not damageable Largetraction force O; ExcellentO ; Good

@ ©

O

@ /k

O O O A ; Ordinary

B. PROHIBITED WORK Do notcarryoutthefollowing operations: [1]Do notoperate and/nor travel ingravel-mixed land, ruggedandsolidrockbed,ferroconcrete, iron scraps, edgesof ironplates.

~GUARANTEE OF RUBBER CRAWLER SHOE Guaranteedoesnot coversuch damagesdoneto therubbercrawler shoethatresultfromimproper working and/or operation as:execution of sitework in suchplaceswherethereare steelplates,Udrains,blockcorners, sharpslashedgraveland stones, ferroconcrete debris, metalscraps andotherswhichmaytearofftherubber crawler shoe,and neglect to observe prohibited operations.

X

and/nortravelin suchplacesas [2]Do not operate river bedswheretherearelotsofstones of different sizes.Therubbercrawlershoetendsto be damagedor comeoff fromtherollers as theresultof beingcaught in thegrooves on therubber crawlershoes.The servicelifeof the rubber crawler shoewillbe reduced if soilis pushed by forcewhentherubbercrawler shoeis slipping.

[3]Do notletoil,fuel,solvents, etc.,comeincontact withrubber shoes.

Ifitdoes, wipeitoffwitha cloth immediately.

Do nottravel on a puddle of oil,etc.on theroad surface.

PR-3-71

3-35

BASIC

MACHINE

OPERATION

fire, [4]Do notentersuchhotplacesas an open-air andsteelplateleftintheopensun.

Donotworkin asphalt leveling.

[5 Whenstoring the machine for longperiods (more thanthreemonths), keepit indoors whichwillnot be exposed to directsunshine andrain.

Referto page3-41forthestoring procedures.

I~

PMJ-3-67 travels usingonesidecrawler, with [6]If themachine thecrawler of another sidefloating, therubber crawler shoemaycomeofffromtherollers or be damaged.

C. CAUTIONS ON USAGE Usecareof thefollowing whenworking: [1]Rubbershoesslipeasily on icysurfaces Takethenecessary safetyprecautions, suchas notdriving on snowy/icy slopes.

[2]Avoidmaking a spinturnon a concrete road. changeof directions because it will [3]Avoidabrupt causeearlywearor chipping of therubber crawler shoe.

-

[4]Exercise careso thattherubbercrawler shoeis not damagedby the bucketwhileworking. themachine by pressing thebucket [5]Do notoperate against concretes andwalls.

o

is liftedup by theattachment, [6]Whenthemachine lower itslowly.

PR-3-75

3-36

BASIC

MACHINE

OPERATION

is operated in saltyor corrosive [7]If themachine places, theadhesion of thecoremetalof theshoe willget loose.Refrainfromusingtheshoe,or washit withwaterafteruse.

[8] The rubbershoeshouldbe usedwithin-25°Cto +55°C(-13°F to 131°F),considering thephysical properties of rubber.

PR-3-76

NOTE: Use the rubbershoeunderpropertensionto prevent it fromcomingofffromtherollers.

Operatetherubbershoecarefully evenwhen tensioning is proper.

[9]Avoidchanging direction of themachine on ground withdifference in level(about20cm/8in).

When crossing overa placewherethereis a difference inlevel, doitat right angles tothedifference in level,see(PMJ-3-70).

[10]Whenclimbingbackon a slope,avoidchanging direction of themachine whileclimbing on a point betweena levelgroundandtheslopelsee(PMJ3-71).

PMJ-3-71

[11]If you travelon a slopeor a concavewithone sideofthemachine lifting, it willdamage therubbercrawler shoe.Alwaystravelwithbothsides of themachine in level.

of themachine withthe [12]Do notchangedirection rubbercrawlershoeon groundwithhighspots, see(PMJ-3-80) asit willcausetherubber crawler shoeto comeoff or be damaged.

PMJ-3-80

3-37

BASIC

MACHINE

3.15 MACHINE OPERATION IN ADVERSE WEATHER CONDITION A. OPERATION IN EXTREME COLD

Whenthetemperature is extremely low,oilflowis reduced dueto increased viscosity, makingstart-up difficult.

Coolant mayfreeze damaging radiator and/ or engine.

[1] FUEL AND OIL

OPERATION [3] BATTERY Whentheambienttemperature lowers, the charging performance goesdownor the batterymay freeze.Keepthe charging rateas closeas possibleto 100%.Coverthebattery withinsulation material.

Performteston the battery.

We recommend the testbe performed at rommtemperature for best results.

Usea hydrometer to checkthespecific gravity of eachcellandcompare thereadings with thetableprovided below.

Usefuelandoilofhighquality andlowviscosity for each system.See MAINTENANCEsection, -10°0 flu fbattery "LUBRICANT, FUEL & COOLANT SPECIFICAid (14°F) Charging rate TIONS"page4-7fordetails.

0°C 20°C (32°F) (68°F)

100% 1.28 1.27 1.26 [2]COOLANT ¯ Whenoperating or storingthe machinein cold 90% 1.26 1.25 1.24 regions, theratio ofmixing antifreeze intothecoolingsystemshouldconformwiththelowestpre80% 1.24 1.23 1.22 dictedambienttemperature.

If coolant freezes, 75% 1.23 1.22 1.21 theradiator, crankcase andcylinder headmaybe damaged.

Donotmeasure thespecific gravity ofbattery fluidjust ¯ Whenshippedfromthefactory, the machine con- afteroperation. tainscoolantmixedwithall-season-type LONG LIFE COOLANT. ¯Whenoperating freeof ice andsnow or storing themachine in extreme NOTE: Keepbatteryterminals to avoid short circuits.

Check thebattery eleccold,inspect thecoolant to maintain proper controlyte (acid) level frequently and fill as needed centration. withdistilled water.

Inextremely coldclimates, removethebattery andstoreit overnight at NOTE: In extremely frigid climates, covering theraroomtemperature. diatoris a methodto aidthe machinewarm up. If necessary to maintain temperatures, covertheouteredgesof theradiator, leaving [4] AFTER OPERATION anopening inthecenter partofthecover; thus, Mud and water adheringto the machinemay avoiding fanoveloading.

Keepa closewatch freezeinterfering withpropermachine operation. on thecluster gaugeforwarning iconsduring Use the following general guidelines as reference operation.

It maybe necessary to usecoolant to prevent malfunctions: heater, fuelheater, engine heater jacket, and/ ¯ Removemud and wateradhering to the machine. oradditional battery powertoaidengine startRemovewateradhering to thetravelsystemthoring.Likewise, mixcoolant to a protection temoughly andparkon dryground to prevent thetravel perature of 5 °C (41°F)lowerthanthe masystemfromfreezing. chinewillexperience duringoperation, stor¯ Retractthecylinder rodsto minimumlengthto ageor transport. reduceexposedareaof therods.Thiswillpreventmud or wateron therod facesfromdamagingtheseal.

3-38

BASIC

MACHINE

B. OPERATION AT SEASHORE OR SALTY CLIMATE [1] BEFORE OPERATION ¯ Checkallmounting hardware forpropertightness.

Torqueto propervalueto aidin preventing salt fromentering the machinesystems. ¯Applygreaseto the electrical equipment as required to prevent corrosion.

[2]AFTER OPERATION Wash the machinethoroughlyto removesalt.

Applyoilor greaseas necessary to prevent corrosion.

C. CARE FOR ELECTRICAL EQUIPMENT Theelectrical equipment is especially sensitive to water.Be careful notto expose theelectrical equipmentto waterwhenwashingthe machineor during rain.Theelectrical components (relays, fuses, etc.) areinstalled at theoperator’s seatof themachine.

Neverexposetheoperator’s seatto water.

D. OPERATION IN DUSTY AREAS [1] AIR CLEANER Cleanor replacetheelementat adequate interval,See"Maintenance Section" fordetails.

[2] RADIATOR Cleantheradiator regularly to prevent theradiatorcorefrombecoming clogged withdust, [3] FUEL Becareful nottoletcontamination in thefuelwhen refueling.

Inspect theelements andfilters at adequate interval.

[4] ELECTRICAL EQUIPMENT Cleanthestarter andgenerator especially, at adequateinterval, to prevent dustfromaccumulating.See"Maintenance Section" fordetails.

3-39

OPERATION

BASIC

MACHINE

OPERATION

3.16 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD Whenstoringthe machinefor morethanone month,observethe following pointsto preventthe machine function fromdeteriorating.

Item

Action

Washingmachine

Washthe machinethoroughly.

Checkthetravelsystemforany malfunctions andservice as required.

Lubricate every required part.

Lubrication

Checkthelubrication oilto makesureit is at theproperlevelandforcontamination.

Replenish if necessary, andchangeif contaminated. ¯ Lubricating oildeteriorates evenwhenthemachine is notused. ¯ Be sureto checktheoilbeforeoperating themachine again.

Applysufficient rustinhibiters toportions whererustislikely tooccur, especially theexposedrodof thecylinders.

Battery

Removethenegative terminal frombattery andcoverthebattery, or removethebattery fromthemachine andstoreit at roomtemperature placing it overa wooddeck.

Chargethe batteryoncea monthto replenish spontaneous discharging.

Coolant

If thereis a possibility thatthecoolant mayfreeze, addantifreeze in thecoolant.

Normally, longlifecoolant is mixedin,so it isnotnecessary to change thecoolant.

Dustandhumidity prevention PMJ-3-76

Keepthe machinein a dry placeindoors.If the machinemustbe keptoutdoors, lay timberon theflatgroundandprotect themachine withcover. ¯ Parkthe machinewiththe exposedpistonrodof the cylinder retracted as muchas possible. ¯Getdownthebucketto thegroundandsettheskidsto thecrawler.

If theoilfilmon thepartsis insufficient andrustoccurs, abnormal wearmayoccurwhen themachine is operated.

Starttheengineandoperate themachine andattachment, etc.oncea monthto lubricate alloftheparts.

Periodical operation¯ Beforestarting theengine, checktheengineoilandcoolant level,andreplenish if forlubrication insufficient. (during storage) ¯ Wipeofftherustinhibiter fromthecylinders andpiston rodthoroughly. ¯Applyrustinhibiters tothecylinder rodsaftertheaboveoperation. ¯Afterstarting theengine, warmup themachine completely.

Repeattraveling, slewing, anddigging several timesto lubricate eachpartof themachine. ¯ Ensureproperventilation duringwarming-up operation.

Beforeplacing themachine backintooperation, proceed as follows beforestarting up.

Operation aftertong ¯ Fullywipeofftherustinhibiters fromthecylinders andpiston rods. ¯ Refill fluids toproper levels andlubricate asrequired. termstorage

3-40

BASIC

MACHINE

OPERATION

3.16 PRECAUTIONS WHEN STORING THE MACHINE FOR A LONG PERIOD Whenstoringthe machinefor morethanone month,observethe following pointsto preventthe machine function fromdeteriorating.

Item

Action

Washingmachine

Washthe machinethoroughly.

Checkthetravelsystemforanymalfunctions andservice as required.

Lubricate every required part.

Lubrication

Checkthelubrication oilto makesureit is at theproperlevelandforcontamination.

Replenish if necessary, andchangeif contaminated. ¯ Lubricating oildeteriorates evenwhenthemachine is notused. ¯ Be sureto checktheoilbeforeoperating themachine again.

Applysufficient rustinhibiters toportions whererustislikely tooccur, especially theexposedrodof thecylinders.

Battery

Removethenegative terminal frombattery andcoverthebattery, or removethebattery fromthemachine andstoreit at roomtemperature placing it overa wooddeck.

Chargethe batteryoncea monthto replenish spontaneous discharging.

Coolant

If thereis a possibility thatthecoolant mayfreeze, addantifreeze in thecoolant.

Normally, longlifecoolant ismixedin,so itis notnecessary tochange thecoolant.

Dustand humidity prevention

~\\\\\\\\\\\~\\\\ PMJ-3-76

Keepthe machinein a dry placeindoors.If the machinemustbe keptoutdoors, lay timberon theflatground andprotect themachine withcover. ¯ Parkthe machinewiththe exposedpistonrod of the cylinder retracted as muchas possible. ¯ Getdownthebucketto theground andsettheskidsto thecrawler.

If theoilfilmon thepartsis insufficient andrustoccurs, abnormal wearmayoccurwhen themachine is operated.

Starttheengineandoperate themachine andattachment, etc.oncea monthto lubricate alloftheparts.

Periodical operation¯ Beforestarting theengine, checktheengineoilandcoolant level,andreplenish if forlubrication insufficient. (during storage) ¯Wipeofftherustinhibiter fromthecylinders andpiston rodthoroughly. ¯Applyrustinhibiters tothecylinder rodsaftertheaboveoperation. ¯Afterstarting theengine, warmup themachine completely.

Repeattraveling, slewing, anddigging several timesto lubricate eachpartof themachine. ¯ Ensureproperventilation duringwarming-up operation.

Beforeplacing themachine backintooperation, proceed as follows beforestarting up.

Operation afterlong ¯ Fullywipeofftherustinhibiters fromthecylinders andpiston rods. termstorage ¯ Refill fluids toproper levels andlubricate asrequired.

3-41

BASIC

MACHINE

NOTES:

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

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

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

3-42

OPERATION

MAINTENANCE

Table

of Contents

Page No. 4.1 GENERAL INFORMATION .........................................................................

4-3 4.2 GENERAL SAFETY& PRECAUTIONS .................................................................

4-4 4.3 LUBRICANT, FUEL& COOLANTSPECIFICATIONS ....................................................

4-7 4.4 FILTERS & ELEMENTS, ANDBUCKET. ................................................................

4-8 4.5 ACCESSORY TOOLS ............................................................................

4-9 4.6 TORQUESPECIFICATIONS FOR CAPSCREWS& NUTS .............................................

4-10 4.7 TORQUE SPECIFICATIONSFOR JOINTS & HYDRAULIC HOSES .............................

4-11 4.8 INSTALLING HYDRAULIC HOSEAND PIPEJOINT...................................................

4-12 4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC OIL SYSTEM ..........................

4-13 4.10 PRESSURIZING HYDRAULIC OILTANK...............................................................

4-14 4.11 BLEEDING AIRIN FUELSYSTEM ....................................................................

4-15 4.12 REPLACEMENT OF RUBBERCRAWLERSHOE.........................................................

4-16 A.REMOVING RUBBERCRAWLER SHOE..................................................................

4-16 B.INSTALLING RUBBERCRAWLER SHOE................................................................

4-17 C.CHECK AND ADJUSTMENT OF TENSION ON CRAWLER SHOE ...............................

4-18 4.13INSPECTION AND MAINTENANCE CHART...............................................................

4-21 4.14WHENREQUIRED ................................................................................

4-24 A.CLEANING RADIATOR CORES.......................................................................

4-24 B.CLEANING OR REPLACEMENT OF RADIATORCAP..................................................

4-24 C.REPLACEMENT OF WORKING LIGHT...................................................................

4-25 D.RECONDITIONING BUCKET. ........................................................................

4-26 1. CHECK FOR ABRASION/DAMAGES ON TOOTH POINT & SIDE CUTTER ...............4-26 2.REPLACING TOOTH POINTS ......................................................................

4-27 3.REPLACING SIDECUTTER ......................................................................

4-28 E.REPLACEMENT OFBUCKET. ........................................................................

4-29 1. REMOVAL OFBUCKET .........................................................................

4-29 2. INSTALLING BUCKET. .........................................................................

4-30 3. ADJUSTING BUCKET MOUNTGAP..................................................................

4-30 F. INSPECTING RUBBERCRAWLER SHOE................................................................

4-32 G.LUBRICATION FOROPERATING LEVERS ...............................................................

4-34 H.CHECKING ELECTRICAL WIRINGANDFUSES..........................................................

4-34 4-158-HOUR(DAILY)INSPECTION AND MAINTENANCE .................................................

4-36 A.CHECKEXTERNALCONDITIONS OF MACHINE.......................................................

4-36 B.CHECK CAPSCREWS AND NUTS FOR LOOSENESS AND DROPPING OFF. .............. 4-36 C.CHECK EACH CYLINDER, PIPING AND HOSE FOR LEAKAGE AND DAMAGES ....... 4-37 D.CHECKTRAVELSYSTEM FOR LEAKAGEAND ABRASION.......................................

4-37 4.16 50-HOUR(WEEKLY)INSPECTIONAND MAINTENANCE..........................................

4-38 A.ADJUSTING CRAWLER TENSION .....................................................................

4-38 B.GREASING PINSAROUND BUCKET. ...................................................................

4-38 C.DRAINING WATER FROM WATER SEPARATOR AND CLEANING .............................

4-39 D.DRAININGWATER AND DEPOSITSFROM FUEL TANK ............................................

4-40 E.CHECKBATTERYFLUID LEVEL AND SPECIFICGRAVITY.......................................

4-41 4.17 250-HOUR(3-MONTH)INSPECTIONAND MAINTENANCE.......................................

4-42 A.GREASING ATTACHMENT AND DOZERPINS...........................................................

4-42 B.OIL CHANGE FORENGINE .........................................................................

4-43 C.GREASING TO SLEWING BEARING ....................................................................

4-43 D.ADJUSTMENT FORBELTTENSION ....................................................................

4-44 E.ADJUSTMENT FORFANBELT.......................................................................

4-44 F. REPLACEMENT OF ENGINE OILFILTER ...............................................................

4-45 G.CLEANING ENGINE FUELFILTER .....................................................................

4-46 H.CHECKING RADIATOR HOSE.........................................................................

4-47 I.REPLACING RADIATOR HOSE.......................................................................

4-47 J. CHECKING/CLEANING/REPLACING AIR CLEANER ELEMENT..................................

4-48 1.CHECK ELEMENT .............................................................................

4-48 2.CLEANING ELEMENT. ..........................................................................

4-48 4-1

MAINTENANCE

4-18 500-HOUR(6-MONTH)INSPECTIONAND MAINTENANCE.......................................

4-49 A.REPLACEMENT OFELEMENT. ......................................................................

4-49 B.REPLACEMENT OF HYDRAULIC RETURNFILTER....................................................

4-50 C.REPLACEMENT OF FUELFILTER ...................................................................

4-51 4.19 1000-HOUR(12-MONTH)INSPECTIONAND MAINTENANCE...................................

4-53 A.REPLACEMENT OF COOLANT. ......................................................................

4-53 B.CHECKAND ADJUSTMENTFOR VALVE CLEARANCE.............................................

4.54 C.CHECK AND ADJUSTMENT FOR STARTER AND GENERATOR ................................

4.54 4.202000-HOUR INSPECTION AND MAINTENANCE ........................................................

4.55 A.OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION STRAINER ..............

4.55 B.CLEANINGLINE FILTER OF PILOT VALVE AND IN-LINE FILTER OF SOLENOID VALVE ........4-57 C.OILCHANGEFOR TRAVELSPEEDREDUCTIONUNIT.............................................

4-59 D.GEAROIL CHANGEFOR LOWERROLLERAND IDLER.............................................

4-60 1.LOWER ROLLER ............................................................................

4-60 2.IDLER .................................................................................

4-62 E. REPLADEMENT OF GREASEIN SLEWINGGREASEBATH .........................................

4-63 F. CHECK AND ADJUSTMENTFOR FUEL INJECTIONTIMING.....................................

4-e3 G.CHECK AND AJUSTMENT FOR CONTAT SURFACE OF INTAKE AND EXHAUST VALVE .........4-63 INSPECTION MAINTENANCE CHECKLIST...............................................................

4-64

4-2

MAINTENANCE 4.1 GENERAL

INFORMATION

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BEFORE PERFORMINGANY INSPECTION OR MAINTENANCE PROCEDURES ON THIS MACHINE , ITS SYSTEMS OR COMPONENTS.

A. It is recommended

by KOBELCO,thatan inspection and maintenance schedulebe developedand maintainedon a regular basisforthismachine.

Developingandmaintaining sucha schedule, helpsto keep the machine in optimumoperating condition. contained in thissection givesthe B. Theinformation properprocedures for performing inspection and maintenance functions forthismachine.

Use these procedures whenperforming inspection and maintenance as theywillguidethetechnician stepby step foreachprocedure.

Also,referto theInspection and maintenance chartsforgeneral service interval recommendations.

C. Basically, lubrication andmaintenance intervals are determined by thehourmeter.

If performing lubricationandmaintenance according to calendar timeis preferred, thehourmeterreading corresponds to the lubrication andmaintenance period(daily, weekly, monthly, etc.)in calendar time;thuscalendar time can be used.Itemsfor whichservicetimecannot be specifiedare explainedin the sectionWHEN REQUIRED.

NOTE: Makesureto consultwithan authorized KOBELCODistributor for the adjustment, disassembling andrepairof theengine, reduction gear andelectronic equipment (controller, etc.).

KOBELt

NOTE: The inspection and maintenance chartsprovidedinthissection giveonlygeneral timeintervals.

It may be necessary to developa customschedule to performmachinemaintenance at morefrequent intervals basedon the workconditions suchas severeapplications, workin dustyor humedcircumstances, etc.

D. UseonlyKOBELCO oils,fluids, lubricants, filters and replacement partsto keepmachinein optimumoperating condition.

Furthermore, usetheoilsandgreases withthespecifiedviscosity depending on the ambienttemperature. ¯Storethevessels andcontainers indoor fortheoils, fluidsandgreases, takingsuitable measures to preventthemfrominvading dust,water,etc.

4-3

SK32004002

Dispose of Waste Properly SK32004003

MAINTENANCE 4.2 GENERAL SAFETY & PRECAUTIONS Do notcarryoutanyotherinspection andmaintenance procedures thanspecified in themanual.

Carryoutthem parking themachine at a fiatandconveniently situated place.

A. Keep Machine Clean Thoroughly cleanmachinebeforeperforming inspectionand maintenance procedures, It is easierand saferto locateproblems, performmaintenance and alsoreducetheriskof hydraulic systemcontaminationwhenmachineis clean.

IOllOIlOIlOIlOIlOI

1

HOUR ME’~.R 1/10H

B. CONFIRMATION FOR HOUR-METER Readthehour-meter daily, andcheckwiththescheduled maintenance book.See pages4-21~4-23for betterreference Proceedwithany maintenance as required.

PM2-10

C. STOP ENGINE Neverattemptany MAINTENANCE with enginerunning.Alwaysstoptheengineand allowmachineto cool.Otherwise, thereisa possibility of danger that yourhandmaybe caughtin the coolingfan or fan beltresulting injury.

Ifitisinevitable tooperate the enginefortheinspection or maintenance, carryout theworkwitha pairof twopersons.

Andeitherpersonmakesthe enginereadyto stopat anytimeat thesignal ofthepartner.

D. "TAG-OUT" MACHINE Beforebeginning anyinspection or maintenance procedures,securea " DO NOT OPERATE"tag to the operators consoleto informthe operator thatthe machine willbe inoperable forinspection andmaintenance.

Thistagwillhelpprevent accidental startingof themachine.

E. OBSERVE PRECAUTIONS Starttheinspection andmaintenance workfullyunderstanding thecontents of safetyprecautions indicatedon the machinedecals.

PMJ-1-9

t~

%

[] PAE-4-1

4-4

MAINTENANCE IF. HOT SURFACES & FLUIDS Usecautionsandwearthepropersafetyequipment whenworkingaroundhot areas.Neverchangeoils, enginecoolant or filters immediately aftermachine has beenstopped.Allowmachineto cooldownbeforeperforming maintenance procedures.

WARM ENGINE OIL Engineoil shouldhavea temperature of between 20-40°C(68-104°F) beforethe oil is changed. necessary runengineuntiltheoilis warmwithin the recommended oil changetemperature.

G. RELEASE HYDRAULIC AND TANK PRESSURE BEFORE MAINTENANCE Releasethe internal pressure beforeremoving the hydraulic system, airsystem, or fuelsystem; piping or coupling of thecooling system; otherrelated parts to whichinternal pressure is applied.

Seepage4-12 TO RELEASE INTERNAL PRESSURE.

PR-1-38

YRM-4-41

H. PREVENT CONTAMINATION Alwayscapor pluglineswhenhydraulic components are removedto preventhydraulic systemcontaminationthatcanbe causedby dirt,dustanddebris entering a lineorport.

YRM-4-42

I.INSPECT WASTE OILS AND FILTERS Before disposal, inspect allwasteoils, fluids andfiltersfordebrisandforeignmaterial.

It is recommendedto cutopentheoilfilters to determine any abnormalwear.

PMJ-4-4

J. CAUTION FOR OIL FILLING Whena strainer isprovided onthefilling port,donot remove itatrefilling fuel, oilorfluid.

PWJ-4-1

4-5

MAINTENANCE K. DISPOSAL OF HAZARDOUS WASTE Dispose of wasteoils,fluids, lubricants, filters and otherhazardous wasteproperly.

Disposeof all hazardous wastein accordance with government environmental regulations, laws and codes¯ PA.-4-2

L. KEEP COMPONENT INTERNAL SURFACES CLEAN Afterremoving theO-ring orgasket, cleantheinstallingface,andreplace witha newone.WheninstallingtheO-ring or gasket, applya thinlayerofoilto theseal, andinstall securely.

M. PROVIDING LOCKING DEVICE Whenthe inspection or maintenance is carriedout underthe attachment, providepropersupportor blocksto securetheattachment.

PW-I-1

N. CAUTION AT CHANGING BUCKET Neverinsert yourfinger intothepinbore.

Whenaligning thepinbores,neverinsertyourfinger,handor armintothe pinbore.Thealignment mustbe carried outvisually.

O. DUSTY CIRCUMSTANCES When the machineis operatedin dusty circumstances, taketheprecaution of doingas follows. ¯ Frequently checkthealarmlampfortheaircleaner clogging.

Cleanup the air cleanerelementmore frequently thanthespecified interval. ¯ Cleanup theradiator coremorefrequently thanthe specified interval to prevent it fromclogging. ¯ Cleanup andreplacethefuelfilterelement more frequently thanthespecified interval. ¯ Cleanup the electricequipment, especially for starter andgenerator, notto allowaccumulation of duston them.

4-6

PW-1-2

MAINTENANCE 4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS The following information is designedto allowusageof the properoils,grease,fuelsand coolantsin various climatesand certainworkingconditions.

Capacities Typeof Lubricant (When changed)

Components

ClimateZone Specified lubricant -22" -4° 14" 32" 50 ° 68° 86° 104 °F ° _30 ° -20 -10" 0 ° ° 10 20° 30° 40°C ~i i~’~i b~, ~’t ~":’" ~8~i~t ~ ~t I KW68 +.................. ~................................ f........

KOBELCO J i * ..... , KW46 genuine parts ~ : ~’4~’-~ ’~, ’:~: ~l" ~ ~i KW32S ’~~ ~i~i~i ~

Tank Hydraulic oil 37liters (9.8gal) tank Hydraulic Totalsystem oil 48liters (12.7gal) Slewingmotor

Automatic circulation of theaboveoil

¯ 3.9liters F-I H Level Engineoilpan

i

I l

!

}

i i

i

’

’ ...........

~i t i..... t........ ~ i...................... l

1(1.03gal) .2liters Engine oil[ _Level"

A.P.I. classification for "service CD"

I

.i Fueltank

Radiator

D-975 | ASTM Grade2-D Diesel fuel 15 liters (4.0gal) .... ~....................... ~- ~ ................

1.....

ASTM D-975 <q.~ ASTM D-975 No.1 I Grade 1-D Coolant

Travelmotor

Radiator 1.5liters (0.40gal) Totalvolume 2.5liters (0.66gal) O.751iters

Gearoil

, , .......... }..................

_J

(460u.in)X2

4

Upperrollers

KOBELCO antifreeze (Ifcommercial coolant isused, the mixing rate oftheLLC should conform with the specified.)

Lowerrollers

6occ (.7cu.in)

Idlers

30cc(1.8cu.in)

~~l~~~~~

Slewing bearing

A.P.I. ....... classification for "service GL-4"

Extremepressure Multipurpose greaseNLGI No.2 Lithium base greaseEP type

20-place

Grease

1 -place

Idler adjuster

2-place

Operating lever& pedal

As required

Slewinggear Grease

1 -place

"~~ .... :~ ’:’~ "~" ~’:’

.................... i........ , ~ ~, ~ ~t.......................

Attachment and dozerpin Swingcylinderpin

~

I I I I

Cartridge 2421Z183 Pailcan 2421Z213 I I

NLG.INo.2 Lithium basewith MoS2grease

Note ; Machinesare shippedfrom factorywith *markedoil.

NOTE : USE OF BIO-DEGRADABLE OILS Whenyou use Bio-degradable Oil (BIOOIL),referto the following information. vegetable-based and synthetic-based.

You are recommended to use the 1.Thereare two typesof BIO OIL available; synthetic-based type, becausethe vegetable-based oil has a maximumusage temperatureof 80°C (176°F).

Becauseof this,the degradation of vegetable-based oil occursmorerapidly, and causesreducedservicelife.

2. Do notmixeithertypeof BIOOILwiththe original factory-filled mineral oil.In casethatyoudo useBIOOIL,it is required to flushthehydraulic systemthatwasfilledwithmineral oiltwotimes.

3. If you use BIO OIL,swingand propelparkingbrakeperformance willbe reduced,becauseof the lowerfriction factorof BIO OILcompared to thatof mineral oil (ThisItemis notapplied forthesmallsizemachine).

4. For furtherinformation aboutrecommended Bio-degradable oil,pleasecontactlocaldealer.

4-7

MAINTENANCE 4.4 FILTERS & ELEMENTS, AND BUCKET Replaceconsumable parts,suchas filtersandelements, duringtheperiodical maintenance or beforethe service life.Themachine canbe usedeconomically if theconsumable partsarechanged properly andtimely.

A. FILTER AND ELEMENT LIST No.

Device

oiltank (1) Hydraulic

Items enclosed inparenthesis { } aretheparts tobechanged at thesametime.

PartsNo. PartsName Qty Replacement Interval After 50hours (initial change) PM50V00012F1 Return filter 1 (ZD11G11000) {O-ring} Every 500hours(from 2nd.change)

oiltank (2) Hydraulic

PM50V00017F1 (ZD11Gl1500)

(3) Aircleaner

(4) Engine oilfilter

Suction strainer {O-ring}

1

Every2000hours

PM11P00004S002 Element PWl 1P01019P1

1

Every500hours

119305-35150

1

After 50hours (initial change) Cartridge

Every250hours(from2nd.change)

(5) Fuel filter

124550-55700 Element (102103-55520) {O-ring}

1

Every500 hours

(6) Waterseparator

171081-55910 Element (102103-55520) {O-ring}

1

Whenrequired

SideCutter (Right) SideCutter (Left) (CapScrew) (Nut)

1 1 6 6

Whenrequired

Tooth Locking Pin ubbeBrock

3 3 3

Whenrequired

B. BUCKET(To be specifiedby KCME) PV69B00002P1 PV69B00003P1 (7) BUCKET (ZS13C16040) (ZS13C16013) PV69B01003P1 PV69B01004P1 PV69B01005P1

(8) BUCKET

7 (Right)

7

1

~\

5

PW-5-3

4-8

MAINTENANCE 4.5 ACCESSORY No.

TOOLS

TOOL NAME

1 PIPE

PART No.

REMARKS FOR GREASE NIPPLE OF IDLER ADJUSTER

PM01T01002P1

2

GREASE

GUN

3

TOOLCASE

PW01T01005P1

4

WRENCH

PV01TO 1004P 1

LABEL (WARNING TAG)

LC20T01001P1

DISCHARGE PRESSURE 250kg .cm2(3560psi) CARTRIDGE 400cc(24cu-in)

PW01T00003F1

FOR ENGINE OIL FILTER

If toolsbecomelostor damaged, contact an authorized KOBELCODistributor to orderthetools.

4-9

MAINTENANCE 4.6 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS The following TorqueSpecifications are providedfor use when actualtorquevalueof a fasteneris not known.

Checkthe capscrewsand nuts for theirloosenessand droppingoff beforethe startof dailywork and at the periodicalmaintenance.

Retightenthe loosebolt and installnew ones when ever lost.For the new machine, checkingand retightening of boltsan nuts must be carriedout at the first50 hoursoperation.

When replacement is needed, make sure to use the same size of KOBELCOgenuine parts.

Refer to the table below for proper tighteningof capscrews. ¯ The tablebelowis not applicable for the capscrews holdingplasticcovers,etc.For propertightening of such capscrews, consult with an authorized KOBELCO Distributor.Over-tighteningmay cause damageson the partsto be fixed. ¯ In casethatthe tightening torqueis specified in the manual,use such torquevalues regardlessto the tablebelow.

¯ Numericalindicationon the capscrewhead shows the classification forstrength (e.g.,7 = 7 T).No indicationis providedfor smallersize of capscrews, M 5 or less.

/CLASSIFICATION

PAE-4-4 1. MetricCoarse ThreadStandardTighteningTorqueValues.Make certainto tightenall Capscrews& Nuts to propertor(ue values.

Classification

4.8 T

7T

10.9 T NOMINALSIZE NO LUBRICATIONlOlL LUBRICATIONNO LUBRICATIONOIL LUBRICATIONNO LUBRICATIONOIL LUBRICATION M6

P=I

M8

P=1.25 1.09+0.11(79+0.8) 0.92+0.09(6.6-+0.7) 2.4-+0.2(17.3-+1.4) 2.0+0.2(14.4+1.4) 4.3+0.4(31-+2.9) 3.6-+0.4(26-+2.9)

0.45--0.05(3.2-+0.4) 0.38+0.04(2.7-+0.3) 0.98--.0.1(7.1+0.7) 0.83-t-0.08(6.0__.0.6) .77"1-0.18(12.8+1.3 1.5:t:0.15(10.8:!:1.1

M10 P=1.5

2.2-+0.2(15.9-+1.4) 1.83--.0.18(13.2+1.3 4.7-+0.5(34-+3.6) 4.0-+0.4(29-+2.9) 8.5-+0.9(61-+6.5) 7.2-+0.7(52-+5.1)

M12 P=1.75

3.7-+0.4(27-+2.9) 3.2-+0.3(23-+2.2) 8.1-+0.8(59-+5.8) 6.8-+0.7(49+5.1 14.6-+1.5(105-+10.8) 12.3::1:12(89-+8.7)

M14 P=2

5.9+0.6(43+4.3) 5.0-+0.5(364-3.6) 12.8-+13(93-+9.4) 10.8-+1.1(78_+7.9) 23-+2(166-+14.5) 19.5-+1.9(140+13.7)

M16 P=2 M18 P=2.5

9.0-+0.9(65+6.5) 7.6-+0.7(55+5.1) 19.5+2(140+14.4) 16.4-+1.6(118+11.5) 35+4(252-+29) 29+3(209+22) 12.4-+12(90+8.7) 10.5-+1.0(76-+7.2) 27_+3(195-+22) 23_+2(166-+14.5) 49-+5(354_+36) 414-4(296_+29)

M20 P=2.5

17.5-+1.7(126_+12.3) 14,7-+1.4(106_+10.1) 38_+4(274-+29) 32-+3(231-+22) 68-+7(491_+51) 57_+6(412_+43)

M22 P=2.5

23-+2(166-+14.5) 19.6-+2(142-+14.5) 51_+5(368-+36) 43-+4(310-+29) 92-+9(665+65) 77-+8(557-+58)

M24 P=3

30-+3(217-+22) 24-+3(173-+22)65-+7(470-+51 53-+5(383-+36) 118-+12(852-+87) 93_+10(673-+72)

M27 P=3

44-+4(318-+29) 36-+3(260-+22) 96-+ 10(694-+72)78-+8(563-+58) 173-+17(1250-+123) 140_+14(1010_+100)

M30 P=3.5

60-+6(433-+43) 50-+5(361 -+36) 131-+13(948-+94) 110-+11 (796-+79) 235-+24(1700-+174) 198-+20(1430_+145)

M33 P=3.5

81_+8(585_+58)68_+7(491 _+51) 176_+18(1270+130) 148_+15(1070_+110) 317_+32(2290+230) 266+27(1920-t-195)

M36 P=4

105-+10(758-+72) 88+9(636_+65) 227-+23(1640-+170) 190-+19(1370-+140) 409-+41(2960-+300) 343_+34(2480_+250) TORQUE VALUEUNIT-kgf-m (Ibf-ft)

2. MetricFine ThreadStandardTighteningTorqueValues.Make certainto tightenall Capscrews& Nuts to propertorquevalues.

Classification

4.8 T

7T

10.9 T

NOMINALSIZE NO LUBRICATIONOIL LUBRICATIONNO LUBRICATIONOIL LUBRICATIONNO LUBRICATIONOIL LUBRICATION M8 P=1.0

1.15-+0.1t(8.3_+0.8 0.97-+0.1 (7.0_+0,7) 2.5_+0.2 (18.0-+1.4) i 2.1-+0.2 (15.2_+1,4) 4.5-+0.4 (33-+2.9) 3.8+0.4 (27-+2.9)

M10 P=1.25 2.3-+0.2(16.6-+1.4) 1.91-+0.19(13.8-+1.4 4.9-+05 (35-+3.6)4.2-+0.4 (30-+2.9) 8.9-+0.9 (64-+6.5) 7.5_+0.7 (54-+5.1) M12 P=1.25

4.0-+0.4 (29-+2.9) 3.4-+0.3 (25+2.2)8.7-+09 (63-+6.5)7.3-+0.7 (53-+5.1) 15.7-+1.6 (114-+11.6 13.2-+1.3 (95-+9.4)

M16 P=1.5

9.4-+0.9 (68-+6.5) 7.9-+0.8 (57-+5.8) 20-+2 (144-+14.5) 17.2-+1.7 (124-+12.3 37-+4 (268-+29) 31-+3 (224-+22)

M20 P=1.5

19-+1.9 (137-+13.7) 15.8-+1.6 (114-+11.6 41+4(296+29) 34-+3 (246-+22) 74-+7 (535-+51) 62-+6 (448-+43)

M24 P=2

32_+3 (2314-22) 27-+3 (195-+22) 70_+7(506+51) 58-+6 (420-+43)126-+12 (9114-87) 105:1::10 (759-+72)

M30 P=2

65-+6 (470-+43) 54-+5 (391 +36) 142’+14(1030-+100) 118-+12 (852 "F87)255-1-26 (1840-+188)212+21 (15304-150)

M36 P=3

109-+ 11(788-+79)91_+9(658_+65) 238-+23(1720_+166) 198_+20 (1430-+145) 428-+43 (3100_+310) 357-+36 (2580_+260) TORQUEVALUEUNIT-kgf.m (Ibf.ft) 4-10

MAINTENANCE 4.7 TORQUE

SPECIFICATIONS

FOR JOINTS

& HYDRAULIC

HOSES

A. SLEEVE TYPE TUBE FITTINGS Tubesize Spanner size(ram) ODXThickness(mm)

Tightening torque kgf.m(Ibf.ft)

10X 1.5

19

4.5+-0.5(33+ 4)

15X 2.0

27

15+ 2.0(110+ 14)

18 X2.5

32

18-+2.0(130+ 14)

22X 3.0

36

22+-2.0(160 -+14)

28X 4.0

41

28+ 3.0(200-+22)

35 X 5.0

55

45+ 4.5(330-+33)

Z2-0~1

B. JOINTS FOR PIPING (O-RING SEALING TYPE) Nominalscrew size(PF)

Spanner size(~m)

Tightening torque kgf.m(Ibf.ft)

1 /8

14

1.7+ 0.2(12-+ 1)

1 /4

19

3.7+_0.2(27_+1)

3/ 8

22

7.5_+0.5(54_+4)

1 /2

27

11.0 _+1.0(80_+7)

3/4

36

16.5 _+1.0(119 _+7)

1

41

26.0 _+1.0(188 _+7)

C. HYDRAULIC Nominal screw size(PF)

O-RING

I

~ J Z2-0081

HOSES Spanner size(ram)

Tightening torque kgf.m(Ibf-ft)

1/8

14

1.5_+0.2(11_+1)

1/4

19

3.0+ 0.5(22-+4)

3/8

22

5.0+ 0.5(36-+4)

1/2

27

8.0-+0.5(58-+4)

3/4

36

12.0 -+1.0(87+ 7)

1

41

14.0 -+1.5(101 -+11)

UNION NUT

1

9E::.

NOTE¯ Alltorquevaluesaresubject to a drycondition.

4-11

-.~:~..

Z2-0051

MAINTENANCE 4.8 INSTALLING HYDRAULIC HOSE AND PIPE JOINT Thefollowing twotypesof jointareusedon thejoint partof hosepiping.

A. Metaljoint(30° Flaretype) Sealing is performed withmetalcompression of the openingof connector(tee,elbow)and hose.Use cautions to disassemble andassemble it to protect the damageon the seatsurface.

A. METAL JOINT SEAL FACE

j ¯

~

SEAT

B. O-ringseal joint Hosefitting is equipped withO-ringwhichsealsthe oilpressure onthejointandprotects itfromoilleakage.

Thetightening torque of thejointofeachhydraulic hose isdetermined bythediameter ofthehosefitting screws.

In caseof anyabnormality detected, thehosepiping jointshouldbe repaired or replaced according to the following procedure evenbeforetheperiodic inspectionofthehydraulic unit. * O-RING be sureto replacetheO-ring [1]At reassembling, witha newone.

[2]Wheretheunionis loosened and oil is leaked, nevertighten it as itis.Install a newO-ring and checkthattheO-ring is securely fitted, andthen tighten it.

[3]Neverinstall a damagedanddeteriorated O-ring evenif it is newone.Theuseof an O-ring other thana specified causes oilleakage andshortlife of hydraulic equipment, because thematerial and hardness differevenif theyarethesamesize. * JOINT notto damagehose,pipe [1]Caremustbe exercised andO-ringgrovefaceandsealface(dent,etc.) of hydraulicequipment.

The use of a damaged partscausesoilleakage.

[2]Usecareto preventcontamination.

Fitting withforeign materials inside causes oilleakage. * HOSE [1]The hoseshouldnotbe twistedandsharplybent forinstallation.

If thehoseis twisted or sharply bent,thelifeof thehosedecreases. of joints,and [2]Cleanthejointsandsurrounding removeanddry the cleaning solventcompletely prior toinstall thejoint.

4-12

ELBOW

(HOSE

SIDE)

SEAT (CONNECTOR SIDE) PME-4-13

B. O-RINGSEAL JOINT HOSE

UNION NUT CONNE(

RING

O-RING

O-RINGFI-I-I-ING

PME-4-14

MAINTENANCE 4.9 RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM Release theinternal pressure of hydraulic systembeforecarrying outmaintenance worksuchas hydraulic oilchange, return filter change, suction strainer cleaning,cylinder repair.

Pressurize thehydraulic oiltankaftermaintenance and bleeding airinthesystem.

A. RELEASING HYDRAULIC TANK PRESSURE

SYSTEM

AND

HYDRAULICOIL LEVEL CHECK POSITION

!:!:i:i:~:i:i:i:i:i¢i:~:~:i:ii~:!iii~i~i!i~i~:~i!iii iii~ii i:i i:i:i:i:i:i:!:!:i:!:i:!:i:i:i:i:!:i:i:i:i:i :: ::: :: :~. ::’:: ::::::::g::::::: :::: :: :: ::::::::::: ::: :: ::::::: ::: :: :: :::::::i:::::i :i:~:~:i: i:i:! :! :!:i:i:i :i:i:i: ::::: :::: ::::::: ::::: :::::: :: :: ::: :::: :i: !: i:i:~:~:! :~: ~:~ :~:! :~:i:i:!:~ :i:~ ~:::i: ~::: ::: PAE-1-22

¯ NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. ¯ RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. ¯ WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY.

Oil Inspection [1]Makethe machineto "Hydraulic Position" as shownin therightsketch, by means of fullycontracting thearmcylinder andbucket cylinder, lowering theboomto getdownthebucket to the ground,and loweringthe dozerto the ground.

In caseof hydraulic pilottype,operate thelever forreleasing theinternal pressure justbefore stoppingtheengine in a lowidlecondition.

NOTE: Theinternal pressure of thehydraulic system can be released onlyby theabovemethod.

4-13

type,operate theleverafter [2]In caseofthemanual stopping theengineto release theinternal pressure. on/off shutoff lockleverto the [3]Turnthegetting "LOCK"position.

[4]Stoptheengine(stator switch to the"OFF"position). oiltank, [5]Openthecoveronthetopofthehydraulic andsupport it withthestay. capof theairbreather onthetop [6]Presstherubber of thehydraulic oiltankseveral (fiveto seven) timesto release theinternal pressure ofthetank.

Nowinside pressure in thehydraulic oiltankis fully released.

Proceedthe inspection and maintenance procedures forthehydraulic system.

MAINTENANCE B. BLEEDING AIR IN HYDRAULIC SYSTEM Bleedtheaircontained inthehydraulic circuit after performing maintenance to thehydraulic system.

[1]Referring to page3-9,starttheengine, andoperatetheengineat lowidleforaround5 minutes.

Thenproceedas follows: [2]Withtheenginerunningin lowidle,extendand retract eachcylinder 4 - 5 times.

However, do not extendand/orretract eachcylinder to theendof itsstroke yet.

[3]Repeat extending andretracting eachcylinder 23 timesbutnowto theendof isstroke.

[4] Airbleeding forthehydraulic circuit hasbeencompleted.

Stopteengine andletit setformorethan 5 minutes o dissipate theairbubbles in thehydraulic oiltank.

PME-4-21

NOTE: Ifengine speedisat highidleduring thebleeding,the pistonand packingsmay be damageddue totheaircontained inthecylinder.

4.10 PRESSURIZING HYDRAULIC OIL TANK Afterhavingperformed maintenance to thehydrauilic system,makesureto pressurize thehydraulic tank asfollows; [1]Startthe engineand keeplow idlingunderthe condition wheretheairplugon thehydraulic oil tankis open.

[2]Slowlyandgradually extendeachcylinder to its stroke endtoobtainthe"Hydraulic OilTankPressurization Position".

(PME-4-22) [3]Tightenplug Tightening torque : 3.0+ 0.3kgf’m(22+ 2 IbPft) thatthetankis freefromoilleakage, and [4]Ensure closethe tankcover.Operatethe attachments andretract thecylinder rodsto pressurize thehydraulic tank.

HYDRAULIC OIL TANK PRESSURIZATION POSTURE BUCKET

CYLINDE~ARM

CYLINDER

Boom CYUNDER-.._J/_

~

SWlNG CYLINDER

DOZERCY L I N DE R .-----i"~-~-~" ~ PME-4-22

AIR PLUG

NOTE: If thehydraulic oiltankisnotpressurized, the hydraulicpump couldbe damaged.Make sure to pressurize it.

PFE-4-2

4-14

MAINTENANCE 4.11 BLEEDING AIR IN FUEL SYSTEM If airenters thefuelsystem, theenginemaybecome hardtostart oritwillmalfunction.

Bleed theairwheneverthefueltankis empty,thewaterseparator is drained, or thefuelfilter element isreplaced.

[1]Setthesafetycontrol leverat "LOCK"position, and stoptheengine.

[2]Makesuretofillthefueltank. thatthehandle offuelfilter andwater sepa[3]Ensure ratoraresetin "OPEN" position.

[4]Unscrew the airbleeding plugon thetopof the waterseparator by a few turnswitha Phillips screwd river. switch to the"START" position to [5]Turnthestarter start theengine.

Theengine willrotate without load tofeedfuel.

[6]Whenfuelwithoutbubblesis foundto comeout fromtheairbleeding plughole, close theairbleedingplug.

NOTE: Don’toperate thestarter continuously for15 secondsor more.

If it is necessary to crankfor15 seconds or more, stopcranking once,andstartcranking againby settingit at "START" position afterapprox.

30 seconds.

AIR PLUG

OFF i

ON

~ (I) /~t

START

(1)15SEC. OR LESS

(2)30SEC. APPROX. PME-4-25

Bymoving thepriming leverat thesideoffuelinjection pumpup anddown,thefuelis fedwhiletheengineis stopped.

Therefore, release theairbeforehand, andtheworktime is shortened.

Additional Information : In caseof themachine withan automatic airbleeder (optional specification), turnthestator switch key the "ON"position to actuatethe fuelfeedpumpto enableairbleeding.

4-15

MAINTENANCE 4.12 REPLACEMENT SHOE

OF

RUBBER

CRAWLER

¯Thisworkmustbe carriedout by two people.The operatoroperateshe machinein accordanc with thesignal of thepartner.

Therubbercrawler shoe replacement is carried outlifting themachine body.

Erroneous falling of themachinebodyduringthe workon the crawlershoeis quitedangerous.

Do notoperate anyotherattachments thanthecrawler. ¯ Greasein tracktensioning mechanismis under extremepressure andcan penetrate skincausing severeinjury.Keep face and body away from grease fitting area.Neveloosen grease fitting more thanoneturn.If grease doesnotrelease afterone turnof thefitting, callanauthorized Kobelco servicedealer forassistance. ¯ Beforeremoving the rubbercrawlershoe,ensure thatthe pressureinsidegreasehas beencompletely released.

Thenturnthesprocket. ¯ It is quitedangerous to allowthespouting outof greasewith any procedures otherthanthe one described in the "REMOVAL OF RUBBER CRAWLERSHOE" below. If the tensionon the crawler shoeis notreleased, consult withan authorized KOBELCO Distributor foritsrepair.

A. REMOVING RUBBER CRAWLER SHOE boom,arm,andbucketto settheattach[1]Operate ment on the groundas shown in (PMJ-1-31).

Slowlyandgradually lowerthe boomto liftone sideof themachine.

[2]Support thelowertravelstructure of themachine withsafetysupports.

[3]Slowlyloosenthe greasenippleon the grease cylinder to allowto discharge thegreaseandreleasetension.

[4]Slowly loosen thegrease nipple lessthanoneturn.

[5]Engagesomesteelpipesintotherubbercrawler shoe,thenslowlyrotatethesprocket backward.

Whentherubber crawler shoefloats fromthesteel pipes, slidetheshoetothesideto remove it.

4-16

PMJ-1-31

PME-3-79

DIRECTION

OF

~j~~

STEEL

I

ROTATION~~~

PIPE

PRE-3-8~

MAINTENANCE B. INSTALLING RUBBER CRAWLER SHOE [1]Operate boom,arm,andbucketto settheattachment on the groundas shown in (PMJ-1-31).

Slowlyandgradually lowertheboomto liftone sideof themachine.

[2]Support thelowertravelstructure of themachine witha safety support, etc.

[3]Engagetherubbercrawlershoewiththesprocket andhangit ontheidler. backward andpushthe [4]Slowlyrotatethesprocket rubber crawler shoeintoitsposition, thenstopthe rotation.

PMJ-1-31

[5]Engagea steelpipeintotherubber crawler shoe, and rotatethe sprocketbackwardagainto securelyengagethe rubbercrawlershoewiththe idler. of sprocket to ensurethatthe [6]Stoptherotation rubbercrawlershoeis securely engagedto the sprocket, idlerandlowerrollers.

[7]Referring to thenextItem"C",carryouttheCheck and Adjustmentof Tensionon RubberCrawler Shoe.

~

STEEL

PIPE PRE-3-84

Afterconfirming theengagement of rubbercrawler [8] shoeto thesprocket, idlerandlowerroller, and alsotheproper tension ontherubber crawler shoe, placethemachineon theground.

r~

~ ILLOWER

~H~

~ ,~ROLLER

RUBBER SHOE"-I II

[II-"METAL CORE

STEEL CORD

Ir,o,e TRAVEL MOTOR

i

SPR

PMJ-3-74

4-17

MAINTENANCE C. CHECK AND ADJUSTMENT OF TENSION ON CRAWLER SHOE An appropriate adjustment of tensionon therubber crawler shoeis important notonlyforprolonging the service lifeof therubbercrawler shoeandmachine but alsopreventing the rubbercrawlershoefrom comingoutof place.

RUBBER

CRAWLER SHOE

Sincecheckingand adjustment for the tensionon therubbercrawler shoeis carried outwiththemachinelifted, it is quitedangerous if themachine is erroneously droppedto theground.Nevermovethe machinewhilechecking andadjusting it.Workhas to be performed be twopeople, andtheoperator must operatethemachinein accordance withthesignal of thepartner.

RUBBER CRAWLER SHOE Sincetheabrasion of therubbercrawler shoevaries depending on theworkingconditions and thenature of thesoil,a frequent checkisrequired forwearand thetension condition.

Especially, on thenewrubber crawler shoe,thereis an initial stretch.

Therefore, frequently checkcrawler tension duringthefirst30 hourson a new machineor newtracks.

1. CHECK crawler shoeso thatthejointing [1]Movetherubber part(M mark)comesto theuppercenter position.

See Fig.PNE-4-57. to placeit at90° (right [2]Swingtheupperstructure angle)to thecrawler frame.Operateboom,arm, and bucketto set the attachment on the ground as shownin (PMJ-1-31).

Slowlyand gradually lowertheboomto liftonesideof he machine.

[3]Measure theclearance (A)between thelowerface of crawlerframeand the upperfaceof crawler shoeat thecenter position of crawler frame.

ProperValue(tension) (A) Rubbershoe; 60-70mm(2.4-2.8in) Steelshoe; 110~120mm (4.3-4.7in) is notproper, adjust itreferring to [4]Ifthetension the next Item 2. ADJUSTMENT.

NOTE¯ The machineoperation withloosenedrubber crawler shoecausestherubbercrawler shoeto come outof placeandwearprematurely.

4-18

PNE-4-57

:~:~:!:!:i$i:~:i:i:i:i:i~:i:i:~:~ :::::::::::::::::::::::::::::::::::: :: ::::: ::::::::: :::::::: ::: ~:::::: ::::: ::::::: :::::::::::::::::::::::::::::::::::::::::: PMJ-1-31

LOWER ROLLER

RUBBER CRAWLER SHOE

STEEL CRAWLERSHOE PM5-43

MAINTENANCE 2. ADJUSTMENT It isrequired toadjust thetension onthecrawler shoe dependingon the workingplaceof the machine.

Whenworking attheplacewitha lotofgravel or round stones, loosertension (upper limitrangeof tension) is preferable.

Andat hardground, stronger tension (lower limitrangeoftension) is preferable.

WARNING Greasein tracktensioning mechanism is underextremepressure andcan penetrate skincausingsevereinjury.Keepfaceand bodyawayfromgrease fitting area.Neverloosengreasefitting morethan oneturn.If grease doesnotrelease afteroneturnof thefitting, callanauthorized Kobelco service dealer forassistance.

2-1) MAKING TENSION STRONGER Providea greasegun.

[1]Feedgreaseto the greasenipple(1) withthe greasegunso thatpropertension on thecrawler shoeis obtainable.

-- 2

and backward to equal[21Movethemachineforward izethetension on bothcrawler shoesof leftand right.

[3]Againcheckthe tensionon the crawlershoes, and repeatthe adjustment to obtainthe proper tension on bothcrawler shoes.

NOTE: Whenthetension on thecrawler shoeis still looseevengreaseis supplied to the grease nipple, it is presumable thatsomefaulty conditions mayexistonthesealin thecylinder or machinebody.Requestthe repairto an authorizedKOBELCODistributor.

PME4-9

PRE-4-74

4-19

MAINTENANCE 2-2) MAKING TENSION LOOSER

Greasein tracktensioning mechanism is underextremepressure and canpenetrate skincausingsevereinjury.Keepfaceand bodyawayfromgrease fitting area.Neverloosengreasefitting morethan oneturn.Ifgrease doesnotrelease afteroneturnof thefitting, callan authorized Kobelco service dealer forassistance.

Gradually loosen thegrease nipple (1)to discharge grease.

Do not loosenthe greasenipple(1) morethan oneturn.

[2]Move the machine(crawlershoe)forwardand backward,whengreasedoes not be discharged adequately. up thegreasenipple.

[3]Tighten Tightening torque : 6 -+1kgf.m(43 -+7 Ibf.ft) Movethe machineforwardand backwardto ensurethecorrect tension on thecrawler shoes.

Againcheckthetension, andifit is notcorrect, adustitagain.

GREASE

GREASE PME-4-61

4-20

MAINTENANCE 4.13 INSPECTION & MAINTENANCE CHART Followthechartbelowfor recommended intervals of regularinspection and maintenance procedures.

Perform inspection andmaintenance according to the calendartimeor operation timeshownby thehour meter,whichever comesfirst.

See the inspection and maintenance procedure mentioned belowfordetails.

~ Components Item

Interval

Check level Engine oil

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE. Symbolsand theirmeanings ; []....................

Necessary regularinspection itemto hourmeter. *...................

Onlyinitial replacing performed.

O..................

Inspection and / or maintenance is needed.

PreWheno[q.e ra-Every Every EveryEvery Lubricant Reference 12 remonths months 2,000h ,etc. quired[8h (Replacing part) page 500h 1,000h

M

4-36 !Engine oil

!Change

4-43

Engineoil filterChange Waterseparator Drain/ Clean

III

Cartridge

4-45

Element

4-39

Clean

4-46

Fuel filter Change LU Z

0 z LLI

Aircleaner element

Element

Check/ Clean

4-51 4-48

Change

Element

Check level

4-49 4-36

Tap water (LLC)

Radiator coolantChange

4-53

Check leakage

4-36

Check

4-36

Adjust

4-44

Fanbelt

4-21

MAINTENANCE Components Item

w z z w

o J

o 7-

Clean

4-24

Radiator cap

Clean

4 -24

Hosesin coolingCheck/ system Change

4-47

Checkcolor,sound, smellof exhaust gas

4-36

ValveclearanceCheck/ Adjust

4-54

Compression pressure

Check/ Adjust

4-54

Injection timing Check/ Adjust

4-54

Starter and generator

Check/ Adjust

4-54

Check level

4-36

Drainwater and deposits

4-40

Check leakage

4-36

Fuel tank

w iiI_

>-

Radiator core

Fuel

w 109 >i

w

~

PreIntervalWhenop.era"Every EveryEvery! Every 12 2,000h LubricantReference re- tion week monthsmonthsmonths ,etc. quired 8h 50h (Replacing part) page 250h 500h 1,000h

Check Hydra- level ulic oil Change Hydraulic tank SuctionClean/ strainerChange

4-36 Hydraulic oil 4-55

Return Change filter

I!

Strainer

4-55

Element

4-50

Checkoilleakage and damageof pipingsand hoses

4-37

Checkoil leakageand damageof cylinders, etc

4-37

Linefilter Inline filter

4-57

Clean

SlewingbearingGrease

Grease

4-43

Greasein slewing grease Change bath

N.L.G.I No.2 Lithium base MoS2grease

4-62

4-22

MAINTENANCE ~~ ~mp0nent~ Item

IntervalWhen )i required-

~

EveryEveryEveryEverY12 LubricantReference weekmonthsmonthsmonths2,000h ,etc.

(Replacing part)page 250h 500h 1,000h

Travelreduction Oil motor Change LLI

W II

Check/Adjust tension of rubber/steel shoe

Gearoil

I!1

4-59 4-18

Checkcrawlers andlinksof =< u_ rubber/steel shoe

4-32

nCheck O

Roller Idler

4-37

i

Change

Gearoil

Checkoilleakage andwearof sprocket/travel reduction motor

4-60 4-37

Bucket

4-38

Greaseforpins

Grease

I-Z W

Boom&Arm cylinder

4-42

7-

Change

4-29

i

Bucket

/

~ mount

Z W

~i-gap~

4-30

Check wear and damageof toothandsidecutters

4-26

Check damage of electrical I wrongs II

4-34

Checkelectrolyte Battery level Measure specific

4-41 ,~

0 W

I gravity

_o

Checkfunction of warning lamps

Distilled water 4-41 4-36

F--

Checkswitches / levers ,,4 ..J W

W 7F-

4-36

Change working light(Lamp)

4-25

Check abnormal deformation and damageof machineexterior Check loosenessand missingof capscrews and nuts

4-36 4-36

Check

0

4-36

Operating lever Lubricate

Grease

4-23

4-34

MAINTENANCE 4.14 WHEN REQUIRED Thoroughly readand understand the sectionSAFETY PRECAUTIONSof this MANUAL before operating or servicing themachine.

A. CLEANING

RADIATOR

CORES

Direct contact ofyourself withcompressed air,steam andhighpressure watercausesinjury.

Makesureto weartheprotective glasses, mask,safety cap,safety shoes, etc.

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

[1]Opentheleftsidecoverandthecoverunderthe seat,referring to page2-12"Open/Close Guard Cover."

[2]Checktheradiator finsforclogging withdustand mud.

[3]Removethe dustand mud on the radiatorcores andfinswithcompressed air.

Because thebattery is installed undertheradiator,do notusesteamandhighpressure waterfor thecleaning.

Itcauses shortcircuit or clogging on feeding capsof battery.

NOTE: To avoiddamageson thefins,takesomedistancebetween thespraynozzleof compressed air and thefins.If the finsgetssomedamages, it causeswaterleakage resulting in overheating.

B. CLEANING TOR CAP

OR REPLACEMENT

OF RADIA-

WARNING USE EXTREME CARE WHEN REMOVEING THE RADIATOR CAP, THE COOLANT IS UNDER HIGH PRESSURE WHEN HOT, NEVER REMOVE THE RADIATOR CAP WHEN THE SYSTEM IS HOT. ALLOW SUFFICIENT TIME FOR THE MACHINE TO COOL DOWN BEFORE REMOVING THE RADIATOR CAP. [1]Removethe radiatorcap afterthe enginehas cooleddownto touchable witha barehand.Slowly i Z2-3O3P loosenthecap to releasethe insidepressure.

Removetheradiator capafterallpressure is released. of dust.

[2]Checkthecap for damagesor adhesion If thetightness of capisinsufficient, itmaycause Cleanitand/or replace it ifneeded. dangerof gettingburneddue to spouting out of [3]Securely tighten thecap. hotwateror steamduringoperation.

4-24

MAINTENANCE C. REPLACEMENT OF WORKING LIGHT A lightbulbof 23 W is usedfortheworking light.

Sincethelightbulbdevelops hightemperature while working, theservice lifeof thelightbulbbecomes shorter ifoilorgrease isadhred onit.

Whenreplacing thelightbulb,holdit at theflange portion nottouching withitsglassportion.

Whentheworking lightis notlightened eventhough theswitch forworking light isturned on,thelight bulb or fusemay be burnedout.

Ifthereisnotrouble onthelight bulb, checkthefuse referring to page2-13.

Thefollowing isthedescription forthechanging procedures oflightbulb. on the ground, andset the [1]Placetheattachment safety control leverto "LOCK" position, thenstop theengine.

[2]Removefourscrews(8)to removetherim(9) thelenspart(10)fromthehousing.

[3]Removethespring(13)fixingthesocket(12).

[4]Removethelightbulb(14)fromthesocket(12), andinstall a newbulb.

Assemble theworking lightin reverse orderof the [5] above.

NOTE: Payattention notto breakthelightbulbat the replacement.

Holdthe lensat removingthe screw (1),otherwise, thelensfalls off.

4-25

10

9

PR-4-31

MAINTENANCE D. RECONDITIONING BUCKET 1. CHECK FOR ABRASION/DAMAGES ON TOOTH POINT & SIDE CUTTER

Whenreplacing thetoothpointandsidecutter, apply a safety blockto thebottomfaceof thebucket.

Checkthe toothpoint(PWE-4-13) and sidecutter (PWE-4-14) fortheirworn-out condition.

The tooth pointholedor crackedmustbe replaced beforethe abrasion on theadapter.

Andtheworn-out sidecutteris alsotobereplaced earlier.

Ifthereplacement istoolate,thebucket bodywillbe damaged.

TOOTH POINTS

2~3mm(O.O8~O.12in)

8~10mm(0.31~0.39in) PWE-4-13

REPLACEMENT OF TOOTH POINT & SIDE CUTTER Consultwithan authorized KOBELCODistributor for thereplacement of toothpointandsidecutter.

SIDE CUTTER

I

OUT

WARNING

CRACK PWE-.4-14

WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

4-26

MAINTENANCE 2. REPLACING TOOTH POINTS

Whileworkingwitha hammer,a metaldebriswould flyabout.Andit maycausesevere injuryespecially whenit enters intoeye.

Makesureto weargoggles, safetyshoes,hardhat, workclothes andworkglovesto peformthisjob.

~~/%~ SAFETYBLOCI~

PU~ NCHI N~RG TOOL ~’TOOTH POINT PME-4-23

to a firmlevelsurface andplace [1]Movethemachine thebucketon a woodblock(lumber) as indicated in (PME-4-23).

[2]Afterthebucketis ina stable condition, setthe safety control levertolockposition, thenstopthe engine.

[3]Removethe sandwichpin (3) witha hammerusingthepunching tool. pin (3).The faultysandwich [4]Checkthesandwich pin(3)suchas crushand damageon insiderubbermustbe replaced witha new one.

[5]Makethesurface of adapter nose(2)cleanwith puttyknife,removing anydirtsuchas mud. cleaning inside thetooth point (1),fitittothe [6]After adapter nose(2).If somedirtremains insidethe toothpoint(1)or anyprotrusion existson it, causes improper fitting of thetoothpoint(1)with theadapter nose(2).

Drive the sandwich pin(3)intotheboreup to the [7] samelevelwiththesurface of toothpoint(1).

× 0 AMAGED RUBBER

DISTORTED PWE-4-17

PWE-4-15

TOOTH POINT ADAPTER NOSE

SANDWICH PIN

2

NOTE: An arrowis stampedon thesandwich pin (3) toshowtheinserting direction intothetooth point (1).

Payattention nottoinsert itatdifferent direction.

MAKE THEM AT THE SAME LEVEL.

hf

4-27

~-

PWE-.4-17-1

MAINTENANCE aftertheinstal[8]Makesuretocheckthefollowing lation. ¯ Slightly drivebackthesandwich pin(3)reversely afteritsinsertion (fromdownward ofthebucket) thathasbeendrivenfromtheupward. ¯ Confirm againif thesandwich pin(3)isbeing thesameleveltothesurface of toothpoint(1). ¯Slightly tapthetoothpoint(1)forupanddown, andleftandright direction. ¯ Ensureagainthefitting condition of thetooth point(1)andsandwich pin(3)through visually.

(1) (2)(3)

PWE-4-18

NOTE: ¯The sandwichpin (3) mustbe replaced witha new oneat everyreplacement of thetoothpoint(1).

Thisisquiteeffective to prevent thetoothpoint(1) fromdropping off.

i

SAFETY BLOCK PWE.-4-19

3. REPLACING SIDE CUTTER aroundthe sidecuttersuch [1]Removetheadhesion as sand,soil,etc.Usea torchto cutoffthecap screws, thenremovethe sidecutters capscrews. surface andinstall a newside [2]Cleanthemounting cutterwithnew capscrews andnuts.

[3]Firmlytighten nutsandspotweldthem.

SAFETY BLOCK PWE--4-24

SPOT WELDINGTT" AT WHOLE J’l L..

NOTE: ¯It isrecommendable toreplace thesidecutter atearly stage.Delayedreplacement wouldcausedamages on thebucketbody.

4-28

CAPSCREW ~.

MAINTENANCE E. REPLACEMENT

OF BUCKET

¯ Replacethebucketon firmflatgroundPayclose attention tosafety. ¯Whenaligning thepinbores, do notinsert yourfingerintothebores.

Itmaycausesevere injury.

Never insert yourfinger intothepinbores.

Makesureto alignthemvisually.

1. REMOVAL OF BUCKET operatetheboomandthearm to remove [1]Slightly loadfromthepins.

(1)ontothebucketboss.

[2]RollO-rings After installing thepins, getthembacktotheoriginalposition. theelastic lockring(2)andlockpin(3), [3]Remove thenremovethepins(4)and (5) to remove bucket (6).

2

9

NOTE : ¯ Payattention notto adhereanysandor dustto the pinsremoved. ¯Payattention notto damagethedustseals(9)which areinstalled in bothendsof thearm(7)andbucket link (8).

II

2

~

9 SECTION A-A

4 PW-4-26

4-29

MAINTENANCE 2. INSTALLING BUCKET [1]Cleaneachpinandpinholeandgrease sufficiently. to matchthepinbores [2]Movethebucketcylinder of thebucket(6)and bucketlink(8)with other; theninsert thepin(4)installing theshims (10). slightly from [3]Raisetheboomup to liftthebucket the ground.

[4]Movethearm (7) to matchthepin boresof the bucket(6)andarm(7)witheachother;then sertthepin(5)installing theshims(10). thelockpin(3)intopin(4)and(5), [5]Insert attach thespring lockrings(2).

Fit the O-ring (1) intothenormal position as shown [6] in therightFigure(PME-4-36).

Applygreaseto the bucketlinkfromthegrease nipples sufficiently.

<7>

I

(6)

(6)

NOTE¯ Replace theO-ring(1)showing cracksor losingelasticity witha newone.

~

(2) (3)

(1)O-RI

B’lrl / \n r-tr rt , . ~H

SECTION B - B

3. ADJUSTING BUCKET MOUNT GAP PME-4-36

WARN I NG Unexpected movementof attachment, whileadjusting the bucketmountinggap is quitedangerous.

Placethebucket on theground in a stable condition, andsetthesafety lockleverto "LOCK" position, then stoptheengine.

If theclearance of thebucketis notproperly adjusted, galling mayoccuron thecontact facesof thebucketand arm,resulting in abnormal noise anddamageof theshaftandO-ring.

An adjusting deviceis provided to adjusttheclearance betweenthe bucketand the arm. When the clearance becomeslarge,adjustthe clearance as follows.

Standard clearance ofthebucket intotal ofbothclearances Normal

BUCKET CLEARANCE C~~ ADJUSTING MECI~~~

0.5ram(0.012in)

[1]Lowerthebucketto thegroundto stabilize, as shownin theFigure(PME-4-37).

Slightly liftboomto remove loadfrombucket pinconnections to properly adjustbucket clerance.

4-30

PME-4-37

MAINTENANCE (1)fromitsnormal position tothe [2]RolltheO-ring bucketbossto avoiddamage.

[3]Slightly swing totheleftdirection toslightly push thearmendto thebucketleftside(whereno adjustingmechanism of clearance is equipped).

By contacting thearmandbucket, totalclearance is obtained on oneplace.

[4]Setthesafetylockleverto the "LOCKED" position;thenstoptheengine.

[5]Measurethetotalclearance "X" between the arm and bucketboss.Theclearance is the existing totalclearance.

Exactclearance is gotteneasily by usinga thickness gauge.

SECTION C-C

ARM BOSS PMJ-4--38

[6]If the measurement valueis 1.0mm(0.04in) more,decrease the clearance.

Removeshims(3) to recondition the clearance "X" afterloosening 3-capscrew (2) withwasher (4).

Theclearance decreases by extruding the bushing (5),depending on thethickness of removed shims.

NOTE: Thickness of shimis 0.5mm(0.02in).

6-shims on theaverageare provided on one capscrew (2).

2,KED

(UP)

POSIT~

PWE-2-7

[Example] When X =2mm Remove3-shim (0.5X3=1.5mm) Remainedclearance=2-1.5=0.5mm Tightening torque; 3.4kgf.m (25Ibf.ft)

BEFORE ADJUSTMENT

I

the3-capscrew (2)withwasher(4)equally [7]Tighten tothespecified tightening torque.

2.0mm(O.O8in) [8]Returnthe O-ring(1) to the normalposition.

(Groovebetweenthe arm and bucketbosses.)

AFTERADJUSTMENT

I

llllllLllll O.5mm(O02in 4-31

1,5mm(O,O6in) PME-4-40

MAINTENANCE F. INSPECTING RUBBER CRAWLER SHOE Repair or replace rubber crawler shoeif itfallsinto thefollowing condition.

(Contact an authorized KOBELCODistributor forrepairor replacement of rubbercrawler shoes) 1.Height oflug (A)wearsoff,traction force [1]Ifthelugofheight decreases.

Replacethe shoewitha new one if (A) decreases below5mm (0.2in).

J-I II/LOWER ~MIi RUBBERCRAWLE"R’I lJ SHOE ~,L~~

LUG

Ill "~iROLLER 11 I’’W METALCORE

STEEL CORD PM5-76

outat anextent thatthesteelcord, [2]If thelugwears in theshoeis exposed overtwolinks, replace the shoewitha newone.

~-STEEL

CO;M~..4.42

I

2. Breakage of steelcord If thesteelcordsof therubber crawler shoearebrokenby morethanonehalfof onesiderow,replace theshoewitha new one.

BREAKAGE OF STEEL CORD PME~3

3. Crackof rubbercrawler shoe If a crackwhichhasdeveloped to about60mm(2.4in) length is seenbetween thelugof rubber shoe,repair theshoe.

However, repair theshoeimmediately if thesteelcord insideis exposedeventhougha crackis smalland short.

NOTE¯ Forrepairsor replacement of rubbercrawler shoes,contactan authorized KOBELCODistributor.

FOR60mrn(2.4in) "" OVER,REPAIRIS NEEDED REPAIR NEEDED

IS~ ~__~.

_

~- REPAIRIS NOT YET NECESSARY

PRE4-54

4-32

MAINTENANCE 4. PEELING OFF OF METAL CORE ON RUBBER CRAWLER SHOE Dependingon the usageof rubbercrawlershoes, theremayoccasionally happena peeling offof metal coreon therubbershoes(innerside)dueto contact withtherollers andidler/sprocket or abrasion, even thoughthereare no externaldamagesor abrasion onthelugside(outer side) ofit.

~

~,~.,- LOWER ROLLER

,NTERFERENCE V THROLLER ~/METAL

CORE

EEL CORE RUBBER

PME.-4-44

NOTE: 1.THE METAL CORE STARTS HAPPENING WITH THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE. 2.FULLY UNDERSTAND THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE REFERRING TO PAGE3-36 "USING RUBBER CRAWLER SHOES." 3. NOTE THAT THE WARRANTY IS NOT APPLICABLE FOR ANY DAMAGES DUE TO THE PROHIBITED USAGE OF THE RUBBER CRAWLER SHOE OR THE USE OF IT WITH IMPROPER TENSION ON IT.

shoeon whichthepeeling off [1]Therubbercrawler of metalcoreshowsevenat one placemustbe replaced witha newone.

.E

PME-4-45

I

CR?PP/NoGROUT O F

[2]The crackedrubbercrawlershoeby whichthe metalcorecomesto thesurface mustbe replaced witha new one.

6

[3]Thecrackedrubbercrawlershoeon thecontactingportion ofthemetalcorewiththeroller is not required torepair.

4-33

MAINTENANCE G. LUBRICATION FOR OPERATING LEVERS Whenany operatingleversbecomeheavyto operate or do not movesmoothly, applygreaseto the sliding androtating portion (A)andthetopportion (B)oftheuniversal joint.

OPERATING LEVER

[1]Movethemachineto firmand levelground,set theattachment on the ground,placethe safety controlleverto "LOCK"positon, thenstopthe engine. raiseup therubber booton thetroubled [2]Carefully operating leverwithhandpaying attention notto giveanydamages to it.

[3]Applygreaseto thesliding androtating portion (A)and4 places of thetopportion (B)of the versal joint.

APPLY GREASE

[4]Setbacktherubber bootto theoriginal position. and if [5]Checkthe pilotvalveforanylooseness, loosened, retighten thesocketcapscrews.

H. CHECKING FUSES

ELECTRICAL

WIRING

AND

WARNING ¯ Whena frequent replacement is requiredforthe fusesor thereareanytraces of shortcircuiting on theelectrical wiring, consult withan authorized KOBELCODistributor. ¯ Beforechecking the electrical system,makesure todisconnect thebattery cableofnegative (-)side.

Erroneous shortcircuiting maycausefire.

All

UZ2-070

4-34

MAINTENANCE *REPLACING

PROCEDURES

Whena newfuseis blownwithina shorttimeof serviceor frequent replacement forfusesarerequired, it maybe causedby troubles in electric sequence.

Consultwithan authorized KOBELCODistributor for repairs.

Themainfuseboxcoveredby thefusebox coveris provided undertheseat.

PM2-63-1

[1]Placethebucketto theground.

[2]Setthesafety control leverto thelockposition. switchto "OFF"to stoptheen[3]Turnthestarter gine.

[4]Openthecoverundertheseat.

[5]The fusebox coveris lockedon one side.Releasethelockandremovethecover.

[6]Whenany fuseis blownas shownin the right, replace it withthesparefusestoredin thefuse box.

[7] Afterreplacing thefuse,makesureto setthecover witha click.

PM-64-.1

WARNING NEVER REPLACE A FAULTY FUSE WITH HIGHER AMPERAGE FUSE. NEVER USE A"JUMPER" IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS.

PRE-2-53

*Fusible Link(Forstarter) In casepowerdoesnotcomewhenthestarter switch isturned "ON",a disconnection of thefusible linkis suspected.

Inspect wiresandfuselink.Replace thefusible linkif needed.

NOTE: Thefusible linkis ofa fusewiring ofbigsize provided in theelectric wiring forlargecurrent.It protects theelectrical equipment and wiringfromabnormal current justlikeas an ordinary fuse.

4-35

FUSIBLE LINK (RED)

FILLERPORTCAP---, (ENGINEOIL)

MAINTENANCE

8Hr

4.15 8-HOUR (DAILY) INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

The following inspection and maintenance shallbe carried outbefore starting / afterstarting andafter work.

REFER TO SECTION 3 "BASIC MACHINE OPERATION" IN THE FOLLOWING ITEMS FOR INSPECTION AND MAINTENANCE ¯ Page3-3forchecking andrefilling of coolant. ¯ Page3-4for checking of coolant leakage. ¯ Page3-6forchecking offuellevel andrefilling. ¯ Page3-6forchecking of fuelleakage. ¯ Page3-7forchecking offanbelt. ¯ Page3-5forchecking ofhydraulic oillevel andrefilling. ¯ Page3-4forchecking ofengine oillevel andrefilling. ¯ Page3-8forchecking of warning lampslightening. ¯ Page3-8forchecking ofworking lightlightening. ¯ Page3-14forchecking of exhaust gascolor,abnormalsoundand smell. ¯ Page3-15forchecking of operating conditions of eachswitchandlever, A. CHECK EXTERNAL CONDITIONS OF MACHINE A dentor distortion whichapparently seemsnotto be severedamage,may be abnormalcontacton internal partsor hoses.

Consult withan authorized KOBELCO Distributor for advise and/or forrepairs.

B. CHECK CAPSCREWS AND NUTS FOR LOOSENESS AND/OR MISSING Checkfor missingcapscrews and nutsand replace as needed.Checkand makesureall capscrews and nutsareproperly tighten.

Likewise, checkandmake sureallhoseclampsareproperly toghten.

The abnormalsound duringoperationmay cause leakageor fire.Use torquevaluesfrompages4-10 and4-11.

NOTE: Usethetoolssuitable fortheworkreferring to page 4-9, ACCESSORY TOOLS.

4-36

PMJ-1-6

MAINTENANCE

8Hr

C. CHECK EACH CYLINDER, PIPING AND HOSE FOR LEAKAGES AND DAMAGES

WARNING Becautions ofhotfluids and surfaces,wear goggles, safety shoes, hardhat,work clothes, andworkgloves to performinspectionand maintenance on thismachine.

WARNING Hydraulic lineisalways highly pressurized.

Makesure to release thepressure in thelinebeforestarting service and/or maintenance, orrefilling.

Neveruse handsto checkfor leaks.Highpressure fluidleakswillpenetrate theskinandcausesevere injury.

Hydraulic oilleakage willslowdowna machine.

Move the machineto firmlevelgroundandplacetheattachment in theoilcheckposition andstoptheengine. leverto "LOCK"position, [1]Setthesafetycontrol thenstoptheengine. of leakage, takea timeto [2]To checkthelocation allowgetting thetemperature on eachportion of the machinedownto around40°C(104"F).

Make sureto wearthe protective glassesandgloves forthecheck. capof theairbreather on thetop [3]Presstherubber of thehydraulic oiltankseveral (fiveto seven) timesto release theinternal pressure of thetank.

Consult withan authorized KOBELCODistributor for adviseandrepairs.

J!’\

I[1

.TAY

NOTE: Whenany abnormalities happenon the machine,immediately stopoperation, andaskfor repairs as needed.

Whenthe volumebecomesinsufficient for the enginecoolant or oildueto leakage, an warning lampisilluminated.

D. CHECK TRAVEL SYSTEM FOR LEAKAGE AND ABRASION [1]Checkthelowerroller, idlerandtravelmotorfor any leakages. idler, andsprocket forab[2]Checkthelowerroller, normalwearandloosened fixingbolts.

Slowly travel the machine and checkfor anyab[3] normalsound.

x._. (c)

NOTE : Consultwith an authorizedKOBELCODistributor foradviseand/or repairs as needed.

)(D) PME-4-54

A B C

4-37

TRAVEL MOTOR SPROCKET LOWER ROLLER

D E F

CRAWLER SHOE SHOE SLIDE IDLER

MAINTENANCE

50Hr

4,16 50-HOUR (WEEKLY) INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

Perform together with8-hour(daily) inspection and maintenance.

A. ADJUSTING CRAWLER TENSION Properadjustment of therubbercrawlertension is essential forextending service lifeof thecrawler and thetravelsystem, and prevention of comingoff of crawler dueto insufficient tension.

IIArl

WARN I NG Theinspection of thecrawler shoetension is carried outwithonesideofmachine lifted.

Itisquitedangerous if the machineis erroneously dropped.Never operate themachine duringtheinspection.

Makesure to carryouttheworkwiththehelpofanother person.

The operatoroperatesthe machinein accordance withthesignal of thepartner.

>-.’"

Referto page4-18forthe checkand adjustment of rubbercrawler shoetension.

B. GREASING PINS AROUND BUCKET Requestfor Greasing Generally thegreasing is required at every50 hours operation or weekly.

Referto page4-42forgreasing underspecial conditions.

[1]Movethemachineto firmlevelgroundandplace theattachment on theground in theoilcheckposition, as indicated in (PAE-4-25). beforegreasing.

Replace [2]Cleanthegreasefittings thegreasenipplewitha newone,if damaged. witha greasegunthruoghthe grease [3]Lubricate fittings shownin (PMJ-4-17) witharrowsandthe tablebelow.

NO.

1 2 3 4

Greasing points Bucketcylinder rodpin Idlerlink/Arm connecting pin Bucket linkpin Arm/Bucket connecting pin

Q’ty 1 1 1 1

RUBBER

CRAWLER SHOE

PME-4-56

PAE-.4-25

~(3)

(4)

PMJ-4-17

[4]Properly wipeoffanygreasesquirted outaround thepinconnection

4-38

Dispose of allhazardous wastein accordance with government environmental regulations.

MAINTENANCE

50Hr

C. DRAINING WATER FROM WATER SEPARATOR AND CLEANING If theredring(D)in thewaterseparator sinksdown to bottomof thecase(F),no wateris mixedin.When thering(D)is floating, wateris mixedin up to the levelof thering.Drainthemixedwaterinaccordance withthefollowing procedures.

Fueloiladheredperiphery may causefire.Wipeit offthoroughly.

leverto "LOCK"position, [1]Setthesafetycontrol thenstoptheengine.

[2]Openthe engineguard.Aftercoolingdowneach portion, pushthehandle(A)of thewaterseparatorupwardto the"CLOSE" position.

[3]Loosenthe ring(H) to removethecase(F), drainthewaterout.

NOTE: Payattention notto losetheredfloat(D)and spring (C).

Checkthewaterdrainedforits contamination.

And whenit is dirty,cleanup theelement (B)andinside ofthecase(F).

[4]Removetheelement (B),andcleanit withdiesel fuel.

[5]ReplacetheO-ring(E)witha new one. theelement (B)tothewaterseparator body.

[6]Install [7]SettheO-ring (E)to thecase(F),thentighten up withring(H).

[8]Pushthe handledownwardto set at "OPEN"position. water,makesureto bleedoutthe [9]Afterdraining airreleasing forthefuelsystem referring topage 4-15.

NOTE: Do not cleanup theelementwithgasoline.

PM5-91

Dispose of allhazardous wastein accordance with government environmental regulations.

PMJ-4..49

PV-4-71

4-39

MAINTENANCE D. DRAINING WATER FUEL TANK

AND DEPOSITS

50Hr

FROM

¯ Make sureto stopthe enginewhendischarging fuelfromthefueltank. ¯ Thoroughly wipeup thespilled fuel.

FUEL TANK

Loosenthedrainplugto drainthewateranddepositsin anemptycontainer.

Sincethewateris deposited duringthenight,it is effective to drainbefore starting up theengine inthe morning. of themachine so that [1]Swingtheupperstructure the drainplug(A)underthefueltankcomes midwaybetweenthe crawlershoesof left and right.

Remove theundercoverunderthe fueltank.

[2] [3]Placean emptycontainer underthedrainplugto catchthefueldischarged. thedrainplugto drainwatermixed [4]Slowlyloosen in anddeposits together withthefuel. tightenup [5]Whenpurefuelbeginsto discharge, thedrainplug(A). theundercoverat theregular position.

[6]Install

NOTE: Checkforfuelleakage aftertightening up the drainplug.

Consultit withan authorized KOBELCODistributor foradvise andrepairs if needed.

Makesureto contain anyfuelspillage.

4-40

(A) PFE-4-8

PW-5-7

MAINTENANCE

50Hr

E. CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY Thebattery fluideasilydecreases withhighambient temperature in summerseason.Checkthe battery fluidlevelin themorning before starting operation.

Continuous useof thebattery withlowfluidlowers batteryperformance.

Check thebattery fluidlevel periodically, andifinsufficient, refill thebattery withdistilled water before startingtheengine (before charging battery).

/;I.i\

(A)INDICATOR INDICATIONS

WARNING

GREEN

¯ Flammable gas(hydrogen gas)is generated in the battery.

Do notallowsparksor flamesto comein contact withbatteries to avoidtriggering an explosion. ¯ Battery fluidhasstrong acidity.

It corrodes metal veryrapidly.

If it adheres on skinor entersinto eys,it causes a burnor blindness.

At suchcases,immediately washskinor eyewith lotsofwater, andaska doctor totreatitassoonas possible.

RED

,RED

~ BLUE GOOD

WHITE RED REFILLINGREQUIRED CHARGING REQUIRED

(1) I

AIR VENT HOLE

Checktheindicator (A) on the battery, andalways keepit at greencolor.Redcolormeansinsufficient battery fluidorbattery charging.

PME..4-66

(2) (1) .,...~ PPER LIMIT

[1]Setthesafetycontrol leverto "LOCK"position, "’~LOWER LIMIT thenstoptheengine.

[2]Putdownthe seatstandforward, and removethe PLATE ~ battery cover oftheleft.

BAI-rERY [3]Removethe caps(1) of eachcellto checkthe fluid level.

(ELECTR~ PVE-4-40 [4]Ifbattery fluid level islow,refill thecellwithdisWhenit is difficult to obtainenoughcranking speed tilledwaterup to thespecified level(10-15mm attheengine start-up, checkthebattery fluidforits (0.39-0.59in) abovetheplate). specific gravity.

If it is insufficient, re-charging isre[5]Makesuretheairventholeson thecaps(1)are quired for the battery.Standard Specific Gravity for cleanandsecurely tighten caps(1).

Battery Fluid: 1.28(20°Cor 68°F) (2)aredirty, washitwithwarmwa[6]Iftheterminal For the specific gravity ofbattery fluid atcoldclimate ter,theninstall itto theposition applying grease or other specific conditions, refer to page 3-39,and or spraying rustpreventive solution.

Iftheterminalisoxidized, polish itwitha wirebrush or sand makethe chargingratearound100%.

Ifitisdifficult evenafter re-charging iscarried out, paper. replacement of thebattery witha newoneisrequired.

NOTE: Measure thespecific gravity of battery fluid witha gravimeter.

Themeasured valuevariesdepending on theambient temperature.

Consultwith an authorized KOBELCO Distributor foradviseand/ or repairs as needed.

4-41

MAINTENANCE 4.17 250-HOUR (3-MONTH) INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

Perform together with8-hourand50-hour inspection and maintenance.

A. GREASING PINS

ATTACHMENT

AND

250Hr

GREASING POSTURE DOZER E

DOZER

NOTE : In ordinary operation, applygreaseevery250hours of operation or everysixmonths,butunderspecial conditions, observe thefollowing lubrication intervals 1 ) Whenoperating themachine witha special attachment,applygreaseeverydaybeforestarting work. digging operation, applygreaseto 2) For underwater theareasto be immersedin watereveryday beforeandafterwork.

3) Wherethe machineis storedfor morethan one month,applygreasebeforeworking. to a firmlevelareaandplace [1]Movethe machine theattachment intheoilcheckposition. beforethe [2]Makesureto cleanthegreasefittings greasing.

Replace thegreasefittings witha new one,if damaged.

[3] Use tablebelowto lubricate all connections throughgreasefittings as shownin (PME-4-68) and(PME-4-69) unilgreasepurgesout.

Properly wipe off anygreasesquirted outaround [4] thepinconnection.

PAE-4-25

DOZER

GREASING

POINTS PME-4-68

IEI~ CYLINDER GREASING POINTS (7)

NOTE: Sincethe dozerfootpin(3)is supported an ironbushing, frequent greasing is required forit whenthedozeris frequently usedat thework.

And whengreasingthe attachment, make sure to grease to dozerfootpin(3),too.

NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Greasing points ~ Dozercylinder rodpin !Dozer cylinder footpin Dozerfootpins Boomfootpin Boomcylinder footpin Boomcylinder rodpin Armcylinder footpin Armcylinder rodpin Boom/Armconnectingpin Bucket cylinder footpin Bucketcylinder rodpin Swingcylinder footpin Swingcylinder rodpin Swingbracket/frame connecting pin

Q’ty 1 1 2 1 1 1 1 1 1 1 1 1 1 2 4-42

ATT ACHMENT GREASING POINTS

12

13

PME-4-69

PW-5-9

MAINTENANCE B. OIL CHANGE

FOR ENGINE

¯ Do notcarryouttheoilchange justafterstopping theengine whichis keptat hightemperature at everyportion.

Allowsufficient timefortheengine to cooldownbeforemaintenance. ¯Thefirstoilchange mustbe carried outat 50 hours operation fora newmachineengine.

Container to receive drained oil: 4 liter(1.1gal)ormorecapacity Oilvolume toberefilled : 3.9liter (1.06 gal) (Upperlimitof standard volume.) to receive thedrainoil [1]Placean emptycontainer underthedrainplug(1)located at thebottom engine.

[2]Removethebottomcover(4)underthedrainplug.

[3]Slowlyloosenthedrainplug(1)so thattheoil doesnotsplashoveryourself.

Makesureto contain anyoilspillage. oil.In casethatlotsof metalpar[4]Checkdrained ticles and/or foreign materials arecontained init, consultwithan authorized KOBELCODistributor foradvise and/or repairs. tighten thedrainplug(1).

[5]Securely [6]Opentheengineguard,andremovethefillerport cap(Yellow) (2).Refill theengine withthespecified oil.

Referto page4-7 for therecommended oil.

[7]Starttheengine, operate it forseveral minutes at idling, andshutit down.

Checkthe oilleveland makesureit is between the"H"and"L"marksonthedipstick (3)referring to page3-4,the section for "CHECK& REFILL-UP OF ENGINEOIL".

C. GREASING

250Hr

TO SLEWING

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

PM5-108

BEARING

Neverswingthe machine, whilefeedinggreaseto theslewing bearing.

Feedgreaseto the swingbearing, swingupperand place itin4 different positions (90 ° apart), until grease purgesout.Onlyonegreasenippleis provided for the slewingbearing.Properly wipeoff any grease squirted outaroundtheswingbearing seal.

4-43

PWJ--4-37

MAINTENANCE D. ADJUSTMENT

FOR

BELT

250Hr

TENSION

Makesureto stopthe enginewhileinspection and maintenance.

Otherwise, your fingeror handmay becaught bythefanor fanbeltresulting ininjury.

Checkthe fanbeltforpropertension, wearconditionsanddamages.

Makesureto adjusttension properly.

Provide a lever(suchas bar,wrenchor handle) and a woodenpiece.

NOTE : ¯Theremay be bigdifferences amongindividuals on theadjustment forthebelttension witha levercausingtoomuchor toolittle belttension.

Makesureto checkfordeflection andtensile forceaftertheadjustment. ¯ Use the leverwiththe lengthof 300-400mm (1216in)suitable fortheadjustment work.

IIAII STOP

STOP

E. ADJUSTMENT FOR FAN BELT screw(1)and theadjusting [1]Loosenthemounting screw (2)slightly before adjusting thefanbelttension. theadjusting bolt(3)to adjust thefanbelt [2]Loosen to thespecified tension, andtighten themounting screw(1)andtheadjusting screw(2). startup theengineandop[3]Aftertheadjustment, erateit at lowidlingforaround5 minutes, then stoptheengine.

Andconfirm thebelttension (deflection andtensile force).Refer to page3-7.

PM5-111

4-44

MAINTENANCE F. REPLACEMENT

250Hr

OF ENGINE OIL FILTER

WA R N I N G BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

Everyportion of theengineis keptat hightemperaturejustafterstopping theengine.

Taketimeto allowcooling downtheengine forinspection andmaintenance.

NOTE : ¯Theoilfilter isof a cartridge typewhichcannotbe reused norcleaned withthefilter disassembling.

Replace itasa unit. ¯ Replace it at 50 hoursoperation forthefirstuseof new machine. ¯ The filterwrenchprovided on the machineis used fordismantling.

Thefiltercartridge mustbe replaced witha newone at 50 hoursoperation for thefirstuseof newmachine. opentheengineguard,andre[1]Stopthe engine, movethe undercover. wrench (B)to thefilter cartridge [2]Applythefilter (A),andturnthewrenchwithspanner to counter clockwiseto remove it. base, [3]Wipeoffanyduston thesealfaceof filter andavoidcontamination.

Thinly applycleanengine oilto thepacking ofnew [4] filter cartridge, andinstall andtighten itup with hand.Thenretighten itby about2/3turns. andoperate it atidling forsev[5]Starttheengine, eralminutes to checkforanyleakage at theinstalling face.

/

SPANNER PME--4-74

~

ENGINOIL

[6]Closetheengine guardandinstall theundercover.

NOTE: ¯ When the machineis operatedin dustycircumstances, a shorter interval isrequired forthereplacement. ¯ Whensomemetalparticles areadheredon the elementremoved,consultit withan authorized KOBELCODistributor.

4-45

PVE-4-47

ImllIillmwm

i

Dispose of allhazardous wastein accordance withI government environmental regulations.

I

MAINTENANCE G. CLEANING

250Hr

ENGINE FUEL FILTER BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

Eachunitis hotimmediately afterthemachinehas beenoperated.

Changethe filterafterthetemperature hascooled down.

Clean up allspilled fueltoavoid a fire.

Prepareemptycontainer.

[1]Stoptheengine,andopentheengineguard.

(A)offuelfilter at "CLOSE" posi[2]Setthehandle tion.Andremovetheretaining ring(B),andtake out thecupcase(D)andelement (C). on the bot[3]Draindustand wateraccumulated tomof cupcase(D)of fuelfilterin theempty container, andclean thefuelfilter.

[4]Washandcleantheelement (C)withdieselfuel, and use compressed air,2~3kgf/cm 2 (28-43psi) fromtheinsideto removedust.

(.A)

NOTE¯ It is strictly prohibited to washandcleanelementwithgasoline.

Replace O-rings (E)andinstall thefuelfilter [5]

~FUEk

FILTER

~L

=----(D) PM5-120

reverse ordershownin theitem[2]. to theitem"BLEEDING AIR [6]Bleedair referring IN FUEL SYSTEM"in page 4-15.

[7]Ensure thatthefilter installing faceisfreefrom possible fuelleakage, afterrunning engineat idling forseveral minutes.

Disposeof allhazardous wastein accordance with government environmental regulations.

\ 4-46

J PV-4-71

MAINTENANCE H. CHECKING RADIATOR HOSE Replacing the hosesbeforeany problemsoccuris botheconomical and goodmaintenance practice.

Thiswillreducecostsand minimize unexpected interruption of working.

Immediately replace thehoseif it is cracked, worn, orif water isleaking fromit.Thiswillprevent serious problems, suchas theengineoverheating. clueto loose [1]Checkthehosesforwaterleakage clampsor crackedand wornhoses.

[2]Tighten anylooseclampsandreplace anycracked or wornhosesfollowing the procedures below.

I. REPLACING

RADIATOR

250Hr RADIATOR

’-’RESERVE TANK

PW-5-13

HOSE

Dangerof highlypressurized steamis generated in theradiator.

Whilethecoolant is keptat hightemperature and pressure, do not loosennor openthe radiator cap. ¯ Whenopening theradiator cap,stoptheengine. ¯Takea goodenoughtimeto allowcoolingdownthe coolanttemperature.

capslowly.

Ensurethatpres[1]Loosentheradiator surehas beenreleased.

Pushthe cap downand holdit downwhileturning to remove.

RADIATOR

Cl~

[2]Removethe undercoverunderthe radiatorand thedraincock.

[3]Drainthecoolant fromthedraincockuntilthecoolantlevelbecomes belowthehoseto be replaced. ~DRAIN the dam[4]Loosenthe hoseclampand disconnect agedhose;thenreplace it witha newone.

[5]Install thedrain cock.

[6]Filltheradiator withcoolant, thenfillthereserve tankwithcoolant, too.Referto page3-3.

[7]After thefill-in, tighten securely theradiator cap.

[8]Install theunder cover.

4-47

COCK PW-5-14

MAINTENANCE J. CHECKING/CLEANING/REPLACING CLEANER ELEMENT

250Hr

AIR

Wearprotective glassesor goggles whenusingcompressed air. iI<--,,, NOTE¯ Stoptheenginebeforeinspecting or cleaning theaircleaner element.

Thiswillprevent theengine fromgettingdamageddueto dust.

STOP

1. CHECK ELEMENT Whenblacksmokeis discharged fromthe exhaust outlet, checktheaircleaner element, andcleanor replace if needed.

2. CLEANING

ELEMENT

NOTE: Do notreusetheelement withdamagedfolds, gasketand/orseal.

Do notheavily taptheelement norhitit to anything elseforcleaning.

[1]Removetwocoverclamps(2)to pullouttheair cleaner element (1).

__.._._-/

PM5-117

tapeto coverthe [2]Usea cleanclothor adhesive engine airintake porton thehousing in orderto avoidcontamination.

Thencleantheinside of the aircleaner housing.

[3]Use compressed air to cleanthe elementfrom insidealongthe folds.Usecompressed dry air lowerthan3kgf/cm 2 (43psi).

Andblowitofffrom outside.

Thenagainblowitofffrominside.

[4]Aftercleaning element, puta light bulbinside the element, andvisually inspect forsmallcracks on the elementmeshes.A faultyelementon the screenand/orpackingmustbe replaced witha new one.

1

-°

PM5-88

18

4-48

MAINTENANCE

500Hr

theengineair [5]Removetheclothor tapecovering intake port. thecleaned element intotheaircleaner [6]Install housing.

[7]Fixtheaircleaner housing to theframewithtwo coverclamps(2).

NOTE: Theelement is reusable up to 6 timesof cleaningorforoneyear, afterthatitmustbe replaced with a new one.

4.18 500 HOUR (6-MONTH) INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

Performtogether with8 to 250-hour inspection and maintenance.

A. REPLACEMENT OF ELEMENT [1]Removetwocoverclamps(2)to pullouttheair cleanerelement, tapeto coverthe [2]Usea cleanclothor adhesive engineairintakeporton thehousing in orderto avoidcontamination.

Takecleantheinsideof the aircleaner housing.

[3]Install a newelement andsecure it withthewing nut(2)by hand.

Do notuseanytoolsto tighten thewingnut(2). housing to theframewithtwo [4]Fixtheaircleaner coverclamps(2).

4-49

PA-4-35

MAINTENANCE B. REPLACEMENT OF HYDRAULIC RETURN FILTER Thereturn filter keepsthehydraulic oilcleanbyremovinganyforeign material thatmaybe in theoil.

Thiswillpreventthehydraulic equipment frombecomingdamagedand prolongthe equipment’s life.

Thus,sincethereturn filter is a veryimportant part, treat itwithcare.

¯ NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM, NOT HOT. ¯ RELEASE HYDRAULIC TANK PRESSURE, BEFORE WORKING WITH ANY HYDRAULIC COMPONENT, ACCORDING TO THE PROCEDURES PROVIDED BELOW. ¯ WHEN REPLACING ANY HOSE OR SEALS, MAKE SURE THE ATTACHMENTS ARE WELL SECURED TO AVOID SUDDEN MOVEMENT OF ATTACHMENT. SLOWLY REMOVE BOLTS TO RELEASE ANY HYDRAULIC PRESSURE DURING DISASSEMBLY¯

[1]Movethemachine to firmlevelground, placethe attachment intheoilcheckposition, andstopthe engine.

See Fig.PAE-1-22. oil [2]Openthecoveron thetopof thehydraulic tankwiththestatorkey,andsupport thecover withthestay. fixing portion clean inordernotto [3]Makethefilter enteranydustor foreign material. several [4]Presstherubbercapof theairbreather (fivetoseven) timestorelease theinternal pressureof thehydraulic oiltank.

[5]Removethe capscrews (1),the springwashers (2)andthecover(3)onthetopof thehydraulic oiltank.

[6]Takethespring(4),thevalve(5)andthe ment(6)outof thetank.

[7]Exchange theO-ring(7)of themounting face thecover(3).

[8]Clean thepartstaken outwithlight oil.

[9]Install theelement in reverse orderof theabove [5]and[6].

4-50

500Hr

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

HYDRAULICOIL LEVEL CHECK POSITION

!iii !~i i!!i i~ ~i iii !i!£~-~~ !~i~ii~i!iiii!iii!i!iiiii!i~i~ iiiiii:.:i i}ii iiiiiii !iii .".~ ~::! ~iii ~i i:i i:! !!i ~i[ PAE-1-22

MAINTENANCE [10]Install thecover (3).

Tightening torque: 23.5+1.96 N.m {2.4+0.20 kgf.m} [11] Starttheengine, operate eachworkleverto make themachine in a posture of hydraulic oillevel inspection, andchecktheoillevel.

[12]Removethestay,returnthecoveron thetopof thehydraulic oiltankto thenormal position and lock.

500Hr

NOTE: Forthemachine withthebreaker, thedeterioration of hydraulic oilisincreased bythebreaker work comparedwith the standarddiggingwith bucket.

Earlier replacement forthelinefilter andhydraulic oilisrequired.

Followthereplacement intervals for them to page8-8 .

WARNING

C. REPLACEMENT

OF FUEL

FILTER

¯ Eachportion of theengine is keptat hightemperaturejustaftertheoperation.

Starttheservicing aftercooling downeachportion. ¯Thoroughly wipeup thefuelspilled over,otherwise it maycausefire.

i

BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

Provide an emptycontainer to receive thefuel.

[1]Stoptheengineandopentheengineguard.

[2]Putfuelcontainer under thefuelfilter.

[3]Setthehandle(A)of fuelfilter at "CLOSE" position.Andremove theretaining ring(B),andtake theelement (C)outof thecupcase(D).At time,caremustbe exercised nottomissthespring whichis placedin thecupcase.

Forthe sakeof safetyandin ordernot to make thegrounddirty, makesureto discharge thefuel intothecontainer andmakethearoundclean.

[4]Replace element (C)andO-ring (E)withnewones.

[5]Install theminreverse order shownintheitem[3]. to item"BLEEDINGAIR IN [6]Bleedair referring FUEL SYSTEM" in page 4-15. minutes to [7]Runtheenginein lowidleforseveral ensure thatthefilter fitting section isfreefrom possible fuelleakage.

Disposeof all hazardous wastein accordance with government environmental regulations.

4-51

PM5-120 I

~i~ ~

BC)DY

-.~( C

........

-11

I ’

~(E) (D)

dsPR, PAE-4-41

MAINTENANCE NOTES: ..............................................

4-52

MAINTENANCE 4.19 1000-HOUR (12-MONTH) INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

Performtogether with8 to 500-hour inspection and maintenance.

A. REPLACEMENT

OF

1000Hr

Danger of highlypressurized steamis generated in theradiator.

Whilethecoolant iskeptathightemperature, do notloosen noropentheradiator cap. ¯ Whenopening theradiator cap,stoptheengine. ¯Allowsufficient timeto cooldowntheenginebeforeservicing.

COOLANT

Useof softwaterwithlessimpurities as basecoolant.Usethe"LongLifeCoolant" mixing it inthecoolantmorethan30%of density to prevent thecooling linefromcorroding andfreezing.

Thedensity of "Long LifeCoolant" mustcorrespond to the expected lowestambienttemperature.

Referto page4-7fortherequired density of "Long LifeCoolant."

Providean emptycontainer to receivethecoolant drained.

¯Theanti-freeze agentis inflammable anddetrimental to humanbody.Keep awayfromflamesand sparks. ¯Payattention notto adheretheanti-freeze agent onskinorenterintoeye.If itadheres on skinor enters intoeye,immediately washskinoreyewith lotsofclean water, andaska doctor totreat it.

[1]Stopthe engine.Openthe engineguard.Start the servicingwith the coolantcooleddown enough.

[2]Loosenthe radiator capslowly.Afterensuring thatthepressure hasbeenreleased, pushthecap downandholdit downwhileturning to remove. thecoolant through thedrainhoseinto [3]Discharge theemptycontainer.

RADIATOR

Ci~

[4]Afterdischarging, closethedraincock.Thenfill thecooling linewiththemixture ofwaterandcleaningsolvent (radiator cleaner). theengine at a speedslightly faster than [5]Operate idlingto raisethecoolanttemperature to 80°C (176°F)or morewithinwhiterangeon thethermometerfor coolanttemperature.

Then,operate theenginefor approximately 10 minutes. draincock.

[6]Stoptheengineandopentheradiator Flushtheradiator withtapwateruntilthewater drainingbecomesclean.

PW-5-14

RAIN COCK (~ACCELERATION

LEVER

J WATER TEMP 4-53

PM5-124

MAINTENANCE draincock.Filltheradiator [7]Closetheradiator with tap water in which LONG LIFE COOLANT hasbeenmixed(30%or more)up to theradiator cap.Rotate theengine fora whiletofullyrelease airfromthecooling system.

2000Hr

Dispose of allhazardous wastein accordance with government environmental regulations.

[8]Stopthe engine.Checkthe coolantlevel(the reservetankwaterlevelshouldbe betweenFULL andLOW).Referto page3-3.Makesurelevelis tospecifications.

[9]Afterchecking forleakage, closetheengine guard. ~ RADIATOR NOTE: When the "LongLifeCoolant"is not used, replacethecoolant twotimesa yearin Springand Fall.

NOTE: The following worksrequirea professional skillbecausetheyare theinspection and maintenanceinsidetheengine.Sincetheadjustment also requires special knowledge andskill,consult them withan authorized KOBELCODistributor.

B. CHECK AND ADJUSTMENT FOR VALVE CLEARANCE Thisisto correct thetimelagon theoperating timing of exhaustandintakevalves.Negligence for this servicecausesfaultssuchas outputshortage, improperexhaust gascolor,noiseandso on.

C. CHECK AND ADJUSTMENT FOR STARTER AND GENERATOR Thereis a possibility of warn-out brushand/or lackof greaselubrication on bearing.

Thisis oftheadjustment togetgoodstartability and powergeneration.

PW-5-17

4-54

MAI NTE NANCE 4.20 2000-HOUR INSPECTION AND MAINTENANCE Thoroughlyread and understandthe section, SAFETY PRECAUTIONS of this MANUAL before operating or servicing themachine.

Perform together with8 to 1000-hour inspection and maintenance.

A. OIL CHANGE IN HYDRAULIC OIL TANK AND CLEANING OF SUCTION STRAINER ¸’, ,/i

¯

2000Hr WARNING BE CAUTIOUS OF HOT FLUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHES, AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.

WARNING

Danger of highly pressurized fluidwithhightemperatureexists inthehydraulic oiltankjustafterthemachineoperation.

Do notstartthefluidchange immediately.

Startitafterthefluid cooled down.

Whenloosening theairplug,loosenit slowlyto releaseinsidepressure.

~ DRAININGOIL RECEIVINGCONTAINER

BU~I~ET

PME-4-58

Container toreceive discharged fluid¯ 40 liter(10.6gal)or morecapacity Volume tobefilled in¯ 37liter (9.8gal) [1]Slewthe machineso thatthe drainplugon the hydraulic oil tankcomesto midwaybetweenthe bothcrawlers. oil [2]Removethe undercoverunderthehydraulic tank. to page4-50Items[2]through [4],pro[3]Referring ceedthe workin accordance withthe sameprocedures. inside pressure fromhydraulic oil [4]Afterreleasing tank, remove theplug(4)ofoilfilling portwith wrench. pump,discharge theoilfrom [5]Usingan oilsuction theoilfilling port(F)intoa container toreceive thedrained oil. oilin thetankis drained fromthe [6]Theremaining drainplug(1).Setup a container to receive the drained oilunderthedrainplugon thebottomof hydraulic oiltank.Thenremovethe drainplug witha spanner (27mm)to drainup theremaining oil.

[7]ChecktheO-ring(5)foranyscores or otherdamagesandreplace it witha newone,if necessary.

NOTE¯ Whenloosening thedrainplug(1).payattentionnotto pourthefluidoveryourself.

4-55

PW-5-15

OIL FILLING PORT~o ~ ~,)~..jri

MAINTENANCE

2000Hr

oil,screwthedrain plug(1)intothe [8]Afterdraining hydraulic oiltank.

Tightening torque: 7.5+0.5 kgf.m(54.2+1.1 Ibf.ft) Thenremovethesuction strainer builtin thehydraulic oiltankforchecking.

[9]Removedirtadheredon thesuctionstrainer (6) andwashitwithcleanlight oilorwashoil.Ifdamageof thesuction strainer (6)is found, exchange itwitha newone.

[10]Checkthebottomof thestrainer (6)andthe ring(7).If wearor damage is found, exchange it.

PW-5-18

[11]Insert thesuction strainer (6)forinstallation.

[12]Supplythespecified amount of hydraulic fluidto thehydraulic oiltankaccording totheitem"Recommended OilViscosity and OilChangeVolume."

[13]Install thecover(4)withthecapscrews (2) thelockwashers (3).

Tightening torque: 2.4+0.20 kgf.m(5.3+0.4 Ibf.ft)

2 3

4 ,~<<

[14]Install theundercoverin thenormal position.

[15]Afterstarting theengine to continue running for several (fiveto seven) minutes, actuate eachcylinderandperform slewing operation.

Thenreturn themachine to theposture ofthehydraulic oillevel inspection, stoptheengine andchecktheoillevel.

If theamount of oilisinsufficient, replenish the oil.

PW5-132

4-56

MAINTENANCE

2000Hr

B. CLEANING LINE FILTER OF PILOT VALVE AND IN-LINE FILTER OF SOLENOID VALVE

¯ Thehydraulic lineis always pressurized.

Do not carryout any checkand servicing before releasing theinsidepressure. ¯Torelease inside pressure in thehydraulic oiltank, loosen theairplugslowly withcare. ¯Makesureto contain anyspillage to avoidfire.

PILOT VALVE

0 - RING

The(P)portsof rightandleftpilotvalves andsolenoidvalveareequipped withconnector withfilter.

Dust,etc.thatadheres onthefilter willdecrease oil flow.If dust,etcenterin thevalveit may cause trouble.

Takeoutandcleanfilter, periodically.

(A)

to firmlevelground, placethe [1]Movethemachine attachment intheoilcheckposition, andstopthe engine.

[2]Carryouttheairreleasing forthehydraulic line referring to page4-13.

(c) (c)

rJ PAE-4-49

[3]Loosen2 bolts(C)on the operating boxto removethecover.

[4]Disconnect thehose(A)connected to "P port" thepilotvalveatfirst, thenremove theelbow(B).

Aftertheremoval, puta blinding plugto thebore toprevent itfrominvasion of foreign materials.

[5]Dusttendsto accumulate on theinsideelbow(B) (dented portion).

Makesuretoproperly cleanparts to avoidcontamination (projected portion).

O - RING

t

FILTER~

PAE-4-50

fordamages, andreplace it with [6]ChecktheO-ring a new one,if damaged.

[7]After cleaning, install ittotheoriginal position in reverse orderof theabove[3]and[4].Referto page4-11forthetightening torque fortheadapter hose.

Thenthein-line filter ofsolenoid valve is removed forcleaning.

. FLOOR MAT

2"LOOR COVER

[8]Remove thefloormatandfloorplate.

SOLENOID VALVE f/~

4-57

-4-51

MAINTENANCE

2000Hr

[9]Afterdisconnecting thehose,removetheinline filterassembly fromtheteeconnected to thesolenoid valve.

Plugtheoilholesoftheteeandthe hoseaftertheremoval.

[10]Afterremoving the caseandthe nipple, remove thestrainer witha flatscrewdriver.

/ 1

[11]Blowoffthestrainer forcleaning withlight oilor compressed air.Alsocleaninside thecase.Check theO-ring, andexchange it if damageis found.

[12] After installing thestrainer tothenipple witha flat screwdriver, assemble thestrainer intheinline filtercase.

Tightening torque: 6 - 8 kgf-m(43- 58Ibf-ft) [13]Remove theplug,install theinline filter assembly to theteeof thesolenoid valve, andconnect the hose.

4-58

2 3

4 5 6 PM5-137

1 2 3

CASE STRAINER LABEL

4 5 6

O-RING NIPPLE O-RING

MAINTENANCE C. OIL CHANGE FOR TRAVEL REDUCTION UNIT

2000Hr

SPEED

¯Theoilis veryhotjustafterthemachine operation.

Starttheservicing aftergetting downtheoiltemperature. ¯ Remaining someresidualpressurein the travel motormaycauseflyingoutof plugor spouting out ofoilatloosening theplug.

Slowlyloosentheplugwithcare.

Container to receive discharged oil¯ 1000cc (61cu.in)or morecapacity Oilvolume to fillin¯ 750cc (46cu.iin) --LH/RH each Changetheoilat 500hoursoperation forthefirst use of new machine.

Set the machineon a levelgroundso thatthe DRAIN(discharge) port(1)comesjustto the tom.

3L 3

1 PW-5-10

undertheDRAINport(1) [2]Providea container receive thedischarged oil.

[3]Slowlyremovethe plugof LEVEL(charge)port (2)witha hexagonal wrenchkey.

Thenremovetheplugof DRAINport(1) to discharge oilintothecontainer. tapeon thethreadof plugof DRAIN [4]Applysealing port(1),andsecurely tighten it.

[5] Slowly fillin oilthrough theLEVELport(2),up overflowing of oilfromLEVEL(charge) port(3).

See page 4-7 LUBRICANT, FUEL & COOLANT SPECIFICATIONS for the appliedgearoil.

PW-5-11

Applysealing tapeon thethreadof plugof LEVEL [6] port(2),andsecurely tighten it.

Thoroughly wipeoffoilspilled over.

[7]Ensureno oil leakagestravelingthe machine slowly.

NOTE" Checkthewasteoil.If anymetalparticles are mixedin it, consult it withan authorized KOBELCO Distributor.

PW-5-12

4-59

MAINTENANCE

2000Hr

D. GEAR OIL CHANGE FOR LOWER ROLLER AND IDLER

WARNING Highly pressurized greaseis contained in thegrease cylinder of truckspring.

Whenloosening thegrease nipple forthetension adjustment of crawler shoesor disassembling, gradually loosenthe greasenipple withinoneturnto slowlyreleasethe pressurized grease PA-4-57

Thelowerrollerand idlerhaveto be removed from thecrawler frameto changethegearoilforeachof them.Thefollowing is to describe theprocedures to remove/reinstall, andthegearoilchange foreachof them.Referto page4-7fortheoilandgreaseto be usedand required volume.

A B C

Idler IdlerAdjuster Shoeslide

D E F

Rubbercrawler shoe Lowerroller Crawlerframe

1. LOWER ROLLER [1]Loosenthe rubbercrawlershoeof the sideto changethegearoilreferring to page4-20.

[2]Thefixingcapscrews (1)of lowerrolleris a bit loosened in advance. (aroundone turn) uptheengine, andliftuptheoilfilling sideof [3]Start the machine,with boom and arm gettingdown thebacksideof bucketto theground. themachine witha safetysupport, etc., [4]Support thenstoptheengine.

~:ii:i :i ~i~i;~ ~~~.~:~!:~.~ ~!:~! !~:’-;.’~$!.~:!.-." :.’~!i:i~ ~!~i."..~!~ PMJ-1-31

[5] Removethe capscrews (1)withwashers(2)which areprovided toinstall thelower roller tothecrawler frameat twopositions of inside andoutside.

Then removethelowerroller(3).

Removethe feedingportplug(4)withthehex[6] agonalwrenchkey,anddischarge thestalegear oil. volume (60ccor 3.7cu.in) [7]Fillin theprescribed gearoilthrough thefeeding port. tapeto threadon theplug(4),and [8]Applysealing securely tighten it.Throughly wipeoffoiladhered to periphery.

4-60

,,

I1 _

(4)

/ _ (2))(1

MAI NTE NANCE 2000Hr [9] ApplyLocktight # 262to threadon thecapscrews (1),andtemporarily install thelower roller (3) thecrawler frame.

[10]Removethe safetysupportwhichsupportsthe machine to get downthemachineto theground, thentighten up thecapscrew (1).

Tightening torque : 18.5_+0.2kgf.m(134 + 1 Ibf.ft)

(R)

(s)

[11]Againliftup themachine to adjustthecrawler shoetension referring to page4-18.

~

23.5mm (0.93in)

PME-4-102

NOTE: Thecollars(5)are available for therubber and steelcrawler shoesby changing theinstalling direction.

(R) ; Rubbercrawlershoe Fitthecollar (5)to theframedirecting thegroove to lowerside.

(S); Steelcrawler shoe Fitthecollar (5)totheframedirecting thegrooveto upperside.

4-61

MAINTENANCE

2000Hr

2. IDLER Forthegearoilchangeof idler,therubbercrawler shoeof the changing sidehas to be removed.

Theremovalandinstallation of therubbercrawler shoerequire toliftup onesideof themachine, Itis quitedangerous if themachine is erroneously fallen down.Neveroperatethe machineexceptthe work forrubbercrawler shoe.

I I

GREASING POINTS shoereferring to page [1]Removetherubbercrawler 4-16.Makesureto applythesafetysupport, etc.

Stoptheengine.

(1)andidler adjuster (2)from [2]Pullofftheidler crawler frame.

Weight ofIdler+ IdlerAdjuster = approx.

22 kg (49Ib)

(6)

I

portplug(3)witha hexago[3]Removethe feeding nalwrench keyto discharge thestalegearoil.

[4]Fillin prescribed volume (30ccor1.8cu.in) ofgear oilthrough feeding port.

[5] Applysealing tapeto threadon theplug(3),and securely tighten it.Throughly wipeoffoiladhered to periphery.

IDLER (3

faceon thepiston(4) [6]Applygreaseto thesliding andcylinder (5)oftheidleradjuster (2).

[7]Install theidler sothatthefeeding portplug(3) idlerandthegreasenipple(6)of idleradjuster arefacing tooutside. therubbercrawler shoereferring to page [8]Install 4-17.

PAE-4-60

on therubbercrawler shoere[9]Adjustthetension ferring to page4-18.

Afterconfirming theengagement of rubbercrawler shoewiththeidlerandtheconditions fortension, getdownthemachineto thegroundremoving the safety support, etc.

4-62

MAINTENANCE

2000Hr

3. UPPER ROLLER Forthegearoilchangeof idler,therubbercrawler shoeof the changing sidehas to be removed.

[1]Afterstopping theengine, ensure thatthemachine is in a parking posture.

[2]Loosentherubbercrawler shoeof thesidewhere gearoilto be changed according to page4-20.

iiiiiiii!iiii!iiii iiiiiii!i!i i, iiii!iiiiii! i!iiiiiiiiiiiiiiiiiiiii iiiili! ’....

[3]Raisetheshoewitha hydraulic jack.

PR-4-117

[4]Removethenuts(2)andthecapscrews (3)of support partfixing theshaft oftheupper roller (1), andremove thisroller.

UPPER ROLLER /

[5]Removetheoilsupplyportplug(4)withan Allen wrench, anddrainoldgearoil.

® [6]Supplythespecified amount(45 cc)of gearoil through theoilsupply port.

-

I

it se[7]Windsealtapeon theplug(4)andtighten curely.

Wipeoffoiladhered aroundtheplug.

Install theroller in reverse orderoftheremoval.

[8] Afterapplyingthreadlockpaste(ThreeBond #1324)on threadof thecapscrews (3),tighten thescrews.

Tightening torque: 6.7+0.7 kgf.m(48+5Ibf.ft)

4-63

I PR-4-118

MAINTENANCE E. REPLACEMENT OF GREASE IN SLEWING GREASE BATH Ifabitwateris mixedin grease, it maybecome muddy intowhitecolor.Whensuchmachine workas immersingin water closely totheslewing bearing isrepeated, grease intheslewing bearing as wellas inthegrease bathmaybe deteriorated.

The deteriorated greasemay causedamageson the piniongearof slewing motorandinternal gearsof slewingbearing.Consultwithan authorized KOBELCODistributor forthejudgement forthereplacementof grease.

NOTE: The following worksrequirea professional skillbecausetheyarethe inspection andmaintenancefor insidethe engine.Sincethe adjustment alsorequires special knowledge andskill,consult themwithan authorized KOBELCODistributor.

F.

CHECK AND ADJUSTMENT FOR FUEL INJECTION TIMING Thisistoadjust thefuelinjection timing to optimize theengineperformance.

G. CHECK AND ADJUSTMENT FOR CONTACT SURFACE OF INTAKE AND EXHAUST VALVE Thisis to ensurethegas-tightness on theexhaust and intakevalvesto optimizetheengineperformance.

4-64

2000Hr

¯ ~:~--------c~SURFACF\~~/J, SLEWING

RIVER_7 \....

BED \

~

’/.7/ BEARING PWJ-3-28

MAINTENANCE MACHINE

MODEL

:

ITEM

SERIAL OK

InspectionMaintenanceCheck List

NO.

MACHINE

MAINT. PERFORMED

ITEM

OK

ENGINE OIL LEVEL

SLEWING REDUCTION OIL

ENGINE COOLANT LEVEL

SLEWING RING GEAR

CHECK FOR FLUID LEAKS

GREASE BATH LEVEL

CHECK BELT TENSION

SLEWING RING PINION

CHECK FUEL LEVEL

SLEWING RING SEAL

DRAIN WATER SEPARATOR

SWIVEL JOINT SEALS

CHECK AIR CLEANER

DRAIN WATER FROM BATH

CHECK ENGINE ELECTRICAL

GREASE SLEWING RING

DRAIN WATER FROM FUEL

CHANGE GREASE BATH

CHANGE ENGINE OIL

CHECK BOLTS/HARDWARE

CHANGE OIL FILTER

CHECK LINES FOR DAMAGE

CHANGE FUEL FILTER

CHECK STEPS

CHANGE WATER SEPARATOR

CHECK FRAME STRUCTURE

CHECK AIR INTAKEINDICATOR

CHECK CRAWLERS

CHECK FAN ASSEMBLY

CHECK SPROCKET

CHECK BELT TENSIONER

CHECK IDLER WEAR

CLEAN RADIATOR

CHECK ROLLER WEAR

CHANGE

CHECK CRAWLER TENSION

ENGINE COOLANT

HOURS

: MAINT. PERFORMED

WEAR

AIR CLEANER ELEMENTS

ADJUST CRAWLER TENSION

ADJUST VALVE CLEARANCE

TRAVEL REDUCTION CHECK

HYDRAULIC OIL LEVEL

BOOM & ARM

CHECK HYD FUNCTIONS

BUCKET TEETH

CHECK FOR OIL LEAKS

SIDE CUTTERS

CHECK HOSES/PIPINGS

GREASE BOOM PINS

CLEAN SUCTION SCREEN

GREASE ARM PINS

CHANGE RETURN FILTER

GREASE BUCKET PINS

PILOT MANIFOLD FILTER

I GREASE SWING PIN

CHANGE HYDRAULIC OIL

GREASE DOZER PIN

CLEAN HYDRAULIC TANK

CHECK COOLANT ADDITIVE

INSPECT ALL WIRING

CHECK CRAWLER

SHOE

BATTERY ELECTROLYTE BATTERY SERVICE HYD. FUNCTION OPERATION CHECK SWITCHES CHECK WARNING LIGHTS CHECK

HORN

CHECK DISPLAY MONITOR Theseiteminclude non-equipped partsby the machine specification.

MECHANIC : SIGNATURE :

4-65

DATE :

MAINTENANCE NOTES: .....................................................

4-66

TRANSPORTATION

Table

of Contents Page No.

TRANSPORTATION ...............................................................................

5-2 A.WHENPREPARING TRANSPORTATION PLANS ................................................................

5-2 B.LOADING/UNLOADING THEMACHINE ......................................................................

5-2 C.SECURING THEMACHINE ............................................................................

5-3 D.LIFTING PROCEDURES FORTHEMACHINE COMPLETE .........................................................

5-4

5-1

TRANSPORTATION 5 TRANSPORTATION A. WHEN PREPARING TRANSPORTATION PLANS ¯ Before preparing to transport themachine, referto the Section6. SPECIFICATIONS and checkthe totalweight, height, width,length, traveling speed, groundpressure,etc. ¯ Surveythe widthof roads,bridges, roadsurface conditions andtraffic conditions fortransportation. ¯ Obtainany permitsrequiredfrompropergovernmentagencies forthemachinetransportation.

B. LOADING/UNLOADING

THE MACHINE

¯Slowspeedtraveling is necessity to loadandunloadthe machine. ¯ It is dangerous to usetheattachment forloading and unloading themachine.

Do nottakesuchmanner. ¯Do notoperate otheroperating levers thanthetravelingleveron thegangboard. ¯ Payattention tothesudden transferring ofthecenterof gravity of themachine on theborder between thetruck/trailer andthegangboard.

USE OF GANGBOARD RefertolPage 1-381for cautions at loading/unloading the machine.

USE OF PLATFORM OR EARTH BANKING (raising the [1]Makethewidthof theearthbanking groundlevel)enoughto themachinewidth.

[2]Makethe earthbankingstrongenoughin order notto turnoverthemachine duringloading/unloadingdue to brokensideslopeof the earth banking.

If necessary, providesomesupporting poststo reinforce bothsideof thebanking. or banking mustcorre[3]Theheightof theplatform spondtothatof thebaseof truck/trailer. climbup to thetruck/ [4]At loadingthe machine, trailer fromfrontendof themachine forthecase of themachinewithattachment, and fromback end forthemachinewithout attachment. at theprescribed position on the [5]Setthemachine truck/trailer.

5-2

15°or less PAE-5-1

TRANSPORTATION C. SECURING THE MACHINE Afterthemachine is loadedandpositioned, fixthe machineby thefollowing procedures.

[1]Getdownthedozer.

OVERALL LENGTH

,._1

then [2]Fullyextendthebucketand armcylinders, slowlygetdownthe boom.

NOTE: To preventthe bucketcylinder fromdamages duringtransport, applya woodenblockto the edgeof bucket linkin ordernotto getdownit tothefloor. lockleverandsettothe"LOCK" [1]Pullupthesafety position.

TurnOFFallswitches andpulloutthestarter key.

[2] Lockallthe capsandthe door(CABSPEC.).

[3]Applytheblocksto boththefrontandrearof the crawler andfixthemwitha wireropeofsufficient strength.

Thiswillprevent themachine frommovingforward/backward or rolling dueto vibration fromthetruck/trailer.

PAD FOR ~ EDGE ~

~ "

’

I"’

PAD

FOR

~EDGE

PAE-1-28

5-3

TRANSPORTATION D. LIFTING PROCEDURES COMPLETE

FOR THE MACHINE

¯Thewireropesto be usedforlifting themachine should havesufficient strength against themachine weight. ¯Improper lifting methodand/orropingmannermight causea movement or slipof themachine whileit is lifted up,resulting in serious injury or damages on the machine. ¯ Do not imposea loadsuddenlyon thewireropes andslings. ¯Whenthelifting workis carried outin cooperation withpluralpersons, makesureto checkeverysituationswithexchanging signals witheachother. ¯During thelifting work,keepanypersons awayfrom aroundtheliftingmachine, especially underthe machine.

A: SK30SR-2 B: SK35SR-2 [CANOPY] LIFTING ANGLE

CABLE O14 A: 2300mm x 1 Q"rY ~. B: 2200mm x 1 Q"W

CABLE ~14 A.B:4400ram x 2 Q’TY

Carryoutthelifting workata levelground. eachoperating leverto takethema[1]Manipulate chinea position as shownin thefigure.

[2]Operatethe boomswingpedalto facethe boom direct front. andmakethesafetylocklever [3]Stoptheengine, to "LOCKED" position.

Thentakeoffthemachine afterensuring forno abnormalities aroundthe operators seat.

[4]Install shackles tobothbores(C)provided atboth endsof thedozerblade,andputthewireropes on them.

[5]Putthewireropesonthe(D)portion of theboom.

WEIGHT A:3,060kg(6.7501b) B:3,570kg(7,8701b)

A:50mm B:23mm PWA-5-2

A: SK30SR-2 B: SK35SR-2 [CAB] LIFTING ANGLE

CABLE O14 A: 2600mm x 1 Q’TY B: 2200mm x 1

Ifanyportions ofthewireropesdirectly gettouch [6] withthe machinewhenthe wireropesare put up, protectthe machinefromdamagesby means of applying a woodenpieceor ragbetween them. liftthemachine to ensure thebalance, [7]Slightly thenliftup themachine.

WEIGHT A:3,130 kg(6,900 Ib) B: 3,640kg(8,03OIb)

A: 50 mm B: 23 mm PWA-5-3

5,-4

SPECIFICATIONS

Table

of Contents Page No.

6.1 GENERAL SPECIFICATIONS ..........................................................................

6-2 A. MACHINE DIMENSIONS .............................................................................

6-2 B. ATTACHMENT WORKING RANGES ........................................................................

6-4 C. BOOM WITH ARMCYLINDER ..........................................................................

6-5 D. ARM&STANDARD BUCKET. ..........................................................................

6-5 E. ARM .....................................................................................

6-5 F. STANDARD BUCKET (Reference Only) ....................................................................

6-5 G. DOZER ....................................................................................

6-,5 H. CRAWLER SHOE ................................................................................

6-6 I. PERFORMANCE SPECIFICATIONS .......................................................................

6-7 1.SPEEDAND GRADEABILITY ..........................................................................

6-7 2.SIDE DIGGING &DOZER ...........................................................................

6-7 3.ENGINE ...................................................................................

6-7 4.HYDRAULIC COMPONENTS ...........................................................................

6-7 J.MACHINE & COMPONENTS WEIGHT .......................................................................

6-8

6-1

SPECIFICATIONS 6.1 GENERAL SPECIFICATIONS A. MACHINE DIMENSIONS A-1 SK30SR-2 [CANOPY]

Unit¯ mm(ft.in)

o

4440(14’6.8") 1810(5’1113") 1520(4’11 8")

---- 775(2’6.5"yl

= i

//, t1I£’1 ~r

(Do

.8’ PWA~-I

[CAB]

-g-.

~o ~ 1520(4’11.8") .

4440(14’6 8’~

" i 810(5,113,D !330(4’4 4") ~’1

4

~_775(2’65")

300

1250(4’1.2") 1550(5’1 0") 2OOO 2370(719 3’)

6-2

PWA-6-2

SPECIFICATIONS A-2 SK35SR-2

Unit ¯ mm(if.in)

0

co~

[CANOPY]

4720(15’5.8") 1520(4’11.8")

I 300 (11.8’",

151o(4’11.4~

q ~_ ,_

17005’69") 2150(7’0.6") 2580(8’5.6")

_

PXA.-6-1

[CAB]

r

o,g ~, <

4720(15’5.8") < 1890(6’2.4’i).__

1520(4’11.8") ~,

’ll’lli

’ - r-

300 <

1700(5’6.9"

6-3

1510{4’11.4~) 1700(5’6.9") -2150(7’0.6") 2580(8’5.6")

PXA-6-2

SPECIFICATIONS B. ATTACHMENT [CANOPY/CAB]

WORKING

RANGES

A

I

K

L

m

PWA-6-3

~Item

Model chment Arm

SK30SR-2

Unit" I mm(ft.in SK35SR-2

1,200 (3’11.2")

1,320 (4’4.0")

0.09m 3 (0.118cu.yd)

0.11m 3 (0.144cu.yd) 5,180(16’11.9")

A

Bucket Max.digging reach

A,

Max.digging reachat groundlevel

4,920(16’1.7") 4,790(15’8.6")

B C D E F G H J K L X Y

Max.diggingdepth

2,830(9’ 3.4")

3,100(10’2.0")

Max.digging height

4,500(14’9.1")

4,530(14’10.3")

Max. dumpingclearance

3,160(10’4.4")

3,220(10’6.8")

Min. dumpingclearance

1,230(4’ 0.4")

Max.vertical walldigging depth

1,260(4’1.6") 2,170(7’1.4")

Min.frontslewradius

2,140(7’0.3")

2,310(7’ 6.9")

Heightatmin.slewradius

3,450(11’3.8")

3,540(11’7.4")

8-feet leveldigging depth

2,320(7’7.3")

2,610(8’ 6.8")

Horizontal digging Stroke strokeat groundlevelMinimum

2,150(7’0.6") 1,640(5’4.6")

2,390(7’10.1") 1,660(5’ 5.4")

Above

305 (1’ 0.0")

330 (1’1.0")

Below

390 (1’ 3.4")

390 (1’ 3.4")

Dozerstrokes

6-4

5,060(16’7.2")

2,320(7’ 7.3")

SPECIFICATIONS C. BOOM

WITH

ARM CYLINDER

t PA-6-4

Model

SK30SR-2

SK35SR-2

2,430X 820 X 255 2,600X 820 X 255 (7’11.7") (2’8.3")(10.0") (8’6.4") (2’8.3") (10.0") Weightw/Armcyl.kg(Ib) 190 (419) 220(485) L X H X W mm(ft.in)

D. ARM & STANDARD

BUCKET

PAE-6.-5

Model

SK30SR-2

SK35SR-2

2,190X 470 X 500 2,330X 470 X 600 (7’2.2") (1’6.5") (1’7.7")(7’7.7") (1’6.5") (1’11.6") 195(430) 215 (474)

L X H X W mm(ft.in) Weightkg(Ib)

E. ARM

PAE-6-6

Model

SK30SR-2

1,550X 400 X 240 1,690X 400 X 240 (5’1.0") (1’3.7") (9.4") (5’6.5") (1’3.7")(9.4") 105 (232) 125 (276)

L X H X W mm(ft-in) Weightkg(Ib)

F. STANDARD

SK35SR-2

BUCKET

Model Heapedcapacitym3(cu.yd) L X H X W mm(in) Weightkg(Ib)

SK30SR-2 SK35SR-2 0.11(0.14) 0.09(0.12) 640 X 620 X 500 640 X 620 X 600 (2’1.2") (2’0.4") (1’7.7") (2’1.2") (2’0.4")(1’11.6") 88 (194) 91 (201)

PA-6-7

G. DOZER w/ocylinder weight Model

SK30SR-2

SK35SR-2 PA-6-8

1,060X 320 X 1,550 1,190X 320 X 1,700 L X H X W ; Ret/Expmm(in) (3’5.7") (1’0.6")(5’1.0") (3’10.9") (1’0.6")(5’6.9") Weightkg(Ib) 124(273) 142(313)

6-5

SPECIFICATIONS H. CRAWLER

SHOE

Type

Model

width Shoe width mm(in) TotalCrawler mm(ft, in)

GroundPressure kgf/cm2 (psi) CANOPY

CAB

Rubbershoe SK30SR-2

300(11.8)

1,55o (5’ 1.o") 0.29(4.1) 0.31(4.4)

SK35SR-2

300 (11.8)

1,700 (5’6.9")

SK30SR-2

300(11.8)

1,55o (5’1.o")0.31(4.4) 0.32(4.6)

SK35SR-2

300(11.8)

1,700 (5’6.9")

0.31(4.4) 0.32(4.6)

PA-6-3

Steelshoe(Option)

Type

Model

0.33(4.7) 0.34(4.9)

Outerwidthmm (in) Heaped Number Weight capacity withside without sideoftooth kg(Ib) Remarks m3 (cu.yd) cutter cutter

Back hoe bucket SK30SR-2 0.09(0.118)

500 430 (1’7.7") (1’4.9")

88 (194)

I

,/

I

Standard size

~t

530 SK35SR-2 0.11(0.144) 600 (I’11.6") (1’8.9")

6-6

91 (201)

SPECIFICATIONS I. PERFORMANCE

SPECIFICATIONS

1. SPEED AND GRADEABILITY SK30SR-2 SK35SR-2 Rubbercrawlershoe Rubbercrawlershoe 9.0 rpm 8.6 rpm Low(1st) High(2nd) Low(1st) High(2nd) 2.6km/h(1.6mph)4.5km/h(2.8mph)2.3km/h(1.4mph)4.1km/h(2.5mph) % (degree) 58 % (30 °) 58 % (30 °) Model

Item SlewingSpeed TravelSpeed Gradeability

2. SIDE DIGGING & DOZER Type

Boomswingby hydraulic cylinder

Boomswingby hydraulic cylinder

CANOPY:80 ° ° / CAB:70 305/ 390(12.0/ 15.4)

CANOPY:80 ° ° / CAB:70 330/ 390(13.0/ 15.4)

IRight

Boom SwingAnglet

/Left

Stroke ofDozer(above/below) mm(in)

3. ENGINE Model YANMAR 3TNE82A - EYBC YANMAR 3TNE82A - EYBD Type Water-cooled, 4-cycle typeSwirlchambertypedieselengine Number of cylinders-Bore x Stroke 3 - 82mmX 84mm(3.23inX 3.31in) TotalDisplacement 1.33liters (81.1 cu.in) OutputRating 23PS/ 2,300rpm {16.9kW/ 2,300min 1} 1} 24PS/ 2,400rpm {17.7kW/ 2,400min Maximum Torque 8.1kgf.m/ 1,400rpm {591bf.ft/1,400rpm} 8.1kgf.m/ 1,500rpm {591bf.ft/1,500rpm} Starting Motor 12V/1.2 kW Generator 12V/ 40 A

4. HYDRAULIC

COMPONENTS

HydraulicPump Hydraulic Motor Hydraulic Motor w/Reducer (Travel) ControlValve

Variable displacement axialpiston+ gearpump Axialpiston 2-Axial piston,2-Speed motor 10-spool multiple control valve

Cylinder(Boom,Arm,Swing, Bucket,Dozer,Framewidth)

Doubleactioncylinder

Return Filter

Safety valvecontaining/Filter Type(30/~)

5. NOISE LEVEL

I Sound PowerLevel

88 dB (A)

I

6-7

I

SPECIFICATIONS J. MACHINE

& COMPONENTS

MODEL COMPLETE

MACHINE

WEIGHT

SK30SR-2 CANOPY CAB

Unit; kg(Ib) SK35SR-2 CANOPY CAB

3,060(6,750)3,130(6,900)3,570(7,870)3,640(8,030)

UPPER FRAME ASSEMBLY(ASSY OF FOLLOWINGS) 1,710(3,770) 1,770(3,900) 1,950(4,300) 2,010(4,430) CANOPY / CAB 129 (284) 194 (428)’ 129 (284) 194 (428) ql UPPER FRAME 360 (794) 360 (794) ENGINE 150 (331) 150 (331) RADIATOR 41 11 (24) 11 (24) HYDRAULIC PUMP 38 (84) 38 (84) HYDRAULIC TANK 30 (66) 30 (66) FUEL TANK 24 (53) 24 (53) CONTROL VALVE 25 (55) 25 (55) SLEWING MOTOR 38 (84) 38 (84) SWING BRACKET ,I 66 (146) 66 (146) SWING CYLINDER 34 (75) 34 (75) COUNTER WEIGHT 330 (728), 560(1,230) GUARD o BONNET 82 (181) 82 (181) BOOM CYLINDER 36 (79) 40 (88) LOWER FRAME ASSEMBLY(ASSY OF FOLLOWINGS) 1,110(2,450) 1,180(2,600) LOWER FRAME ( 320 (706) 350 (772) SWIVEL JOINT 22 (49) 22 (49) SLEWING BEARING 43 (95) 43 (95) RUBBER CRAWLER SHOE 145X2(320X2 ) 15ox2_(331_x_2)_ TRAVEL MOTOR 42X2 (93X2) 42X2 (93X2) LOWER ROLLER 8X8 (18X2) < 8x8(18x8) FROMT IDLER 27X2 (60X2) 4 27X2 (60X2) SPROCKET 14X2 (31X2) 14X2(31X2) IDLER ADJUSTER 16X2 (35X2) ( 16X2(35X2) DOZER 124 (273) 140 (309) DOZER CYLINDER 21 (46) 23 (51) HOE ATTACHMENT 415 (915) 435 (959) BOOM 100 (221) 130 (287) ARM 71 (157) 75 (165) BUCKET 88 (194) 90 (198) ,t ARM CYLINDER 31 (68) 36 (79) BUCKETCYLINDER < 21 (46) 21 (46) BUCKETLINK 9 (20) 9 (20) IDLERLINK 3X2 (7X2) 3X2 (7X2), FLUIDS 82 (181)i 82 (181) HYDRAULIC OIL 43 (95) 43 (95) COOLING WATER 4 (9)) 4 (9) FUEL 32 (71) 32 (71)

6-8

TROUBLESHOOTING

Table

of Contents Page No.

7.1GENERAL TROUBLESHOOTING ...........................................................................

7-2 A.OPERATING ...................................................................................

7-2 B.TRAVEL .....................................................................................

7-2 C.HYDRAULIC ...................................................................................

7-3 D.GAUGE CLUSTER DISPLAY ............................................................................

7-3 E.ENGINE .....................................................................................

7-3

7-1

TROUBLESHOOTING 7.1 GENERAL TROUBLESHOOTING Thistroubleshooting information coversthecomponentsand systemsas described in thisMANUAL. Shouldin depthtroubleshooting, repairor replaceSYS

mentof components or adjustment of valvesbe required,contactan authorized KOBELCODistributorforassistance.

PROBLEM PROBABLE CAUSE 1.Alloperating speeds area. Lowhydraulic oillevel sloworpower islost. b.Airleaking intothesuction pipe c. Hydraulic pumpis damaged d. Pilotgearpumpis damaged e.Mainrelief valve isnotadjusted correctly

POSSIBLE REMEDY a.Fill oiltospecified level a.Tighten suction pipehose clamp orreplace hose a.Repair or replace a.Repair or replace a.Adjust or replace

f.Pilot relief valve isnotadjusted correctly a.Cylinder sealis damaged

a.Adjust orreplace a.Repair orreplace

c.Pilotvalveis damaged

a.Repair orreplace

2.A specific cylinder functions improperly or b.Control valveoroverload valvefunctions incorrectly a. Repair or replace/Remove losespower. orthere aresigns ofairinthecylinder airfrom cylinder

d.Pilot valve piping isloose 3.Thecylinder position willa.Cylinder sealisscored notholdwithoperatingb. Control valveor overload valveis damaged lever inneutral. c.Overload valveis notoperating Id.Pilotvalveisdamaged

a. Retighten a. Repair orreplace a. Repair orreplace a. Repair orreplace a. Repair orreplace

doesnotslew. a.Hydraulic nuJ 4. Machine orreplace motor(slewing) isnotworking orslewinga. Repair O gearis damaged b. Slewing bearing is damaged c.Pilot valve isnotworking d. Slewing reduction unitis damaged

a. Repair orreplace a. Repair orreplace a. Repair orreplace

e.Solenoid valve is notworking f.Control valve isnotworking g LeverlockSoI.V. isnotworking

a.Repair or replace a.Repair or replace a.Repair or replace

5.Slewing speedisslow. a.Control valve isnotworking b.Hydraulic motor(slewing) is notworking c.Hydraulic pumpis notworking d.Pilot valve isnotworking

a.Repair or replace a.Repair or replace a.Repair or replace a.Repair or replace

6.Abnormalsoundoccurs a.Insufficient lubrication of slewing gearandbearings a.Grease whenslewing. a.Repair or replace b.Pilot valve isnotworking c.Control valve is notworking 1.Machine doesnottravela. Toomuchcrawler tension smoothly. b.Dirtyor clogged crawler shoes c.Brakevalveisnotworking d.Travel reduction unitis damaged _.1 LJJ

e.Control valveisnotworking

n" I--

f. Travelmotordamaged g.Mainrelief valve pressure issetincorrectly h.Swivel jointisdamaged

poweris 2.Traveling insufficient.

a.Repair or replace a.Adjust crawler tension a. Cleancrawlers a. Repair orreplace a. Repair orreplace a. Repair orreplace a. Repair orreplace

a. Hydraulic pumpis damaged

a.Adjust orreplace a. Repair orreplace a. Repair orreplace

b. Poorengineperformance c.Mainrelief valve pressure issetincorrectly

a. Repair orreplace a. Adjust orreplace

7-2

TROUBLESHOOTING SYS

PROBLEM 2.Traveling poweris insufficient.

PROBABLE d.Lowhydraulic oillevel

CAUSE

POSSIBLE REMEDY a.Fill toproper level

e. Hydraulic motor (travel) isnotworking f. Brakevalveisnotworking g.Sealinswivel joint isscored oroilisleaking

a.Repair or replace a.Repair or replace

of hydraulic travel motorhas c.Performances deteriorated

a.Repair orreplace.

d. Unbalanced flowfromcontrol valve

a. Repair orreplace

e. Unbalanced discharge fromhydraulic pump f. Unbalanced flowfrombrakevalve

a. Repair orreplace a. Repair orreplace

g. Unbalanced flowbetween RH swiveljoints

!a.Repair or replace

a.Repair or replace 3.Machine doesnottravela. Unequal tensions on crawlers a.Adjust tension. ..J iii ina straight line. b. Setpressures of mainrelief valves unbalanced a.Adjust. > I--

(J J

1.Temperature risein the a. Oilcooler coreclogged hydraulic oiltemp. b.Engine fanbeltslipping c.Lowhydraulic oillevel d. Wrongtypehydraulic oilused

a >:E 1.Engine oilpressure is toolow.

~a.Clean a.Adjust orreplace a.Refill tospecified level a.Replace withcorrect, newoil

e. Hydraulic pumpis notworking a.Engine oillevel low

a.Repair or replace

b.Oilleaking

a.Repair & filltoproper level

a.Fill tospecified level

c.Wrong oilviscosity a.Replace withproper oil <~ 2. Abnormal risein the a. Lowcoolant a.Fill toproper level coolant temperature. b. Coolant leaking co a.Repair & filltoproper a level n," iii c. Looseradiator cap a.Tighten Io9 d. Radiator coreclogged a. Cleancooling system _J (o e. V-beltlooseor damaged a.Tighten toproper tension iii (.9 f.Rustorscale in coolant a.Flush system/fill tolevel < g.Faulty thermostat a. Replace (.9 3. Battery charge. a. Battery terminals disconnected, loose, orcorrodeda. Cleanandconnect b.Lowbattery electrolyte a. Replenish c. Slipping ofV-belt ordamaged

a. Adjust orreplace

d.Battery service lifehasrundown a. Replace 1.Starter doesnotturnor a. Battery disconnected a. Connect turnsslowly whichdoes b.Battery discharged a. Charge notstart theengine. c.Battery terminals disconnected, loose, or corrodeda. Cleanandconnect d. Groundcabledisconnected iii e.Engine oilviscosity toothick (Cold Weather) Z 2.Starter turns butenginea.Insufficient fuel doesnotstart. b.Improper starting procedure c.Airinfuel line d.Clogged fuelfilter e.Clogged aircleaner f.Airheater circuit malfunctioning 7-3

a. Connect a. Change toproper oil a.Refuel a.RefertoSection 3 a. Remove(Seepage4-15) a. Replace element a. Replaceelements a.Check circuit

TROUBLESHOOTING SYS

PROBLEM Engine tendsto stopat 3. low speed

PROBABLE a. LowidlingRPM b.Fuelfilter clogged

CAUSE

c.Aircleaner clogged d. Improper valveclearance 4. No power

a.Fuelfilter clogged b.Aircleaner clogged c. Improper valveclearance d. Loose clamps ontheairinlethose

5. Engineoverheats.

9.Engine oilpressure doesnotrise.

a. KOBELCOServiceman a. Replaceelement a. Replaceelement

e Cracked airinlethose a.Insufficient coolant

a.Refill coolant

b. Clogged radiator

a.Cleancooling components

c. V-belt to looseor damaged

a.Adjust orreplace belt a. Replace a. Replace elements a. KOBELCOServiceman a. KOBELCOServiceman a. Replace elements a. Tighten clamps

d. Cracked suction hose e.Engine oillevel istoohigh

a. Replacew/newhose a.Reduce tospecified level

a.Improper oil

a.Replace withcorrect oil

b.Oilleak

a. KOBELCOServiceman

c.Improper oilreplacement intervals

a.Changeat correct interval

d. Improper warming-up operation

a. Referto page3-10 a.Fill tospecified level

a. Lowoilvolume b.Oilleak c.Improper oilviscosity

10.Battery diesoften.

a. Replaceelement a. Replaceelements

a. KOBELCOServiceman a. Tighten clamps a. Replacehose

d.Faulty thermostat 6. Engine exhaust is black.a.Aircleaner clogged b. Improper valveclearance w 7. Poorfuelconsumption a.Fuelleak Z b.Aircleaner clogged Z w c. Looseclampson suction hose

8.Excessive oil consumption.

POSSIBLE REMEDY a. KOBELCOServiceman

a. KOBELCOServiceman a.Replace withproper oil

a.Battery terminals disconnected loose, orcorrodeda.Clean& tighten terminals b.Lowbattery electrolyte

a.Fill cells w/distilled water

c. V-belt looseor damaged

a.Adjust orreplace belt

d.Defective battery

a. Replace battery

7.4

OPTIONAL

Table

EQUIPMENT

of

Contents

Page No. 8.1 OPERATION OFHYDRAULIC BREAKER ANDNIBBLER ...........................................................

8-2 A. SELECTION OFHYDRAULIC BREAKER ANDNIBBLER ...........................................................

8-2 B. BEFORE OPERATING BREAKER ANDNIBBLER ................................................................

8-2 C. PRECAUTIONS FORIMPURITY ANDHYDRAULIC OIL...........................................................

8-2 D. OPERATION ..................................................................................

8-3 E. CONNECTION TOHYDRAULIC CIRCUIT FORATTACHMENT. ......................................................

8-3 F. SELECTOR VALVE SHIFTING PROCEDURES ..................................................................

8-4 8.2 SAFETY PRECAUTIONS .............................................................................

8-,,5 8.3 PERIODIC INSPECTION ANDMAINTENANCE INTERVAL .........................................................

8-8 A. REPLACEMENT INTERVAL ............................................................................

8-8 B. MAINTENANCE RECORD SHEET (Example) ..................................................................

8-8 C. PUMP DISCHARGE CAPACITY (For reference) ...............................................................

8-8

8-1

OPTIONAL

EQUIPMENT

8.1 OPERATION OF HYDRAULIC BREAKER AND NIBBLER A. SELECTION OF HYDRAULIC BREAKER AND NIBBLER Wheninstalling a hydraulic breaker or nibbler to themachine, selecttheoptimal breaker or nibbler taking the matters intoconsideration suchas stability, beating force, grasping force, required hydraulic oilvolume, etc.

B. BEFORE OPERATING BREAKER OR NIBBLER ¯ Consult withan authorized KOBELCO Distributor fortheadditional pipingworkandreinforcement forthearm to install thebreaker or nibbler tothemachine. ¯Whenusingthebreaker or nibbler, fullyunderstand andperusetheoperation manualof itsmanufacturer and the SAFETYPRECAUTIONS for the workmentioned in thisMANUAL,in orderto displayfullperformance of thempayingattention to damageson the machine andhydraulic breaker or nibbler.

C. PRECAUTIONS FOR IMPURITY AND HYDRAULIC OIL Whenthehydraulic breaker or nibbler is removed afteritsinstallation, applya blinding plugto thestopvalves attached on thetipof armandopenings on thehydraulic pipings forthehydraulic breaker or nibbler to prevent themfrominvasion of dust,water, etc.

Beforetheoperation, checkthelooseness on theclampswhicharefixingthepipingforattachment, andthe leakageon connections of tubesandhoses.

D. OPERATION Therearetwospecifications forthemachine, oneis single hydraulic circuit forbreaker only,andtheotheris combined hydraulic circuits forbothbreaker andnibbler.

An option pedalisprovided at leftfrontoftheoperator’s seatto operate them.

1. Operating Pedal [1]Single Hydraulic Circuit forBreaker only Release thepedallockfortheoperating pedallocatedat leftfrontofdriver’s seat,andoperate the pedal.

PedalDepressing Direction Operation LeftSide(A) Breaker isnotoperated.

Right Side(B) Breaker isoperated.

Breaker stops atreleasing pedal.

PWA-8-1

Hydraulic Circuit forBreaker andNibbler [2]Combined Release thepedallockfortheoperating pedallocatedatleftfrontof driver’s seat,andoperate the pedal. * Hydraulic BreakerOperation Operation PedalDepressing Direction LeftSide(A) Breaker isnotoperated.

Right Side(B) Breaker isoperated.

Breaker stops atreleasing pedal.

NibblerOperation PedalDepressing Direction Operation Grasping operation LeftSide(A) Right Side(B) Opening operation

8-2

Do notputfooton thepedalexceptduringoperation.If youputfooton thepedalandmistakenly stepfooton it,themachine maymovesuddenly to causea serious accident.

OPTIONAL

EQUIPMENT

2. PedalLockDevice Thisisa device to lockthepedal.

(2) Makesureto setthepedallockto "LOCK"position whilethebreaker or nibbler is notused.

CarelesscontactwithUNLOCKED positionof pedal may causesevereaccident andinjury.

LOCK (1) Position .................

(2) Position .................

UNLOCK

PWA-8-2

E. CONNECTION TO HYDRAULIC CIRCUIT FOR ATTACHMENT Connectthehydraulic circuitfor the breakerand nibbler withthefollowing procedures.

STOP VALVE

ARM

[1]RemovethePF 1/2blinding plugs(A)on pipings forstopvalves (2points ofleftandright).

Pay attentionnot to giveany damageson the blinding plugsremoved, or losethem.

(A) PLUG(PFI/2)

STOP VALVE

[2]Connect thehydraulic pipings forthebreaker and nibbler to thepositions wheretheblinding plugs areremoved at theabove[1].

NOTE : Stopvalves aretostoptheflowofhydraulic oil. ¯ LOCK:Thehydraulic oilflowis stopped. ¯ FREE: Thehydraulic oilflows. ¯Wheninstalling or removing thehydraulic breaker or nibbler, makesureto setthestopvalveat "LOCK" position andattach theblinding plugs.

NOTE: ¯The enginemustbe operated at 85% of ratedspeed whiletheworkforbreaker or nibbler. ¯ Fromtimeto time,stoptheworkfor a while,and maketheengine speedat idling to coolthehydraulic oil.

LOCK POSITION

FREE POSITION PAE-8-3

TO AELv EOTO PAE-8-4

85% __

LOW IDLING /

POS~/IIIIII~

PAE-8-5

8-3

OPTIONAL

EQUIPMENT

F.SELECTOR VALVE SHIFTING PROCEDURES Wheninstalling thehydraulic beakeror nibbler, the selector valve(1)mustbe installed tothemaincircuit.Itisnecessary to shift theselector valve toeitherofproper position.

1

NOTE : ¯ Improper shifting of the selector valvemay cause deterioration of working efficiency andlowering the workingspeedas wellas damageson the machine occasionally.

Makesuretoshifttheselector valveto theproper position. ¯Theselector valveneedsto be periodically shifted everyoneor two timesa month.

PM8-11

. SHIFTING PROCEDURES NOTE¯ To shifttheselector valve,makesureto stop the engineand lowerthe attachment to the groundmakingthe machineat stableconditions.

TOOLS

NEEDED

Select0rValve MarkPosition Tool (1)

Maincircuit Arench(width across flats 24ram)

PM8-12

A enwrench (5mm)

[1]Openthecoverof therightof themachine toidentifytheselector valve (1).

[2]Removethecapscrews withtheAllenwrench(2). position withthe [3]Turnthevalveto thespecified wrench(4).

Install thecapscrews (3)atthespecified position.

Selector valveengraving description B: Breaker; N: Nibbler (Crusher)

Selector ValveShifting Procedure Totank Totank ~_ Perform ~1-_..LL.~. j~engraving attachment

~

Tocontrol valve

When breakerused

To ~D attachment L~Tocontrolvalve

Whennibblerused PM8-13

[4]Closethecover

8,-4

OPTIONAL

EQUIPMENT

8.2 SAFETY PRECAUTIONS Thefollowing safetyprecautions shouldbe usedin conjunction withallothersafetyprecautions found in thisMANUAL.

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

A. USE FOR INTENDED PURPOSE Usetheattachment onlyforitsintended purpose.

If notusedin accordance withthemanufactures instructions,theexcessive pressure exertedon theboom, armand framestructure of the machinewillcause premature failure of thecomponents.

PMJ-8--6

B. PASSENGERS Neverallowpassengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT Whenoperating attachments thatproduce flyingdebris,itis highlyrecommended to procure andinstall protective guardson the machine andclosetheall window to protect theoperator fromflying debris.

Also theoperator andallpersonnel in thevicinity of the machineshouldwearprotective gearsuchas safety shoes,hardhat,glovesandfaceshieldor goggles.

PMJ-I-1

D. CYLINDERS Do not operateboom,arm or bucketcylindersat strokeendswhenusinga breakerattachment.

Doingthiscancauseunduestresson thecylinder rods andresultin damage.

PMJ-8-13

E. AVOID CONTINUOUS OPERATION Operate thenibbler/breaker in 30 sec.intervals.

Operation forlongerthan30 sec.at a timecancause highoiltemperatures and damagetheaccumulators, cylinder sealsand possibly pumpdamage.

PMJ-8-7

8-5

OPTIONAL

EQUIPMENT

IF. HOSE SURGE Shouldthehydraulic hosesbeginto surgeor vibrate abnormally duringoperation of a Breaker or Nibbler, immediately stopoperation andcontact an authorized KOBELCODistributor for assistance.

Thisproblem oftenis a resultof damagedaccumulators and can alsoresult invalve failure.

PMJ-8-8

G. DO NOT USE DROPPING FORCE Neverusethe dropping forceof the attachment to breakordriveobjects.

Thiswillcauseextensive damageto the attachment andmachinestructure.

PMJ-8-9

H. DO NOT USE SLEW/SWING FORCE Neveruse theslew/swing forceof the machinefor pushing or sliding objects.

Thiswillcausepremature failureof theattachment andothermachinecomponents.

)

°.

PMJ-8-10

I. DO NOT LIFT Neverusean optional attachment to liftor transport objectsor material.

Doingso can causeextensive damageto the attachment, the machinestructures or causeinjuryor deathdueto slipping or dropping of loaddueto improper attachment.

X

PA-8-1

8-6

OPTIONAL J. WORKING

EQUIPMENT

RANGES LATERAL WORK PROHIBITED

Neveroperate an optional attachment overthesides of themachine.

Onlyoperate overthefrontor rear of themachine.

The balanceon the machinebecomesunstableat theposture shownin therightsketch involving a possibility of turning overthemachine.

Nevercarryout thebreaker workwiththisposture.

NOTE : ¯ Referto thisSECTIONfor theworkwiththeother attachment thanthehydraulic breaker, too. ¯Usethereinforced armfortheworkwiththehydraulicbreaker, etc.Theuseof standard armforsuch work may causedamageson the arm.

PMJ-8-17

K. TO PRY AND BREAK FORCIBLY Do not use the breakerto pry and breakrockand concrete.

Thismay damagethe hydraulicbreaker,and also boom,armand cylinder.

I

PMJ-8-11

L. ARM IN VERTICAL POSITION Thearmshouldnotbe operated in thevertical positiontoprevent thearmcylinder fromvertical shocks.

This may damagethe rod packingand pistonand causetheoilleaking fromthosesections.

PMJ-8-12

8-7

OPTIONAL

EQUIPMENT

8.3 PERIODIC INSPECTION AND MAINTENANCE INTERVAL A. REPLACEMENT INTERVAL Contamination anddeterioration of hydraulic oilwillcausemalfunctioning of thecontrol valves, earlywear andseizure of thehydraulic pumpandconsequential failure of theentirehydraulic circuit.

Operation of breaker hastendeterioration of hydraulic oilcomparing withnormaloperation usingbucket.

Replace filters andhydraulic oil,referring tothefollowing table : Inspection / maintenance

Replacement interval Location First

2nd replacement

Hydraulic oil Hydraulic tank

Eve~ 600h

Return filterHydraulic tank

B. MAINTENANCE DATE

RECORD HRS

Regular

25h

SHEET

100h

Eve~ 200h

(EXAMPLE)

FILTER REPLACEMENT

8-8

HYD. OIL CHANGE

SPECIFICATIONS

Table

(EPA ENGINE)

of Contents Page No.

THE EPA REGULATIONS

1.ENGINE IDENTIFICATION .............................................................................

9-2

2.REQUIREMENTS ONENGINE INSTALLATION CONDITION .........................................................

9-3

3.EMISSIONS-RELATED PARTS ...........................................................................

9-3

4. MAINTENANCE SCHEDULE .............................................................................

9-3

5.EMISSION SYSTEM WARRANTY STATEMENT ..................................................................

9-4

9-1

SPECIFICATIONS (EPA ENGINE)

technicalbulletin ISB-99-017-1 Nov. 16, 1999

To ¯ All customers

THE

EPA

REGULATIONS

TheEPAregulations Fornon-road engines.

(Engines which willbe usedintheNorthAmerican market.)

Theinformation on engines to comply withtheEPARegulations forNon-road Engines arereleased andyouare kindly requested tomakeevery effort to comply withthem.

Theregulations covered Yanmar Engines of all"TNE"ENGINEMODELS. 1. ENGINEIDENTIFICATION Withtheregulations on engine emission worldwide, it hasbecome necessary to identity engines in a manner to determine which regulations theycomply with, hence. a) Emission control labelas shownbelowwhichwillcontain: ~IMPORTANT ENGINEINFORMATION"

Range> 37 kW

37 kW < Range

*Emission Control is accomplished through Engine Modification (EM-Design)

¯ Enginefamily nameas assigned

by EPAidentifying engine familygroup YYDXL2.78P4N andthisidentifies Y YDX L 2.78 P 4 N

l__

Method ofairaspiration Number of cylinders Combustion chamberdesign Displacement (liter) Non-road largeDiesel YanmarDiesel *2000ModelYear

X*:1999 Y : 2000 1 : 2001 2 : 2002 3 : 2003

b)Labellocation Thetypical location ofthislabel foreachengine isonthe"exhaust sideorintake sideofrocker armcover" or the"topof rocker armcover".

A supplement label maybeusedin certain applications forimproved visibility.

9-2

SPECIFICATIONS

(EPA ENGINE)

2. REQUIREMENTS ON ENGINE INSTALLATION CONDITION The followings arerequired fromthepointof viewof engineinstallation in orderto complywiththeEPA regulations.

Unless otherwise satisfying these, engines exhaust gasemission willnotbe withintheregulated valueof the EPARegulations for Non-road Engines.

2-1)MaximumExhaustGas Restriction shallbe 600 mm H20 or less for 2TNE68 1200 mm H20 or less for 3TNE68and 3TNE74 1560 mm H20 or less for 3TNE78A,3TNE82A,3TNE84,3TNE88 4TNE84, 4TNE88, 4TNE94, 4TNE98 and 4TNE106 600 mm H20 or less for 3TNE84T,4TNE84Tand 4TNE106T 2-2)Maximum airintakerestriction shallbe 635mm H20or lessandcleanaircleaner element eachtimewhen airintakerestriction exceeds 300mm H20at ratedpowercondition.

3. EMISSIONS-RELATED PARTS TheEPAregulates specific emissions-related partsarewarranted fortheperiodin thefollowing table.

However,ultimate purchasers areobligated to useandmaintain theenginecorrectly.

WarrantyPeriods Power Range kW (Grosspower)

Otherthan Constant-speed

Constant-speed Under3,000rpm

Range < 19 19 ~_ Range < 37

Greater thanor equalto 3,000rpm

1,500hoursor 2 years 3,000hoursor 5 years

37 ~ Range

1,500hoursor 2 years

3,000hoursor 5 years * Actualhoursor yearsof operation whichever occursfirstis applied.

Thespecific emissions-related partsare1) Fuelinjection nozzle, 2) Fuelinjection pump,3) Turbocharger.

4. MAINTENANCE SCHEDULE To maintain optimumengineperformance andcompliance withthe EPARegulations Non-roadEngines, it is necessary thatthe maintenance schedule be adheredto. Regularscheduled maintenance is a majorkeyto engineservice lifeandemissions regulations compliance.

It is of utmostimportance thatscheduled maintenance,requirements are performed on a timelybasis.

See the maintenance scheduleprovidedin the YanmarOperation Manual.

9-3

SPECIFICATIONS

(EPA ENGINE)

5. EMISSION SYSTEM WARRANTY STATEMENT U.S. EMISSIONS CONTROL WARRANTY STATEMENT YanmarDieselEngineCo.,Ltd.(Hereinafter referred to as Yanmar)warrants intialownerandeachsubsequentownerthattheengineis designed, builtandequipped so as to conform withapplicable regulations for itswarranty period.

Specific emissions-related partsand components are warranted for theperiodspecified in "3 Emissionsrelated parts" whichever comesfirst, afterthedateof delivery totheinitial owner.

If anyemission-related part is defective duringthewarranty period, thepartwillbe repaired or replaced

by Yanmar.

To maintain engineperformance andcompliance withtheregulations, theowneris responsible fortheperformanceof therequired maintenance listedin theowner’s manualduringthe warranty period.

Thisemission warranty doesnotcover: 1.Failure caused by anyofthefollowing : ¯ Abuse,neglect, improper maintenance or useof non-genuine parts. ¯ Useof fueloilandlubricating oilnotrecommended fortheengine. ¯ Improper application andinstallation.

2. Add-onor modification affecting engineemissions.

3. Incidental or consequential damage.

The complete enginewarranty statement, exceptfor emissions-related partsand components, is provided separately in the "YANMAR WARRANTY HANDBOOK".

Yours faithfully

Y. Sugita Quality Control Dept.

EngineDiv. PowerSystemOperation Div.

9-4

KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. Part Number North American English 245 E NORTH AVENUE Printed in U.S.A. CAROL STREAM, IL 60188 U.S.A

S2PW00003ZE-01

September 03 Bur