Kobelco SK130 IV SK130LC IV Hydraulic Excavator Operator's Manual PDF

OPERATOR'S MANUAL HYDRAULIC EXCAVATOR

SK130 IV SK130LC IV

Applicable: SK130 IV LPU0201 ~ Applicable: SK130LC IV YPU2001~ SK1304RMMC2-1R

04/04

Operator’s Manual

FOREWORD GENERAL ¯ This manualcontains proceduresto aid the operator gain peakperformance througheffective, economicalmachine operation and maintenance for the KOBELCO MarkIV SK130Hydraulic Excavators. ¯ Beforeoperatingthe machine,operatorsmustthoroughlyread andunderstandall Safety, OperationandMaintenance instructions foundin this manual.Failure to follow the instructionsgivenin this manual mayleadto seriousinjury to personsandor equipmentfailure. ¯ Operatorsandpersonsworkingwith this machine shouldcontinually study this manualuntil properSafety, Operation and Maintenanceproceduresare completely understood. ¯ This manualdescribesthe basic operatingtechniques.Skill is gainedas the operatorutilizes thesetechniquesand perfects themwith an actual machine. ¯ Some illustrated pictures maybe different from your machine,as technical improvement is continuous.Manuals are periodically updatedto reflect thesechanges. ¯ This manualmaynot contain attachments andoptional equipment that are available in your area. Pleasecontact an authorizedKOBELCO Distributor for any optional attachmentsrequired. ¯ Materialsandspecificationsare subjectto change withoutnotice.

PERIODICINSPECTIONS ¯ After delivery of a machine,the AuthorizedKOBELCO Distributor will makeperiodic service inspections.These inspectionswill be free of chargeto the ownerof the machine andwill be at time intervals set by KOBELCO. Contact an authorizedKOBELCO Distributor for anyServicerelated questionsnot explainedin this manual.

NOTICE ¯ Thecontentsof this manualmaynot reflect the specifications of the machine delivered. Contactan authorized KOBELCO Distributor to obtain assistancein specifications for machines equippedwith options not containedin this manual. ¯ Owingto the policy of continual improvement,changesmaybe madeby KOBELCO AMERICA, Inc. to any of its products without any obligation on the part of KOBELCO AMERICA, INC.

TABLE OF CONTENTS Section I- SAFETY PRECAUTIONS ............................................................... ...........................................

Section II- MACHINE FAMILIARIZATION ...................................................................................................

Section III- BASIC MACHINE OPERATION ................................................................................................

Section IV-MAINTENANCE ......................................................................................................................

SectionV-SPECIFICATIONS .....................................................................................................................

SectionVI-TROUBLESHOOTING ...............................................................................................................

SectionVII- ELECTRICAL SCHEMATICS ...................................................................................................

EQUIPMENT ........................................................................................................

SectionVIII- OPTIONAL Section IX-SPECIAL PROCEDURES .........................................................................................................

1-0 ~ 1-18 2-0 --,2-21 3-0 ~ 3-22 4-1 ,-,4-49 5-0 ~ 5-6 6-0 ~ 6-3 7-0 ~ 7-2 8-0 ,-,8-8 9-0 ~ 9-7

©1998 KOBELCO AMERICA, INC., Calhoun, Georgia USA.All rightsreserved.

Anyuseof editorialor pictorialcontentis stdctlyprohibited withoutexpress writtenpermission from KOBELCO AMERICA, INC., Calhoun, Georgia USA.

Section

I-SAFETY PRECAUTIONS

Table of Contents GENERAL SAFETY INFORMATION ............................................................................................................................

1-1 SAFETY PRECAUTIONS .................................................................................................................................... 1-1~ 1-3 PRE-START SAFETY ...........................................................................................................................................1-4~ 1-6 SAFETY DURING OPERATION ..........................................................................................................................

1-6~ 1-9 INSPECTION &MAINTENANCE SAFETY ........................................................................................................

1-9~ 1-11 BATTERY SAFETY ................................................................................ i .....................................................................

1-12 WARNING LABELS &DECALS ......................................................................................................................

1-13~ 1-16 PROHIBITED MACHINE OPERATION .......................................................................................................

1-17 ~ 1-18 END OFWORK SHIFT SAFETY ............................................................................................................................

1-18 I~~

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~ ~ ~ ~) ~ ~ ~ ~ ~ ~1

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFOREA’I-I’EMPTING ANY OPERATION,INSPECTIONOR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS. KOBELCOCANNOTANTICIPATE EVERYPOSSIBLE CIRCUMSTANCE THAT MIGHTINVOLVEA POTENTIALHAZARD.THE WARNINGS IN THIS PUBLICATIONAND ON THE PRODUCT ARE THEREFORE NOTALL INCLUSIVE. IF A TOOL, PROCEDURE, WORKMETHOD OR OPERATING TECHNIQUENOT SPECIFICALLYRECOMMENDED

BY KOBELCO IS USED, YOUMUSTSATISFY YOURSELF THAT IT IS SAFE FOR YOU AND OTHERS.YOUSHOULDALSO ENSURETHAT THE PRODUCTWILL NOT BE DAMAGED OR MADEUNSAFEBY THE OPERATION,LUBRICATION,MAINTENANCE AND/ORREPAIRPROCEDURESYOU CHOOSE.

1-0

Section

I-

SAFETY PRECAUTIONS c. CAUTIONIndicates a potentially hazardous situation which,if not avoided,mayresult in minor or moderate injury. It mayalso be usedto alert against possible damage to the machine andits components andis representedas follows:

1.1 GENERAL SAFETYINFORMATION

DoNotoperateor perform anymaintenance on this machine until all instructions found in this manual have beenthoroughly readandunderstood.

Improper operation or maintenance of this machine may causeaccidents andcouldresultin serious injuryor death.

Alwayskeep this manual inthe operators cab.

If it is missingor damaged, place an order with an authorized KOBELCO distributor for a replacement.

If you have any questions, please consult an authorized KOBELCO distributor.

4. it is verydifficult to forecasteverydanger that may occurduring operation.However,safety canbe ensuredby fully understanding properoperating proceduresfor this machineaccordingto methods recommendedby KOBELCO. .

1. Mostaccidents,whichoccurduringoperation,are due to neglectof precautionary measures andsafety rules.

Sufficientcareshouldbetakento avoidtheseaccidents.

Improperoperation,lubrication or maintenance servicesare very dangerous andmaycauseinjury or deathof personnel.Thereforeall precautionary measures, NOTES,DANGERS,WARNINGS and CAUTIONS containedin this manualand on the machineshouldbe read andunderstoodby all personnelbeforestarting anyworkwith or on the machine.

2. Operation,inspection, andmaintenance shouldbe carefullycarriedout, andsafetymustbegiventhe first priority. Messages of safety are indicatedwith marks¯ Thesafety informationcontainedin this manual is intendedonly to supplement safety codes,insurance requirements, local laws, rules andregulations.

3. Messages of safety appearin this manualandon the machine.

All messages of safety are identified by the words "DANGER","WARNING" and "CAUTION". a. DANGERIndicates an imminently hazardous situationwhich,if notavoided, will result in deathor seriousinjury andis represented as follows:

=

Whileoperatingthe machine,be sure to performwork with great care, so as not to damage the machine, or allow accidentsto occur.

Continue studyingthis manual until all Safety,Operation and Maintenance proceduresare completely understoodby all personsworkingwith the machine.

1.2 SAFETYPRECAUTIONS

! ane properand safe lubrication and maintenance for this machine,recommended

by KOBELCO is outlined in the OPERATORS MANUAL for this machine.

Improperperformance of lubrication or maintenanceproceduresare dangerous and couldresult in injury or death. Readandunderstand the OPERATORS MANUAL before performing any lubrication or maintenance.

Theserviceman or mechanic maybe unfamiliar with many of the systemson this machine¯This makes it important to use caution whenperformingservice work. A knowledgeof the systemand/or components is importantbefore the removalor disassembly of anycomponent.

b. WARNINGIndicates a potentially hazardous situationwhich,if not avoided,couldresult in death or seriousinjury andis represented as follows:

/ix 1-1

Because of the size of someof the machine components, the servicemanor mechanicshould checkthe weights notedin this manual.Useproperlifting procedures when removingany components.

Section

I-SAFETY

Thefollowingis a list of basicprecautions that mustalwaysbe observed.

PRECAUTIONS 8. Usesteps and grabhandleswhenmountingor dismountinga machine.Cleananymudor debris from steps, walkways or workplatformsbeforeusing. Alwaysface the machinewhenusing steps, ladders and walkways.

When it is not possibleto usethe designed accesssystem,provideladders,scaffolds, or work platformsto performsafe repair operations.

1. Readandunderstandall Warningplates and decals on the machine beforeOperating,Maintainingor Repairing this machine.

2. Alwayswearprotective glassesand protective shoes whenworkingaroundmachines.In particular, wear protective glasses whenusing hammers, punchesor drifts on anypart of the machine or attachments.

Use weldersgloves, hood/goggles, apronandthe protective clothingappropriateto the weldingjob being performed.

Donot wearloosefitting or torn clothing.

Remove all rings fromfingers, loosejewelry, confine longhair andlooseclothing beforeworkingon this machinery.

3. Disconnectthe battery anddischargecapacitorsbefore starting to workon the machine.Hanga "DoNot Operate"tag in the OperatorsCompartment.

4. If possible,make all repairs with the machine parked on a level, hardsurface.Blockthe machine so it does not roll while workingon or underthe machine.

5. Donot workon anymachine that is supportedonly by lift jacksor a hoist. Always useblocksor jack stands, capableof supportingthe machine,before performing anydisassembly.

9. Toavoidbackinjury, usea hoist whenlifting componentswhichweigh23 kg (50 Ibs) or more.Makesure all chains,hooks,slings, etc., arein goodcondition andare the correct capacity. Besure hooksare positionedcorrectly. Lifting eyesare not to beside loaded duringa lifting operation.

10.Toavoidburns,be alert for hot parts on machines whichhavejust beenstoppedandhot fluids in lines, tubes and compartments.

11. Becareful whenremovingcoverplates. Gradually backoff the last twobolts or nutslocatedat opposite endsof the coveror deviceandcarefully pry cover looseto relieve anyspringor otherpressure,before removing the last twobolts or nutscompletely.

12. Becareful whenremoving filler caps,breathersand plugs on the machine.Hold a rag over the capor plug to preventbeingsprayedor splashedby liquids underpressure.Thedangeris evengreaterif the machinehasjust beenstoppedbecausefluids can behot.

13.Alwaysusethe propertools that are in goodcondition andthat are suited for the job at hand.Besureyou understandhowto use thembefore performingany servicework.

Do not operatethis machine unlessyou have read andunderstand the instructionsin the OPERATORS MANUAL.Improper machine operationis dangerous andcouldresult in injury or death, 6. Relieveall pressure in air, oil or watersystems before anylines, fittings or related itemsare disconnected or removed.Alwaysmakesure all raised components are blockedcorrectly andbealert for possiblepressure whendisconnectingany devicefrom a system that utilizes pressure. to 7. Lowerthe bucket,blade, ripper or other implements the groundbefore performingany workOnthe machine. If this cannotbe done,makesurethe bucket, blade,ripper or other implement is blockedcorrectly to preventit fromdroppingunexpectedly.

1-2

14.Reinstall all fastenerswith the samepart number.

Do not usea lesser quality fastenerif replacements are necessary.

15. Repairswhichrequire weldingshouldbe performed onlywith the benefitof the appropriate referenceinformationandby personneladequatelytrained and knowledgeable in weldingprocedures.Makereferenceto "Techniques of Structural RepairCourse".

Determine type of metalbeingweldedandselect correct weldingprocedureandelectrodes,rods or wire to providea weldmetalstrengthequivalentat least to that of the parentmetal.Always,makesure to disconnect the negativeterminalfromthe batteries before weldingon the machine.

Section

I-SAFETY

PRECAUTIONS 22. Cautionshouldbe usedto avoid breathingdust that maybe generatedwhenhandling componentscon tainingasbestos fibers. If this dustis inhaled,it can be hazardousto your health. Components in KOBELCO products that maycontain asbestos fibers are brakepads,brakebandandlining assemblies, clutch plates andsomegaskets.Theasbestos usedin thesecomponents is usually boundin a resin or sealedin someway.Normalhandlingis not hazardous as long as airborne dust whichcontains asbestosis not generated.

16.Donot damage wiring during removaloperations.

Reinstallthe wiringso it is not damaged, norwill be damaged, in operationof the machine by contacting sharpcorners,or by rubbingagainst someobject or hot surface.Donot connectwiring to a line containingfluid.

17. Besure all protectivedevicesincluding guardsand coversareproperlyinstalled andfunctioningcorrectly beforestarting a repair. If a guardor shieldmustbe removed to performthe repair work,useextra caution andreplacethe guardor shieldafter repair is complete.

If dustwhichmaycontainasbestos is present,there are several common senseguidelinesthat shouldbe followed.

18.Looseor damaged fuel, lubricant andhydrauliclines, tubesand hosescancausefires. Donot bendor strike highpressurelines or install oneswhichhave beenbent or damaged.

Inspect lines, tubesand hosescarefully. Donot checkfor leakswith your hands.Pin hole(very small) leakscanresult in highvelocityoil stream that will beinvisible closeto the hose.This oil canpenetratethe skin andcause personalinjury. Usecardboard or paperto locate pin holeleaks.

a,

b.

d,

e,

to the correct torque. Makesure 19.Tightenconnections that all heatshields, clamps andguardsare installedcorrectly to avoidexcessive heat, vibration or rubbingagainstother parts duringoperation.Shields that protect againstoil sprayonto hot exhaustcomponents in eventof a line, tubeor seal failure must beinstalledcorrectly.

20. Donot operatea machine if anyrotating part is damagedor contactsanyother part during operation.

Anyhigh speedrotating component that has been damaged or altered should be checkedfor balance beforereusing.

21.Ontrack-typemachines, be careful whenservicing or separatingthe tracks. Chipscanfly whenremoving or installing a track pin. Wearsafetyglasses.

Trackscanunroll very quickly whenseparated.Keep awayfrom front and rear of machine.Themachine can moveunexpectedlywhenboth tracks are disengagedfrom the sprockets. Blockthe machine to preventit frommoving.

1-3

f. g. h.

Neverusecompressed air for cleaning.

Avoidbrushingor grinding of asbestos containingmaterials.

For clean up, use wet methodsor a vacuum equippedwith a high efficiency particulateair (HEPA) filter.

Useexhaustventilation on permanent machiningjobs.

Wearan approved respirator if there is no otherwayto control the dust.

Complywith applicable rules andregulations for the workplace.

Followenvironmental rules andregulations for disposalof asbestos.

Avoid areas whereasbestosparticles maybein the air.

Section

I-SAFETY

PRECAUTIONS

1.4 PRE-START SAFETY Manyfailures that occur during machineoperation or servicing result from neglecting fundamentalsafety precautions.Thefollowing safety precautionsare given to preventsuchfailures but, theyare only a part of what youmustfollow. Read,understand andfollow all safety precautions found in this manualand on the machine thoroughlybefore operatingthe machine.

A. OBSERVESAFETYPRECAUTIONS Followall safetyrules, precautions, andoperating procedures.

If there are other personneland flagmenworkingin the area, havethemobserve the specifiedsigns.

B. WEARPROTECTIVECLOTHING Wearwell-fitting safety shoes,hardhat, and workclothes, put on protectiveglasses,face shield, ear protectionandgloves.When necessary, weara reflective vest.

C,

READand UNDERSTAND THE OPERATORS MANUAL Beforeoperatingthe machine,read and understandthis operatorsmanualthoroughlyin orderto usethe machine effectively andsafely.

D=

KEEPOPERATORS MANUAL IN MACHINECAB Keepthis manualin the specified storagearea locatedbehingthe OperatorsSeat for quick reference. Shouldthe OperatorsManualbecome lost or damaged, contact an authorized KOBELCO distributor to order a replacement.

E,

DO NOT MODIFYMACHINEWITHOUT PERMISSION KOBELCO is not liable for anydamage or injury arising frommodificationwithoutprior written permission from KOBELCO AMERICA, INC. Consult an authorized KOBELCO distributor before modifyingthe machine.

OBSERVEALL SAFETYPRECAUTIONS

WEARPROTECTIVECLOTHING

READMANUAL / KEEPIN MACHINECAB

u’

DO NOT MODIFYMACHINE

R PREPAREFOR EMERGENCIES Have a fire extinguisherandfirst aid kit ready for emergencies.

Knowhowto operatethe Fire Extinguisherandknowwherethe First Aid Kit is located for easyaccessin caseof emergency.

PREPAREFOR EMERGENCIES

1-4

Section

I-SAFETY

PRECAUTIONS

G. ENSURESAFETYAT THE WORKSITE Knowthe work areal Before operating the machine,carefully surveyandrecordthe geographical andgeologicalfeaturesof the worksite to preventthe machine fromfalling - or the soil fromcavingin.

H. PERFORM PRE-STARTINSPECTION Beforestarting the machine,performa PRESTART inspectionof the machine.If anyproblems are found, repair or replacedefectivecomponents immediately. DO NOTOPERATE THEMACHINE until all problem areasare properlyrepaired.

Alwayskeepthe windshield, workinglamps,and mirrorscleanfor goodvisibility.

ENGAGESAFETYLOCKBEFORELEAVING MACHINE Beforeleavingthe operator’sseat, placethe attachmentson the groundand movethe SafetyLockLeverto the "LOCKED" position. This will preventoperationof anyHydraulicControls shouldtheybe accidentallymoved.

If the lever is not set to the "LOCKED" position andhydraulic controlsare touchedaccidentally,the machine may move suddenly,resulting in seriousinjury.

ALWAYS, lower the bucket and attachments to the ground,place the Safety Lock Lever in the "LOCKED" position, stop the engineand removethe ignition key.

J. SIGNS, SIGNALS& FLAGMEN Install signson soft shouldersandgroundareas, Havea flagmandirect the operationif necessary.

Theoperatorshouldnote marksandfollow signals fromthe flagman.All personnelshouldknowthe meaning of the signs, marks,andsignals. Only oneflagmanshouldgive the signsandsignals.

K. KEEPFIRE AWAYFROMFUELANDOIL Oil, antifreeze,andespeciallyfuel arehighly flammable.Neverusefire near the machine.

Securelytightenall fuel andoil caps.Keepfuel andoil in the designated storageareas. Promptly cleanup anyall spills anddisposeof waste properly.

L. USE CAUTIONNEARNOISE If noiseis highduringoperation,hearingloss may result. Approved hearingprotectionshouldbeused if personnelwill be exposed to highnoiselevels for a longperiodof time.

WORKSlTESAFETY- KNOWTHE AREA

PRE-START INSPECTIONOF MACHIi~E

SAFETYLOCKLEVER

KEEPFIRE AWAY FROMFUEL& OIL

USE CAUTIONNEARNOISE

1-5

Section

I-SAFETY

USE GRIP BARS AND STEP

MOUNTING& DISMOUNTINGMACHINE Whengetting on and off the machine,always maintainthreepoint contactby usingthe handrails andstep. Inspectandcleanhandrails,steps, and mountingparts. Remove slippery materials, such as lubricants, andmud.Alwaysplacethe cabdoor entrance parallel to the tracksbeforestoppingthe enginefor dismounting.

M,

AVOID HOT SURFACES & AREAS Immediately after the machine is operated,the temperatureandpressureof the enginecoolant, engineoil, andhydraulicoil are veryhigh. Burns mayresult if capsare removed, or oil, water,or filters are changed undertheseconditions.Wait until the temperature goesdown,before attempting to checkfluids or change filters. .

PRECAUTIONS

MOUNTING/DISMOUNTING MACHINE

USE THE PROPEROPTIONALATTACHMENT Useonly Optional Attachments designedfor and approvedby KOBELCO. Read, understandand Followall instructions in the Manual accompanying the OptionalAttachment.Useof anyOptional Attachmentnot approvedby KOBELCO in writing, cancauseseriousinjury to personnel,damage to the machineandits components andshortenthe life of the machine.

Contactan authorized KOBELCO distributor for Optional Attachments availablefor the machine.

P. PREVENTFIRES Leakingor spilled fuel, lubricantsandHydraulic oil arefire hazards.Cleanandproperlydisposeof spills as theyoccur.Repairor replaceall leaking components to preventfire. Also, cleanthe machine regularly removing all debris to help preventfires, payparticular attentionto removal of leaves,sticks, paper,etc. Keep fire extinguisher in an accessibleareaand knowhowto usethe fire extinguishershoulda fire occur.

,,///lIllljlsl, HOT SURFACES

USE PROPERATTACHMENT

PREVENT FIRES- CLEANUP SPILLS

1.5 SAFETYDURINGOPERATION A. STARTINGENGINE Sit in the operator’sseat.

Sound the hornbeforestarting the engineto alert peoplethe machine is beingstarted.

Donot shortcircuit thestarter circuit or batteryto start the machine.This maycauseseriousinjury or causedamage the electrical system, SOUNDHORNBEFORESTARTING

1-6

Section

I-

SAFETY PRECAUTIONS

B. PASSENGERS Thisequipment is not intendedor designed for the transportationof persons.Neverallow personsto ride on the machine.

Seriousinjury or deathcan result fromallowingpassengers on or in the machine.

C. TRAVEL Make certain of the location of the TravelMotors beforeoperatingtravel controls. Sound Horn before, and useTravel Alarmwhenmovingthe machine to inform personsthat the machine is travelling. Positionthe attachment as shown in illustration beforebeginning travel. Move the machine at slowspeeds.Donot turn suddenlyon roughterrain. Avoidtravelling overobstacles.

Shouldit become necessaryto travel over an obstacle, keepthe attachmentlow to the ground andtravel at extremelyslowspeed.

NO PASSENGERS

D. SWING Makecertain the SwingAreaof machine is clear of all personsandobstaclesbeforeoperating SwingControls. SoundHornbefore swinging machine.If necessary,havea Flagman signal operatorduringoperationto helppreventinjury to personsor damage to obstacles andequipment.

KNOWTRAVELMOTORPOSITION

E. BOOM,ARM& ATTACHMENTS Give the workyouare doingyour undivided attention. Makecertain the attachment beingused is suitedfor the job at hand.Make certainof obstaclesin the workareaandoperatethe machine within thoselimits. If necessary havea Flagman signal the operatorto preventinjury to personsor damage to the machineor obstacles in the workarea.

ALWAYS PLACE ATTACHMENTS ON THE GROUNDAND LOCK THE SAFETY LEVER BEFORELEAVINGTHE CAB. F. OPERATING ON INCLINESOR SLOPES Operationof this machine on an incline or slope maycausethe machineto become unstable or unbalanced.

WorkUpandDowninclines or slopes never across. NeverSwingor Turn Machine aroundon slopes.Build a level areafor the machine to operatefrom. OperateControls carefulty to preventsuddenmovements whichmay causethe machine to slide or tip over. Usea Flagman to direct the operator.

1-7

SWINGSAFETY/USESWINGFLASHERS

©

BUILD BANKINGFOR SLOPEOPERATION

Section

I-

SAFETY PRECAUTIONS

G, WORKINGAROUNDUTILITIES If it is suspected that utility lines suchas, gas, water, phoneor electrical powerare in the work area,contactthe local utility authority for line location BEFORE beginning work in the area. Use extremecaution aroundelectrical powerlines.

Keepa sufficient distance awayfrom electrical lines during operation. SeeChart belowfor minimumdistances.

LINEVOLTAGE 0 ~ 50,000

MINIMUM DISTANCEM(FEET) 3.0M (10) ORMORE

50,000~ 200,000

4.5M (15) ORMORE

200,000~ 350,000

6.0M (20) ORMORE

350,000~ 500,000

7.5M (25) ORMORE 10.5M (35) ORMORE

500,000~ 750,000 750,000~ 1,000,000

13.5M (45) ORMORE

KEEP A SAFE DISTANCEFROMUTILITIES

H. LIFTING This machineis an excavator. Useextremecaution whenlifting or movingheavy loads. Useproper lifting equipment rated at a capacity to handlethe load. NEVERUSE BUCKETTEETHTO LIFT OR MOVE HEAVY LOADS. I.

FROZEN& SNOWCOVEREDWORKSITES Use extreme caution whenoperating the machine on frozen or snowcoveredworksites. Operateall controls slowly and cautiously to prevent sudden movementsthat maycause the machineto unexpectedlyshift, slide or move.Evenon the slightest slope, whensnowis present or workarea is frozen, a machinecan unexpectedly move.

Snowon shoulders or snowdrifts can be much deeper than expected. The machinecan easily becomeburied under such conditions. Use extreme caution while operating the machine aroundor in snow.

USE PROPERLIFTING DEVICES

FILLED OR UNSTABLE GROUND Becertain the condition of the worksite is stable and capable of supporting the machineduring operation. Donot operate attachmenttoo close to the machine. Operation of the machineon shoulders or filled areas could causethe machine to becomeunstable presenting a work hazard, Position the Travel Motorsto the rear of the machine,allowing for quick retrieval, shouldthe work area becomeunstable.

1-8

WORK ON STABLE GROUND

Section

I-SAFETY

PRECAUTIONS

RESTRICTEDWORKAREAS In worksites with limited heightandswingareas suchas tunnels, bridges,aroundelectrical power lines, otherutilities, or insidestructures,use extremecautionin keepingthe machine andits attachmenta safe distanceawayto prevent personalinjury andor equipment or structure damage.

Usea Flagman to direct the operator.

PARKINGTHE MACHINE Alwayspark the machine on a firm, level surface¯ If a firm, level surfaceis not available,blockthe tracks andlowerattachments to the groundto help prevent machinemovement.

Shouldthe machinebe parkedon a roadway,move the machine to the shoulderto allow passingof traffic¯ Alsopostreflective Warning Signsand Markersat a distancefromthe machine to safely warnmotorists¯Referto local codeandregulations regardingthe posting of workarea Warningsand Markers.

M. STABILIZEAI-rACHMENTS Stabilized all attachments removed fromthe machine to preventthe attachment falling over.

BE AWAREOF OBSTACLES

PARKINGSAFETY

1.6INSPECTION& MAINTENANCE SAFETY A. "TAG-OUT" MACHINE Beforeperformingany inspectionor maintenance procedures to the machine, fill out andpostto the operators controls a "DONOTOPERATE" tag to warnpersonsnot to start the machine.

Alsoinform the Supervisorandall operatorsthat the machine is underinspectionor maintenance andthey will be informedwhenthe machine is readyfor normal operation.

STABILIZE ATTACHMENTS WHENREMOVED

TOOLS& EQUIPMENT Usethe propertools andequipment for the task at hand.Know the properuseof the tools and equipment beforestarting anyinspectionor maintenance procedures.

PERSONALEQUIPMENT Wearwell- fitting WorkClothes,HardHat, Safety ShoesandGloves.Confinelong hair, loose clothing andremove all jewelry beforeattempting anyinspectionor maintenance procedures to this machineor attachments.

USE PROPERTOOLS

1-9

Section

I-SAFETY PRECAUTIONS

D=

STOPTHE ENGINE BE CERTAINTO TURNENGINE"OFF "AND PLACETHE SAFETYLOCKLEVERIN THE "LOCKED" (UP) POSITION before attempting any inspection or maintenance proceduresto the machine, Failure to stop enginecouldresult in seriousbodilyinjury or death.

E,

SET THE ATTACHMENT Alwaysset the machine in the HydraulicOil Check Positionbeforeattemptinganyinspectionor maintenance procedures to the machine.

If it is not possibleto put the machine in this position, securethe boom,armand attachmentsto help prevent sudden movement.ALWAYS PLACE AI"FACHMENTS ON THE GROUND ANDLOCK THE SAFETYLEVERBEFORELEAVINGTHE CAB.

F. CLEANTHE MACHINE Keepthe machine cleanandfree of debris, excess or spilled lubricants,fuel andfluids. Useapproved solvents, detergentsandwaterto clean the machine andits components on a regular basis.

Becareful not to allowwaterto reachelectrical components.

Serious damage can occur to the electrical systemby allowingwaterto reachthe electrical components.

Nevercleaninside of cab, or electrical components with pressurizedwater or steam.

STOP ENGINE/ENGAGE SAFETYLOCKLEVER

HYDRAULIC OIL CHECKPOSITION

KEEP MACHINECLEAN G. PRESSURIZED FLUIDS & LUBRICANTS AlwaysreleasepressurefromHydraulicReservoir, EngineCoolant,Fuel Systemandall systems containingpressurebefore removinganycapsor components.

Becautiousof Hot Fluids andGasses from systemson machinesthat havejust been stopped.Allowampletime for systemsto cool beforeperformingany inspection or maintenance procedures.

H. SUPPORTTHE MACHINE If it becomes necessary to raise the machine for inspection or maintenance, alwayssupportthe machineby positioning the machineas shownin the illustration andusesafetysupportsor blocks, with a sufficient capacityrating to supportthe machine, under the tracks. NEVER INSPECTOR PERFORMMAINTENANCEPROCEDURES UNDERA RAISEDMACHINETHAT IS NOT SUFFICIENTLYSUPPORTED.

(1st DESIGN) REMOVE

(2nd DESIGN)

RELEASEHYDRAULICTANKPRESSURE

SUPPORTMACHINEPROPERLY

1-10

Section

I-

SAFETY PRECAUTIONS

I. REFUELING Move the machine to a well- ventilated areafor refueling. Useonly specifiedfuel as described in the Specifications sectionof this operatorsmanual.

Immediately cleanup all spilled fuel anddispose of properly.After refuelingis complete, securely tighten FuelCap. J. HYDRAULICPRESSURE Undernormalconditions,all circuits of the HydraulicSystemare underextremepressure.

When inspectingfor leaks, usea small pieceof cardboard,woodor metalto locate leaks. Small (pinhole) leakscanbe dangerous if contactwith skin or eyesis made.Wearapprovedsafety glassesor faceshield, gloves,hardhat, safety shoesandworkclothes during all inspectionand maintenanceprocedures.

K=

TRACKSHOE TENSION Thegreaseusedto adjust the TrackShoeTension is underextremepressurein the cylinder. Use extremecautionwhenadjustingtrack shoetension to keepface, handsandlegs awayfromthe grease nipple area.Carefullyandslowly, loosenthe greasenipple whendecreasingtrack shoe tension. Neverloosengreasenipple morethan one completeturn.

L°

ELECTRICALSYSTEM Beforeperformingany inspectionor maintenance to the electrical system,or performing anywelding procedures,disconnectthe Negative(-)cables fromthe battery terminals.Notdisconnecting the Negative(-) cable could causeextensivedamage to the electrical system.

REFUELING

CHECKINGFOR HIGH PRESSURE LEAKS

USE CAUTIONWHENADJUSTINGTRACKS

M°

N=

USE APPROVED WORKLIGHTS Useonly approvedworklights whenperforming inspectionandmaintenance procedures to prevent possiblefire or explosion.Certaintypesof work lights shouldnot beuseddueto the possibility of ignition of certain flammable gassesandfluids from the machine.

DISCONNECTBATTERY NEGATIVE (-) CABLEWHEN INSPECTINGELECTRICAL OR WELDING

ELECTRICALSYSTEMPRECAUTION

DISPOSE OF WASTEPROPERLY Dispose of oils, fuel, coolant,solvents,filters, batteriesetc. according to Federal,StateandLocal codesand regulations regarding Hazardous Wastedisposal. ContactLocalauthorities for properdisposalmethods of suchmaterials.

USE PROPERLIGHTING

1-11

Section

I-SAFETY

PRECAUTIONS

1.7 BA’I-FERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wearlong sleeveshirt, gloves and approvedsafety glassesor face shield whenworking with or around batteries. Battery electrolyte (acid) will cause severeburns if allowed to makecontact with clothing, skin or eyes.

Shouldelectrolyte (acid) comein contact with clothes, skin or eyes, immediatelyremoveaffected clothing, flush area with clean water for 15 minutes and get promptmedical attention.

B=

WEAR PROTECTIVE CLOTHES

KEEP AWAYFROM FIRE OR FLAMES Neverallowbatteries in the vicinity of fire or flames and do not smokewhenworking with batteries.

Explosive hydrogengas is producedby the electrolyte (acid) in the batteries. Alwaysworkwith batteries in a well ventilated area.

C. CHARGING BATTERY Chargebattery off of, and awayfrom machinein a well- ventilated area. Whencharging battery, removecell covers to allow gassesto escape.

Avoid breathing gasses from battery. Wear approved Safety equipment whenworking with batteries.

D.

KEEP AWAYFROM FIRE OR FLAMES

USING BOOSTER CABLES Wearproper safety equipment whenworking with batteries.

If using anothermachineor vehicle to boost batteries, makecertain the machineor vehicle DOESNOTtouch the disabled machine.

Makecertain of the Positive.(+) and Negative(-) Terminalson the Booster Battery and the Disabled Machinebefore connecting Booster Cables.

Connectthe Positive (+) Cablefirst, Negative(-) Cable.

KEEP AWAYFROM FIRE OR FLAMES

then connect

Whendisconnecting, disconnect the Negative (-) Cablefirst, then disconnectthe Positive (+) Cable.

Refer to MaintenanceSection of this Manualfor proper proceduresfor use of booster cables.

Connect boostercablesusingfollowingprocedure.

1. Connect booster cableto positive(+) batteryterminal of discharged battery.Connect otherendof boostercableto positive batteryterminalof normal battery.

2. Connect otherboostercableto negative(-)batteryterminal of discharged battery. Connect otherendto upperframeof troubledmachine.

3. Start engineandremove boostercablesin reverseorder.

1-12

Section I-

SAFETYPRECAUTIONS

1.8 WARNING LABELS& DECALS Warning LabelsandDecalsare affixed to the machine to remindoperatorsandpersonnel1of specific Safety Precautionsin certain areasof the machine.The followingare illustrated examples of all Warning LabelsandDecalsalongwith their locations,

4. PREVENTBATTERYEXPLOSIONS-WARNING Locatedon battery boxaccessdoor.

Part Number-YN20T01001P

PREVENT BATrERY EXPLOSION ¯ Batteries give off hydrogen gessesthat can explodeandcausepersonalinjury. ¯ Keepsparks, openflames and cigarettes away frombatteries. ¯ Keepmetallic articles awayfrombatteries. ¯ Keepall ventilation capstightly secured. ¯ Nevercheckchargeby placing metal articles acrossbattery terminals. ¯ Leavebattery boxopento improveventilation whencharging.

YN20T01001 P

1. SWING- DANGER Locatedon eachside of the rear counterweight.

Part Number-YN20T01003P1 (2-REQ’D)

5. BOOSTERCABLE-WARNING Locatedon battery boxaccessdoor.

Part Number-YN20T01015P1

2. HOT COOLANT-WARNING Locatedon top of engineradiator.

Part Number-YN20T01010P1

Improper

booster

cable

connections

cancausean explosionresulting in personal injury,

±F............. .......... i1±

Connect boostercablesusingfollowing procedure.

1. Connect boostercableto positive(+) batteryterminalof discharged battery, Connect otherendof boostercableto positivebatteryterminalof normal battery.

2. Connect otherboostercableto negative(-) batteryterminalof dis charged battery,Connect otherendto upperframeof troubledmachine, booster 3. Start engineandremove cablesin reverse order,

Steamof hot coolant can cause injury or blindness.

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

Before openingradiator cap: ¯ Cool downengine completely. ¯ Coverradiator with cloth rag. ¯ Loosen cap slowly to relieve pressure.

YN20T01010P1

’

’

3. STOPENGINE-WARNING Locatedon top of engineradiator.

Part Number-YN20T01009P1

I"

~

CONNECTING A’B{)OSTERCABLE(RED)

NORMALBATTERY (BLACK)

DISCHARGED BATrERY TOTHEUPPER FLAME OFA TROUBLED MACHINE

YN20T01015P1

6. AVOID ACID BURNS-WARNING Locatedon battery boxaccessdoor.

Part Number-YN20T01017P1

AVOID ACID BURNS

Rotatingparts cancausepersonalinjury, Keepawayfromfan andbelt whenengineis running.

Stopenginebeforeservicing, YN20T01009P1

1-13

¯ Electrolyte is an acid and cancauseinjury or blindnessif it contactswith skin or eyes. ¯ Weareye protection and protective clothing whenhandling or servicing batteries. ¯ If electrolyte contactsskin or eyes, flush affected areas immediatelywith clean water and seek medical attention YN20T01017P1

Section

I-SAFETY PRECAUTIONS 10. ROTATING & HOT PARTS- CAUTION Located on Engine Cover.

Part Number- YN20T01012P1

7. PRESSURIZEDHOT OIL-WARNING Locatedon top of Hydraulic Reservoir.

Part Number-YN20T01002P1

Pressurizedhot oil can causeburns.

Rotating enginefan, hot engine parts and drive belt can causesevereinjury.

Relieve tank pressurewith engineoff by removingcap slowly.

YN20T01002P1

Donot openengine cover or service engine with engine running.

YN20T01012P1

8. RELEASE AIR PRESSURE-CAUTION Locatedon Hydraulic Reservoir Air Breather.

Part Number- 2446U260S9

11. ACCUMULATORCONTAINS PRESSURIZED GAS- WARNING Locatedon side of hydraulic reser ~side main pumpaccess door.

Part Number-YN20T0

ACCUMI Pressuri: \

F~ESSURIZED GAS. severe injury as a result

I * Donol ¯ Do not plug in service. . Do not dispose without relieving gas by loosening plug.

YN20TO1011P1 I

I

12. HANDLING PILOT HOSES-WARNING Locatedon panel, inside engineair cleaneraccess door.

Part Number- 2432P3383

"Late Style"

Part Number-YN57VO0002SO07

Hydraulic oil can be hot after machineoperation.

Allow oil to cool before starting maintenancework.

Before disconnecting hydraulic hoses, loosen the air breather on the hydraulic oil tank and bleed off the remaining pressure left in the hydraulic system.

9. DO NOT CLIMB-WARNING Located on Fuel Tank.

Control pattern functions must correspond to black and white decal located on the control console.

LH (P/V) SWING(L) LH(P/V)ARM(R)--]

CA/ARM

Whenservicing or repairing machine,keep surfaces free of oil, water,grease,tools, etc. to avoidpossible slipping and I or falling from machine,whichcan causepersonal injury.

2432T6111

1-14

(H)

"~

[ RH (PN) BOOM I ~RH(P/V)

~’~=e~

~ LH (PN) SWING(RH) J L__- RH (P~ BOOM (R)

I

c/v BUCKET (H} -CA/BOOM (H) C/VBUCKET (R) [ ¢-.~-C,/VBOOM(R) ~WlNGMOTOR(RH) C/VARM (R)

C/V: CONTROL VALVE PN: PILOT VALVE

2432P3383

Section

I-SAFETY PRECAUTIONS 16.AUTOMATICTWOSPEEDTRAVEL-WARNING Locatedinside cabon R.H.Panel.

Part Number-YN20T01048P1

13. LIFTING FRONTWINDOW-WARNING Locatedin Cabon R.H. Window Part Number-2432T6108

Pull out the connectorwhenlifting the front window.

Locksecurely whenopeningandshutting the front window.

Automatictwo speedtravel systemchangestravel speed automatically and can adversely affect machine control whendescending a slope and loading or unloadingon a trailer.

Personal injury can occur from suddenchangein machinecontrol.

Put travel speed select switch in low speed position whendescendinga slope and loading or unloadingon a trailer.

2432T6108

14. WARM UP HYDRAULIC OIL- CAUTION Locatedinside cabon R.H.Panel.

Part Number-2432T6129

YN20T01048P1

17, ELECTRICALPOWER LINES-WARNING Locatedinside cabon R.H. Panel.

Part Number-YN20T01006P1

~i!~ ~i~ ~!~:.i’ ~ii~: /.Ix, i~!~:~ii~’~il: ~;~ ~:;tl,~i~l~i~i ~i~,~ ~iili~ it~......=~!

Do not attempt normal machineoperations when the lamp that indicates cold hydraulic oil, is illuminated.

~i~/~i~ ~;~ :: ;~i~ ::!~::::~ii~,’~ ~ Contactwith electrical powerlines will result in severeinjury or death,

Slow or unexpected movementof the hydraulic functionsmayresult whenthe hydraulicoil is cold. e

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

Keepmachineand attachment a safe distance from electrical powerlines as per following instruction.

VOLTAGE (Volts) 50K OR LESS 50KTO 200K 200K TO 350K 350K TO 500K 500K TO 750K 750K OR OVER

Alwayskeeppersonnel awayfrom thearea around the machine during the warm up procedure.

2432T6129

SAFETY’ DISTANCE 3.0M (10FT) 4.5M (15FT) 6,0M(20FT) 7,5M(25FT) 10,5M (35FT) 13.5M(45FT) YN20T01006P1

18. BUCKETTO CAB CONTACT-CAUTION Locatedinside cabon R.H.Panel.

Part. Number-2432P3380

15.AUTO ACCEL SWITCH-WARNING Locatedinside cabon R.H. Panel.

Part Number-YN20T01047

When

~F

lever and/or travel switch ON, engine speed and can cause sudden whichcanresult in personal

CAUTION

machin, injury or death.

Whenloading or unloading machinefrom trailer or workingin close quarters, set Auto Accelswitch to OFFposition.

YN20T01047P1

ERE

Bucket can contact and damage cab when machineequipped with some attachments.

Check clearance betweenbucket and cab before operation.

Exercise care when operating a bucket near cab.

2432P33880

1-15

Section 19.

I-SAFETY PRECAUTIONS

FRONT WINDOW- CAUTION Located inside cab, aboveand behind operators seat on R.H. Side.

Part Number- LE20T01019P1

22. GENERAL PRECAUTIONS-WARNING Locatedinside of cab door.

Part Number-YN20T01016P1

woo °°°’" Falling front windowcan cause injury, Always lock securely in place with lock pins on both sides, LE20T01019P1 20, HANDRAIL- WARNING Locatedinside of cab door.

Part Number- 2432T6109

DO NOT INSTALL ANY OBJECTSONTHEHANDRAIL This can cause welds that fasten the handrail to the operators cab to fatigue and crack due to excessive vibration during machineoperation.

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

2432T6109

¯

Read and understand the operators manual before operating or performing maintenance on this machine.

Failure to follow or pay attention to instructions in operators manualcan result in injury or death.

It is your responsibility to be awareof and follow all local laws and regulations.

Before starting machine, make sure hydraulic control lever is in lockout position and all control levers are in neutral.

Soundhorn to alert people.

Ensure bystanders and obstacles are clear of machine before moving machine or its attachments.

Do not carry riders on machine.

Before leaving operators compartment, park on level ground, lower attachments to ground, make sure hydraulic control lever is in lockout position and stop engine.

YN20T01016P1

23. CALIFORNIA PROPOSITION 65-WARNING Locatedinside of cab in front of ashtray.

Part Number- 2432T6457

21. ADJUSTING TRACK TENSION- WARNING Locatedinside of cab door.

Part Number- 2432T6110

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

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

2432T6457

24. DO NOT USE ETHER-WARNING Locatedon face of engineair cleanercover.

Part Number- 2432T6574

Extreme high pressure in track adjustment cylinder can cause personal injury when adjusting crawler tension.

Loosengrease nipple with care to relieve pressure gradually.

2432T6110

/~

WARNING

THIS MACHINEIS EQUIPPED WITH A GRID AIR HEATER. DO NOT USE ETHER.2432T6574

1-16

Section

I-SAFETY PRECAUTIONS

1.9 PROHIBITEDMACHINEOPERATION Thefollowing examplesof machineabuseandmisuseshouldneverbe attemptedby eventhe mostexperiencedoperator, Suchabuseandmisuseof this machine andits attachments canresult in serious bodily injury, death, severeequipmentdamage and shortened servicelife of the machine.

Underno circumstance shouldanyof theseoperationsbe at tempted.Use common senseand follow proper operation procedures foundin this OperatorsManual while operatingthis equipment.

:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: DO NOT USE TRACTIVEFORCE

DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT. Doingso will exert excessiveforce on the machine structure andfront endattachmentsandcouldcausesevereinjury or death.Use tracks for normaltravel operationsonly.

DO NOT USE SWINGING FORCE OF THE MACHINE FOROPERATIONS. Doing so will exert excessive force to the machine structure,front endattachments andshortenlife of the swinging system of the machine.

Also,seriousinjury or death couldresult fromsuchoperations.

DO NOT PERFORM"HAMMERING"OPERATIONSWITHTHEBUCKET. Performing operations suchas hammering andpiling will causeextensive damage to the machineand its components. Thesetypesof operationscanalso result in seriousinjury or death.

D.

I

DO NOT USE SWINGINGFORCE

DO NOT HAMMERWITH ATTACHMENT

DO NOT USE THIS MACHINEFOR ANYTHING OTHERTHANITS INTENDEDPURPOSE. This machineis designedand manufactured for digging andloadingoperationsonly. Anyother use canexert excessive force to the machine, its components,its systems andresult in seriousbodily injury or deathto the operatorsandotherpersonnel workingin the vicinity of or with the machine.

USE ONLYFOR INTENDEDPURPOSE

1-17

Section

I-SAFETY

E,

DO NOT OPERATE BUCKET AND ARM CYLINDERSTO STROKEEND REPEATEDLY. Extending the bucketandarmcylindersto stroke endto cleandebrisfromthe bucket,will cause impactto the bucketcylinder causingcylinder damage.

Usewateror manuallyremovestubborn materialfromthe bucket,

F,

DO NOT OVER EXERT THE MACHINE’S CAPACmES. Knowthe limitations of the machine and its attachmentsandoperatethe machine within thosespecifications.Nevertip or raise the machine to obtain powerto movematerial. This could causeextensivedamage to the machine and its components as well as result in seriousbodily injury or death.

1.1 0 ENDOF WORK SHIFT SAFETY Performall of the followingprocedures after each shift is complete to insurethe machine is in optimaloperatingconditionfor the nextshift or job site.

A. Movethe machine to a firm, level surface.

B. Lowerattachmentto the ground.

C. Refill fuel tankto full markto reduce air volume andcondensation (moisture). This will decrease the possibilityof freezingin the fuel tank,rusting dueto moisture,andother problemsassociated with start up andoperation. in place to prevent D. Closeandsecureall windows wateror moisturereachingthe electrical componentsof the machine.

E. Thoroughlyclean andinspect the machine.Performlubrication maintenance andrepair or replace anyproblemareasfoundbeforerestarting the machine.

F. If operatingthe machine in cold climates,it may be necessary to remove the batteries fromthe machine andstore themin a warmwell ventilated area.Install the batteriesin the machine before nextstart up. Thiswill helppreventpremature battery deterioration. key from keyswitchandlock all doors G. Remove andaccesspanels.

PRECAUTIONS

DO NOT CYLINDERSTROKEEND ARM/BUCKET

iliiiii!Hil ii!i!iiii!ii!iii DO NOT OVEREXERTTHE MACHINE

CLEANMACHINEAT END OF SHIFT

[] 1-18

NOTES

Section II-MACHINE FAMILIARIZATION Table of Contents FAMILIARIZATION .........................................................................................................................................................

2-1 2-1 GENERAL MACHINE NOMENCLATURE ....................................................................................................................

OPERATOR CAB NOMENCLATURE ...........................................................................................................................

2-2 COMPONENT &CONTROLS NOMENCLATURE .............................................................................................

2-3 ~ 2-13 Right Hand Operator Console ..................................................................................................................... 2-3 - 2-6 LeftHand Operator Console ....................................................................................................................... 2-7 ~ 2-8 Optional Switches .................................................................................................................................................

2-8 Rear Panel ...................................................................................................................................................2-9 Operating Levers &Controls ............................................................................................................

2-10 ~ 2-12 Gauge Cluster Display ................................................................................................................................

2-13 Operator Cab .....................................................................................................................................2-14 - 2-20 Machine Access Panels &Doors ......................................................................................................

2-20 - 2-22

~ ~’~i~

~,

~

~;~ ~

’i~; ,,

~!

~

’=

~’i~i~

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUAL BEFOREATTEMPTING ANY OPERATION,INSPECTIONOR MAINTENANCE OFTHIS MACHINE,ATTACHMENT OR SYSTEMS.KOBELCO CANNOTANTICIPATE EVERYPOSSIBLECIRCUMSTANCETHAT MIGHT INVOLVEA POTENTIALHAZARD.THE WARNINGS IN THIS PUBLICATION ANDON THEPRODUCT ARE THEREFORENOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORKMETHOD OR OPERATING TECHNIQUENOT SPECIFICALLYRECOMMENDED

BY KOBELCO IS USED, YOUMUSTSATISFY YOURSELF THATIT IS SAFE FOR YOU AND OTHERS.YOUSHOULDALSO ENSURETHAT THE PRODUCTWILL NOT BE DAMAGED OR MADEUNSAFEBY THE OPERATION,LUBRICATION, MAINTENANCE AND/ORREPAIR PROCEDURES YOU CHOOSE.

2-0

Section II-

MACHINEFAMILIARIZATION

2.1 FAMILIARIZATION All operators,service mechanics andpersonnelresponsiblefor operation,inspectionandmaintenance of the machine shouldbecome thoroughlyfamiliar with the controls andcomponents andtheir functions before workingwith or on this equipment.

Studythe informationin this sectionto become familiar with the controlsandcomponents of this machine.

--ARM

2.2 GENERALMACHINENOMENCLATURE TheNomenclature drawingbelow(Figure2.1), points out locations of major components of the KOBELCO SK130 (LC) MarkIV HydraulicExcavators.Studythese areasand locate thesecomponents on the machine.

Specific informationregardingthesecomponents are explainedonthe followingpagesof this section.

-OPERATORCAB (SEEFIGURE 2.2)

CYLINDER BOOM BOOM WORK LIGHT

-- SWIVELJOINT --

SLEWING RING ¯ SWINGMOTOR MIRROR --

MAIN CONTROL. VALVE HANDRAIL FUEL TANK --

BUCKET CYLINDER IDLER LINK

HYDRAULIC OIL RESERVOIR ENGINE MUFFLER

BUCKET

PUMPACCESS DOOR

BOOM CYLINDER --

EACHSIDE)

HYDRAULIC PUMPS --

Iq

REAR WORK LIGHT

)

FLASHER BUCKET OPERATOR CONTROLS

TRACKIDLER (1 EACHSIDE) --

| I|

TRACK SPRING (1 EACH SIDE) MOUNTING STEP(:

CUMMINS4BT3.9 REAR COUNTERWEIGHT

UPPER ROLLER (1 EACHSIDE’) SK130 (2 EACHSIDE) SK130LC TRACK SHOEASSEMBL~ (600mm STANDARD) LOWER ROLLER(6 EACHSIDE) SK130 (7 EACHSIDE) SK130LC ENGINEAIR CLEANER ACCESS DOOR BAI-rERIES TRAVEL TRAVEL MOTORSPROCKET

FIGURE 2.1

2-I

ENGINE RADIATOR WORKLIGHT HYDRAULIC OIL COOLER ENGINE COOLANTRESERVOIR

Section II-MACHINE FAMILIARIZATION 2.3 OPERATOR CAB NOMENCLATURE TheOperatorCabNomenclature (Figure 2.2), points out locations of OperatorControlsof the KOBELCO SK130 (LC)MarkIV HydraulicExcavator OperatorCab.

Studythese areas andlocate these components on the machine.

Specific informationregardingthese components are explainedon the following pagesof this section. m RIGHTTRAVEL LEVER (REMOVABLE)

LEFT TRAVELLEVER (REMOVABLE)

RIGHTTRAVELPEDAL

LEFT TRAVEL PEDAL~ RIGHT FOOTREST

LEFT FOOTREST

"ONE.OUCH" DECEL SWITCH HORN SWITCH RIGHT CONTROL LEVER

SAFETYLOCK LEVER (FOR HYDRAULICS)

RIGHT SWITCH PANEL

LEFTCONTROL~ LEVER

ENGINE EMERGENCY STOP CONTROL GAUGECLUSTER THROTTLE LEVER KEY SWITCH

LEFTSIDE SWITCHPANEL RIGHTSIDE SWITCHPANEL

STORAGE I COMPARTMENT (SEAT BACK)

HEADREST (ADJUSTABLE)

FIGURE2.2

2-2

OPERATORS SUSPENSIONSEAT (3 WAYADJUSTABLE)

Section II2.4

MACHINEFAMILIARIZATION FRONTLIGHTS CONTROL SWITCH

COMPONENT& CONTROLSNOMENCLATURE Thefollowing information providesa brief description and function of the components and controls of the KOBELCO SK130(LC)Hydraulic Excavators. All personnel associated with this machineshould read and understand this information BEFORE beginning any work with or on this equipment.

REARLIGHTS CONTROLSWITCH

A. RIGHT HAND OPERATOR CONSOLE 1. Key Switch- FIGURE2.3 The Key Switch is located on the Right Hand Operator Console and has 4 operating functions. a. "HEAT"-This position is usedfor starting the enginein cold climates. Theengineis equipped with anelectric inlet air grid heater.

SeeSectionII1. b. "OFF"-WhenKeyis turned to this position, the enginestops and electrical powerto the machine’selectrical systemsis stoppedafter approximately 4seconds. c. "ACC"-WhenKey is placed on this position, electrical poweris only suppliedto the radio, as well as the 24 V cigarette lighter and the 12 V auxiliary connection. d. "ON"- WhenKeyis in the ONposition, electrical poweris suppliedto all the machine’s electrical systems. e. "START"-Whenkey is turned to this position electrical poweris suppliedto the starter solenoid causingthe starter to crank the engine. After engine starts Key should be released. The key will return to the "ON"position by itself.

2. Throttle Control Lever- FIGURE2.3 The Throttle Lever is located on the Right Hand Console and controls Engine RPM.Whenthe lever is pulled to the rear side of the panel, the RPMincreases, whereas the RPMdecreases whenthe lever is moved to its forward position.

3. Swing Flasher Switch- FIGURE2.3 The Swing Flasher Switch is located on the Right HandControl Consolenext to throttle control lever. The SwingFlasher is a 2 position rocker switch whichis usedto turn on the swing flashers to use during swingingoperations.

Pushthe symbol side of sWitch clown to turn swing flashers ON. Pushthe emptyside of switch downto turn swing flashers OFF.

~_

2-3

FIGURE2.3

--

Section

II-MACHINE FAMILIARIZATION

4. Wiper & WasherSwitch- FIGURE2.4 TheWiper& Washer Switchis located on the Right HandOperatorConsolebehindKey Switchandhas4 operatingfunctions. a. "OFF"-When switchis turnedto this position, operationof Wiperstops. b. ~ - Whenswitch is turned to this posi tion, wiperoperates intermittently. c. ~ - Whenswitch is turned to this position, the wiperoperatescontinuously. d. Tooperatethe washer,pushswitchdownand washerfluid will be sprayedontowindshield.

FIGURE2.4

I Makecertain the Washer reservoir haswasherfluid beforeoperatingwasher.

I

.

CabFan Switch- FIGURE 2.5 TheCabFanis located behindthe R.H. Side of the operatorseat. It utilizes a 3 position ToggleSwitch for "SLOW", "FAST"and "OFF".

Theswitchis locatedat the baseof the fan.

Indicator 6. LowHydraulic Oil Temperature Lamp-FIGURE2.6 TheCold HydraulicOil Indicator Lampis locatedon the RightHandOperatorConsole,betweenthe WiperControl switch and the Cab ClimateControls.

FIGURE2.5

Its purpose is to informthe operator,uponstart up of the machine, that the HydraulicOil is too coldfor operation.

Thelampwill goout whenthe hydraulicoil temperaturereaches10°C(50°F). Normaloperating temperature of the hydraulicoil is 45°C55°C(113°F~ 131°F). Neverperformnormal operationof the machine whileindicator lampis on.

I ~I‘ ’~’‘" ~=~’~" . ~’ ~ =i~ ~

~,

~

IN OPERATINGTHE MACHINEWITH COLDHYDRAULICOIL, THE OPERATOR MAYEXPERIENCE SLOWOR UNEXPECTEDMOVEMENTOF FUNCTIONS. DAMAGETO HYDRAULIC COMPONENTSMAY RESULTDUETO THE COLDOIL NOTPROVIDING ADEQUATE LUBRICATION.

2-4

FIGURE2.6

Section II-

MACHINEFAMILIARIZATION

7. Heater FanSwitch- FIGURE 2.7 TheHeaterFanSwitchis located on the rearmostswitch panelandhas4 operatingpositions. a. "OFF"-Turn the switch counterclockwise to stop heaterfan operation. b. "LOW"-Turn switchto the first (.) position for the lowestair volumefromheaterfan. c. "MEDIUM"-Turn switch to the second(e) for moreair volumefromheater fan. d. "HIGH"-Turnswitchto the third (e) for the highestair volumefromthe heaterfan.

Control- FIGURE 2.8 8. Heater Temperature TheHeaterTemperature Control is located in front of the HeaterFanSwitchandcontrols the amountof warmwatercirculating throughthe heater core by pulling up or pushingdownthe control.

"PULL"-Pull up to allow morewarmwaterto circulate throughheatercorefor higher temperature in cab.

"PUSH"-Pushdownto decreasethe amount of warmwatercirculating through heatercore.

9. Inside/OutsideAir Exchange ControlFIGURE2.8 TheInside/OutsideAir Exchange Controlis locatedto the right of the HeaterTemperature Control andis also a "PUSH/PULL" control.

"PULL"- Pull controlupto allowcirculationof outsideair withinthe cab.

"PUSH"-Pushcontrol downto decreaseor stop thecirculationof outsideair in thecab.

10.DefrosterSelect Control- FIGURE 2.8 TheDefrosterSelectControlis locatedto the right of the Inside/Outside Air Exchange Control andis a "PUSH/PULL" Control.

"PULL"- Pull the controlupto allowair circulation fromthe ventslocatedon eachside of the operatorseat at the floorboardof cab.Fig. 2.9.

"PUSH"-Pushthe control downto allowcirculationof air fromthe ventslocatedat the rear of the operator seatin backof cab.Fig. 2.9.

FIGURE2.7

FIGURE2.8

FIGURE2.9

11. LocationForTheA/CSwitch- FIG. 2.10 Thelocationfor the A/Cswitch, If the machine is equipped with Air Conditioning, is as indicated in Figure2.10,onthe right rear cornerof the Right SidePanel.

FIGURE2.10

2-5

Section

II-MACHINE FAMILIARIZATION

12. Working Lights Select SwitchesFIGURE 2.11 TheWorkingLights Select Switchesare located on the front sideof the right panel.These press typeselectswitchesareusedto turn the front andrear workinglights ONandOFF.Thecenter switchis usedto controlthe front working lights andthe left switchis usedto controlthe rear lights.

2.11 13.Travel SpeedSelect Switch-FIGURE TheTravelSpeed SelectSwitchis locatedto the R.H.side of FrontWorking Light SelectSwitch.

ThisSwitchis a singleposition,presstypeswitch andis usedto increaseor decrease travel speed.

Eachtimeengineis started,travel speedis automaticallyset to 1 st ( ~ ) speed.

- Depress the switch to either activate or deactivatethe HighTravel Speed (~1~).

NOTE TheIndicatorlight for the HighTravelSpeed on the panel will light everytimethe HighSpeed is selected.

Automatic twospeedtravel systemchanges travel speedautomatically and can adversely affect machinecontrol whendescendinga slope and loadingor unloading ona trailer, Personalinjury can occurfromsuddenchangein machinecontrol.

Put travel speedselect switch in low speed position whendescending a slopeandloadingor unloading ona trailer,

NOTE Thetravel systemon the machine incorporatesan automatic shift from FASTto SLOW speedwhencertain terrain conditions are sensed.Referto page1-15 for Two SpeedTravel Warning.

2-6

FIGURE 2.11

Section II-MACHINE FAMILIARIZATION B. LEFT HANDOPERATOR CONSOLE FIGURE 2,12: 1, Travel AlarmSwitch- FIGURE 2.13 TheTravelAlarmSwitchis locatedon the up perright cornerof theleft sidepanel.TheTravel AlarmSwitchis a singlepositionrockerswitch andis usedto turn the TravelAlarmOFF.When travel is engaged the alarmsoundsautomatically. After5 seconds of travelling,the Travel Alarmcanbeturnedoff.

- Depress this side of switchto turn Travel Alarm"OFF"after 5 seconds of travelling.

NOTE Thetravel alarmwill soundagainif travel is stoppedand restarted. Likewise,the travel systemon the machine incorporates an automaticshift from "FAST"to "SLOW" speedwhencertain terrain conditions are sensed.Refer to Page1-15 for TwoSpeedTravel Warning.

FIGURE2.12 USE TRAVELALARMDURINGALL TRAVELOPERATIONS,

2. Extra ControlSwitch-FIGURE 2.14 (Optional) TheExtraControlSwitchis locatedonthe L.H. ControlConsole.This switchis a twoposition rockerswitch,andis usedto turn "ON"or "OFF" the Extrahydraulicfunction of the machine.

~

FIGURE2.13

to turnthis "ON"the function.

-~ - Depress sideExtra of the switch

NOTE It is necessary that the ExtraControlSwitchbe keptin the "OFF"positionduringexcavating functions,for propermachine performance.

FIGURE2.14

2-7

Section II-

MACHINEFAMILIARIZATION

~

4. LIGHT CONTROL SWITCH- FIGURE2.15 (Optional for Europe) Thisswitchis locatedto the right of the Ether Injection Switch.Thisswitchis a single position rockerswitchandits basicfunctionis to turn "ON"or "OFF"the cabfront andrear light simultaneously.

~

BEACONLIGHT CONTROL SWITCHFIGURE 2.15 (Optionalfor Europe) This switchis locatedbelowthe Travel Alarm ControlSwitch,andit is a singlepositionrocker switch. Its basic function is to turn "ON"or "OFF"the cab top BeaconLamp.

w

PRESSHERE TO TURNTHE LIGHTS"OFF"

LOCATIONFOR LIGHT CONTROL SWITCH (Optional for Europe)

CONTROLSWITCH (Optional for Europe)

MANUAL"ONE-TOUCH"DECELSWITCH= FIGURE2.16 This momentary contact, dual function switch wouldbe located on the Right ControlHandle.

Thisswitchis usedto activateor deactivate the Decel System. .

PRESS HERE TO TURNTHE LIGHTS"ON"

PRESSHERE FOR"ON" PRESSHERE FOR"OFF"

FIGURE2.15

HORNCONTROL SWITCH-FIGURE2.17 Thispressbuttontypeswitchis locatedon the left sidecontrolhandle,andits functionis to activatethe horn.

’ ~ ~I

.

~

.

FIGURE2.16

TO INDICATETOPEOPLEAROUNDTHE MACHINE, THATTHEMACHINEIS GOINGTOBE OPERATED, ALWAYSMAKESURETOACTIVATETHEHORN TWICE BEFORESTARTINGUPTHEENGINE

FIGURE2.17

2-8

Section

II-MACHINE FAMILIARIZATION

C. REAR PANEL 1. 24 Volt CigaretteLighter- FIGURE 2.18 TheCigaretteLighter is locatedon the rear panelbehindoperatorseat on the right hand side. Tousethe CigaretteLighterthe KeySwitch mustbein the ONposition. Pushthe lighter in andwait approximately 30 seconds for it to "POP" out. Pull lighter fromthe socketto use.

Replace lighter backinto its socketafter use.

I Do Not Use the C’igarette Lighter as a powersource for 12Volt accessories.

It is a 24Volt outlet.

I

.

12 Volt PowerSupply-FIGURE 2.18 The12 Volt PowerSupplyis locatedbeside the CigaretteLighter.

For use of common auto accessoriessuchas a fan or otheraccessories requiring12 vdcpower, pull coverawayfrom12 Volt PowerSupplyand insert 12 Volt MaleSocketinto powersupply.

Replacecoverafter use.

FIGURE2.18

The12 Volt PowerSupplycannotbe usedas a cigarettelighter.

MAXIMUM CONTINUOUS OUTPUT-2.5 Amps MAXIMUM INTERMITrENTOUTPUT-6.0 Amps

.

Fuse Box- FIGURE2.19 TheFuseBoxis locatedbehindthe left side of the operatorsseat. It containsall necessary fusesfor the electrical circuits of the machine.

Shouldit become necessaryto inspect or changea fuse, removethe fuse boxcover by gently pulling eachendawayfromthe box.

Shoulda fuse require replacement, usea replacementfuse of the sametype and amperage. Turnkey Switchto "OFF"andwait approximately4 seconds for all electrical powerto stop before removingor replacing a bador blown fuse. Usea fuse puller to remove fuses. Refer to the Maintenance Sectionof this Manual for a detailed diagramanddescriptionof fuse box.

2-9

FIGURE2.19

NOTE 30 ampfuse is usedonly on units equipped with in-line style fuel injectionpumps.

Section II-

MACHINE FAMILIARIZATION

D. OPERATINGLEVERS& CONTROLS 1. Safety LockLever-FIGURE 2.20 TheSafetyLockLeveris locatedon the front outside of the Left HandOperatorConsoleand it’s knobis Redin color.TheSafetyLockLever is usedto lock-outthe pilot-operatedhydraulic controls. TheSafetyLockLeverhas2 operating positions.

a. "UP"-When placedin the up position the SafetyLockLeverstops pilot-operatedhydraulic controls fromfunctioningandallows the operatorto enterandexit the operator seat. b. "DOWN"-When placed in the downposition, the SafetyLockLeverallowspilot operatedfunctionsof the hydrauliccontrolsto resumeand aJsolocks the Left HandOperating Console in operatingposition.

~,LWAYSPLACEATTACHMENTS ON THE GROUND ANDLOCKTHESAFETYLEVERIN THEUP POSMON BEFORELEAVINGTHECAB. NEVERLEAVETHEMACHINEUNATrENDEDWITH ENGINERUNNING OR LEVERIN THE DOWN POSITION.

FIGURE2.20

2. EngineEmergency Stop ControlFIGURE2.21 TheEngineEmergency Stop Control is locatedat the lowerright handsideof the operators seat. It is usedonly in an emergency situation to stopthe enginequickly.It has2 operatingpositions. a. "IN"- Releases the fuel stoplever on the governorto allow normalstarting of the engine. b. "OUT"-Activatesthe fuel stoplever on the enginegovernorto immediately stopthe engine,

FIGURE 2.21 I

D~~ine when operating at high RPM.Doingso maydamage turbo or engine.

2-10

Section II-MACHINE FAMILIARIZATION ¯ ARMOUT Hydraulic Controls are designed for and set to ISO Operating Pattern for optimum machine performance and safety. Changingthe Control Pattern will effect the performanceof the machine.

SWINGLEFT

3. Left HandOperator Control LeverFIGURE2.22 The Left HandOperatorControl Leveris located at the top front of the L.H. operatorconsole.Its puCpose is to allow the operator to control op-erations of the Swingand Arm. Operatingspeed of function is variable fromstop to full stroke dependingon howfar lever is operated. The Left HandOperator Control Lever has 5 basic operational functions. a. "FORWARD"-VariableSpeed Arm Out. b. "BACKWARD"Variable Speed Arm In. c. "LEFT"- Variable SpeedLeft Swing. d. "RIGHT"- Variable SpeedRight Swing. e. "CENTER"-Neutral Position.

4. Right HandOperator Control LeverFIGURE2.23 The Right HandOperator Control Lever is Io cated at the top front of the R.H. operator con sole. Its purposeis to allow the operatorto con trol operations of the Boomand Bucket. Operating speedof function is variable from stop to full stroke dependingon howfar lever is oper ated. The Right HandOperator Control has 5 basic operational functions. a. "FORWARD"-Variable Speed Boom Down. b. "BACKWARD"-Variable Speed Boom Up. ¢. "LEFT"-Variable SpeedBucket In (Digging). d. "RIGHT"- Variable SpeedBucket Out. e. "CENTER"-Neutral Position.

5. Left and Right Travel Lever & PedalsFIGURE2.24 The Travel Lever & Pedalsare located in front of operator seat. They are used to movethe Left or Right track of the machineeither forward or backward.Thesecontrols have 3 basic operational functions. a. "FORWARD"-VariableSpeed Forward Track Movement. b. "BACKWARD"Variable Speed Reverse Track Movement. c. "CENTER"Neutral Position.

Theseoperations are with travel motors at the rear of the machine.If travel motorsare positioned in front of the machinethe functions of the Travel Leverswill be opposite.

2-11

t

SWINGRIGHT

ARMIN

FIGURE2.22 BOOMDOWN ~j~

I

BUCKET OUT

FIGURE2.23

FIGURE2.24

Section II-MACHINE FAMILIARIZATION E. CLUSTERGAUGEPANEL I

I

^

~/HENTHEIGNITIONSWITCH IS PLACED IN THE"ON"POSITION, rilE ENGINEOIL PRESSURE ANDTHE BATTERY CHARGE INDICATINGLAMPSWILL LIGHT UNTIL THEENGINEIS STARTED, THESELAMPSSHOULD GOOFF AFTERTHE ENGINESTARTS, MAKESURETOOBSERVETHE PANELREGULARLYTO BE AWARE OF ANYPROBLEMS ON THE MACHINE.

TheCluster Gauge is located on the right side panel,andits functionis to keepthe operatorinformedon the workingconditionsof the machine at all times.SeeFigure2.28.

1. High Travel SpeedLamp Thisindicatorlampilluminatesevery timethetravelspeed is selected to high speed.

2. Air Filter RestrictionLamp Thisindicator lampilluminatesand the alarmbuzzerwill soundif the Air Filter is clogged.

Check the Air Filter andreplaceit if needed when this lampcomeson.

3. EngineOil PressureLamp Thisindicatorlampilluminatesand the alarmbuzzerwill soundif the enginelubrication oil pressureis excessively low. Makesure to checkthe engineoil level if this conditionis presentwhile the engineis running.If the oil level is withinspecifications,andthis condition persists,contactyourclosest Cummins dealer immediately.

4. Fuel Level Lamp This indicator lampilluminates whenthe fuel level reaches14 liters (3.7 Gal)or less. If this lamp comeson, addfuel immediately.

5, EngineStarting Aid Lamp This indicator lampilluminates whenthe starting aid is activated during sub-zerotemperatureenginestarting.

6. Battery ChargeLamp Thisindicatorlampilluminatesif a problemoccurs in the electrical chargingsystemwhile the engine isrunning. Checkthe charging system if this conditionpersists.

2-12

FIGURE2.28 .

Coolant TemperatureLamp Thisindicator lampilluminateswhenthe temperatureof the coolantrises above 105-°C(211-°F).If this lampcomes on, stop the machine operationimmediately, andlet the enginerun at low speedto lower its temperature.Thencheckthe coolantlevel, fan belt tension,radiator clogging, etc. (with enginestopped only !)

8. Hydraulic SystemOverloadLamp (For Europe only) This indicator lamp illuminateswhenthe pressureinside the boom cylinders exceeds the pressureat whichthe system is set. If this condition appears,contact your closest Kobelco dealerfor properadvice.

9. FuelLevelIndicator Thisindicatesthe amount of fuel remaining in the tank.

F: Full tank, about250Liters (66gal).

E: Theremainingfuel is about31 Liters (8 gal).

10. CoolantTemperature Indicator This indicates the temperatureof the enginecoolant. Thetemperature of the engineis normalin the whiteareaof the gauge.

If theindicatorenterstheredarea, stop the machineoperation, andlower the enginespeeduntil the temperature dropsto the whitearea. Checkandmake surethe coolantlevel is withinspecs,and that the radiator is not clogged.(with enginestoppedonly !)

1. HourMeter Thisindicatesthe total timethe engine hasrun. Themeterruns as long as the engineis running.

Section II-MACHINE FAMILIARIZATION R OPERATORCAB 1. Locking/Unlocking CabDoor Usethe KeySwitchKeyto lock or unlockcab door.Insert Keyinto doorlock andturn counterclockwiseto unlockor turn clockwiseto lock cabdoor. SeeFigure 2.29.

FIGURE2.29 2. CabDoorLatch & ReleaseLever a. TheCabDoorcanbe latchedin an openposition by openingdooruntil it is lockedopen by the doorlatch located on the cab. See Figure2.30.

FIGURE2.30 b. Releasedoorlatch by pushingor pulling releaselever downto releasedoor from latch. SeeFigure2.31.

DO NOT USE THE RELEASEDOORLATCHLEVER AS A HANDHOLDTOCLIMB UP OR DOWNONTHE MACHINE.PERSONAL INJURY MAYRESULT.

FIGURE 2.31

2-13

Section !1- MACHINEFAMILIARIZATION 3. Opening& ClosingWindshield a. Toopenwindshielddisconnectthe wiper motorwiring harnessas shownin Figure 2.32.

b. Releasethe twowindshieldlocks by pulling towardcenterof window androtating up into lockedposition. SeeFigure2.33.

FIGURE2.32

¢. Graspeachwindshieldhandleandcarefully movewindshieldup andover the operator seatuntil top of windshield stopsat rear locking tabs. SeeFigure2.34.

FIGURE2.33

FIGURE2.34

2-14

Section II-MACHINE FAMILIARIZATION d. Usingwindshieldlocks, lock windshieldin position on bothsides. SeeFigure2.35.

MakeCertain windshieldlocks are fully engaged before operatingmachine. e. CloseWindshield in reverseorder.

EACH

FIGURE2.35 4. Removing& Storing LowerFront Window a. Raisewindshieldandlock in raisedposition. b. Carefully pull LowerFront Window up and out of track. SeeFigure2.36. c. Turn window on edgeandplace into storage tracks on R.H.Sideof operatorseat. See Figure2.37.

FIGURE2.36

FIGURE2.37 5. OpeningRight Side Windows a. GraspWindow Lock, squeeze to releaselock and slide windowopen. SeeFigure 2.38. b. Closeby sliding window to the closedposition.

Neverput heador arm(s)out Right Side Window.

If the boom is operatedwith heador arm(s) outsidewindow, seriousinjury or deathcouldresult.

FIGURE2.38

2-15

Section II-MACHINE FAMILIARIZATION 6. Opening & ClosingSky Light a. Toopen,pull handleson SkyLight Latches towardcenter of SkyLight andpushSky Light up. SeeFigure2.39. b. Toclose, pull SkyLight down.Make certain latchesare in lockedposition.

FIGURE2.39 7. Removing SunVisor a. Pull backof SunVisorfree fromfabric fastener andcarefully pull visor fromunderSky Light latches. Storebehindoperatorseat.

SeeFigure 2.40.

FIGURE2.40 8. CabDome Light a. Turn CabDome Light "ON"by movingthe Dome Light Switchto the right. b. Turn"OFF"by movingswitchto the left. See Figure2.41. ¢, Place Dome Light Switch in the "CENTER" positionandthe light will beoperated by the doorswitch. When door is opened the light will come"ON"andwhenthe dooris closed the light will turn "OFF".

FIGURE 2.41

2-16

Section II-MACHINE FAMILIARIZATION 9. Insulated StorageCompartment A specially insulated storagecompartment is locatedbehindthe operatorseat on the L.H. side. SeeFigure2.42.

FIGURE2.42 10. Storage Compartment TheOperatorand Parts ManualStoragecompartmentis a pouchlocatedon the backof the OperatorsSeat. Keepthe Operatorand Parts Manual for this machine in this locationat all timesfor quick, easyreference.SeeFigure 2.43.

11. ManualStorage TheOperatorandParts Manuals for the Machine shouldbe storedin the pouchlocated on the backof the OperatorsSeat.Keepthese Manuals in this locationat all timesfor availability andquickreference.SeeFigure2.44.

FIGURE2.43

FIGURE2.44 12. OPERATOR SEAT ADJUSTMENTS Theoperatorseat incorporatesseveraladjustment mechanisms to insure operatorcomfort, easeof operationandoperatorsafety. Theadjustment areasare as follows: a. OperatorWeightAdjustment-FIGURE 2.45 1. Rotatethe weightadjustmentknobuntil weightclosest to the weightof the operator is at thetopof thedial.

FIGURE2.45

2-17

Section II-MACHINE FAMILIARIZATION a. Seat HeightAdjustment-FIGURE 2.46 1. Pull HeightAdjustment Leverup to raise or lowerrear of seat 2. PushHeightAdjustment Leverdownto raise or lowerfront of seat.

FIGURE2.46 b. Seat Reclining Adjustment-FIGURE 2.47 Pull Reclining Adjustment Lever up to set 1. desiredreclining angle.

2. ReleaseRecliningAdjustment Leverto lock seatin position.

FIGURE2.47 c. Seat Front to BackAdjustment-FIGURE 2.48 1. Pull up on SeatAdjustmentBail andmove seat forwardor backward to desiredposition.

SeatAdjustment Bail to lock seatin 2. Release positionselected. d. ControlStandFront to BackAdjustmentFIGURE2.48 1. Pull up on ControlStandAdjustment Bail and moveentire ControlStand(including Control Consoles) to desiredposition.

ControlStandAdjustment Bail to lock 2. Release controlstandin desiredposition.

USE BOTTOMBAIL TO ADJUST CONTROL STAND

FIGURE2.48

e. ArmRest Adjustment-FIGURE 2.49 Lower Arm Rest and with finger, turn adjust1. mentwheeluntil ArmRestis in desiredposition.

FIGURE2.49

2-18

Section II-MACHINE FAMILIARIZATION f. HeadRest Adjustment-FIGURE 2.50 1. MoveHeadRest forwardor Backward to desiredreclining angle.

2. Raiseor LowerHeadRestto desiredheight.

TODESIRED POSITION

g. SeatBelt 1. Sitting in operatorseat,bring endsof seat belt aroundwaistandinsert L.H. endinto latch (R.H. end). SeeFigure2.51.

2. Adjustseat belt until snugaroundwaist by pulling looseendof belt on R.H.side. See Figure2.51.

3. Remove Seat Belt by pushingred release button on latch end. SeeFigure2.52.

FIGURE2.50

ALWAYS WEARSEATBELT WHILESITTING IN OPERATOR SEAT. ALWAYSCHECKCONDITIONOF SEAT BELT AND SEAT BELT MOUNTINGHARDWARE TO MAKE CERTAINSEATBELT IS IN GOOD CONDITIONAND PROPERLYSECURE. FIGURE2.51 G. MACHINEACCESSPANELS& DOORS 1. EngineCoolantTank/Battery,EngineAir Cleaner AccessDoors-FIGURE 2.53 Locatedon the Left RearSide corner of the machine,this doorallowsaccessto the Engine CoolantExpansionTank, Air Cleanerand the Batteries. Usethe KeySwitchKeyto lock and unlockthis door.

NOTE Makesure to securedoor openwith door lock barduringservice.

FIGURE2.52

FIGURE2.53

2-19

Section II-MACHINE FAMILIARIZATION 2. Main PumpAccessDoor-FIGURE2.54 Locatedon the R.H. RearCorner of the machine, this door allows accessto the Main Pumps,Hydraulic Oil Level Sight Gauge,SuperFilter, as well as Testports for conducting pressuretests on the machine’s hydraulicsystem. This Doorcanalso be lockedor unlocked by the KeySwitchKey. NOTE Makesure to securedoor openwith door lock barduringservice.

FIGURE2,54 2.55 3, StorageBoxAccessDoor- FIGURE Locatedon the R.H. Front of the upperframe structure, this doorallowsaccessto the StorageBox. This accessdoor is also lockedand unlockedwith the KeySwitch.

FIGURE2.55 4. Fuel Cap- FIGURE 2.56 To refuel machine,raise Fuel CapLockCover andunlockFuel Capusing KeySwitchKey. Re movecapby rotating counterclockwise.

Replace capafter refuelingandlock usingkey.

FIGURE2.56

2-20

Section I!-MACHINE FAMILIARIZATION 5. EngineCover-FIGURE 2.57 ToopenEngineCover,Pull LatchHandlesback andawayfromcover.Carefullyraise coverusing handhole. Raiseuntil proprod locksinto position. Closeby placingproprod into track andcarefully loweringEngineCover.Secure coverwith latches. Theright EngineCover Latchcanbe lockedandunlockedusing the Key SwitchKey.

FIGURE2.57

6. MainControl Valve AccessCoverFIGURE 2.58 Usea 19 mmwrenchto removethe four bolts that securethe MainControlValveAccessCover.

Placeit to the sideto obtainaccessto the Main ControlValve.

FIGURE2.58

2-21

Section III-BASIC

MACHINEOPERATION

Table of Contents PRE-START CHECK ......................................................................................................................................................

3-1 STARTING &STOPPING MACHINE ENGINE ABOVE 8°C(45°F)............................................................................

3-1 Starting Engine ............................................................................................................................................ 3-1 Stopping Engine ............... . ..........................................................................................................................

3-1 Emergency Engine Shut Down ....................................................................................................................

3-1 STARTING & STOPPING MACHINE ENGINE BELOW 8°C(45°1=)...........................................................................

3-2 Starting Engine ............................................................................................................................................ 3-2 Stoppng Engine .......................................................................................................................................... 3-2 Emergency Engine Shut Down ....................................................................................................................

3-2 STARTING MACHINE WITH BOOSTER CABLES ..........................................................................................

3-3 - 3-4 Connecting Booster Cables .........................................................................................................................

3-3 Starting Disabled Machine ................................................................................... ........................................ 3-,$ Disconnecting Booster Cables .....................................................................................................................

3-4 MACHINE WARM-UP ............................................................................................................................................

3-4 Engine .................................... . ......................................... . ..................................... ~....................................

3-5A Hydraulic Oil................................................................................................. . ................................... . ..........3-5A Hydraulic Oil in FrigidTemperatures .........................................................................................................

3-5A Operation of Optional Hydraulic Warm-up Circuit......................................................................................

3-5B OPERATOR’S CONTROLS ......................................................................................................... : .......................

3-6 OperatingPattern ......................................................................................................................................... 3-6 BASIC OPERATION OFHYDRAULIC CONTROLS ......................................................................................

3-7 - 3-14 Safety Lock Lever ........................................................................................................................................ 3-7 Machine Travel Controls.., .................................................................................................................. 3-8 - 3-10 Machine Attachments &Swing Controls ...........................................................................................

3-11 ~ 3-13 PRACTICES TOIMPROVE EFFICIENCY ....................................................................................... , ...........

3-14 - 3-15 OPERATING THE SHOVEL ......................................................... ~.......................................................................

3-15 MACHINE OPERATION IN ADVERSE WEATHER .................... i ...........................................................................

3-16 FLAGMAN HAND SIGNALS .....................................................................................................................

3-17 ~ 3-22

.~<~Z~~ ~"~~ ’.~ ~

~ ~,~Z~i~ ~;~~!

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUAL BEFORE A’I-I’EMPTING ANY OPERATION,INSPECTIONOR MAINTENANCE OF THIS MACHINE,ATTACHMENT OR SYSTEMS.

3-0

Section

III-BASIC

MACHINE OPERATION

3.1 PRE-STARTCHECK PerformPre-StartInspectionandMaintenance proceduresbeforestarting the machine.Referto the Maintenance Sectionof this manual for specific instructions.

3.2 STARTING& STOPPINGMACHINEENGINEWITH TEMPERATURE ABOVE 8°C (45°F) A. STARTINGENGINE 1. Move TheThrottle ControlLeverto the LowIdle position. SeeFigure3.1 2. Insert the Ignition Keyinto the Ignition Switch andturn it to the "ON"position. SeeFigure3.1.

3. Soundhomto warnpersonnelthat the machine is beingstarted. SeeFigure3.2.

4, Turn the Keyto the "START" position and releaseas soonas the enginestarts. Keywill automaticallyreturnto the "ON"position.

FIGURE 3.1

Releasekey after 30 seconds of crankingif engine doesnot start.

Waitat least 2 minutesbeforeattemptingto start engineagainto allowstarter motorto cool.

FIGURE3.2 NOTE: If enginefails to start after 3 attempts,inspectfuel system andcorrect any problemsfound.

When crankingengine, the absence of "Blue" or "White" smoke fromthe exhaustindicates no fuel is reachingthe enginecylinders.

B. STOPPINGENGINE- NORMALCONDITIONS 1. Movemachine to a firm, level areaandplace the attachment in the HydraulicOil CheckPosition. SeeFigure3.3.

2. MoveThrottle Control to "LO"Position. See Figure3.1. Allowengineto idle for 5 minutes.

3. Turn KeySwitchto "OFF".

MACHINEON FIRM, LEVEL’SURFACE

FIGURE3.3

C. EMERGENCY ENGINE SHUT DOWN In only casesof emergency shouldthis method be used.

1. Pull out the EngineEmergency Stop Control locatedon the lowerR.H.side of control stand.

SeeFigure3.4.

2. Turn KeySwitchto the "OFF"position.

En3. Beforerestarting engine, pushEmergency gineStopControlin.

FIGURE3.4

3-I

Section III-BASIC i

!

ii

MACHINEOPERATION

i

3.3 STARTING & STOPPING MACHINE ENGINEWITH TEMPERATURE BELOW8°C (45°F) A, STARTINGENGINE 1. MoveThrottle Control to the LowIdle position.

SeeFigure 3.5.

2. Insert Keyinto Ignition Switch and turn to the left, to the engineheat position. SeeFigure3.5.

Heatindicator, battery charge,andengineoil pressure lights will comeon. Switchis spring loaded andwill return to the off position whenreleased.

Sincethere is no thermostat,timer, or readyindicator for the pre-heater, follow these pre-heat guidelines: Above8°C (45°F) No pre-heat is required.

Heat for 10 seconds.

8 ~ -8°C (45 ~17°F) -8 ~ -19°O(17 ~ -2°F) Heat for 20 seconds.

-19°C > (-2°F >) Heat for 30 seconds.

3. SoundHorn to warn any personnel that the machine is being started. SeeFigure 3.6.

4. Turn Key to the "START"position and crank the engine for 30 seconds. (Figure 3.5) If engine doesnot start, stop cranking and wait 2 minutes to allow the starter to cool before attemptingto start the engine again. Pre-heat cycle can be repeated during this cool downperiod. Release the Key as soon as the engine starts. Key will automaticallyreturn to the "ON"position.

II

NOTE If enginefails to start after 3 attempts,inspectfuel system and correct any problemsfound. When cranking engine, the absenceof "Blue"or "White"smoke fromthe exhaustindicatesno fuel is reachingthe enginecylinders. In climatesbelow -19°C(-2°F) it maybe necessary to usea coolantheater,fuel heater,engineheaterjacket and/oradditionalbattery powerto aid in starting the engine.

I

II I

FIGURE3.5

FIGURE3.6

WARNING

THIS MACHINE lSEQUlPPED ..... - ~..iO0= NOTi=: USE ,~HER, " ........... .

WITH AGRID AiR HEATER~ . ...... .... ......... ...... ............... : =~4~ FIGURE3.7

I I|

B, STOPPING ENGINE- NORMALCONDITIONS 1. Movemachineto a firm, level area and place the attachmentin the Hydraulic Oil CheckPosition.

SeeFigure 3.8.

2. MoveThrottle Control Leverto the LowIdle Position. SeeFigure3.5. Allowthe engineto idle for 5 minutes.

Turn KeySwitch to "OFF".

3.

C. EMERGENCYENGINE SHUT DOWN In only cases of emergencyshould this method be used.

1. Pull out the EngineEmergency Stop Control located on the lower R.H. side of control stand.

SeeFigure 3.9.

2. Turn KeySwitch to the "OFF"position.

3. Before attempting to restart the engine, push Emergency Engine Stop Control in.

FIGURE3.8

FIGURE3.9 ii

3-2

I:

ATTACHMENT IN HYDRAULIC OIL CHECK POSITION

Section

III-BASIC

MACHINE OPERATION

3.4 STARTINGMACHINEENGINE WITH BOOSTER CABLES A. CONNECTINGBOOSTERCABLES 1. Movevehicle or machine to be usedfor boosting as closeto the batteryboxof the disabled machineas possible.

/ix, ¯ DO NOTALLOWTHE VEHICLEOR MACHINE USED FOR BOOSTINGTO TOUCHMETALTO METALWITH THE DISABLEDMACHINE.THIS COULDSHORTCIRCUIT ELECTRICALSYSTEMS ANDCAUSEEXTENSIVEDAMAGE TO THE GAUGE CLUSTERAND OTHERCOMPONENTS.

FIGURE3.10

Useonly vehicles or machines with 24vdc ~tectrical systemfor booststarting this machine.

2. Makecertain KeySwitchof disabled machine is in the "OFF"position beforeproceeding with boostercable connection.SeeFigure3.10.

WEARHARDHAT, APPROVED SAFETY GLASSES OR FACESHIELD, GLOVESANDOTHERSAFETY EQUIPMENTWHENWORKINGWITH BATTERIES. 3. Locateandconnectoneendof the boostercable to the Positive(+) terminalonthe batteryof the disabledmachine.SeeFigure 3.11. other endof positive boostercableto 4. Connect positive (+) terminalof battery beingusedfor boosting.

5. Locateand connectsecondcable to the Negative (-) terminalof the batterybeingusedfor boosting. other endof Negative(-) cableto the 6. Connect upperframeof disabledmachineas far away frombattery as possible. SeeFigure3.12.

THE NEGATIVECABLE, WHENCONNECTED TO THE UPPERFRAMEOF DISABLEDMACHINE, MAY ARCCAUSINGSPARKS.SPARKSCOMINGIN CONTACT WITH BATTERIES, COULDTRIGGERAN EXPLOSION. NEVERCONNECTNEGATIVECABLETO NEGATIVE(-)TERMINALOF DISABLEDBATTERY.

3-3

FIGURE 3.11

FIGURE3.12

Section

III-

BASIC MACHINE OPERATION

B. STARTING DISABLEDMACHINE ENGINE 1. Start engineof disabledmachine in normal manner accordingto climateconditions.Refer to pages 3-1& 3-2for specificstartinginstructions.

C. DISCONNECTING BOOSTER CABLES engineis running,dis1. After disabledmachine connectthe Negative(-)Cablefromdisabled machine upperframe.SeeFigure 3.13.

Negative(-)CablefromBatteryused 2. Disconnect for boosting.

3. Disconnect Positive(+)Cablefrombattery used for boosting.

4. Disconnect Positive(+)Cablefromterminal disabledmachine.SeeFigure3.14.

FIGURE 3.13 NOTE Makesure to securedoor openwith door lock bar duringservice.

Whenusing Booster Cables remember; 1. ConnectPositive (+) CableFirst.

2. DisconnectNegative(-) CableFirst.

5. After disabledmachine is runningandbooster cableshavebeenproperlydisconnected, performBatteryMaintenance as describedin the Maintenance Section.

/ I

NEVERPERFORMBATTERYMAINTENANCE WITH A RUNNINGMACHINE!

FIGURE 3.14

3-4

Section III-

BASIC MACHINE OPERATION

3.5 MACHINEWARMUP A. ENGINE 1. Allow the engineto run for 5 minutesunderno load conditionswith Throttle Controlat low idle position. SeeFigure3.15.

2. Duringwarmup, visually andaudiblyinspect enginefor abnormal conditionssuchas unusual exhaustcolor, excessivevibrations andexcessive or unusualnoises.

3. Shouldproblemareasbe noticed, stop engine, locateandrepair areasbeforerestarting or operating the machine.

B. HYDRAULIC OIL 1. Donot operatemachineuntil the ColdHydraulic Oil IndicatorLamp is out. SeeFigure3.16.

Throttle Controlto "HI" idle position.

2. Move 3. Operate Bucketin andholdoverrelief for 10 to 15 seconds,then operatebucketout andhold overrelief for 10to 15seconds.

Repeat this operationfor 5 to 10 minutes to helpoil to reach operatingtemperature.SeeFigure3.17, Throttle Controlto Midposition andoper4. Move ate the Boom,ArmandSwingcontrols for 5 to 10 minuteseach.SeeFigure 3.18A. the Cold HydraulicOil Indicator Lamp is 5. When out, normalmachineoperationsmaybegin.

C. HYDRAULICOIL IN FRIGID TEMPERATURES 1. PerformnormalHydraulic Oil Warm-Up procedures.Perform theseuntil IndicatorLamp is out.

Warm-Up timewill takelongerin frigid temperatures.

NOTE If machine is operatedin frigid temperatures daily, it may be necessaryto changethe HydraulicOil to an oil designedfor operationin frigid climates.Referto maintenancesectionfor hydraulicoil specifications.

IN

FIGURE3.15

FIGURE3.16 BOOM DOWN BUCKET IN

J R.H.

CONTROLLEVER

BOOM UP

FIGURE3.17 L.H.

CONTROLLEVER

ARM OUT

SWING LEFT

Duringoperationof the machine with cold hydraulicoil, the operator mayexperienceslow or unexpected movement of functions.

Damage to Hydraulic components mayresult due to the cold oil not providingadequate lubrication.

NOTE If your machineis equippedwith the OPTIONAL HYDRAULICWARM-UP CIRCUIT,follow instructions given on next page.

FIGURE3.18A

3-5A

Section

III-

BASIC MACHINE OPERATION

D. OPERATION INSTRUCTIONS FOR OPTIONAL HYDRAULICWARM-UP CIRCUIT 1. Start engine.FollowOperatorsManual instructions(Par.3.5.A,above),for properengine warm-up procedure.

Move throttle control to highidle position,after 2. engineis sufficiently warmed up. SeeFigure 3.18B. start switchonleft consoleonce.

3. Pushwarm-up SeeFigure 3.18C. 4. Orange indicatorlamplocatedto the left of the warm-up switch shouldcomeon. Lamp indicates system is in operation.Warm-up circuit will not start (orange indicatorlampwill not turn on)unless the red ColdHydraulicOil IndicatorLamp locatedonright consoleis on.

5. Hydraulicoil will besufficiently warm for normal operationwhenbothlampsturn off.

NOTE Besureto warm-up attachment cylinders, swingandtravel motorsby cycling thesefunctionsbeforebeginningnormaloperation.Warm-up procedure is described in Par.3.5.B, above. Thesefunctions maybe cycled during warm-up system operation,but system will shutoff duringthat time.

When controls are released, warm-up systemoperation will continueonceagain,as longas the red ColdHydraulic Oil IndicatorLamp is still on.

FIGURE3.18B

6. Machine is nowreadyto beginnormaloperation.

7. Operationof warm-up systemcanbe stoppedby pushingthe warm-up switch again, anytime duringit’s operating cycle.

FIGURE3.18C

3-5B

Section III-BASIC

MACHINEOPERATION

3.6 OPERATOR’S CONTROLS A. OPERATING PA’I-rERN TheOperatingandTravel Controlsof this machine are factory set to ISOstandardoperatingpatterns for optimum performance of the machine andits systems.

andunderstand the directions eachcontrol can be operated,andthe functionsassociatedwith eachmovement of a particular control, Detailed instructionsfor eachcontrolandits functionsare explainedonthe followingpagesof this section.

B. OPERATING PATTERN Figure3.19representsthe Operator’s "CONTROLS" functions. Studythis figure

LEFT TRAVEL LEVER AND

RIGHT TRAVEL LEVER AND

OOO FIGURE 3.19

3-6

Section

III-

BASIC MACHINEOPERATION ii

3.7 BASIC OPERATIONOF HYDRAULICCONTROLS Thefollowinginstructions are aimedat providingan operatorwith the basicfunction of eachhydraulic control. Useof theseinstructionsandpracticewith a machine,will allow a givenoperatorto become more efficient in the operationof this equipment.

Eachoperatormustread, understand andfollow these basicinstructionsalongwith all safetyprecautions foundin this manualandon the machine beforeoperating this equipment.

Normalpositioningof the machine for the sakeof determining front, rear, forwardandreverseare with the travel motorslocatedat the backof the machine.See Figure 3.20.

ALWAYSKNOWTHELOCATIONOFTRAVEL MOTORSBEFOREOPERATINGANY HYDRAULICCONTROLS. When travel motorsare locatedin front of the machine, the travel controllever andpedalactions will be reversed.

FIGURE3.20

(UP) POSITION

A. SAFETYLOCKLEVER-FIGURE3.21 1. Unlocked Position Beforeanypilot-operatedHydraulicOperation is possible, the SafetyLockLevermustbe placed in the "UNLOCKED" (DOWN) position. Placing the Safety LockLever in the UNLOCKED (DOWN) positionalso positionsthe L.H. Operators Consolein its operating position.

2. Locked Position Beforeleavingthe operatorcab, placethe SafetyLockLeverin the "LOCKED" position by pulling lever up. WithSafetyLockLeverin the "LOCKED" (UP) Position, no pilot-operatedhydraulic operationis possible,andallowseasy accessin andout of the operatorseat.

m ALWAYSPLACE THE ATTACHMENTS ON THE GROUND AND PLACE THE SAFETYLOCK LEVER IN THE"LOCKED"(UP) POSITIONBEFORE LEAVING CABTO PREVENTANY OPERATION OF HYDRAULICCONTROLS. FAILURE TO PLACESAFETYLOCKLEVERIN THE LOCKED(UP) POSITIONCOULDRESULT SERIOUSINJURY OR DEATHASWELLAS SERIOUSDAMAGE TO THE MACHINEANDITS COMPONENTS.

FIGURE 3.21

3-7

Section

III-BASIC

MACHINE OPERATION

C. MACHINETRAVELCONTROLS This machine incorporatesseveralTravel Controls for the convenience of the operator.Eachtrack canbe operatedindependently to turn the machine or simultaneously to spin turn the machine or travel straight. Referto Figure3.20andWarning for trave/ motorposition.

1. OperatingBothTravel LeversTogether a. Pushboth TravelLeverstowardfront of machine and machinewill travel "FORWARD".

SeeFigure 3.24. b. Pull BothTravelLeverstowardoperatorseat ~ and machinewill travel in "REVERSE".

See Figure3.24. c. Returnboth Travel Leversto "NEUTRAL" (center)positionandmachine will stop. Parking Brakesare automaticallyapplied when TravelLeversare in Neutralposition.

TRAVELALARMSWITCH PRESS HERE FOR"OFF"

FIGURE3.23

NOTE Travel Alarmmaybe turnedOFFafter approximatelyfive seconds after travel is engaged.

SeeFigure3.23.

NOTE ThedistanceTravel Leversare Pushedor Pulled determinesTravel Speedof the Machine.

EXAMPLE: Travel Leversare pulled or pushedto full stroke- Machine will Travelat top speed.

Travel Leversare pulled or pushedto mid position- Machine will Travel at 1/2 speed.

2. Useof Travel SpeedSelect Switch a. For fast travel speed,depressandrelease the Travel SpeedSelect Switchoncebefore operatingthe travel controls.SeeFigure3.25.

This puts the travel motorsin "FAST"(4p) travel speedandthe greenL.E.D. indicator lampfor "FAST"(,I~,),on the Gauge Cluster Display,will comeon. b. Toreturn to "SLOW" travel speed,stoptravel and depressand release Travel SpeedSelect Switchonce.SeeFigure3.25.

This returns travel motorsto "SLOW" or normaltravel speedandthe greenL.E.D. indicatorlampfor "FAST"(#O) will turn off.

FIGURE3.24

IPRESSTOSEILECT FASTOR SLOWTRAVEL I SPEED I

Use"FAST"(/Ip)Travel Speedon Firm, Level SurfacesOnly.

FIGURE3,25

3-8

Section

III-

BASIC MACHINE OPERATION

3. TurningMachine a. Pushthe L.H.TravelLevertowardthe front of the machine to turn it RIGHT in ForwardMotion. SeeFigure3,26. b. Pull the L.H.TravelLeverbacktowardoperator seat to turn machine to the LEFTin reversemotion.SeeFigure3.26. c. Pushthe R.H. Travel Levertowardthe front of machineto turn machineto the LEFTin forwardmotion.SeeFigure3.27. d. Pull R.H.Travel Levertowardoperatorseat to turn machineto the RIGHT in reversemotion. SeeFigure3.27

FIGURE3.26

4. SpinningMachine a. Pull L.H. Travel LeverBACK andPushR.H. Travel Lever FORWARD to spin machineto the LEFT.SeeFigure3.28. b. Pull R.H.Travel Lever BACK andPushL.H. Travel Lever FORWARD to spin machineto the RIGHT.SeeFigure 3.29.

NOTE Noticethat all theseTravel functionscanbe performed usingeither the Pedalsor the TravelLevers.

FIGURE3.27 --

RIGHT LEVER

USE THE TRAVELALARMDURING ALL TRAVELOPERATIONS

on Shoetype and groundconditions this 1. Depending °machinehasa maximum climbing ability of 35 (70%)Maxfmum.

(Limited by EngineLubrication). approachingor descendinga slope, operate 2. When the TravelSlowly.

3. For Brakingslowly, returnTravelLeversor pedalsto the Neutral(center) position. Brakesare engaged automatically.

4. DoNot Travelthe Machine for morethan two(2) hours 5. In extremelycold conditions,below-20°C(-40°F), the TravelLeveror Pedalaction maybe "heavier" thannormal.Thisis normaldueto the viscosity of the HydraulicOil in Frigid Climates.

FIGURE3.28 LEFT LEVER FORWARD RIGHT LEVER BACK TO SPIN MACHINERIGHT

FIGURE3.29

3-9

Section

III-BASIC

MACHINE OPERATION ii

5. TRAVELLEVERREMOVAL & STORAGE a. Removal 1. Usinga 17ramwrench,loosenthe Travel Lever ClampBolt on eachTravel Lever. See Figure3.30.

2. Carefullypull TravelLeverfree fromclamp andtighten clampbolts with 17ramwrench. b. Storage 1. Moveoperator seat completelyforwardand adjustseat backreclining positionforward.

Referto Figure2.46~ 2.47.

2. Loosenthe Travel Lever StorageClamp MountingBolts using a 17mm wrench.See Figure3.31.

3. Place Travel Leversin StorageClampsand tighten clampbolts securelywith 17ram wrench.SeeFigure 3.31.

FIGURE3.30

6, TRAVELSAFETY a. Makecertain Travel MotorLocationis known beforeperforminganytravel operation. b. Travelon firm, level surfacesas muchas possible. ¢. When Travelingon roughterrain, travel in SLOW(~I~ ) speedwith engineat a low idle. d. When traveling or operating machineon snow or icy surfaces,cleantrack shoesfrequentlyto preventclogging.This will help keepthe machinefromsliding unexpectedly. e. Keepa safe distancefromstationaryobjects andelectrical power~ines. f. Be awareof LoadCapacitiesof bridgesand roadshoulders.Reinforceif necessary. g. Usedeckingor plating to protect roadsurfaces as muchas possible. Becareful whenturning or spinningmachine on hot asphalt. h. Donot allow large or heavyobjectsto strike travel motors. i. Donot Traveloverlarge objectssuchas boulders, rocksetc. j. If necessary to travel or operatemachine in a river or other water,the bedmustbe firm and watercurrent slow. Watermustnot be deeper thanindicatedin the chart in Figure3.31A.If SwingBearing becomes submerged in water, immediategreaseandswingbearingsumpbath changeand/or swingbearingrebuild are required. SeeMaintenance Section~ k. Onsoft groundor mudthe machine cansink.

Stay constantlyawareof undercarriage position.

3-10

FIGURE3.31

--

L

MODEL

~

BED MUST BE FIRM & STABLE ~LMAXIMUM WATERDEPTH I

FIGURE3.31A

Section

III-

BASIC MACHINE OPERATION

D. MACHINEATTACHMENT & SWINGCONTROLS Thefollowinginstructionsfor Operation of AttachmentControlsfor usewith HoeBucketattachment.

If other attachments are beingused,consultthe OperatorsManualfor the particular attachment.

NOTE It is necessary that the ExtraControlSwitchbekeptin the "OFF"positionduringexcavating functions,for propermachineperformance.

(If so equipped.)

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTION DURINGALL OPERATIONS OF THIS MACHINEANDITS ATTACHMENT.

PULL BACK BOOMUP

1. BoomOperation- FIGURE 3.32 a. Operationof the Boom is performed by pushing andpulling the R.H.ControlLeverForwardand Backward.BoomSpeedis deter minedby howfar the Leveris activated.

1. Pulling R.H.Control LeverBACK raises Boom.

2. Pushing R.H. Control Lever FORWARD lowers Boom.

Returning R.H.Control Leverto the Neu3. tral (center)positionstopsoperation the Boom.

2. ArmOperation- FIGURE 3.33 a. Operationof the Armis performed by pushing or pulling the L.H. ControlLeverForward and Backward.ArmSpeedis determinedby howfar the Leveris activated.

1. Pushingthe L.H. Control Lever FORWARD movesthe Armout. moves 2. Pulling the L.H. Control LeverBACK the Armin.

3. Returningthe L.H. ControlLeverto the Neutral(center)position, stopsoperation of the Arm.

PUSH FORWARD BOOMDOWN

FIGURE3.32 PULL BACK ARMIN

PUSH FORWARD ARM OUT

FIGURE3.33 PUSHLEFT BUCKETIN

PULL RIGHT BUCKET OUT

3. BucketOperation- FIGURE 3,34 a. Operationof the Bucketis performed by moving the R.H.ControlLeverto the Rightor Left.

1. Movingthe R.H. ControlLeverto the LEFT operatesthe BucketIn (digging).

2. Movingthe R.H. ControlLeverto the RIGHT operatesthe BucketOut (dumping).

FIGURE3.34 BE CAREFULWHENOPERATINGCERTAIN ATTACHMENTS CLOSETO THE CAB. STOPATTACHMENT A SAFE DISTANCEAWAY FROMCABTO AVOID DAMAGE OR INJURY.

3-11

Section

II!-BASIC

MACHINE OPERATION PULL LEFT

4. SwingOperation- FIGURE 3.35

PUSH RIGHT SWING RIGHT

SWING LEFT

NOTE UseSwingFlashersduring SwingOperations.

a. Swingoperationis performedby movingthe L.H.Controllever to the right andleft. Swing speedis determinedby the amount the lever is moved.

1. Movingthe L.H. Control Lever to the LEFT swingsthe machine to the left.

2. Movingthe L.H. ControlLeverto the RIGHT swingsthe machine to the right.

3. Returning control to the Neutral(center) position stopsswing. ~’~

~,

~

~

~

MAKECERTAINAREAIS CLEAROF OBSTACLES ANDPERSONSTO ALLOWSWINGOF THE MACHINE. SOUNDHORNBEFOREBEGINNING SWINGOPERATIONS.

ALWAYSPLACETHE MACHINEATTACHMENTS ON THE GROUND AND LOCKUP THE SAFETYLEVER BEFORELEAVINGTHE CAB. FAILURETO DO SO, COULDRESULTIN SERIOUSINJURYOR DEATH.

3-12

FIGURE3.35

Section

III-BASIC

MACHINE OPERATION

E. USINGMANUAL "ONE-TOUCH" DECELSYSTEM TheKOBELCO "One-Touch" Decel System,located onthe right handside joystick, is designed to be used during operations whenthe machinemay sit idling for a periodof time,suchas waitingbetweentrucks during loading operations.Its purposeis to manuallydecreaseand increase engine RPM withoutuseof the throttle control.

1. Set Throttle Controlto HighIdle position. See Figure3.39.

2, Depressthe DecelSwitchto the "ON"position to reducethe RPM to approximately 1050 RPM.See Figure 3.40. the DecelSwitchto the "OFF"position 3, Depress to resume normalloadingoperations.SeeFigure 3.40. TheDecelSystem will automatically increasethe engineRPM to matchthe Throttle Controlsetting.

FIGURE3.39

DO NOTUSE ONE-TOUCH DECELSYSTEMFOR NORMAL DIGGINGOPERATIONS,LOADINGOR UNLOADINGMACHINEOR OPERATIONSWHERE FINE CONTROL IS REQUIRED.

FIGURE3.40

3-13

Section

Iil-BASIC

MACHINE OPERATION

3.8 PRACTICES TO IMPROVE EFFICIENCY

USE ARMPULLINGACTION AS MUCHAS POSSIBLE

A. UseArmPulling Action- FIGURE 3.41 Operatethe bucketat shallowdepthsandusethe ArmPullingForceto fill the bucket.Settingthe buckettoo deepwill decrease the machine’s efficiency.

FIGURE 3.41 B. Operate BoomSmoothly-FIGURE3.42 AlwaysbeginandendBoom Operationslowly with smoothcareful movement of the control lever. Do not performsuddenstarts andstops of the boom as this createsunnecessary stress on the machine and its components.

OPERATEBOOMSMOOTHLY DURINGALL BOOMOPERATIONS

f

FIGURE3.42 C. BucketTeeth Direction- FIGURE 3.43 Alwayspoint bucketteeth in the direction the machinewill be diggingto reducediggingresistance andthe possibility of bucketteeth damage.

ALWAYSPOINT BUCKETTEETH IN DIRECTIONOF DIGGING

FIGURE3.43 D. Maximum DiggingForcePosition-FIGURE 3.44 Theattachmentwill provide maximum digging force whenthe ArmandBoom are at 90° ~ 110° of eachother.

MAXIMUM DIGGINGFORCEIS OBTAINED WITHBOOM ANDARMAT 90° ~ 110° OF EACHOTHER

FIGURE3,44

3-14

Section

III-

BASIC MACHINEOPERATION

E. CleaningSand& Soil from Bucket-

OPERATE BUCKET IN & OUTWITH ARMOUT TO DISLODGEMATERIALFROMBUCKET

FIGURE 3.45

~’ ,,~,~"~1"~

OperateArmto a nearlevel position andbring the bucketto a dumping position. If sandandsoil do not fall out, movethe bucketlever backand forth a fewtimes. ’ ,,~ ........ ,.,~i~:~~ ’ .... ~,,,~.~,,,,~ Avoidshakingout soil usingshocksat the endof the bucketcylinderstroke.

~

F. Stop SwingMotionEarly- FIGURE 3.46 Tostopswingaction, releasethe swinglever before youget to yourfinal point of diggingor dumping.

~ ~.,

~>

FIGURE3.45

RELEASESWINGBEFOREREACHINGDESIRED DIGGINGPOSITION

G. BackFilling & Leveling- FIGURE 3.47 Forbackfilling andlevelingworkafter digging, movethe bucketbackandforth horizontally.

NOTE Donot pushandpull materialwith the bucketlike a bulldozerwhileusingthe machine for leveling material.

FIGURE3.46 1. In leveling groundtowardmachine, pull the arm gently, lift the boom a little andwhen the arm haspassedthe vertical point, lowerthe boom gently and manipulatethe machineso the bucketmoveshorizontally.

2. For leveling groundawayfrommachine,reverse operationin step 1 above.

3. In the aboveoperation, bucketmotionmaybe usedtogetherwith the boom.Bycontrolling the action of the boom worklever, youcandig a slopelike slopefacingoperation.

4. Nevertravel with attachmenttouchingthe ground.Severestructural damage could occur.

U S E A RMTOMOORE BUvCEKLIETGH ORIZO N TALLY

FIGURE3.47 H. Operatingthe Shovel-FIGURE 3.48 Diggingwith the shovelslightly differs fromdigging with backhoe.

1. Usingthe armcylinder, scrapethe ground.

2. Scrapethe groundat 2°-3° to improvedraining in areasnearthe groundwater level. the reversedbucket 3. Becareful not to bump into the cab.

4. Theexcavatingpowerduring shoveloperations is less than that duringbackhoe operations. bucketis equipped with a lifting 5. If machine eye, checkto make sure that the eyewill clear armwith bucketcylinderin full extended (full dump)position.

3-15

GRADE AT A 2 ~ 3° SLOPEFORDRAINAGE

FIGURE3.48

Section

III-

BASIC MACHINE OPERATION

I. MACHINEOPERATION IN ADVERSEWEATHER CONDITIONS o not allowDirt andDebristo accumulate in the radiator 1. Operationin ExtremeCold a. Followprocedures on page3-2 as Starting fins, oil coolerfins or debrisscreen. enginemaybe difficult dueto extremelycold temperatures. c. Keepall Belts properlytensioned. b. Usean engineoil, HydraulicOil andFuelOil d. Make certain that the enginecoolantmixture designed for usein cold climates.Also, keep is sufficient to keepthe machine safe. battery fully charged. e. If the machine becomes overheated,Idle the ¢. Makecertain to perform MachineWarm-Up machine to help cool the engine,turn engine procedures as describedon page3-5 to pre"OFF"andcheckcoolantlevel. After filling to vent prematurewearor damage to pumps, properlevel, if the machine continuesto over motors and other components. heat, stop engine,allow to cool, drain and flush entire coolingsystem andrefill with the NOTE propermixtureof fresh, cleancoolant.

In extremelyfrigid climates, coveringthe radiator is a f. Check the batteryelectrolyte(acid) level fremethod to aid the machine warm-up.

If necessary to mainquentlyandfill as necessary with distilled tain operationtemperatures, coverpart of the radiator. water.

However,keepa close watchon the Temperature Gauge g. Keepwatchof theTemperature Gaugeand and WarningLamp.

Lamp,and Oil PressureLampduring opera tion. Avoidunnecessary low speedrunningof d. Make certain that the enginecoolantmixture the engineduringoperation.Duringslowor no is sufficient to keepthe machine safe.Take workperiods,placethrottle controlin "LO"Idle into considerationwindchill factors when position. mixingcoolantratios.

3. Operationin HighAltitudes NOTE a. Dueto low atmospheric pressureat highaltiMixcoolantto a protectiontemperature of 5°C(41°F)lower tudes, a decreasein enginepowerwill be than the machine will experience during operation,storexperienced as well as a decrease of air denageor transport. sity for enginecooling.Beawareof this fact whenplacing machineunder heavyload in e. KeepBatteryTerminals free of ice andsnow. highaltitude climates.

Ice andsnowcould causethe terminals to b. Keepclose watchon the EngineTemperashort circuit andcauseextensivedamage to ture Gauge to avoidoverheatingof the enthe machine systems.Checkthe battery elecgine. trolyte (acid) level frequentlyandfill as nec4. Operationin SandyandDustyareas. essarywith distilled water.If the machine will a. Checkthe EngineAir CleanerElementsFrebe left outsideovernight,it is recommended quentlyin Sandyor Dustyconditions. to remove the batteries andstore in a warm b.

When Air CleanerRestrictionIcon isdisarea. played, Change Filters immediately regardless of time intervals.

NOTE ¢.

Service Fuel Pre-Filter, FuelFilter, Water The KOBELCO Mark IV Excavators incorporate a Heavy Separator, and all Hydraulic Filters frequently.

DutyStarter andHeavyDutyBatteries as Standardequipment.Thereforeevenin frigid climates,it shouldnot be 5. Operationat Seashore or Salty Climate necessary to install a highercapacitystarter or batteries. a. Thoroughly washmachine daily to help avoid corrosionof machined areas,electrical comf. Donot park machine lower rollers in water. ponentsandcylinder rods.

Freezingof rollers mayoccur causingthem b. Frequentlycheckall mountinghardwarefor to leak. propertightness. Torqueto propervalueto aid in preventingsalt fromenteringthe ma2. Operationin ExtremeHeat chine systems. a. Usean engineoil, HydraulicOil andFuelOil designed for usein hot climates.Also, keep 6. Operationin HumidClimate battery fully charged. a. In Climateswith high humidity,thoroughly b. CleanRadiator,Oil CoolerandDebrisScreen washthe machine daily andcoat all bare often to preventdamage or overheatingof surfaceswith an oil basedlubricant to help the machine. preventcorrosion.

I

3-16

Section

III-

BASIC MACHINEOPERATION

3.9 FLAGMAN HANDSIGNALS Thefollowingis a compilationof the HandSignalsto be usedwhena flagmanis required for Excavator Operation.All personnelassociatedwith the operation of the excavatorshouldknowthesesignals and their meaning beforeattemptingto operatethis machine.

1

A. RAISE LOADVERTICALLY FaceMachine Operator,raise right forearmvertical, with indexfinger pointingup andmove hand in a small circular motion.SeeFigure3.49.

FIGURE3.49 B. LOWER LOADVERTICALLY FaceMachineOperator,extendright armdown, point index finger downandmovehandin a small circular motion.SeeFigure3.50.

FIGURE3.50 C. MOVELOADIN HORIZONTALLY FaceMachineOperator,extendright armtoward operatorwith handfacing operatorandmovehand in directionof movement required.SeeFigure3.51.

FIGURE3.51 D. MOVELOADOUT HORIZONTALLY FaceMachineOperator,extendright armtoward operatorwith backof handfacing operatorand movehandin direction of movement required. See Figure3.52. g, tit

/-i/

= |l

Jf ¯ ¯ i !

FIGURE3.52

3-17

Section

III-BASIC

MACHINE OPERATION

E. RAISE BOOM FaceMachineOperator,extendright armout horizontallyfromshoulder,make a fist with thumb up. SeeFigure3.53.

t

FIGURE3.53 F. LOWERBOOM FaceMachineOperator,extendright armout horizontally fromshoulder,make a fist with thumb down.SeeFigure 3.54.

FIGURE3.54 G. SWINGLEFT FaceMachine Operator,extendright armout horizontally fromshoulder,make a fist with indexfinger pointingin swingdirection. SeeFigure3.55.

FIGURE3.55 H. SWINGRIGHT FaceMachine Operator,extendleft armout horizontally fromshoulder,make a fist with indexfinger pointing in swingdirection. SeeFigure3.56.

FIGURE3.56

3-18

Section

III-BASIC

MACHINE OPERATION

I. ARM IN FaceMachine Operator,bendat elbowswith arms facing operator,makefists andpoint thumbs in towardeachother. SeeFigure 3.57.

FIGURE3.57 J. ARMOUT FaceMachine Operator,bendat elbowswith arms facing operator,makefists andpoint thumbsout awayfrom eachother. SeeFigure3.58.

FIGURE3.58 K. COUNTER ROTATELEFT FaceMachine Operator,place right handon top of hardhat, bendleft armat elbowto the right, make a fist with left handwith indexfinger pointing out androtate handin a reversecircular motion. SeeFigure3.59.

FIGURE3.59 L. COUNTER ROTATERIGHT FaceMachine Operator,place left handon top of hardhat, bendright armat elbowto the left, make a fist with right handwith indexfinger pointing out androtate handin a forwardcircular motion. SeeFigure3.80.

FIGURE3.60

3-19

Section

III-BASIC

MACHINE OPERATION

M. TRAVELFORWARD FaceMachineOperator,bendboth elbowsin, make fists androtate fists oneoverthe otherin a reversecircular motion.SeeFigure3.61.

FIGURE 3.61 N. TRAVELREVERSE FaceMachineOperator,bendboth elbowsin, make fists androtate fists oneoverthe other in a forwardcircular motion.SeeFigure3.62.

FIGURE3.62 O. CLOSEBUCKET(BUCKETIN OR DIG) FaceMachine Operator,hold left handin,closed andstationary,holdright handin, make a fist with index finger pointing towardleft handandmove right handin a small forwardcircular motion.See Figure3.63.

J FIGURE3.63 P. OPENBUCKET(BUCKET OUT OR DUMP) FaceMachine Operator,hold left handin,open andstationary,holdright handin, make a fist with index finger pointing towardleft handandmove right handin a smallforwardcircular motion.See Figure3.64.

FIGURE3.64

3-20

Section

III-

BASIC MACHINE OPERATION

Q. TURNLEFT FaceMachine Operator,raise right forearmup, make fist with right handandholdstationary,bend left armin, make fist with left handandrotateleft fist in a smallreversecircular motion.SeeFigure 3.65.

i FIGURE3.65 R. TURNRIGHT FaceMachine Operator,raise left forearmup, make fist with left handandhold stationary,bend right armin, make fist with right handandrotate right fist in a smallforwardcircular motion.See Figure3.66.

FIGURE3.66 S. MOVETHIS MUCH FaceMachineOperator,raise both forearmsup, handsopenand facing eachother, movehands in laterally indicatinghowfar to go. SeeFigure 3.67.

FIGURE3.67 T. MOVESLOWLY FaceMachine Operator,raise left armout horizontally towardright shoulderwith handopenand facing down,point right indexfinger up toward openleft handandrotate right handin a reverse circular motion.(RaiseLoadSlowlyis Illustrated.)

SeeFigure 3.68.

FIGURE3.68

3-21

Section

III-BASIC

MACHINE OPERATION

U. STOP FaceMachine Operator,raise left armout horizontally fromshoulderwith handopenandfacing down,movearmin a horizontal motionbackand forth. SeeFigure3.69.

FIGURE3.69

V. EMERGENCY STOP FaceMachine Operator,raise both armsout horizontally fromshoulderswith handsopenandfacing down,movearmsin a horizontal motionback andforth. SeeFigure3.70.

FIGURE3.70

W. STOPENGINE FaceMachine Operator,right armat side, draw left thumb or indexfinger acrossthroat. See Figure3.71.

FIGURE3.71

3-22

Section IV- MAINTENANCE Table of Contents

GENERAL INFORMATION ................................................................. : ...............................................................................................

4-2 Inspection &MAINTENANCE Schedule ........................................................................................................................

4-2 ~ 4-52 KOBELCO Supplies &Parts ..................................................................................................................................................... 4-2 GENERAL SAFETY ..................................................................................................................................................................

4-2 ~ 4-4 INSPECTION &MAINTENANCE CHART ................................................................................................................................

4-5 ~ 4-6 FLUIDS &FILTERS ..................................................................................................................................................................

4-7 ~ 4-8 Required Fluids &Quantities ...................................................................................................................................................4-7 Required Filters .........................................................................................................................................................................

4-7 KOBELCO Fluids &Lubricants ................................................................................................................................................ 4-7 Lubricant Specifications ............................................................................................................................................................

4-8 PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE ......................................................................................

4-9 ~ 4-21 Engine OilLevel .........................................................................................................................................................................

4-9 Engine Coolant Level ................................................................................................................................................................

4-9 Engine Fluid Leaks ....................................................................................................................................................................

4-10 Fan BeltWear &Tension ..........................................................................................................................................................

4-10 Fuel Level .......................................................................................................................................................................

4-10~ 4-11 Water Separator .......................................................................................................................................................................

4-11 AirCleaner .................................................................................................................................................................................

4-12 Engine Electrical ........................................................................................................................................................................

4-13 Fuel Tank Drain ..........................................................................................................................................................................

4-13 Hydraulic OilLevel ........................................................................................................................................................

4-13~ 4-14 Hydraulic Functions .................................................................................................................................................................

4-15 Hydraulic OilLeaks ...................................................................................................................................................................

4-15 Machine Electrical ....................................................................................................................................................................

4-15 Step &Handrails ......................................................................................................................................................................

4-16 Frame Structure .......................................................................................................................................................................

4-16 Tracks &Components .................................................................................................................................................4-16 ~ 4-17 TrackTension .............................................................................................................................................................................

4-18 Boom &Arm .............................................................................................................................................................................

4-19 Blade Cutter, BucketTeeth &Side Cutters ...........................................................................................................................

4-19 4-20 ~ 4-32 50HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE ......................................................

Fuel Pre-Filter ..........................................................................................................................................................................

4-20 Engine Oil&Filter.....................................................................................................................................................................

4-21 Fuel Filter ....................................................................................................................................................................................

4-22 AirIntake System .......................................................................................................................................................................

4-23 Fan ..................................................................................................... ; .......................................................................................

4-23 BeltTensioner .......................... . ..................................................................................................................................................

4-23 Vibration Damper .....................................................................................................................................................................

4-23 Radiator, OilCooler &Debris Screen ..................................................................................................................................... 4-24 Hydraulic Return Filter..............................................................................................................................................................

4-25 PilotManifold Filter/Screen .....................................................................................................................................................

4-26 Batteries ........................................................................................................................................................................

4-26 ~ 4-27 Swing Motor Reduction Oil......................................................................................................................................................

4-28 Slewing Ring ............................................................................................................................................................................

4-29 Travel Motors .............................................................................................................................................................................

4-30 Attachment Lubrication ..................................................................................................................................................

4-31~ 4-32 500,1,000& 2,000HOUR INSPECTION & MAINTENANCE ............................................ . ..........................

4-28,4-29,&....4-33~ 4-39 Cleaning Hydraulic Suction Screen ........................................................................................................................................ 4-33 Changing Engine Coolant .......................................................................................................................................................4-34 HydraulicTank Breather .........................................................................................................................................................

4-35 Change Hydraulic Oil....................................................................................................................................................

4-36 ~ 4-38 Heater Filter .................................................................................................................................................................................

4-38 Change Oilin Swing Motor Reduction Unit...........................................................................................................................

4-28 Change Grease in Slewing Ring Grease Tub ........................................................................................................................

4-29 Change Oilin Travel Reduction Unit..................................................................................................................................... 4-39 Attachment Dust Seals .................................................................................................................................................

4-40~ 4-41 Windshield Washer ....................................................................................................................................................................

4-41 MISCELLANEOUS ..................................................................................................................................................................

4-42~ 4-49 Fuses ........................................................................................................................................................................................

4-42 Towing theMachine .............................................................................................................. ...................................................

4-43 Periodical Inspection Items ..........................................................................................................................................

4-43~ 4-45 Machine Storage .......................................................................................................................................................................

4-46 Transporting Machine .............................................................................................................................................................

4-47 LiftingMachine Less Attachment ............................................................................................................................................ 4-48 Inspection &MAINTENANCE Checklist (Sample) .................................................................................................................

4-49

4-1

SECTION IV-

MAINTENANCE

4.1 GENERAL INFORMATION

h READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONS CONTAINEDIN THIS MANUAL BEFOREPERFORMING ANY INSPECTIONOR MAINTENANCE PROCEDURES TO THIS MACHINE ITS SYSTEMSOR COMPONENTS. A. It is recommended

by KOBELCO AMERICA, Inc. that an Inspection and Maintenance Schedulebe developed andmaintainedon a regular basis for this machine.Developingandmaintainingsucha schedule,helps to keepthe machinein optimum operatingcondition. SeeFigure4.1.

B. Theinformationcontainedin this Sectiongivesthe properprocedures for performingInspectionand Maintenance functionsfor this machine. Usethese procedureswhenperformingInspection and Main tenanceas they will guidethe Technician step by stepfor eachprocedure.

Also, refer to the Inspection andMaintenance Chartsfor generalservice interval recommendations.

NOTE TheInspection and MaintenanceCharts provided give only generaltime intervals. It maybe necessary to develope a Custom Scheduleto performmachinemaintenance at morefrequentintervals basedon the workconditions.

C. Useonly KOBELCO oils, fluids, lubricants, filters andreplacement parts to keepmachine in optimum operatingcondition. SeeFigure 4.2.

4.2 GENERAL SAFETY A. Disposalof HazardousWaste-FIGURE 4.3 Dispose of wasteoils, fluids, lubricants,filters and other hazardouswasteproperly.

FIGURE 4.1

KOBELCO

FIGURE4.2

Dispose of Waste Properly FIGURE4.3

/IX Disposeof all Hazardous Wastein accordance with Federal, State, and Local Government Environmental Regulations,LawsandCodes.

B. KeepMachineClean- FIGURE4.4 Thoroughlyclean machinebefore performingInspectionandMaintenance procedures.

It is easier andsafer to locate problems,performmaintenance andalso reducesthe risk of HydraulicSystem contaminationwhenmachineis clean.

4-2

FIGURE4.4

i C=

Section IV- MAINTENANCE

Hot Surfaces& Fluids- FIGURE 4.5 Usecaution andwearthe propersafety equipment whenworkingaroundhot areas. Neverchange oils, enginecoolantor filters immediately after a machine hasbeenstopped.Allow machine to cool before performing MAINTENANCE procedures.

D. WarmEngineOil Engineoil shouldhavea temperatureof 20°C~ 40°C(68°F~ 104°F)beforeoil is changed.

If necessaryrunengineuntil oil is warm.

FIGURE4.5

O

E. "Tag-Out"Machine-FIGURE 4.6 Before beginningany Inspection or MAINTENANCE procedures, secure a "DO NOTOPERATE"Tagto the operatorsconsoleto inform the operatorthat the machine will be inoperablefor inspection and MAINTENANCE and take the keys out of the operator’scab.Thistag will help preventaccidentalstarting of the machine.

DO NOT OPERATE o

F. Inspect WasteOils andFilters- FIGURE 4.7 Beforedisposal,inspectall wasteoils, fluids and filters for debrisandforeignmaterial.Thiscanhelp in determiningproblemareas.

FIGURE4.6

G. Prevent Contamination-FIGURE 4.8 Alwayscapor plug lines whenhydraulic componentsare removed to help preventhydraulicsystemcontamination that canbe causedby dirt, dust anddebrisenteringa line or port.

Neverallow a hydraulicline or component to become contaminated.This could causesevere systemdamage.Contact an authorized KOBELCO dealer to obtain the propercapsandplugs to be used on this machine.

FIGURE4.7

H. Seals& "O"-Rings Alwaysreplace seals and"O"-Ringswith new parts. Neverreusea seal or "O"-Ringduringreassemblyof components.

Beforeinstalling a new sealor "O"-Ring, coatwith a thin layerof oil to helpsealingability.

FIGURE4.8

4-3

Section IV- MAINTENANCE I. StopEngine Never attempt any MAINTENANCE with engine running. AlwaysStop the Engineand allow machineto cool.

J. WearSafety Equipment-FIGURE 4.9 WearHardHat, Safety Gogglesor FaceShield, WorkGloves,Safety Shoesandwell fitting work clothes whenperforminginspection and maintenanceprocedureson this machine.

FIGURE4.9 CAP

K. CleaningParts Useonly approvedcleaningsolvents andproper equipment to clean parts.

(2nd DESIGN)

NEVERUSE GASOLINE,DIESELFUEL OR OTHER FLAMMABLE SOLVENTSTO CLEANPARTS, ALWAYSCLEANPARTSIN AWELLVENTILATED AREA. L°

HydraulicTankPressure Alwaysreleasethe internal pressureof the hydraulic tankbeforeperforminginspectionor maintenanceprocedures. la.(lst. Design)Remove capfromTankAir Breather.

I b.(2ndDesign)Not necessaryto remove cap on Breather.SeeFigure4.10.

2. Depress relief valvestemto releaseall Hydraulic TankInternal Pressure.SeeFigure4.11.

FIGURE4.10

FIGURE 4.11

Gassesfrom Hydraulic Tankmaybe Hot. Wearsafety equipment.

M. WeldingSafety 1. TurnKeySwitchto "OFF".Wait4 seconds for electrical powerto disconnect.

SeeFigure4.12.

2. Remove Negative(-) Cablefrom BatteryTerminal. SeeFigure4.13.

3. Attachweldergroundcablelm (3’-3") awayfrom component being welded. certain weldergroundis not locatedat a 4. Make sealor bearing.

FIGURE4.12

FIGURE4.13

4-4

Section IV- MAINTENANCE

/h

CHART 4,3 INSPECTION& MAINTENANCE Followthe chartbelowfor recommended intervals of regular inspectionandMAINTENANCE procedures.

SYSTEM

MAINTENANCE TO PERFORM

COMPONENT LOCATION

S~a~E

READ, UNDERSTAND ANDFOLLOWALL SAFETY PRECAUTIONS FOUNDIN THIS MANUALBEFORE PERFORMING INSPECTION& MAINTENANCE, INTERVAL ( HOURS ON HOURMETER) 8 | 50 120 250 500 1,000 2,000 ~ .....~ ............... ~,~%~ ~

REF.PAGE #

~’~..........

I~

CHECKCOOLANT LEVEL

RESERVOIR

4-9

CHECKBELT TENSION

FRONTOF ENGINE

©

4-10

DRAIN WATERSEPARATOR

PUMP DOOR

©

4-11

©

4-13

CHECKENGINE ELECTRICAL COMPLETEENGINE

PUMPDOOR

¯

©

4-20

CHANGEENGINE OIL

OIL PAN

¯

© ©(opt

4-21

CHANGEFUEL FILTER

L.H. SIDE OFENGINE

CHECKFAN ASSEMBLY

FRONTOF ENGINE

¯

CHECKVIBRATION DAMPER FRONTOF ENGINE ~;,~~’ ii~: ~ ~ =~ i~;~ ......

¯

CLEAN PRE FILTER BOWL =

ENGINE

CLEAN DEBRIS SCREEN

CHANGEAIR CLEANER ELEMENTS

HYDRAULIC

4-22

©

BETWEEN RADIATOR ANDOIL COOLER

©

4-23

© ©

4-23

4-24

~’~?~ ................... !,:i,~

AIR CLEANER

©

©

4-12

HYDRAULICOIL LEVEL

!

SIDE OF HYDTANK

CHECKFOR OIL LEAKS

HYDRAULICSYSTEM

CLEAN SUCTION SCREEN

HYDRAULICTANK

©

4-33

CLEAN PILOT MANIFOLD FILTEPJSCREEN

PILOT MANIFOLD

©

4-26

©

4-13 4-10,15,29

¯ ~ ~,~i CLEAN HYDRAULICTANK

©

HYDRAULICTANK

4-36 -38

~....

I~;~

~:’~ ~ ~ ’~ ~i-~ ~- ;~ ~¼~BB~E~’’~ ~ ............................. ~i~%’" ~"%~ ,NSPECTALLW,B,NG COMPL T..CHIN©

4-13

~;~ ~,~=~1~ ~.~ ~.~

ELECTRICAL P~ BA’I-rERY MAINTENANCE

!

BATTERIES

¯

© - Regular Inspection & MAINTENANCE Required. ¯ - Break-In Inspection & MAINTENANCE Required. (opt) - A Special ~00 Hour Oil Pan & Filter is Optional. (see Page4-7)

4-5

©

4-26-27

Section IV- MAINTENANCE SYSTEM

MAINTENANCE TO PERFORM |

I COMPONENT LOCATION

CAR! I c~cK SWITCHES

8

©

CHECK SWING BRAKE

CAB

©

CHECK BUZZER

CAB

O

CHECK HORN

CAB

©

CHECKSWING REDUCTION OIL LEVEL& FILL

UPPER FRAME

CHECKSLEWINGRING & PINION WEAR

SIGHT WINDOW IN BATTERYBOX

3HECKSWIVEL JOINT SEALS

SWIVELJOINT

GREASESLEWINGRING

SLEWINGRING

INTERVAL ( HOURSON HOURMETER 50 120 50~ 1,00C ,000

~

NO N

~~t~ES~

UPPER FRAME

CHANGESWING REDUCTION UNI~.~IIL

t

CHECKFOR OIL LEAKS

i~c

~

~i

CHECK STEPS

CHECKTRACKS& LINKS

LOWER FRAME

CHECKIDLER WEAR

CHECKTRACK TENSION !~.[~

CHECKTRAVELREDUCTION UNITOIL LEVEL& FILL

¯

O

CHECK BOLTS/HARDWARE

¯

O

I=I Ni @ @I t£!11t ..............................................

BUCKET ARM

© - Regular Inspection

& MAINTENANCE Required.

¯ - Break-In Inspection & MAINTENANCE Required.

4-6

Section IV- MAINTENANCE 4.4 FLUIDS& FILTERS Thefollowing chartslist all thenecessary lubricants, oils, greases, fuels,coolants andfilters required for the KOBELCO MarkIV SK130(LC) HydraulicExcavators. Alsoa chartis provided givingspecificinformationfor theproper lubricants, oils, greases, fuelsand

coolantsto be usedin certainclimates.Contactan authorized KOBELCO dealerto orderthe requiredFilters, FluidsandLubricants.

B. REQUIRED FILTERS

A. REQUIRED FLUIDS& QUANTITIES TYPE FLUID

HYDRAULIC

LOCATION OF USE

’

QUANTITIES REQUIRED SK130(LC)

.......

HYDRAULIC

" "’:~" 140 Liters

SYSTEM

(37 GAL)

LOCATION OF FILTER USE

SK130(LC)

® TOTAL ENGINE

11 Liters

VOLUME

(2.90 GAL)

MOTOROIL IDLER

200CCX 2 (,05GALX 2)

SWING MOTOR

6.2 Liter

REDUCTIONUNIT

(1,6 GAL)

OPERATING

"U" JOINT

LEVERJOINT

EACHSIDE

SLEWINGRING GEAR

1 PLACE 90° X 4

MOS=

SWING GEAR

6.4 kg

GREASE

SUMP(BATH)

(14.1 Ibs)

EP GREASE

,,,i

* WITH OPTIONAL FACTORYBREAKERKIT. ** CUMMINS& FLEETGUARD NUMBERS FOR REFERENCE ONLY.

ENGINE COOLANT

C. KOBELCO (Brand) FLUIDS& LUBRICANTS

17 Liters (4.5 GAL)

FUEL

NOTE ~__ t..S.tandard EnoineOil Panis cast. This is a | 250 HR.Oil Change interval pan, & usesOil I Filter (PIN: YNSOVU0001D4) [ 2. Ootional EnoineOil Pan is stampedsteel. | This is a 500 HR. Oil Changeintervalpan, | &mustuse Oil Filter(P/N: YN02PU1011P1)

4-7

PART NUMBER

DESCRIPTION

KSP1000-1001

ENGINEOIL- SAE 15W/40 (QUARTS)

KSP1000-1005

ENGINE OIL- SAE 15W/40 (5 GALLON)

KSP1000-1055

ENGINE OIL-SAE 15W/40 (55 GALLON)

KSP1000-2005

HYDRAULICOIL- AW 46 (5GALLON)

KSP1000-2055 KSP1000-4014

HYDRAULICOIL- AW 46 (55 GALLON) GREASEEP/2-14 OUNCE

KSP1000-4035

GREASEEP/2- 35 POUNDS

KSP1000-120

GREASEEP/2-120

KSP1000-3035

GEAR OIL 80W90- 5 GALLONS

POUNDS

Section IV- MAINTENANCE D. LUBRICANTSPECIFICATIONS Thefollowinginformationis designed to allowusageof the properoil, grease,fuels andcoolantin various climatesandcertain workingconditions.

LUBRICANT HYDRAULIC OIL FRIGID (ANTI-WEAR,ANTIOXIDANT -30°C- 15°C AND NON-FOAMING) (-22°F. 59°F) * MobilDTE13M oil with HighViscosityIndex ISOVG22

CLIMATEZONE FRIGID-WARM WARM .25°C ~ 40oc .5oc ~ 40°C ~13OF~ 104OF) (23°F - 104°F)

FRIGID .20oc ~ 30oc (-4OF~ SS°F)

ISOVG32S*

ISOVG32

LUBRICANT

ISOVG68

CLIMATEZONE

ENGINEOIL* A.P.I. CLASSIFICATION FOR"SERVICE CE" * ALL ENGINES SHIPPED FROMFACTORY WITHSAE15W40 OIL IN ENGINE OIL PAN.

FRIGID -30°C~ 10°C (-22°F. 50°F)

WARM -5oc ~ 40oc (23°F- 104°F)

VERY HOT 40°C and Above (104°F and Above)

SAE5W30

SAE15W40

SAE15W50

LUBRICANT

CLIMATEZONE FRIGID -15°C- -25°C (-5°F. -13°F) WINTERIZED ASTMNo. 2 D

FUEL

LUBRICANT ENGINEOIL (FORGENERAL PURPOSE LUBRICATION)

ISOVG46

VERY HOT 5oc ~ 55oc (41°F - 131OF)

WARM -5°C~ -150C (5°F ~ 23°F)

VERY HOT -5°C and Above (23°F andAbove)

ASTMNo. 2 D

ASTMNo. 2 D

FORROLLERSANDIDLERS ON ALL MODELS. FOR SWINGMOTORREDUCTIONUNIT AND TRAVELMOTORREDUCTIONUNITS ON THE SK130(LC) A.RI. Classification for "SERVICE CE"- SAE30

LUBRICANT

GENERALLUBRICATION EXTREMEPRESSUREMULTIPURPOSE

GREASE

GREASE N.L.G.I. No.2 LITHIUMBASE,

SWINGGEARSUMP(BATH) N.L.G.I. No.2 LITHIUMBASEWITH

EP TYPE GREASE

MoS 2 GREASE

LUBRICANT

ANTIFREEZE (LLC)

ENGINE COOLANT

-34°C(-29.2°F) Mixture ratio shouldprotectto 5°C(41 °F) lowerthanthe coldesttemperature the machine will

(50% MIXTURE)

experience.

Takeinto considerationWindChill Factors.

E. USEOF BIO-DEGRADABLE OILS NOTE: When youuseBio-degradable Oil (BIOOIL), refer to the followinginformation: 1. Thereare two types of BIOOILavailable; vegetable-based andsynthetic-based.Youare recommended to usethe synthetic-based type, because the vegetable-based oil hasa maximum usagetemperatureof 80°C (176°F).Because of this, the degradation of vegetable-based oil occursmorerapidly, andcausesreduced servicelife.

2. Donot mixeither typeof BIOOILwith the original factory-filled mineraloil.

In the casethat youdouseBIOOIL,it is requiredto flush the hydraulicsystem that wasfilled with mineral oil two(2) times.

3. If youuseBIOOIL, swingandpropel brakeperformance will be reduced,because of the lower friction factor of BIOOILcompared to that of mineraloil.

Bio-degradable oil, pleasecontactyourlocal dealer.

4. For further informationaboutrecommended

4-8

Section IV- MAINTENANCE 4.5 PRE-START(EVERY 8 HOURS)INSPECTION MAINTENANCE The followingprocedures are to be performed every8 hoursor daily, Beforethe machine is started.

/t,, BE CAUTIOUSOF HOT FLUIDS ANDSURFACES. WEARGOGGLES,SAFETYSHOES, HARDHAT, WORKCLOTHES AND WORKGLOVESTO PERFORM INSPECTIONANDMAINTENANCE ON THIS MACHINE

FIGURE4.13

A. ENGINEOIL "LEVEL 1. Raiseenginecoverandlock with safety rod.

2. Locateandpull enginedipstick. Wipedipstick cleanusinga clean,dry, lint free clothandreinsert into engine.Pull againandvisually inspect the engineoil level ondipstick.SeeFigure4.13.

3. If necessary to addoil, remove Oil Fill Capon top of valvecoverandfill engineto properlevel usingsametype andweightof motoroil. See Figure4.14andrefer to page8 for oil specifications.

FIGURE4.14 NOTE After adding oil, checkoil level, replaceoil filler cap,replacedipstick andcloseenginecover.

B. ENGINECOOLANT LEVEL 1. Open Left AccessDoorandinspectcoolantlevel in enginecoolantreservoir. SeeFigure4.15.

"FULL"and 2. Propercoolant level is between "LOW"marks.SeeFigure 4.15. to addcoolant, remove reservoir 3. If necessary capandfill to properlevel with freshcoolant.

SeeFigure4.15 andrefer to page8 for proper coolantspecifications.

4. If nocoolantis in reservoir,checkcoolantlevel in radiator.Fill radiatorto properlevel andreplacecap.SeeFigure4.16. Thenfill reservoir to properlevel.

FIGURE4.15

NEVERREMOVERADIATORCAP WHENENGINE IS HOT. ALLOWENGINETO COOLBEFORE REMOVING RADIATORCAP.

FIGURE4.16

4-9

Section IV- MAINTENANCE C. ENGINEFLUID LEAKS 1. Inspectcomplete enginefor signsof fluid leaks.

2. When inspecting aroundpressurelines and hosesusea stiff pieceof cardboard.See Figure4.17.

±

±1

Never usehandsto checkfor leaks. Highpressurefluid I leakswill penetratethe skin andcausesevereinjury. J

FIGURE4.17 D, FAN BELTWEAR& TENSION 1. Inspect fan belt for excessivewearor damage.

SeeFigure4.18.

2. Measure belt tensionon longestspanof belt.

Belt deflection shouldbe 9.Smm ~ 12.7mm (3/8" - 1/2"). SeeFigure4.18.

3. Adjustbelt by insertinga 3/8" driveratchetinto squareholein belt tensionerandadjust up or downto obtain properbelt tension. SeeFigure 4.19.

4. After adjustingbelt tension, checkTensioner MountingBolt Torque.TorqueMountingBolt to 4 kgf/m(32 ft. Ibs). SeeFigure4.19.

FIGURE4.18

FIGURE4.19 E. FUELLEVEL 1. Turn KeySwitchto "ON"position.

2. Visually watchFuel Level Gaugeon Gauge ClusterDisplay.SeeFigure4.20.

FIGURE4.20

4-10

Section

IV-

MAINTENANCE

3. Tofill FuelTank,openFuelFiller Capwith Key SwitchKeyandfill tankto properlevel with Diesel Fuel. SeeFigure4.21 andrefer to page8 for FuelSpecifications.

NOTE Donot remove the strainer frominside neckof fuel tank for fueling.

FIGURE 4.21

F. FUELPRE-FILTERBOWL 1. Locatethe Fuel Prefilter Bowlinside mainpump accessdoor. Securedoor openwith door lock barwhileperformingmaintenance.

Placea waste containerbelowdrain valve.

2. Turnthe drain valveon the bottomof the water separatorcounterclockwise until fuel beginsto drain. SeeFigure4.22. in the watersepa3. Allowall waterandsediments rator to draininto wastecontainer.Thenturn the drainvalveclockwise to closeit.

FIGURE4.22

NOTE If large quantitiesof waterandsediment drain fromwater separator,it maybe necessaryto primethe fuel system to avoidproblems with air in the fuel system.SeeFigure 4.23.

FIGURE4.23

4-11

Section IV- MAINTENANCE G. AIR CLEANER 1. OpenL.H. AccessPanelto gain accessto the EngineAir Filter. SeeFigure4.24. Securedoor openwith doorlock bar while performingmaintenance.

ENGINE AIR CLEANER

NOTE Performair filter maintenance with enginestoppedor serious enginedamage could result.

2. Remove WingNut from the Air Cleanercover.

SeeFigure 4.25.

3. Remove WingNut from the Air CleanerOuter Elementand removeelementfrom the housing. SeeFigure4.26. the WingNut from the Inner Element 4. Remove and removeelementfrom the housing. See Figure4.26.

CLEANINGANDINSPECTION Cleanandinspectthe filter elements.

Replace themif necessary.Blow-outthe outer filter with low pressurecompressed air, frominsideout. Usea light sourceinsidethe elementsfor inspection. Donot useany elementsthat haverips, tears, or damage to the filter media.Donot cleanthe inner safety air filter element/It mustbe replacedonly, when dirtjz.

FIGURE4.24

FIGURE4.25 OUTERELEMENT

INNER ELEMENT

5. Cleanthe inside of the housingusinga clean, lint free cloth dampened with water.

6. Thoroughly dry the inside of the housingwith a clean,dry, lint freecloth.

7. Reinstall Air CleanerElements in reverseorder. SeeFigure4.26.

NOTE Filter Elementsshouldbe servicedwhenthe EngineAir Cleanerindicator lamplights on the Gauge Cluster Display. SeeFigure4.27.

FIGURE4.26

NOTE ForadditionalAir Filters, contactanauthorized KOBELCO Dealerandorderthe followingPart Numbers: OUTERAIR FILTER ELEMENT-2446R277S5 INNERAIR FILTER ELEMENT-2446R277S6 FIGURE4.27

4-12

Section IV- MAINTENANCE H. ENGINEELECTRICAL 1. Visuallyandmanually inspectall engineelectrical wiring, connectors andcomponents for signs of damage and malfunction. SEEFIGURE 4.28.

2. Repairor replaceall damaged or malfunction ing wiring, connectorsandcomponents before resumingoperationof the machine.

REPAIROR REPLACE ALL DAMAGED OR FAULTY ELECTRICALCOMPONENTS

± OPERATINGTHE MACHINEWITH DAMAGED OR MALFUNCTIONINGELECTRICAL COMPONENTS CAN CAUSESERIOUSDAMAGE TO THE MACHINEANDSERIOUSINJURYTOPERSONNEL. REPAIR OR REPLACEFAULTYCOMPONENTS IMMEDIATELY.

FIGURE4.28

I. FUELTANKDRAIN 1. LocateandopenFuel TankDrainValveon bottomof fuel tank. SeeFigure4.29.

2. Allowall waterandsediment to drain fromfuel tankinto a wastecontainer,thenclosethe drain valve.

FIGURE4.29

J. HYDRAULIC OIL LEVEL 1. Placethe machine in the Oil CheckPositionon a firm surfaceas shown in Figure4.30.

........ |

FIGURE4.30 AccessDoor, secureit open 2. OpenMainPump with the doorlock barandviewthe hydraulicoil level in the sight glasson sideof hydraulicoil tank. SeeFigure4.31.

Forsafeoperationon inclines, the Hydraulicoil level MUST be maintainedbetween"ProperLevel" and"UpperLimit" mark.

FIGURE 4.31

4-13

Section IV- MAINTENANCE 3. Usethe followinginstructions to addhydraulic oil: a. Releasehydraulictank pressure.SeeFigure 4.32.

(1st

DESIGN) REMOVE

!

~

,i

//~

I//~ IThe KOBELCO SK130(LC)doesnot have a Hydraulic lOll Filler Cap.Fill HydraulicTankthrough the Return Filter Cover Plate Only.

I

(2nd DESIGN)

FIGURE4.32 b. Remove the four (4) mountingbolts fromthe HydraulicReturnFilter CoverPlate. See Figure 4.33. Remove spring and bypass valve.

NOTE TheReturnFilter CoverPlate is spring loaded. Slowly removebolts andCoverPlate. c. AddHydraulic oil through thereturnfilter, filling hydraulictank to the properlevel. See Figure4.33.Addingoil throughthe returnfilter will help remove anydebristhat maybe in the oil. Referto Page8 for properhydraulic oil specifications.

FIGURE4.33

d. BeforereplacingFilter Cover,replace"O"Ring. Order KOBELCO Part Number ZD11G19000.SeeFigure 4.34. e. Install bypassvalveandspring. Placenew "O"-Ringin seat. Placecoverover opening andinstall mountingbolts with Iockwashers. f. Torquemounting bolts to propervalue. Refer to TorqueSpecificationsTable.

CLEANUP ALL SPILLEDOILTO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTEACCORDING TO ENVIRONMENTAL LAWSAND REGULATIONS, FIGURE4.34

4-14

Section

IV-

MAINTENANCE

K. HYDRAULICFUNCTIONS 1. Checkall HydraulicControlsfor properfunctionality beforeoperatingthe machine.

See Figure4.35.

NEVEROPERATETHE MACHINEWITH A FAULTYCONTROL OR FUNCTION. MAKEALL NECESSARY REPAIRS BEFOREALLOWINGANY OPERATION.

FIGURE4.35 L. HYDRAULIC OIL LEAKS 1. Checkcompletehydraulicsystemfor leaks. Use a small piece of cardboardwhenchecking areaswith high pressure.SeeFigure4.36.

everusehandsto checkfor leaks. Highpressurefluid eakswill penetratethe skin andcausesevereinjury.

2. Checkall hosesandlines for signsof damage. hosesandlines 3. Repair or replace damaged beforeallowinganyoperation.

FIGURE 4.36

CLEANUP ALL SPILLEDOILTO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTEACCORDING TO ENVIRONMENTAL LAWSAND REGULATIONS. M. MACHINEELECTRICAL 1. Checkall switchesfor properoperation. for 2. Visually checkall wiring andconnectors signsof damage, corrosionetc.. or faulty electri3. Repairor replaceall damaged cat components beforeattowfng anyoperation of the machine.

4. Checkall Gauges andPanelfor properoperation. SeeFigure4.37.

FIGURE4.37

DAMAGED OR FAULTYELECTRICAL COMPONENTS CAN CAUSE SEVERE DAMAGETO THE MACHINEANDCAUSE SERIOUSPERSONAL INJURY OR DEATH.

4-15

Section IV- MAINTENANCE KEEPSTEPSCLEANANDIN GOODCONDITION

N. STEPSAND HANDRAILS 1. Carefullyinspectall mounting steps, handrails andcat walkson the machine to makesure they are clean andin safe workingcondition. See Figure4.46.

2. Repairor replaceall areasbeforeallowingany operationof the machine.

Usesteps, andhandrails whenmountingand dismountingthe machine.Keepsteps, handrails and cat walkscleanandin safe workingcondition.

ALIGN UPPERANDLOWERSTRUCTURES FOR EASYACCESSTO CAB MAINTENANCE AREA

O. FRAMESTRUCTURE 1. Carefullyinspectthe entire framestructurefor signs of damage, brokenweldsetc.. found 2. Repairor replaceall framecomponents to be damaged before allowing any operation of the machine.

3, In caseswhereweldingrepair is required, consult an authorized KOBELCO MAINTENANCE Dealer for proper proceduresconcerning weldrepairs.Useonlycertified weldingpersonnelfamiliar with structural weldingmethodsto performrepairs requiring welding.

FIGURE4.46

DISCONNECTBA’n’ERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

FIGURE4.47 DISCONNECTBATTERIESBEFOREWELDINGON THIS MACHINE.SEEFIGURE4.47.

CONNECTWELDERGROUNDCABLE 1M (3’-3") AWAYFROMAREATO BE WELDED P. TRACKS & COMPONENTS 1. Track Shoes a. Visuallyinspecttrack shoesfor signsof excessivewearor damage.SeeFigure 4.48. b. Haveall repair or replacement workdoneby an authorized KOBELCO MAINTENANCE Dealer. c. Checktightness of shoemountingbolts and nuts. If loose,torqueto 86kg~ 105kg(618ft Ibs ~ 756ft Ibs). SeeFigure4.49.

FIGURE4.48

FIGURE4.49

4-16

Section

IV-

MAINTENANCE

2. Track Links a. Inspectlinks for signsof excessivewearor damage.

SeeFigure 4.50. b. Haveall repair or replacement workcloneby an authorized KOBELCO MAINTENANCE Dealer.

FIGURE4.50

3. Sprockets a. InspectSprocketsfor excessivewearand damage.SeeFigure 4.51. b. Shouldthe sprocketsrequire MAINTENANCE, contact an authorized KOBELCO MAINTENANCE Dealer for assistance. c. Checkandmakesure all sprocketbolts are properlytightened.

FIGURE 4.51 4. Idlers a. InspectIdlers for excessivewearand damage.SeeFigure 4.52. b. Shouldthe Idlers require MAINTENANCE, contact an authorized KOBELCO MAINTENANCE Dealer for assistance.

FIGURE4.52 LOWER ROLLER

UPPER ROLLER

5. Rollers a. InspectRollers for excessivewearand damage.SeeFigure 4.53. b. Shouldthe Rollers require MAINTENANCE, contact an authorized KOBELCO MAINTENANCE Dealer for assistance.

FIGURE4,53

4-17

Section IV- MAINTENANCE Q. TRACKTENSION 1. OperateSwing, Arm, Bucket and BoomControls until machine is set upas shown in Figure 4.54. //~ ! ,..... ~ /~kk ~ . ii1~ ~.~. ~ ..... .....

SUPPORTLOWERFRAMEWITH SUITABLE BLOCKS.

2. In centerof track, measure the distancebetween the bottomof framerails andsurfaceof shoe.

SeeFigure4.55.

3. Performsteps1 and2 on right track.

4. Toincreasetrack tension, set machine as shown in Figure4.54andwith greaseguninject ExtremePressureN.L.G.I. No. 2 Lithium Base Grease into idler adjustment greasefitting until propertensionis reached.SeeFigure4.56.

Performthis procedure on both tracks.

NOTE After injecting grease,operatethe travel control forward andreversefor the track beingadjusted.This will balancethe tensionbetween the Idler andthe Sprocket.Then re-measureas shownin Figure 4.55.

FIGURE4.54

MODEL

DIMENSION "A"

SK130(LC)

270mm~ 300mm(10.6" ~ 11.8")

FIGURE4.55

5. Todecreasetrack tension, set machineup as shown in Figure4.54.

6. Carefully loosenthe adjustment greasefitting to allow greaseto escape.SeeFigure4.56.

NEVERLOOSENGREASEFITTING MORETHAN ONE(1) COMPLETE TURN. 7. Tightengreasefitting, measure-track tensionas shownin Figure4.55.

8. If necessary, performsteps5 through7 on other track.

4-18

FIGURE4.56

Section IV- MAINTENANCE R. BOOM.ARM& BUCKET 1. Inspect Boom,ArmandBucketstructures for signs of excessivewearanddamage.

SeeFigure4.57.

2. Shouldrepair or replacement be necessary, contact an authorized KOBELCO MAINTENANCE Dealer for assistance.

DISCONNECTBATTERIESBEFOREWELDINGON THIS MACHINE. SEEFIGURE4.58.

CONNECTWELDERGROUNDCABLE 1 M (3’-3") AWAY FROMAREATO BE WELDED. NOT GROUNDWELDERSO THAT CURRENT FLOWSTHROUGH SLEWINGRING, OR ANY PIN ANDBUSHINGON CYLINDER.

INSPECT BOOM,ARM & BUCKETFOR DAMAGE FIGURE4.57

S. BUCKETCUTTINGEDGE. BUCKETTEETH& SIDE CUTTERS 1. Inspectbucketteeth andside cutters for signs of excessivewearand damage.SeeFigure 4.59. be required,fol2. Shouldrepair or replacement low bucket manufacturersrecommendations.

FIGURE4.58 WEARGOGGLES,SAFETYSHOES, HARDHAT, WORKCLOTHESAND WORKGLOVESTO PERFORM INSPECTIONAND MAINTENANCE ON THIS MACHINE 3. Inspectbladeandcutting edgefor signsof excessive wearand damage.SeeFigure 4.59. be required, 4. Shouldrepair or replacement contact your KobelcoDealerServiceDepartmentfor properadvice.

FIGURE4.59

4-19

Section IV- MAINTENANCE 4.6 50 HOUR(WEEKLY)& NEWMACHINE BREAK-IN INSPECTION & MAINTENANCE PROCEDURES. NOTE Performall Pre-Start(Every8 Hours)Inspection& MAINTENANCE Proceduresalong with the following 50 Hour Inspection and MAINTENANCE Procedures.

A. FUELPRE-FILTER Change after first 50 hours of machineoperation onnewmachine.Then changeevery250 hours.

1. With machineon a level surface, openMain PumpAccessDoorand securewith door lock bar. LocateFuel Pre-Filter. SeeFigure4.60.

2. Loosenthe drain valve on the bottomof the Pre-Filter bowlby turning counterclockwise and drain into a wastecontainer.SeeFigure 4.61.

3. After draining,carefullyturn bowlcounterclockwise to removebowl. SeeFigure 4.62. Remove bowlby handonly, usingtools couldcausedamageto the bowl. filter cartridge by hand.Remove "O"4. Remove Ringfromfilter mounting nipple.

"O"-Ringseal from Pre-Filter bowl and 5. Remove filter mounting nipple. Thoroughly cleanthe bowl andfilter mounting surface.SeeFigure4.63.

6. Coatnew"o"-Ringswith motoroil. Install new "O"-Ringoverfilter mounting nippleandinstall new"O"-Ringseal into bowl. SeeFigure4.63.

Install bowlontofilter andhandtighten1/2turn after sealmeets filter.

7. Fill filter andbowlwith fresh, cleanfuel andin stall filter ontostud.Tightenfilter by hand1/2 turn after filter makes contactwith "O"-Ring.

8. PrimePre-Filter by depressing fuel primerseveral times.SeeFigure4.63. Thiswill helpprevent excessair fromenteringthe enginefuel system.

NOTE Shouldit become necessaryto bleed the fuel system, Referto the engineoperatorsmanualfor properbleeding instructions.

/h

FIGURE4.60 PRE-FILTER

FIGURE 4.61 FILTER PART NUMBER

YN02PU10~

"O’-RING COATWITHOIL BEFORE INSTALLING

FILTER HI Nil

~ mln

iml

Nil

mmmm

"()’.RING COATwrrH OIL BEFORE INSTALLING BOWL PART NUMBER YN02PU1004S003

FIGURE4.62

/h

CLEANUP ALL SPILLEDFUEL. FUELOIL IS HIGHLYFLAMMABLE. SPILLEDFUEL CANCAUSEFIRES.

4-20

FIGURE4.63

Section

IV-

MAINTENANCE

B. ENGINEOIL & FILTER Change the engineoil andfilter on a newmachineafter the first 50 hoursof operation.Then chanoe the enoineoil at every250 hoursof operation.

NOTE Onenewoil filter is shippedwith the machine in the supportkit. Thisis to beusedat the50houroil &filter change.

1. Movethe machine to a firm, level surfaceand run enginefor 5 minutesto warm the oil. ii ~ ........ i ............ ~ ~’,i ~’ ~’~.....

FIGURE4.64 DO NOTCHANGEOIL ON A MACHINETHAT HAS JUST STOPPED WORKING.THE OIL WILL BE EXTREMELY HOT. ALLOWTHE ENGINETO COOL UNTIL OIL IS JUSTWARM BEFORECHANGING. 2. Remove the threeretaining bolts fromthe oil panaccesscoveron the bottom,rear center of machine.SeeFigure 4.64.

3. Raiseenginecoverandremove oil filler cap.

SeeFigure 4.65.

4. Placea 11 liter (3 gal) capacitycontainer underoil panandremove oil drain plug. See Figure4.66.

5. Allowall oil to draininto container, cleanoil drain plugandinstall backinto pan.Tightenplugsecurely.

6. Usingthe appropriatefilter wrench,locate and remove engineoil filter. SeeFigure4.67.

With a clean, lint free cloth, cleanmounting sur7. faceof filter bracket.

8. Lubricate newfilter sealwitha thin coatof fresh, cl, eanmotor oilTfill filter withoil andinstallfilter.

NOTE Oncefilter seal touches surfaceof housing,turn filter one completerevolution BYHAND to tighten. DONOTUSE FILTER WRENCH TO TIGHTENFILTER.

FIGURE4.65

FIGURE4.66

9. Referto the chart onpage4-7 for the properoil to usein the engineandfill engineto proper level withnewoil.

10.Install oil filler cap.Clean upall spilledoil.

11.Start engine,run for 5 minutes.Whilerunning, checkfor oil leaks.

12. Shouldanyoil leaksbe found,repair immediatelyandrefill engine to level withproperoil.

13. CheckOil Levelandclosecover.

NOTE For additional EngineOil Filters, order KOBELCO Part Number: YN50VU0001D4, (for Standard 250HR. Pan).

> (see Page4-7)

4-21

FIGURE 4.67

Section IV- MAINTENANCE C. FUELFILTER Change the Fuel Filter on a newmachine after the first 50 hoursof operation.Thenchange the Fuel Filter at every500hoursof engineoperation.

NOTE OnenewFuel Filter is shippedwith the machinein the supportkit. Thisis to beusedat the 50hourfilter change.

1. Raiseenginecoverandlocate the fuel filter on the L.H. side of engine.SeeFigure4.68.

2. Usingappropriatefilter wrench,turn counterclockwiseto remove Fuel Filter.

3. Emptycontentsof FuelFilter into a wastecontainer.

4. Remove "O"-Ringfrom filter head. SeeFigure 4.69.

5. Witha clean,dry cloth, cleanfilter headmounting surfacefor the filter. SeeFigure4.69.

6. CoatNew"O"-Ringwith a thin layer of fresh, cleanmotoroil andinstall ontofilter head.

7. Fill FuelFilter with fresh, cleanfuel andinstall ontofilter head.SeeFigure4.70.

8. TightenFuel Filter accordingto manufacturer instructions.DoNotUseFilter Wrench to Tighten FuelFilter.

FIGURE4.68

FIGURE4.69

NOTE To help keepair fromenteringthe fuel system,the fuel primercanbe depressed several time to insure that the FuelFilter andfilter headarecompletely full of fuel. See Figure4.71.

NOTE For additional Fuel Filters, contact an authorized KOBELCODealerandorder the following Part Number: FUELFILTER- YN50VU0001 D2

SEPARATOR WITH FRESH,CLEANFUEL

[I RLLRL’’’--’ / I OO"O’’O FIGURE4.70

9. Disposeof hazardous wasteaccordingto all Federal,State, andLocal environmental codes, laws,andregulations.

FIGURE 4.71

4-22

WITHFILTER WRENCH

Section IV- MAINTENANCE HOSE& CLAMPSFROM AIR CLEANERHOUSING

D. AIR INTAKESYSTEM Inspectall hosesandclamps of the Air Intake Systemon a newmachine after the first 50 hoursof operation.Thenat every_500hoursof engineoperation.

1. Inspectall hosesfor damage andtightenall hose clamps.SeeFigure 4.72. before 2. Replaceany hosefound to be damaged allowinganyoperationof the machine. hosesor clampscan cause 3. Looseor damaged severe enginedamage.

HOSE& CLAMPS TO TURBO

FIGURE4.72

E. FAN Inspect Fan assembly on a newmachineafter the first 50 hoursof operation. Thenat every 1,000 hours of engineoperation.

Also 1. Inspectall fan bladesandhubfor damage. checktorqueof fan mountingbolts. Proper torquevalueis 6kgf/m(43 ft Ibs). SeeFigure 4.73.

2. ReplaceFanassemblyimmediatelyshould any damage to bladesor hubbe found.

3. Operationof enginewith brokenor damaged bladescancausedamage to radiator or overheatingof engine.

F. BELTTENSIONER Inspect Belt Tensionerassembly on a newmachineafter the first 50 hoursof operation.Then at evew1,000 hours of engineoperation.

1. InspectBelt tensionerbearingfor wear,inspect idler for damage.

Also checktorqueof mount ing bolt. Propertorquevalueis 4kgf/m(32 ft Ibs). SeeFigure4.74.

2. ReplaceBelt Tensionerassemblyimmediately shouldanydamage or excessivewearis found.

G. VIBRATIONDAMPER Inspect Vibration Darnperon a newmachine after the first 50 hoursof operation.Thenat every2,000 hours of engineoperation.

1. Inspect Vibration Damper for damage such as piecesof the rubbermissing.Also, checkfor movement of the damperhubfrom the inertia member.SeeFigure 4.75. of 2. If piecesof rubberare missingor movement the damperhub alignmentmarkis morethan 1.59mm (1/16") apart from the inertia member mark,replacevibration damper immediately.

4-23

FIGURE4.73

lie FIGURE4,74

FIGURE4.75

Section IV- MAINTENANCE H. RADIATOR,OIL COOLER& DEBRIS SCREEN 1. Cleanradiator after evem50 hoursof operation usingpressurized water.

2. Open enginecoolanttank accessdoorfor cleaning the radiator andoil cooler.Secure dooropen with doorlock bar during service.SeeFigure 4.76.

Open enginecoverandremovethe wing nuts 3. retaining the debris screenbetween the radiator andoil cooler.SeeFigure4.77. Carefullyremovedebris screenandclean with pressurized water.

4. Remove washout accesscover from bottom of machine.SeeFigure 4.77A. 5. Rinseall dirt anddebris fromenginecompart merit. Reinstall debris screenandwashout accesscover.

FIGURE4.76

Becareful not to bendor damage coolingfins of the radiator or oil cooler. Replace debrisscreenif damage is found. Repairdamaged coolingfins of radiator andoil cooler.

NOTE Donot usehigh pressurewaterblaster for cleaning purposes on the radiator nor the oil cooler

FIGURE4.77

FIGURE4.77A

4-24

ii

ii

Section IV- MAINTENANCE

I. HYDRAULIC RETURN FILTER Change the HydrauficTankReturnFilter on a newmachine after the first 50 hoursof engine operationthen changeevery500hours. iiii

(1st DESIGN)

i

NOTE OnenewHydraulicReturnFilter is shippedwith the machinein the supportkit. Thisis to be usedat the 50 hour filter change. i

./........

1

REMOVE ""f/CAP DEPRESS f

n

(2nd DESIGN)

1. ReleaseHydraulicTankPressure.SeeFigure 4.78.

I

L- :

i

NOTE Donot allow debristo fall into the hydraulictank. Clean surfaceareaof the hydraulictankcoverbeforeopening.

/h

FIGURE4.78

/h

NEVERCHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING.ALLOW MACHINE TO COOLFIRST UNTIL OILS AND FLUIDS ARE WARMNOTHOT. RELEASEHYDRAULICTANK PRESSUREBEFORE WORKINGWITH ANY HYDRAULICCOMPONENT.

FIGURE4.79

2. Remove the four (4) mountingbolts fromthe HydraulicReturnCoverPlate. SeeFigure4.79.

Slowlyremove the mounting bolts. Thefilter cover plate is underspringtension.

VALVE

3. Remove "O"-Ring,filter springandbypassvalve.

SeeFigure 4.80.

4. Remove the filter fromthe housing.SeeFigure 4.81.

5. Install newfilter, bypass valveandspringinto housing.

6. Install New"O"-Ring.

7. Install CoverPlateandtorquemounting bolts to propervalue.Referto Specifications Sectionfor torquevalue.

FIGURE4.80

NOTE: OrderPart Number 240467.15ElementKit. This kit includesI Filter (Part Number 2446R147) and 1 "O"-Ring (Part Number ZD11P13000).

FIGURE 4.81

4-25

Section IV- MAINTENANCE J. PILOT MANIFOLD FILTER/SCREEN Cleanthe Pilot ManifoldFilter~Screenon a new machine after the first 50 hoursof engineo.oeration. Thenclean every 500hours.

(1st DESIGN) REMOVE

1, ReleaseHydraulic TankPressure.SeeFigure 4.82.

A’, NEVERCHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING.ALLOW MACHINETO COOLFIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. RELEASEHYDRAULICTANK PRESSUREBEFORE WORKINGWITH ANY HYDRAULICCOMPONENT.

(2nd DESIGN)

FIGURE 4.132

"O"-RINGS

2. Openthe Main PumpAccessDoor and locate the Pilot Manifoldmounted to the side of the HydraulicTank.SeeFigure 4.83. Securedoor open.

3. Remove Pilot ManifoldFilter/Screenfrom manifold block. SeeFigure4.83.

"O"-Ringsfrom Filter/Screen bodyand 4. Remove cleanFilter/Screenin an approved solvent.

Replace "O"-Rings with new parts.

OrderSeal 5.

Kit Part Number-24100P5113.

6. Install Filter/Screeninto manifoldblockand torqueto 7-8kgf/m(51 - 58 ft Ibs.).

K. BA3-rERIES Perform complete battery MAINTENANCE on a newmachine after the first 50 hours of engine operation. Then.checkelectrolyte (acid) every 120 hours and perform completebattery MAINTENANCE every 250 hours.

FIGURE4.83

A’, 1. WEARSAFETYCLOTHES,GOGGLES OR FACE SHIELD, GLOVESAND SAFETYSHOESWHEN WORKING WITHBA’I-rERIES. 2. WORK IN A WELLVENTILATED AREA. 3. BA’n’ERY ELECTROLYTE (ACID) IS CORROSIVE. IF IT COMES IN CONTACTWITH SKIN, EYESOR CLOTHING, FLUSHWITH LARGEAMOUNTS OF WATERAND SEEK IMMEDIATEMEDICAL ATTENTION. SEEFIGURE4,84.

4. BATTERYELECTROLYTE (ACID) PRODUCES HYDROGEN GAS THATIS HIGHLYEXPLOSIVE. DO NOT ALLOWNEARSPARKS,FIRE OR FLAMESAND DO NOT SMOKEWHENWORKING WITHBATTERIES.SEEFIGURE4.84, FIGURE4.84

4-26

Section IV- MAINTENANCE 1. OpenBattery AccessDoorandsecureit open.

SeeFigure4.85. top coverplate andbattery cell caps.

2. Remove Visuallyinspectelectrolyte(acid) level. Proper level is 10-15mm(.39"~.59") abovecell plates.

SeeFigure4.86. fill eachcell to properlevel with 3. If necessary, distilled wateronly. cables from terminals and clean with 4. Remove hot water.Coateachterminalwith a thin layer of petroleum jelly. Cleancablesin the same manner andreinstall ontobattery.

5. If cablesare foundto bein poorcondition,replace with newparts immediately. to checkthe specific gravity 6. Usea Hydrometer of eachcell. Compare readingsto the chart below.

FIGURE4.85

III

NOTE Usehydrometer accordingto its manufacturer’s instructions.

CHARGE%

ATMOSPHERIC TEMPERATURE O°C -10°C 20°C (68°F) (32°F) (14°F)

100%

1.26

1.27

1.28

9O%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

FIGURE4.86

disconnectingbatteries, removethe 7. When Negative(-)cablefirst. When connectingbatteries, connectthe Negative(-)cablelast. See Figure4.87. the battery requirescharging; 8. When a. Disconnect battery cablesfromterminals. b. Remove all cell caps. ¢. Check for properelectrolyte(acid) level. d, Connect chargerleadsto the properbattery terminals.

FIGURE4.87 ,,, i~!i

I

I ,,~

Z_Lti Make certain not to crossPositive andNegative terminalswhenconnectingcharger. e. Stopchargerif batteryoverheats. f. Periodicallycheckthe specificgravity of the batteries with a hydrometer.

Stopcharging batteries when100%charged.

NOTE Battery life canbe shortenedby overchargingandover dischargingof the battery. Replace anybattery that will not holdcharge or is difficult to charge.

4-27

Section IV- MAINTENANCE L. SWINGMOTOR REDUCTION OIL Checkthe oil level of the SwingMotorRedu~-tion Unit on a newmachineafter the first 50 hoursof engine operation. Thencheckevery 120 hours.(Also see item 4. below) Locatethe Dipstickon the right side of the swing motor.SeeFigure4.88. Pull dipstick, wipeclean andreinsertall the wayin.

Pull Dipstickandreadoil level. SeeFigure4.89. .

3. If necessary to addoil, remove plugfromoil fill portandfill to full level with properoil. See Figure4.90andrefer to page4-7for oil specifications.

Changeoil in the SwingMotor Reduction .

Unit on a newmachineafter the first 250 hoursof operation, then chanqeevery 2,000 hours. a. Todrain oil fromSwingMotorReduction Unit; locate drain port underrear of machine.

See Figure4.91. b. Placea 16liter (5 gallon) containerunder drain port, andremove plugallowingoil to drain into container. c. Replace plugandtightensecurelyafter all oil is drained. d. Fill throughfill port usingproperoil. See Figure4.90. Referto capacitytable below andpage4-7for oil specifications. .

MODEL

SWINGMOTOR REDUCTION UNIT CAPACITY

SK130(LC)

6.2 LITERS(1.6 U.S. GALS)

FIGURE4.88

FIGURE4.89

h NEVERCHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING.ALLOW MACHINETO COOLFIRST UNTIL OILS AND FLUIDS ARE WARMNOT HOT.

FIGURE4.90

FIGURE 4.91

4-28

Section IV- MAINTENANCE M. SLEWINGRING Checkthe greaselevel of the Slewing Ring Gear GreaseBath on a newmachineafter the first 50 hours of enoine operation. Thencheck every 120 hours.

At 2.000 hours, grease in Slewing Ring Gear Grease Bath must be changed, perform steos 6-8 as listed below.

1. Raise Tool Compartment Door and locate Sight WindowCoverPlate on its L.H. side SeeFigure 4.92.

2. RemoveSight Windowand visually inspect greaselevel to insure all the slewingring gear teeth are well coatedwith grease.

3. To add grease, insert end of grease gun into sight windowand add grease to proper level using N.L.G.I. No. 2 Lithium Basewith MoS2 grease ONLY.

IF OVERFILLED, SUMP BATH GREASECOULD BE PUMPEDINTO SWING MOTORREDUCTION UNIT AND CAUSE SEVERE DAMAGE. USE ONLYN.L.G.I. LITHIUM BASE WITH MoS2 GREASEIN SLEWING RING GEAR SUMPBATH,

FIGURE4.92

FIGURE4.93

4. Replacesight windowand tighten securely’.

5, Drain water by removingdrain plate located in tower framecavity. SeeFigure 4.93.

If the Slewing Ring ever becomes submergedin water, I it is mandatory that the sump bath grease be changed. I 6. To changethe sumpbath grease, it will be necessary to completely removemachineupper frame from the machinetower frame.

7. Onceupper frame is removed,thoroughly clean sumpremoving all grease from sump, slewing ring gear teeth and pinion gear teeth.

8. Refill with newN.L.G.I. Lithium Basewith MoS2 Grease. See Figure 4.94 and chart below.

SUMP BATH GREASE QUANTITY CHART GREASETYPE N.L.G.I. No.2 UTHIUM BASE w / MOS2

SK130(LC)

6.4kg (14.1Ibs)

NOTE Makesure to regularly inspect the Swivel Joint Area, and repair any leakage found. SeeFigure 4.94A FIGURE4.94A

4-29

Section IV- MAINTENANCE 9. GreaseSlewingRing on a newmachineafter the first 50 hoursof engineoperation.

ThenFreaseevery_500 hoursor as conditionsdictate. a. Locatethe grease fitting at the front of the slewingring andremove protective cap.

SeeFigure 4.99. b. Usinggreasegunfilled with EPGrease, lubricate slewingring with severalshots from greasegun. ¢. Swingmachine 90° right, andrepeatstep b. SeeDecalon frame. d. Continueto swingmachine at 90° incrementsandlubricating slewingring until ring hasbeencompletelygreased.

10. InspectSlewingRingseal for signs of damage. SeeFigure 4.99.

FIGURE4.99

NOTE Thisis a flush typeseal andsomegreasepurgeis normal

N. TRAVELMOTORS Inspect Oil Level of TravelMotorReduction Unit ona newmachine after the first 50 hoursof engine operation.Thencheckevery120 hours. to a firm, level surface. Operate 1. Movemachine travel until "FILL/LEVEL" Plugson travel motors are at 9 o’clockposition.SeeFigure4.100.

2. Stop engineand removethe Travel MotorReduction Unit Oil FILL/LEVEL Plug. SeeFigure 4.100.If oil just seepsfromLevelport, oil level is correct. the oil fill plugandaddMotor 3. Toaddoil, remove oil until oil just beginsto flow fromthe FILL/ LEVEL plug. Referto page4-8 for properoil specifications.

4. Useteflon tape on plugs and replace them.

Tightensecurely.

FIGURE4.100

¯ , ;~j,~ ......... = ~:i,,~i

Alsorefer to paqe4-39 for 500 and2,000 hour Maintenance Procedureof Chanqinq Off in Travel Reduction Units.

NOTE Regularly,makesure to inspect the Travel MotorCovers for damage; likewise, if youhaveoperatethe machine in muddyareas, weeklyremovethe covers to avoid accumulationof dirt in ’the areabetween the TravelMotorsand the Covers.SeeFigure 4.100A.

4-30

FIGURE4.100A

Section IV- MAINTENANCE P. A’I-rACHMENTLUBRICATION Lubricate AttachmentPins evew8 hours of engine operation. UseExtremePressureMultiPurposeGreaseN.L.G.I. No. 2 LithiumBaseEP TypeGrease.Lubricateall points until o_ rease pur_cles.

4. ArmRodEndPin and Arm-Boom Pin. SeeFigure 4.104.

1. Boom Cylinder HeadPins. SeeFigure 4.101.

FIGURE4,104 5. Bucket Link Pins. See Figure 4.105Aand 4.105B. FIGURE4.101 2. Boom FootPin. SeeFigure 4.102.

FIGURE4,105A FIGURE4.102 3. Boom Cylinder RodPins andArmCylinder Head Pin. SeeFigure4.103

PIN

FIGURE4.105B

FIGURE4.103

4-31

Section IV- MAINTENANCE

6. Idler Link to ArmPin andArmto BucketPin. SeeFigure 4.105C.

FIGURE4.105C 7. BucketCylinder Headendpin. SeeFigure 4.106.

FIGURE4.106

4-32

Section IV- MAINTENANCE 4.7 500, 1000 & 2000 HOURINSPECTION AND MAINTENANCEPROCEDURES Performall other Inspection & MAINTENANCE Proceduresas previouslydescribed in this section.

(1st DESIGN)

A. CLEANINGHYDRAULICTANK SUCTION SCREEN-500 HOURS

REMOVE CAP

I L,.

BE CAUTIOUSOF HOTFLUIDS ANDSURFACES. WEARGOGGLES,SAFETYSHOES, HARDHAT, WORKCLOTHESAND WORKGLOVESTO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.ALLOWENGINETO COOL BEFORECHANGING FLUIDS ANDFILTERS.

FIGURE4.108

1. ReleaseHydraulic TankPressure.SeeFigure 4.108.Cleanthe surfaceof the areaaroundthe coversto avoiddebrisfalling into hydraulictank.

Slowlyremove the four (4) retainingbolts from the SuctionStrainer CoverPlate. SeeFigure 4.109. Theis underspring pressure.

.

Remove "O"-Ring,removeSpringfrom Strainer Rodcarefully pull SuctionStrainerfromHydraulicTank. SeeFigure4.110.

.

,

FIGURE4.109

Remove "O"-Ringfrom SuctionStrainer, clean strainer in an approved solventandthoroughly dry. SeeFigure4.111.

Replacedamaged Strainer 5. Inspect for damage. with new. Order Part Number2448R307Sl .

1

Replaceboth "O"-Ringswith newparts. Order Part Numbers; 45Z91D6Strainer"O"-Ringand ZS11G18500.

FIGURE4.110

Insert Strainerwith new"O"-Ringinto Hydraulic Tank.Make certain Strainer is seatedoversuction tubein tank.

8. Insert Springinto Strainer Rod.SeeFigure 4.110.

1

Install New"O"-Ringinto plate mounting surfacegrooveandinstall plate. Tightenbolts to propertorquevaluel

NOTE Makecertain bosson plate is insertedinto strainer rod againstspring.

4-3:3

FIGURE 4.111

Section IV- MAINTENANCE B. CHANGING ENGINECOOLANT-1000 HOURS

/t,, BE CAUTIOUSOF HOTFLUIDS ANDSURFACES. WEARGOGGLES,SAFETYSHOES, HARDHAT, WORKCLOTHESAND WORKGLOVESTO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE.ALLOWENGINETO COOL BEFORECHANGING FLUIDS. 1. Raiseenginecover andsecure. Slowlyremove radiator cap. SeeFigure4.112.

2. Locatecoolant drain accesspanelunderL.H. rear of machineSeeFigure 4.113. Remove the four (4) panelretainingbolts.

3. LocateradiatorDrainValve,placea 20liter (5 Gal) capacitycontainerunderdrain tubeand turn drain valve counterclockwise to open.See Figure4.114.

4. Locateenginedrain plugat coolantinlet, removeplug andusing a funnel with an attached hoseallow anyadditionalcoolantto drain into container. SeeFigure4.114.

5. After all coolantis drained,replaceenginedrain plugandcloseradiator drain valve.

6. Flushengineand cooling systemaccordingto enginemanufacturer’s instructions.

7. Fill coolingsystemthroughradiator with fresh, cleancoolant mixedwith waterto the proper ratio. Referto Page8 for propercoolantand ratio.

8. Donot fill abovebottomof filler neck. Check coolantlevel in coolantreservoirandfill to between "FULL" and "LOW"marks. See Figure 4.115.

FIGURE4.112

FIGURE4.113

FIGURE4.114 NOTE Total cooling systemvolumeis approximately: SK130(LC)-17 LITERS(4.5 U.S. GAL)

DISPOSEOF ALL HAZARDOUS WASTEIN ACCORDANCEWITH GOVERNMENT ENVIRONMENTAL REGULATIONS,LAWSAND CODES.

FIGURE4.115

4-34

Section IV- MAINTENANCE C. HYDRAULICTANKBREATHER-2000 HOURS 1. ReleaseHydraulicTankPressure.SeeFigure 4.116.

(1st DESIGN) REMOVE

(2nd DESIGN)

FIGURE4.116

Breather HousingRetaining Nut and 2. Remove Fiber Washer.SeeFigure 4.117.

3. Remove Breather Housing.SeeFigure 4.117.

FIGURE4.117 old Filter, cleanmountingsurfacesand 4. Remove install newfilter. SeeFigure4.118.OrderPart Number2446U260S2.

5. Install BreatherHousing.

6. Install NewFiber Washer.Part Number 2446U260S4.

7. Install RetainingNutandtighten securely.

8. Install a newPackingWasherPart Number 2446U260S11 onto top of nut andinstall protective cover.

FIGURE 4,118

4-35

Section IV- MAINTENANCE D. CHANGEHYDRAULICOIL-2000 HOURS NOTE Thefollowingprocedures are to be usedfor normalchanging of the HydraulicTankOil only.

If necessary to change the HydraulicOil Viscosity, change HydraulicOil dueto hydrauliccomponent failure or changing main pump,contact an authorized KOBELCO MAINTENANCE Dealer for assistance.

FIGURE4.119

BE CAUTIOUSOF HOT FLUIDS AND SURFACES. WEARGOGGLES,SAFETYSHOES, HARDHAT, WORKCLOTHESAND WORKGLOVES TO PERFORM INSPECTION AND MAINTENANCEON THIS MACHINE.ALLOWHYDRAULICOIL TO COOL BEFORECHANGING. 1. Move the machine to a firm, level surfacewith the attachment in the HydraulicOil CheckPosition. SeeFigure4.119.

(2nd DESIGN)

FIGURE4.120

I

NOTE If machine is cold, warmthe hydraulicoil by operating attachmentcontrols before placing machinein the Hydraulic Oil Check Position.

2. ReleaseHydraulicTankPressure.SeeFigure 4.120.

3. Slowlyremove the four (4) retaining bolts from the SuctionStrainer CoverPlate. SeeFigure 4.121.

4. Remove "O" - g,RinSpring and Suction Strainer from HydraulicTank. SeeFigure 4.121.

5. Install SpecialSuctionStopper,Part Number 24100P978F2, over suction tube inside hydraulictank. SeeFigure4.122.

NOTE Special SuctionStopper, Part Number 24100P978F2, is a Kobelco ServiceToolavailable throughyour nearest KobelcoDealer.

SLOWLYREMOVE BOLTS& COVER

REMOVE "O"-RING, SPRING& STRAINER

FIGURE 4.121 HYDRAULIC TANK

SUCTION STOPPERASSEMBLY PARTNo, 24100P978F2

SUCTION TUBE

FIGURE4.122

4-36

Section IV- MAINTENANCE 6. Slowlyremove the four (4) retaining bolts from the HydraulicReturnFilter CoverPlate. See Figure4.123.

7. Remove "O"-Ring,BypassValveandFilter from HydraulicTank.SeeFigure4.124.

6. Locatethe HydraulicDrain Plugon bottomof HydraulicTank.SeeFigure4.125.

7. Placea 210liter (55 Gal)capacitycontainer underDrainPlug. Remove plugandallow all oil fromhydraulictankto drain into container.

8. After all oil hasdrained,carefullyandthoroughly cleaninside of HydraulicTank.

9. ReplaceDrainPlugandtighten securely.

10. CleanBypassValve, SuctionStrainer andCovers usingapproved solventanddry thoroughly.

Inspect filters and old oil for signsof contamina11. tion for troubleshooting purposes.

12. Install NewReturnFilter (Seenotebelow), alongwith the cleanedBypassValveand Spring.

BOLTS& COVER

FIGURE4.123

NOTE SK130(LC): OrderPart Number 24046Z15 ElementKit. This kit includes 1 Filter (Part Number 2446R147) and1 "O"-Ring (Part NumberZD11P13000).

FIGURE4.124

13, Remove SuctionStopperandclean outside of suctiontubewith a clean,dry cloth.

14. Carefully inspectSuctionStrainer for damage.

If anydamage is found,replaceStrainer with newpart. Orderpart number2446R307S1.

45Z91D6) 15. Install new"O"-Ring(Part Number into SuctionStrainer. SeeFigure4.126.

FIGURE4.125 DISPOSEOF ALL HAZARDOUS WASTEIN ACCORDANCEWITH GOVERNMENT ENVIRONMENTAL REGULATIONS,LAWSANDCODES.

FIGURE4.126

4-37

Section IV- MAINTENANCE 16. Install Strainer Assembly onto SuctionTube.

17. Install Springinto SuctionStrainerHolder.See Figure4.127.

18. Install new"O"-Ring,part number ZD11G16500, in cover plate mountingsurface grooveandinstall SuctionStrainerCoverPlate onto HydraulicTank.Makecertain Plate Boss is insideSuctionStrainerHolder.

19.Torqueretainingbolts to propervalue. Referto SpecificationsSection.

20. Fill HydraulicTankto properlevel with fresh, cleanHydraulicOil throughHydraulicReturn Filter. SeeFigure4.128.

FIGURE4.127

/.._t_3

Usesameviscosity oil in HydraulicTankas was drained.Referto Page4-7 for oil Specifications.

NOTE Thedecal affixed abovethe Hydraulic Oil Level Sight Glassindicatesthe hydraulicoil that wasin the tankwhen shippedfromthe factory.

E. HEATER FILTER- 500 & 2000 HOURS. Cleanthe in-cabheaterfilter every500hours.

Change the filter every2000hours.

1. Movethe Seat andSeat Basecompletelyforward.

2. LocateHeaterFilter behindTravel LeverStorageBrackets.SeeFigure 4.129.

3. Replacefilter with newfilter Part Number 24100U1496S12.

FIGURE4.128

FIGURE4.129

4-38

Section IV- MAINTENANCE F. CHANGE OIL IN TRAVELMOTOR REDUCTIONUNITS: Change Oil in Travel MotorReductionUnits on a newmachine after the first 500hoursof engine operation. Thenchanoeevery2000hours.

1. Movemachine to a firm, level surface.Operate travel untiJ "FILL/LEVEL" Plugson travel motors are at 12and6 o’clock position. See Figure4.130. Stopengine.

2. Place3.8 liter (1 Gal)capacitycontainerbelow the Reductionunits Drain Plug.Remove the Travel Motor ReductionUnit Oil FILL/LEVEL Plug. SeeFigure 4.131.

3. Remove Drain plug anddrain oil completely.

SeeFigure 4.132.

4. Useteflon tapeon drain plugsandreplacethem.

2 (36-47ft-lbs).

Tightenplugsto 5 - 6.5 Kg/cm Fill throughFILL/LEVEL port using SAE30 Motor Oil. Referto chartbelow for capacityof travel reductionunits.

5. Useteflon tape on FILL/LEVEL plugs and re2 (36-47ftplacethem.Tightento 5 - 6.5 Kg/cm Ibs).

MODEL

TRAVELREDUCTION UNIT CAPACITY

S K130(LC)

3.0 LITER(0.8 U.S. GAL)X

FIGURE4.130

FIGURE4.130

FIGURE4.130

4-39

Section IV- MAINTENANCE & DUSTSEALS G. A TTACHMENT 1. BucketClearance a. Inspectbucketclearancefrequentlyfor wear.

If clearancebetweenbucketandbucket/ink and/or betweenarmandbucketis greater than1.2mm(O. 05".) adjust clearanceaccording to bucketmanufacturers instructions.

2. ReversingBackhoeBucket a. Move the machine to a firm ,level surfaceand rest the bucketon the ground,makingcertain the bucketis stable. SeeFigure4.133. b. Roll "O"-Ringsonto bucketboss.SeeFigure 4.134. c. Remove JamNuts, Nuts and Pin Retaining Bolts. SeeFigure4.135. d. Carefully removeMainPins mountingarm andbucketlink to bucket.Beverycareful not to damage the lip seals. e. Rotatebucket180° or movemachine,install ArmandBucketLink in their respective positions. SeeFigure4.136.

FIGURE4.133

FIGURE4.134 NOTE Makecertain "O"-Ringsare on bucketbossfor reinstallation. f. Install pins, retainingbolts andnuts.Torque to propervalue. Install jamnuts andtorque to propervalue. g. Roll "O"-Ringsinto groovesbetween bucket/ armandbucket/bucketlink.

NOTE Inspect "O"-Ringsfor damage or excessivewear.If worn or damaged replacewith newparts to protect seals, pins andsurfacesfrom dirt anddebris whichcancauseprematurefailure.

SK130(LC): Bucket"O"- Ring(4 Required) Part Number2445Z869

FIGURE4.135

SLOWLYCYCLEBUCKET.CHECKFOR INTERFERENCEWITH ARM, PARTICULARLY WITH LIFTING EYE WELDEDON BUCKETBOTTOM.

FIGURE4.136

4-40

Section IV- MAINTENANCE 3. DustSeals a. Theattachmentincorporatesseveraldust sealsthat shouldbe periodically checked for damage and excessivewear. SeeFigure 4.137. b. If excessivewearor damage is foundremove seal andreplacewith newparts.

NOTE Orderthe followingpart numbers for replacement seals: SK138(LC) BOOM FOOT-2445R138D6 (2 Req’d) ARMTO BOOM-2445R138D6(2 Req’d) ARMTO IDLERLINK-2445R138D3 (2 Req’d) IDLERLINK TO B KT LINK-2445R138D3 (2 Req’d) BKT CYLINDERTO BKT LINK-2445R138D3(2Req’d) BKTLINK TO BKT-2445R220D2 (2 Req’d) ARMTO BKT- 2445R220D2(2 Req’d)

LOCATIONOF ATTACHMENT SEALS

FIGURE4.137 LIP OUT

:OMPONENT

III

/

sealsas shown in Figure c. Install replacement 4.138.

H. WINDSHIELDWASHER Fill the windshieldWasher Fluid as reauiredusinq approved windshieldwashingfluid.

1. Pull upfloor matin operatorcabto locatewasher fluid reservoir.SeeFigure4.139.

2. Pull Capoff andfill with properwindshield washingfluid.

3. Replacecapandrepositionfloor mat.

BUSHING SEAL

FIGURE4.138

FIGURE4.139

4-41

Section IV- MAINTENANCE 4.8

MISCELLANEOUS A. FUSES Follow the proceduresbelowto replace "blown" or faulty fuses.

1. Moveseat and seat base completely forward.

2. RemoveFuse Box Cover from fuse box. See Figure 4.140.

3. Locate and removefaulty fuse. Replacefuse with sameampfuse as removed. ¯ ~ ~; .....

~’,~

~ .......

1 ~ "

[m

FIGURE4.140

NEVER REPLACEA FAULTY FUSEWITH A HIGHER AMP FUSE. NEVER USE A"JUMPER"IN PLACEOF A FUSE. NEVER SPLICE ACCESSORIESDIRECTLY INTO FUSETERMINALS.

1

2

3

4

5

14

15

6

7

8

9

10

4. Refer to Fuse Box Coveror Figure 4.141 for Fuseamperage and their functions.

i

NOTE Whenordering replacementfuses, order the following part numbers: 1 AMP- Part Number2487U41S2 5 AMP- Part Number2479R655S10 10 AMP- Part Number2479R655S8 20 AMP- Part Number2479R655S9

11

12

13

FO.C.,O.

l MI

2

NOTE Thein line fuse for the Fuel Shut Off Solenoidis located behind the Operator’s Seat within the Hamess Bundle. See 3hotosbelow.

1.~

IK.P.S,S.

Solenoid Valve

4

10~ ~, CigaretteLighter24V

6

10~

8

5l

10

20,

StarterSwitch

12

5l,

Buzzer,Swing Flasher

i

14

20~.

Wiper

i O=

16

20,~. Working Light

!8

20,~

Heater

20

20 ~,

Etherstart I Fan

Horn

" 7

~

FIGURE4.141

4-42

(N/A)

I

011

Section IV- MAINTENANCE B. TOWINGTHE MACHINE 1. If the machine shouldbecome stuckin soft soil areasit maybe necessaryto tow the machine.

Attacha wire ropeor chainwith the capacityto pull the machine out to the lowerframeeye.

SeeFigure 4.142.

2. Attachotherendto the vehicleusedto pull the machine.Operatethe Machine’sTravel Controls in the properdirectionwhilepullingwith the othervehicle.

C. PERIODICALINSPECTIONITEMS Sincethereis nodefinitetimetablefor thereplacementof hydrauliclines, tubesandhoses,inspect the followingperiodicallyfor tightnessandsigns of damage.

Replaceall damaged lines, tubes and hoseswith newparts. Referto the Parts Manual for correct part numbers whenordering.

FIGURE4.142

Im DO NOT BEND, STRIKE OR DAMAGEHIGH PRESSURELINES. DO NOT INSTALL BENT OR DAMAGEDLINES, TUBES OR HOSES. REPLACE ALL DAMAGEDLINES, TUBES AND HOSESIMMEDI. ATELY. TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONSTO THE PROPERTORQUE VALUE. CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELYTOHELP PREVENTFIRES. NEVER USE HANDS TO CHECK FOR LEAKS

FIGURE4.143

CAREFULLYINSPECT ALL LINES, TUBES AND HOSESFOR: 1. FITTINGS & CONNECTIONSDAMAGEDOR LEAKING. 2. OUTER COVERING OF HOSES WORN, CUT OR DAMAGED EXPOSING WIRE REINFORCEMENT. 3. HOSE SWELLING OR "BALLOONING".

4. EVIDENCE OF HOSE BEING KINKED OR COLLAPSED. 5. STEEL PROTECTIVE COVERING WORNOR DAMAGED. 6. LOOSE FITTINGS AND CONNECTIONS. MAKE CERTAIN ALL CLAMPS, GUARDSAND HEAT SHIELDS ARE IN PLACE AND SECURE. THIS WILL HELP PREVENTVIBRATION, EXCESSIVE WEAROF COMPONENTS AND EXCESSIVE HEAT DURING OPERATION.

1

=

,

Heater Hoses Inspect the HeaterHosesbetweenHeaterand Enginefor signs of damage and wear.See Figure4.143.

FIGURE4.144

BoomHoses& Tubes Inspect BoomHeadand RodHosesand Tubes for damage,wearand loose connections.See Figure 4.144.

ArmHoses& Tubes Inspect ArmHeadand RodHosesand Tubes for damage,wearand loose connections.See Figure4,145.

4-43

FIGURE4.145

Section IV- MAINTENANCE =

.

BucketHoses& Tubes Inspect BucketHeadand RodHosesand Tubes for damage,wearand loose connections.See Figure4.146.

Fuel Lines and Hoses Inspect Fuel Lines andHosesfor damage, wear andloose connections.Repairor replaceFuel Lines andHosesbeforeoperatingthe machine.

FIGURE4.146 6. HydraulicSuctionTubes& Hoses Inspectall HydraulicTubesandHosesfor damage, wearand loose connections.SeeFigure 4.147.

FIGURE4.147 7. Radiator Hoses& Cap Inspectthe RadiatorHosesfor signsof damageor deterioration. Replacehosesif found to bein badcondition.Inspectthe RadiatorCap Seatfor signs of damage anddeterioration and replacewith newpart if foundto be in badcondition. SeeFigure4.148.

FIGURE4.148 8. FoamSeals Inspect the FoamRubberSeals aroundthe Radiator,Oil Coolerandon the EngineCover.

MakeCertain they are in place andsecureto preventoverheatingof the engine.SeeFigure 4.149.

FIGURE4.149

4-44

Section

IV-

MAINTENANCE

g. FuelFiller Strainer Inspectthe FuelFiller Strainerbeneath Fuel Filler Capfor damage, dirt anddebris.Make Cer tain the Straineris cleanandin placebefore fueling the machine.

SeeFigure4.150.if the Strainer is damaged, replacewith a newpart.

Order Part Number 2446R326.

FIGURE4.150

4-45

Section

IV-

MAINTENANCE

D. MACHINESTORAGE Performthe following procedure to preparethe machine for long termstorage. proce1. Performall InspectionandMaintenance duresas previouslydescribed in this section.

2. Thoroughly clean the machine,inspect for damagedor wornparts andcomponents andreplace or repair all damaged or wornparts.

3. Completely fill fuel tankwith fresh, cleanfuel to aid in preventingcondensation or moisturein sidethe fuel tank.

4. Movemachine to an indoorlocation for storage.

5. Operatebucketandarmcompletely"IN" extending cylinders. Thenlowerboom until attachment is restingonthe floor. SeeFigure4.154.

6. Coatcylinder rods with a heavycoat of grease to preventcorrosionduringstorage.

7. Remove Batteriesandstore in a well ventilated, warmarea.

Protect gaugecluster and all electrical components from water and steam whencleaning the machne.

POSITION MACHINEAS SHOWN INSIDE A STORAGEBUILDING

I

HEAVILY GREASE ALL CYLINDER RODS TO PREVENT CORROSION

FIGURE4.154 E. CAREDURINGSTORAGE 1. Every30 daysduringstorage,it will be necessaryto start andrun the machine to circulate the fluids throughthe systems.Beforestarting cleancylinderrods andafter runningto-grease cylinderrods.

NOTE Runand operate machinefor approximately1 hour to allowall fluids to circulate well andreachnormaloperating temperatures.

4-46

F. REMOVINGMACHINEFROMSTORAGE 1. Performall InspectionandMaintenance proceduresas described in this sectionbeforebringing machine out of storagefor normaloperation.

2. Remove drain plugs from Travel Motorand SwingGearReductionUnits to drain off any moisture whichmayhaveaccumulatedduring storage.

3. Carefullyandcloselyinspectall HydraulicHoses after longperiodsof storagefor signsof deterioration. Replaceall hosesshowingthese signs.

Section IV- MAINTENANCE E. TRANSPORTINGMACHINE 1. MachinePreparation a. Knowthe total weight, length, width, and height of the machine.SeeFigure4.155. b. Know route to be traveled. Investigate bridges,overpasses, trusselsandtraffic flow onroute. c. Obtainanypermitsrequiredfrompropergovernmentagenciesfor transport of machine. d. Useonlya truck with a ratedcapacitysufficient to transportthe machine. e. Makecertain truck hasrampsor a rampis availablefor loadingandunloadingthe machine.

2. LoadingMachine

I

~

~ "~

~;~i

0 ~

~ ....

i

3 Dimensionsand weights are with 3.0m (9’-10") Arm, 0.40m 0.52 cu yd) Bucket, 4.6m(15’-11") Boomand 600 mm(24") SK130LCOperating Weight= 12,625 Kg (27,8401bs)

I ’t~

-¢:

7.62M (24’-11").

~.-,-.---~---.. ,~--------~, ~1 . _

FIGURE 4.155

~ ’~

NEVERUSE ATTACHMENT AS AN AID IN LOADING OR UNLOADING THE MACHINE. i NOTE Thefollowinginstructionsare specificto a "Detatch"style trailer. a. Applyparkingbrakesontruck andchocktruck wheelsbefore attemptingto load or unload machine. e. Place Travel SpeedSelect Switch on machine in 1 (~) Speedposition and move ThrottleControlto the "LO"Idle position.See Figure4.156. f. If the machineis equippedwith the "OneTouch"DecelOption,placethe Switchin the "OFF"position.

SeeFigu re 4.157.

"ON". WITH DECELSWITCH"ON", SUDDEN FLUCTUATIONS IN ENGINERPMCOULDBE EXPERIENCED CAUSINGPOSSIBLEDAMAGE, SERIOUSINJURYOR DEATH.

FIGURE4.156

FIGURE4.157

FIGURE4.158

g. Slowlyload the machineon the truck and position it on the truck as shown on Figure 4.155. h. Placethe ignition switchon "OFF"position.

SeeFigure 4.158. i. Makesure to placethe SafetyLockLeverin the upright position, as shownon Figure 4.159, beforeleavingthe cab. j. Securemachineproperly on the truck as shownon Figure 4.155.

FIGURE4.159

4-47

.

Section IV- MAINTENANCE F. LIFTING MACHINE(LESS ATTACHMENT) Thefollowingprocedures are for lifting the machine, less attachment,as built by KOBELCO AMERICA, INC. Theseproceduresdo not take into accountmodificationsmadeto the machinethat affect machine weightor centerof gravity.

350mm (13,7S")

1. Locatelifting locationsat the front andrear of eachcrawler frame.SeeFigure4.160.

2. Attachcablesor wire ropewith a capacityrating sufficientto lift the machine, at lifting locations.

"",,~

950mm (37.4")

SPROCKET END

FIGURE4.160

IPlacea hardwoodor Steel block betweencables and I crawler frameto preventdamage to the tracks from cables during lifting.

See Figure 4.161.

I 3. Bringloose endsof cablestogetherat machine centerof gravity andattachto an overhead lift ing devicewith a ratedlifting capacitysufficient to lift the machine.

SeeFigure4.162.

NOTE It maybe necessaryto place reinforced spreaderbars between lifting cablesto preventdamage to the machine duringlifting. SeeFigure4.162.

PLACE L BETWEEN EACH CABLE AND FRAME

FIGURE 4.161 OVERHEAD ¯ LIFTING DEVICE

4. Slowlylift tion.

andmovemachine to desiredloca-

ALWAYS USE PROPERLIFTING EQUIPMENT ANDDEVICES. USE OF IMPROPERLIFTING EQUIPMENTCOULD ALLOWTHE LOADTO SHIFTOR FALL CAUSING SEVEREDAMAGE,SERIOUSINJURY OR DEATH.

MACHINE MODEL

SK13 LC)

BARS

WEIGHTOF THE MACHINEWITHOUT ATTACHMENTS. INCLUDES600MM (24") SHOES 10,750Kg(23,640Ibs)

3ENTER OF GRAVITY

FIGURE4.162

4-48

INSPECTION & MAINTENANCE CHECKLIST MACHINEMODEL:SK ITEM

SERIALNO.:

MACHINEHOURS:

OK MAINT. PERFORMED

ENGINEOIL LEVEL

ITEM HYD. FUNCTIONOPERATION

ENGINE COOLANTLEVEL

CHECK SWITCHES

CHECKFOR FLUID LEAKS

CHECK TRAVEL ALARM

CHECKBELT TENSION

CHECK SWING BRAKE

ICHECK FUEL LEVEL

CHECKWARNINGLIGHTS

DRAIN WATERSEPARATOR

CHECK BUZZER

CHECKAIR CLEANER

CHECK GAUGES

CHECKENGINE ELECTRICAL

CHECK HORN

DRAIN WATERFROM FUEL

CHECKDISPLAY MONITOR

CLEAN PRE-FILTER BOWL

SWINGREDUCTIONOIL

CHANGEENGINE OIL

SLEWINGRING GEAR

CHANGE OIL FILTER

GREASEBATH LEVEL

CHANGEFUEL FILTER

SLEWINGRING PINION

CHANGEWATERSEPARATOR

SLEWINGRING SEAL

CHECKAIR INTAKE SYSTEM

SWIVEL JOINT SEALS

CHECKFAN ASSEMBLY

DRAIN WATERFROMBATH

CHECKBELT TENSIONER

GREASESLEWINGRING

CHECK VIBRA~ON DAMPER

CHANGEGREASE BATH

CLEAN RADIATOR

CHECK BOLTS/HARDWARE

CLEAN DEBRIS SCREEN

CHECKFOR OIL LEAKS

CHANGEENG COOLANT

CHECKLINES FOR DAMAGE

AIR CLEANERELEMENTS

CHECKSTEPS

ADJUST VALVE CLEARANCE

CHECK FRAMESTRUCTURE

CHANGEETHER CYLINDER

CHECKTRACKS&LINKS

HYDRAULICOIL LEVEL

CHECK SPROCKET WEAR

CHECK HYDFUNCTIONS

CHECKIDLER WEAR

CHECKFOR OIL LEAKS

CHECK ROLLER WEAR

CHECK HOSES~INES

CHECKTRACK TENSION

CLEAN SUCTION SCREEN

ADJUST TRACKTENSION

’CHANGERETURNFILTER

TRAVELREDUCTIONOIL

PILOT MANIFOLDFILTER

CHECK BOOM &ARM

CHANGEHYDRAULICOIL

BUCKETTEETH

CLEAN HYDRAULICTANK

SIDE CUTTERS

INSPECTALL WIRING

GREASEBOOMPINS

BATTERYELECTROLYTE

GREASEARM PINS

gATTERYSERVICE

KOeeLCO KOBELCO AMERICA,INC

~CALHOUN,GEORGIA¯ STAFFORD,TEXAS

~OKI MAINT. PERFORMED

GREASE BUCKETPINS

MECHANIC: SIGNATURE:

4-49

DATE:

NOTES

Section V- SPECIFICATIONS Table of Contents

GENERAL SPECIFICATIONS .............................................................................................................................

5-1 - 5-5 Machine Dimensions ............................................................................................................................................. 5-1 Attachment Working Ranges ...............................................................................................................................

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

5-2 5-2 Arm ..........................................................................................................................................................................

Bucket ......................................................................................................................................................................

5-2 5-2 Shoes .......................................................................................................................................................................

Performance Specifications ................................................................................................................................. 5-3 Travel Speed ......................................................................................................................................................

5-3 Swing Speed ......................................................................................................................................................

5-3 Gradability .........................................................................................................................................................

5-3 5-3 Engine ................................................................................................................................................................

Hydraulic Components .................................................................................................................................... 5-3 Machine &Components Weights ........................................................................................................................

5-3 LiftingCapacities ...................................................................................................................................................

5-4 5-5 Bucket &Arm Combinations ................................................................................................................................

5-5 ~ 5-6 TORQUE SPECIFICATIONS ...............................................................................................................................

Capscrews &Nuts .................................................................................................................................................5-5 5-6 Nuts &Sleeves .......................................................................................................................................................

5-6 FlareTypeFittingJoints................. i .....................................................................................................................

Nylon Tube Fitting Joints ...................................................................................................................................... 5-6

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUALBEFOREATTEMPTINGANY OPERATION,INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

5-0

Section V- SPECIFICATIONS 5.1 SK130LCGENERAL SPECIFICATIONS Thespecifications foundin this sectionare givenon the StandardSK130(LC) MarkIV HydraulicExcavator as manufactured

by KOBELCO AMERICA, INC. Nomodifications or options are takenin to consider ationin regardto thesespecifications.

A. MACHINE DIMENSIONSFigure 5.1 1. Thesedimensions considerthe following: a. Standard Boom-4.6 meter(15’-1"). b. Standard Arm-3.0 meter(9’-10").

3 (0.52 cubicyard). c. Bucket-0.40m d. Shoe-600ram (23.6") Triple Grouser.

I

~---2,430mm(7’-11 ") 7,600mm(24’-11 ")

I -~1’295mm i 1.295mm

=--I ...... ;- I ,F

+11

t n P

~

l

t,

<--- 2,150mm (7’-1 ") -->

I

.....

I.

.....

I- 3,035mm (9’-11’;)~1~= I" 3,740mm(12 -3 ’) i~

6OOmm (23.6,,)-Jt,_.~ 2,590mm(8’-6")

_

~1

--~

FIGURE5.1 10668

(863

B. ATTACHMENTWORKING RANGES-Figure 5.2 1. StandardAttachment WorkingRanges: a. BOOM4.6 M(15’-1") b. ARM3.0 M(9’-10") c. BUCKETSAEHeaped0.40@(0.52 cu yd) 3 (0.39 cu yd) Struck0.30m Widthwith SideCutters-820ram (32") Widthw/oSideCutters-720ram (28") Weight-320kg(710 Ibs) ITE M~

9,144

(3o’) 7,620

(26’) 6,096

(203 4,572

(~5’) 3,048

FUNCTION

m

It-in

(10’)

(63

/ .....

1,524

b

Max Digging Reachat GroundLevel

8.61

28’- 3"

C

MaximumDepth-Bucket Hinge Pin i

4.82

15’-10"

®. d

Max. Height-Bucket Hinge Pin

-1,524

(-6’) I

7,64

25’- 1" -3,048 (-10’)

f

1.53

5’- 0"

-4,572

N

(-16’)

h

i

Digging Depth at 8’ Level Bottom

2.53

8’- 4"

5.89

19’ - 3"

-6,096 (-20’)

-7,620 (-26’) 10,668

*Without including height of shoe lugs.

(36’)

9,144 (30’)

7,620 (26’)

6,096 (20’)

4,672 (15’)

FIGURE5.2

5-1

8,048 (10’)

1,524 (5’)

0

Section V- SPECIFICATIONS C. BOOM-Figure 5.3 1. StandardBoom is 4.6 Meter (15’-1") A- Lengthis 4.76 M (15’-7") Distance between Boomends.

B- Height is 1.34 M (4’-5") FromGroundto top of Arm Cylinder Boss.

C-Width is 58.0 cm (1 ’-11") From edge to edge of BoomFoot.

WEIGHT-Approximately 940 kg (2,070 Ibs)

/--ARM CYLINDER

¯ :......

.... " FIGURE5.3

D. ARM-Figure 5.4 1. StandardArmis 3.00 Meter ( 9’-10" A- Length is 3.82 METER (12’-6") Distance between Arm ends.

B-Width is 27.4cm (10.8") From edge to edge of Arm Mounting Boss.

WEIGHT-Approximately422 kg (928 Ibs)

E. BUCKET-Figure 5.5 1. StandardBucket is 0.40m3 (0.52 cu yd)

A FIGURE5.4

A- Lengthis 1.17 Meter (3’-10") B- Height is 1.04 Meter (3’-5") C-Width Without Side Cutters is 72cm (28") D-Width with Side Cutters is 82cm (32") WEIGHT-320kg (710 Ibs)

F. SHOES-FIGURE5.6 1. Standard Shoesfor the SK130are 600mm (23.6") Triple Grouser.

2. Quantity of shoes; SK130- 43 per track.

SK130LC - 46 per track.

OPERATING WEIGHT AND GROUNDPRESSURE In standardtrim, with 9’10" (3.0m) arm, and 0.52cu yd. (0.40m3) SAE/PCSA bucket.

SHAPE

FIGURE5.5

TRIPLEGROUSER SHOE 23.6

27.6

SHOE WIDTH

In (ram)

(6o0)

(7OO)

OVERALLWIDTH

ft-in (mm)

8-6 (2,590)

(2,69o)

4.5

8-10

3.9

psi GROUND PRESSURE (kg/cm=)

(0.32)

(o.2s)

Ib OPERATING WEIGHT (kg)

27,840 (12,625)

28,28O (12,825)

FIGURE5.6

5-2

I ;I’L

Section V- SPECIFICATIONS H. MACHINE& COMPONENT WEIGHTS Thefollowing WeightSpecificationsare basedon the StandardSK130(LC) Machinewith Standard Attachment.

2. ComponentWeights unit: kg (Ibs.)

G. SK130(LC) PERFORMANCE SPECIFICATIONS ThefollowingPerformance Specifications are basedonthe Standard Machine with Standard Attachment.

1. Travel S )eed, SwingSpeed& Gradebility DESCRIPTION TRAVEL SPEED

COMPONENT

SPECIFICATION 7.0 km per hr (4.3 mph) in ~ mode.

4.0 km per hr (2.5 mph in ~ mode.

SWING SPEED

12.7 RPMIN"Hl"ldle.

GRADEBILITY

°70% ) (35

SK 130 COMPLETE MACHINE(STANDARD) UPPERFRAMEASSEMBLY COUNTERWEIGHT

2. Engine a. MajorEngine Specifications Engine Make Model Type Numberof Cylinders- Bore X Stroke Displacement CompressionRatio Net OutputRating Net MaximumTorque MaximumRPMat No Load- High Idle MaximumRPMat No Load- Low Idle Ignition Order Injection Timing Intake Valve ClearanceCold ExhaustValve Clearance Cold Electrical System Starting Motor Alternator Batteries Engine DryWeight* Thermostat Cooling Fan Drive Method Air Cleaner

WEIGHT

CUMMINS 4BT3.9 4-Cycle,WaterCooled,Direct Injectionwith Turbocharger, Diesel 4-102mm X 120mm (4.02" X 4.72" 3,920cc(239.3cu in.)

16.1:1 69.4kw@2,200 rpm(SAEJ 1349) (93HP@2,200 rpm) 382N-m@1,500 rpm (282Ibs-ft @1,500rpm) 2330~2365rpm 850~900rpm 1-3-4-2 ClockwiseRotation 15° °+/- 1 Before TopDeadCenter 0.254mm (.010") 0.508ram (.020") D.C. 24V 24V-4.0K3N 24V-50A 2- t 2V-(75AH) 338kg(745 Ibs) Beginto openat 82°C(180°F).

Full openat 93°C(200°F). a559(E~22")SuctionTypeBelt Drive PulleyRatio: 0.96 Dry Typewith Safety Element

CAB

2,050(4,520) 240(530)

BOOMCYLINDER*

100(220) X

ENGINE*

338(745)

RADIATOR*

53(120)

PUMPASSEMBLY CONTROL VALVE

105(230) 70 (170) 105(230)

HYDRAULIC TANK* SWINGMOTOR & REDUCTION UNIT

150(330) 4,500(10,000) 4,900(10,700)

SLEWINGRING TRAVELMOTOR & REDUCTION UNIT

165(360) X

IDLER ASSEMBLY

66 (145) X

LOWERROLLERASSEMBLY

26 (57) X

26 (57) X

UPPERROLLERASSEMBLY

8(t5)x 58(130) x

8 (18) X

TRACKTENSIONERASSEMBLY SPROCKET

37 (80) X

~.J

145(320)

925(2,040)x

990(2,180) X

TRACK LINK WITH700mm(28") SHOE ASSY.

1,030 (2.270) X

1,1oo (2,430) X

TRACKLINK

300(660) X

310(680) X

1,900(4,200)

BUCKETASSEMBLY (STANDARD)

320(710)

ARMASSEMBLY (STANDARD)

580(1,280)

ARM

422(928)

BUCKET CYLINDER*

86 (190)

IDLERLINK

26(57)

BUCKET LINK

30(86)

PIN (2 PCSfor mountingarmcyl & bucket)

38(84)

TYPE

HYDRAULIC PUMPS

Axial-Piston 2 X 118 Liters/min (2 X 31 US Gal/min) (VariableDisplacement Type)

BOOMASSEMBLY (STANDARD)

960(2,120)

BOOM

780(1,720)

GearType-23.3 Liters/min (6.2 USGal/min)

ARMCYLINDER* PIN(Mountingthe Arm)

155(340)

CONTROL VALVES OIL FILTRATION OIL COOLER RELIEF VALVES BOOM CYLINDERS ARM CYLINDER BUCKET CYLINDER

Two, double-acting: (4.1" X 3’ 7") stroke One, double-acting: (4.7" X 3’ 10") stroke One, double-acting: (3.9" X 3’ 0") stroke

4.J

TRACK LINK WITH600mm (24") SHOEASSY.

ATTACHMENT (STANDARD)

Axial-Piston Type, with spring-applied hydraulically-released parking brakes 5-spool in Main C/V+l-spool for Swing Onereturn filter w/replaceable element and a suction strainer Finned tube, Forced ventilation Primary and Secondary on each circuit

4,,,J

30(58)

COMPONENT

PILOT OIL PUMP SWING & TRAVEL MOTORS

4-J

LOWERFRAMEASSEMBLY

SWIVELJOINT

3. Hydraulic Components

+J

55(19o)

FUELTANK*

*Lessflywheelandelectrics.

SK130LC

12,000(26,500) 12,825(28,280) <.= 5,600(12,300)

4-u

4--=

15 (33)

FLUIDS

353(780)

HYDRAULIC, ENGINEOIL, GREASE

131(290)

FUEL

205(450)

WATER

18 (42)

4..=

* DRY WEIGHT

105mm X 1,097mm 120mm X 1,185mm

USE ONLY LIFTING

DEVICES AND EQUIPMENTWITH RATED

CAPACITIES SUFFICIENT TO LIFT THE SPECIFIC

100mm X 915mm

COMPONENT(S) BEING REMOVEDOR INSTALLED.

5-3

Section I.

V- SPECIFICATIONS

SK130LCLIFTING CAPACITIES 1. Lifting Capacity Specifications for a Standard Machinewith Standard Attachmentand 600mm Shoes.

SK 130LCLIFTING CAPACITIES

Basedon a machineequippedwith 9’-10" (3000mm) arm Arm ~) Bucket SAEheaped0.52 cu. yd. (0.4m Bucket Shoe 24" (600mm)TripleGrouserShoe

LOADRADIUS 20’ (6.1m)

~

~

5’ (1.5m)

20’ Ib kg (6.1m) 15’ Ib (4.6m) kg 10’ Ib (3.0m) kg Ib 5’ kg (1.5m) GROUND Ib LEVEL kg --5’ Ib (-1.5m) k~l -10’ Ib (-3.0m) kg -15’ Ib (-4.6m) kg -20’ Ib kg (6.1 m)

*5400 *2400 "10000 *4500 *15700 "7100

*5400 *2400 "10000 *4500 *15700 "7100

"13500 "6100 *17200 *7800 "18100 *8200 "16900 *7600 "12900 *5800

11900 5400 10700 4800 10400 4700 10500 4700 10900 4900

*6700 *3000 *8800 *4000 9900 4500 9600 4300 9600 4300

*6700 *3000 bZUU 2800 5700 2600 5500 2500 5500 2500

1. Donotattempt tolift or holdanyloadthat(s greater thanthese ratedvalues at their specified loadradiusandheight.

Weight of all accessories must be deducted fromtheabove lifting capacities. arebased onmachines standing onfirm. levelanduniform 2. [Jffingcapac~ies ground.

Usermust make allowances for job conditions suchassoft of uneven ground, outoflevelconditions, sidereeds,sudden stopping of loads,haZardous conditions, experience ofpersonnel, etc.

3. Rating atbucket ][;t hook.

*5400 *2400 *6000 *2700 6500 2900 ~uu 2800 6100 2700

4300 1900 4200 1900 3900 1700 3700 1600 3500 1600

4.Theabove ratedloadsare in compliance with" SAE H~rauli¢ Excavalor Lift Caoacity Rating Standard JICg7, They donotexceed 87% of hydraulic liftingcapacity or 75% oftippingload.

Rated taods marked withanasterisk(*} arelimitedbyhydraulic capacity ratherthantippingload.

5. Operator shouldbefully aqualnted withthe operator’s andMaintenance thst r~ctions before operating 61ismachine and rulesfors.~feoperation of equipment should beedherad to at all times. applyto onlymachine asoriginallymanufactured andnormally 6. Capacities equippedby KOBELCO AMERICA, INC. 2432N3528

2. Lifting Capacity Specifications for a Standard Machinewith Standard Attachmentand 700mm Shoes.

SK 130LCLIFTING CAPACITIES

Basedon a machineequippedwith 9’-10" (3000mm) arm Arm SAEheaped0.52 cu. yd, (0.4m3) Bucket Bucket 28" (700mm)TripieGrouserShoe Shoe

LOADRADIUS

20’ Ib (6.1m) kg 15’ Ib (4.6m) k9 10’ Ib (3.0m) kg 5’ Ib kg (1.5m) GROUND Ib LEVEL k9 -5’ Ib (-1.5m) k~l -10’ Ib

(--3.0m) kg -15’ Ib kg (-4.6m) -20’ Ib (-6.1 m) k¢l

*5400 *2400 *10000 *4500 *15700 "7100

*5400 *2400 *10000 *4500 *15700 .7100

*13500 "6100 *17200 *7800 *18100 *8200 *16000 *7600 *12900 *5800

12100 5400 10900 4900 10600 4800 10700 4800 11100 5000

*6700 *3000 *8800 *4000 10100 4600 9800 4400 9800 4400

*6700 *3000 6300 2900 5800 2600 5600 2500 5600 2500

to lift or h~danyloadthatis greater thantheseratedvalues 1.DOnot~.ttempt at their specified loadradiusandheight.Weight of eJIaccessories must be deducted fromtheabove tiffing c=paciltes.

2. lifting capacities arebe,sodonmachines stendJng onfirm, levelanduniform ground, Usermustmeke allowances for joboondlfions suchassoft or uneven ground, outof ]ovalconditions, sideloads,sudden steapdlg of loads,ndz~rpeus conditions, expeflence ofpersonnel, eto.

3. Rating e,t buretlift hook.

5-4

*5400 *2400 *6000 *2700 6600 3000 6400 2900 6200 28OO

4400 2000 4200 1900 4000 1800 3700 1700 3600 1600

4. Theshove ratedloadsamin compliance with SAE Hydraulic Excavator Lift Caoacity Rafing Standard J 1097.

They dor~t exceed 87% of hydraulic liftingcapacity or75% of tippingload.

Rated laodsmarked withanaaledsk (~) arelimitedbyhydraulic capacity ratherthentippingload.

5.Operator should befully shuainted withtheoperator’s and Mainterlarlce Inalr~alions before operating thismschioe e.rtdrulesfor safeOperation of equipment should beadhered tOat ati times.

6. Capec~es appiyto onlymachine as originallymanufactured andnormshy equippedby KOEELCO AMERICA, INC. 2432N3530

Section V- SPECIFICATIONS J. SK130LCBUCKET SELECTIONGUIDE Width BUCKET DUTY Capacity (SAE) Cubic Yard (Meter) Inches (Meters)

Bucket Weight Lbs (Kg)

Arm 9’-10" H

General

0.58(0.443)

835 (379)

M

Purpose

0.00(o.672)

1015(461)

X

1200(545)

X

H- Used with material weight up to 3,000 Ibs per cubic yard, M- Used with material weight up to 2,500 Ibs per cubic yard.

Heavy

0.44 ~33~....

780(354)

H

Duty

0.73(o.sss)

975(443)

L

1.02(0.779)

1210 (550)

X

L- Used with material weight up to 2,000 Ibs per cubic yard.

31(0.767)

1230(55s)

M

X- Not recommended.

48(1,219)

1570(714)

X

Severe

~~t

Duty

0~70(0.673)

5.2 TORQUE SPECIFICATIONS Thefollowing TorqueSpecificationsare providedfor usewhenactual torque valueof a fasteneris not known.

A. CAPSCREWS & NUTS & Nuts to 1. Metric CoarseThreadStandardTighteningTorqueValues.Makecertain to tighten all Capscrews propertorque values.

Classification

4

7

T

T

10

NO LUBRICATION

OIL LUBRICATION NO LUBRICATION

M6

P=I

0.454-0.05(3.2±0.4)

0.38-+0.04(2.7±0.3) 0.984-0.1(7.1±0.7) i 0.83-+0.08 (6.04-0.6)1.77±0.18(12.8-+1.31 1.5±0,15(01.8-+1.1)

M8

P=1.25

1.094-0.11(7.9±0.8) 0.92±0.09(6.6+0.7)

M10

P=1.5

2.2-+0.2(15.9-+1.4) 1.834-0.18(13.24-1.3) 4.7-+0.5(33.9-+3.6) 4.0-+0.4(28.9-+2.9) 8.54-0.9(61.3±6.5)

M12

P=1.75

2.24-0.2(26.7-+2.9)

3.2_-,_--K).3 (23.1±2.2)

8,1-+0.8(58.5-+5.8) 6.8_+0.7(49.1-+5.1) 14.6-+1.5(105-+10.8) 12.3-+1,2(88.84-8.7)

M14

P=2

5.9-+0.6(42.64-4.3)

5.0-+0.5(36.1 ±3.6)

12.8-+1.3(92.5±9.4) 10.8±1.1(78,0-+7.9)

M16

P=2

9.0±.09(64.9-+6.5)

7.6±0.7(54.84-5.1) 19.54-2.0(140-+14.4)16.4-+1.6(118±11.5) 35-+4(252±28.9)

2.44-0.2(i7.34-1.4)

OIL LUBRICATION NOLUBRICATION

T

NOMINALSIZE

OIL LUBRICATION

2.0-+0.2(14.44-1.4) 4.3_+0.4(31.0_+2.9) 3.6-+0.4(26.0.+-2.9)

23±2(166±14)

7.2-+0.7(52.0-+5.1)

19.54-1.9(1404-14) 29-+3(209-+21.6)

M18

P=2.5

12.4-+1.2(89.64-8,7) 10.5-+1.0(75.8-+7.2)

27-+3(195-+22)

23_+_2 (166-+14)

494-5(3544-36)

41-+4(2964-29)

M20

P=2.5

17.5_+1,7(126-+12.3) 14.7-+1.4(106-+10.1)

38-+4 (274±29)

32-+3(231__.22)

68±7(491-+51)

57±6(412-+43)

M22

P=2.5

23+_2(166±14)

19,64-2.0(142_+14)

514-5(368_+36)

43±4 (310±29)

92±9(6634-65)

774-7(5554-58)

M24

P=3

30±3(217_+22)

244-3(173-+22)

65-+7(469_+51)

53¢5 (383±36)

118±12(8524-87)

96±10(6934-72)

M27

P=3

44-+4-(318±29)

364-3(260-+22)

96-+10(693_+72)

784-8(5634-58)

1734-17(1250¢120) 140±14(1010-+100)

P=3.5

604-6(4334-43)

110±11(7944-79) 235-+24(1700-+170) 198-+20(14304-140)

50±5(361 ±36)

131-+13(946-+94)

M33

P--3.5

81+8 (585-+58)

68±7(491±51)

176-+18(1270-+130) 1484-16 (1070-+11O) 3174-32(2290±200) 266-+27(1920-+200)

M36

P=4

1054-10(758-+72)

884-9(6364-65)

227±23(1640-+170) 1904-19(13704-140) 409-+41(2950_+300) 343±34(24804-250)

M30

TORQUE VALUEUNIT- kgf-m (ft.

Ibs.)

& Nutsto 2. Metric Fine ThreadStandardTighteningTorqueValues.Makecertain to tighten all Capscrews propertorque values.

Classification

4

T

7

T

10

T

NOMINALSIZE

NO LUBRICATION

OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION

M8

P=1.25

1.15_+0.11 (8.3-+0.8)

0.974-0.1(7.0±0.7)

2.54-0.2 (18.04-1.4) 2.14-0.2(15.2-+1.4) 4.5±0.4(32.54-2.9)

3.84-0.4(27.44-2.9)

M10

P=1.5

2.3:~-0.2(16.6-+1.4) 1.914-0.19 (13.8-,1.4) 4.94-0.5 (35.4_+3.6) 4.2-+0.4(30.3-+2.9) 8.9-z0.9(64.2-+6.5)

7.5_+0.7 (54.24-5.1)

M12

P=1.75

4-,04-0.4(28.9-+2.9)

3.44-0.3(24.5-+2.2) 8.7±0.9 (62.8-+6.5)

M16

P=2

9.4-+0,9(67.94-6,5)

7.9-+0.8(57.04-5.8)

204-2 (144-+14)

17.24-1.7(124±12)

37-+4(2674-29)

31-*3 (2244-22)

M20

P=2.5

i9±9 (137±14)

15.8_+1.6(114_+14)

41~4(296-+29)

34±3(2464-22)

74±7 (535±51)

624-6(4484-43)

M24

P=3

324-3 (231±22)

274-3 (195±22)

70±7 (506±51)

58±6 (419±43)

1264-12(910±87)

1054-10(7584-72)

M30

P=3.5

65±6(469±4-3)

544-5(390±36)

1424-14(10304-100) 1 i 8±12(852±87) 2554-26(1840-+190) 212±21(15304-150)

M36

P=4

109±11(787±79)

914-9(6574-65)

2384-23 (17204-170) 198.-+20(1430±140)4284-43(30904-310) 357±36(2580±260)

7.3±0.7(52.7_+5.1) 15.74-1.6(113±13) 13.2_+1,3(95.3±9.4)

TORQUE VALUEUNIT- kgf-m (ft.

5-5

Ibs.i

Section V- SPECIFICATIONS 3. Nuts & Sleeves SLEEVE

NUT

1

o,o,

ot’o MANUFACTURER’S NAME

I~

300 (4270)

NIPPONA.M.C.

OPPOSINGFLATS

10 X 1.5 (0.394 X 0.059)

19

5+_1(0.36¢0.07)

15 X 2.0 (0.591 X 0.079)

27

12¢1.2(0.88+0.09)

18 X 2.5 (0.709 X 0.098)

32

15+_1.5 (1.09+_0.11)

22 X 3.0 (0.866 X 0.118)

36

22+-2.2(1.59-+0.16)

28 X 4.0 (1.10 X 0.157)

41

28+-2.8(2.03¢0.20)

35 X 5.0 (1.38 X 0.20)

55

45+-4.5(3.25.-0.33)

300 (4270)

IHARA KOATO

4. Flare TypeFitting Joints Overtighteningof Flare Type(UnionNut Type) metal joints maycausedamage to nuts, seat surfacesandpreventoptimum sealingresulting in oil leaks.

1.

PIPE

THREADS

TORQUEVALUE

1/4"

2.5+_0.3 (18.1 ,-1.8)

3/8"

5+_0.5(36.2-+3.6)

1/2"

6¢0.6 (43.4+-4.3)

3/4"

12+-1.2(86.8-+8.7)

1 i|

14±1.4 (101 ±10)

1-1/4"

17±1.7 (123±12)

1-112"

21-.2.1 (152-+15)

mm

DimensionB

5. N=(Nylon)Tube Fitting Joints 1. Cleantube and makecertain tube end is trimmedsmooth.

2. Insert tubeinto fitting until tubeendis securely seatedin fitting body.

3. Tightenthe nut by hand.

4. Usea spannerwrench,securily tighten nut by turning1-1/4turns.

unit: kg-m(ft. Ibs.)

NOMINAL SIZE

I’2

TORQUEVALUE 2 (ft. Ibs.) kgf-cm

TUBE SIZE O.D. X THICKNESS mm(in)

WORKING PRESSURE kgf/cm= (PSI)

PLASTIC SLEEVE

42-*4.2 (304_+30)

BODY---, NUT

........i

4/,

It

/"

NYLON TUBE

[] 5-6

NOTES

Section VI- TROUBLESHOOTING Table of Contents GENERAL TROUBLESHOOTING ......................................................................................................................

/I\ READ, UNDERSTANDAND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURESFOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCEOF THIS MACHINE, ATTACHMENTOR SYSTEMS.

6-0

8-1 ~ 6-3

Section VI- TROUBLESHOOTING 6.1 GENERALTROUBLESHOOTING This troubleshootinginformationcoversthe componentsand systemsas describedin this operators manual.Shouldin-depthtroubleshooting,repair or SYS

PROBLEM

replacementof components or adjustmentof valvesbe required, contactan authorized KOBELCO Service Dealer for assistance.

PROBABLECAUSE

1. All operatingspeedsare a. Lowhydraulicoil level slowor poweris lost. lb. Air leakinginto the suctionpipe ¢. Hydraulic pumpdamaged d. Pilot gear pumpdamaged e. Mainrelief valveis not adjustedcorrectly f. Pilot relief valveis not adjustedcorrectly 2. A specific cylinder a. Cylinder seal is damaged functionsimproperlyor b. Controlvalve or overloadvalvefunctions loses power incorrectlyor therearesignsof air in the cylinder c. Pilot valve is damaged d. Pilot valvepipingis loose !3. Thecylinderpositionwill a. Cylinderseal is scored not hold with operating b. Control valve or overloadvalve is damaged z leverin neutral. c. Overloadvalve is not operating d. Pilot valve is damaged .= 4. Machinedoes not a. Brakevalve is not working 0 swing. b. Hydraulicmotor(swing)is not working or swinggear is damaged. c. Swingbearing is damaged. d. Pilot valveis not working. e. Swingreduction unit is damaged 5. Swingspeedis slow. a. Brakevalve is not working b. Controlvalveis not working. c. Hydraulicmotor(swing)is not working d. Hydraulicpumpis not working 6. Abnormalsoundoccurs a. Insufficient lubrication of swinggearandbearings whenswinging. b. Lowoil level in the swingre ductionunit 7. With swingstopped,the a. Brakevalve malfunctions machine drifts andis b. Set pressureof brakevalveis incorrect hardto control. ¢. Brakelining is worn 1. Machinedoesnot travel; a. Toomuchtrack tension smoothly. b. Dirty track links andshoes ¢. Brakevalve is not working d. Travel reductionunit is damaged 2, Travelingpoweris insuf- a. Hydraulic pumpis damaged ficient. b. Poor engine performance n¢. Mainrelief valvepressureis set incorrectly Id. Lowhydraulicoil level e. Hydraulicmotor(travel) is not working f. Brakevalveis not working g. Sealin swiveljoint is scoredor oil is leaking

6-1

POSSIBLE REMEDY a. Fill oil to specified level. a. Tightensuctionpipehose clampor replace hose. a. Repairor replace a. Repairor replace a. Adjustor replace a. Adj ust or replace a. Repairor replace a. Repairor replace/Bleed air fromcylinder a. Repairor replace a. Retighten a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a, Repairor replace a. Grease a. Refill with properoil a. Repairor replace a. Adjustor replace a. Repairor replace a. Adjusttrack tension a. Cleantracks a. Repairor replace a. Repairor replace a. Repairor replace a. Repairor replace a. Adjust or replace a. Fill to properlevel a. Repairor replace a. Repairor replace a. Repairor replace

Section VI- TROUBLESHOOTING

,,

PROBABLECAUSE POSSIBLE REMEDY PROBLEM a. Adjusttension.

3. Machinedoesnot travel a. Unequaltensionson tracks ..J LLI in a straightline. b. Set pressuresof mainrelief valves unbalanced a. Adjust. a. Repairor replace. c. Performances of hydraulic travel motorhas I-deteriorated ’a. Clean 1. Temperature rise in the a. Oil coolercore clogged a. Adjustor replace hydraulicoil temp. b. Enginefan belt slipping a. Refill to specifiedlevel ¢. Lowhydraulicoil level <¢ I= a. Replacewith correct, new d. Wrongtype hydraulic oil used >oil 2: a. Repairor replace e. Hydraulicpumpis not working a. Fill to specifiedlevel 1. Engineoil pressure is too a. Engineoil level low a. Repair& fill to properlevel low. (Buzzersounds b. Oil leaking a. Replacewith properoil andicon displays). ¢. Wrong oil viscosity a. Fill to properlevel #. 2. Abnormalrise in the a. Lowcoolant a. Repair & fill to properlevel coolant temperature. b. Coolantleaking a. Tighten ¢. Looseradiator cap (Buzzer soundsand I,U I-a. Cleancooling system d. Radiator core clogged icon displays). ¢/) a. Repairor replace e. Foam insulation aroundradiator and/oroil cooler ..J misplacedor deteriorated UJ t3 a. Tightento propertension f. V-belt loose or damaged a. Flushsystem/fill to level g. Rustor scalein coolant {5 a. Replace h. Faulty thermostat a. Replaceelements 3. Air cleanerclogged. a. Cloggedair cleaner a. Clean,repair or replace (Buzzer soundsand b. Hosesfrom air cleanerto turbo clogged. icon displays). a. Connect 1. Starter doesnot turn or a. Battery disconnected a. Charge turns slowly whichdoes b. Battery discharged not start the engine. c. Battery terminalsdisconnected, loose, or corroded a. Cleanand connect a. Connect d. Groundcable disconnected a. Change to properoil e. Engineoil viscosity too thick (ColdWeather) a. Refuel 2. Starter turns but enginea. Insufficientfuel a. Referto pages3-2~3-4 doesnot start. b. Improperstarting procedure ![i a. Bleed(SeeEng. Manual’ c. Air in fuel line Z a. Replaceelement d. Clogged fuel filter z IJJ a. Replaceelements e. Cloggedair cleaner a. Checkcircuit & cylinder f. Etherinjection circuit malfunctioning a. Check elect, circuit g. Electric systemor shut off rele malfunctioning a. KOBELCO Serviceman 3. Enginetendsto stop at a. Lowidling RPM a. Replaceelement low speed b. Fuelfilter clogged a. Replaceelements ¢. Air cleanerclogged a. CUMMINS Serviceman d. Impropervalve clearance a. Replaceelement 4. No power a. Fuelfilter clogged i a. Replaceelements b. Air cleanerclogged a. CUMMINS Serviceman ¢. Impropervalve clearance d. Looseclamps on the air inlet hose(with turbocharger)a. Tightenclamps a. Replacehose e. Cracked air inlet hose(with turbo charger)

SYS

_o,

|

6-2

Section SYS

PROBLEM 5. Engineoverheats.

VI-

TROUBLESHOOTING PROBABLECAUSE

POSSIBLE REMEDY a. Insufficient coolant a. Refill coolant b. Cloggedradiator a.Cleancooling components c. V-belt to loose or damaged a. Adjustor replacebelt d. Faulty thermostat a. Replace 6. Engineexhaustis black. a. Air cleanerclogged a. Replaceelements b. Impropervalve clearance a. CUMMINS Serviceman 7. Poorfuel consumption a. Fuel leak a. CUMMINS Serviceman b, Air cleanerclogged a. Replaceelements I!1 c. Looseclampson suction hose(with turbo charger) a. Tightenclamps Zm d. Crackedsuction hose(with turbo charger) a. Replace w/newhose ,,=i, 8. Excessiveoil consump-a. Improper oil a. Replacewith correct oil tion. b. Oil leak a. CUMMINS Serviceman c. Improperoil replacement intervals a. Change at correct interval d. Improperwarming-upoperation a. Referto page3-5 9. Engineoil pressuredoes a. Lowoil volume a. Fill to specifiedlevel notrise. b. Oil leak a. CUMMINS Serviceman c. Improper oil viscosity a. Replacewith properoil 10. Batterydies often. a. Battery terminals disconnected loose, or corroded a. Clean& tighten terminals b. Lowbattery electrolyte a.Fill cells w/distilled water c. V-belt loose or damaged a. Adjustor replacebelt d. Defectivebattery a. Replacebattery

[] 6-3

Section VII-

SCHEMATICS

Table of Contents ELECTRICAL CIRCUIT DIAGRAM (A).......................................................................................................................

ELECTRICAL CIRCUIT DIAGRAM (B).......................................................................................................................

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READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUAL BEFOREA’I’TEMPTING ANY OPERATION,INSPECTIONOR MAINTENANCE OF THIS MACHINE,AI-i’ACHMENTOR SYSTEMS.

7-0

7-1 7-2

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Section VIII-

OPTIONALEQUIPMENT

Table of Contents SAFETY PRECAUTIONS ............................................................................................................................

8-1 - 8-2 NIBBLER & BREAKER SYSTEM - (Machineset-up for Breaker, Tamper,etc. - OneorTwopumpflow) ...... 8-3 - 8-4 NIBBLER & BREAKER SYSTEM - (Machineset-up for Shear, Thumb, etc. - Oneor Twopumpflow) ........

8-5 - 8-6 ADDITIONAL MAINTENANCE FOR BREAKER ...........................................................................................................

8-7 VANDALISM GUARD ..............................................................................................................................................

8-8

! CAUTION !

MOST BREAKERS AND TAMPERS REQUIREONE PUMP FLOW ONLY!

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUALBEFOREATTEMPTINGANY OPERATION,INSPECTIONOR MAINTENANCE OF THIS MACHINE,ATTACHMENT OR SYSTEMS.

! CAUTION! CHECK FLOW REQUIREMENT OF ATTACHMENT BEFORE SELECTING TWO PUMPS !

I Optional equipmentoffered by KobelcoAmericaInc. 1. BreakerKit- Hydraulicpilot operated,foot pedalcontrolled, single pump flow system.ProvidesUni-directional(oneway)oil flow fromonepump only. System hasattachmentflow selector (stop) valveslocated on both sides of arm(refer to Figure8.13), anda Single-Acting controlpedalmounted on the right handsideof the travel pedalsin cab(refer to Figures 8.14-8.16).Thiscircuit operatesat mainsystempressure,unlessa separaterelief valveis installed.

2. ExtraKit - Hydraulicpilot operated,foot pedalcontrolled,separate"LowFlow"circuit. ProvidesBi-directional(two-way) oil flow froma flow divider, that usessome oil fromeachhydraulicpump.

Flowdivider is electrically controlledfroma dash mounted switch (marked-"EXTRA"),in the operatorscab. (Flow divider mustbe switched-off during normalexcavator operations.)A Double-actingcontrol pedalmounted on the righthandside of the travel pedalsin cab(refer to Figures 8.14~8.16), controlsa Bi-directionalauxiliary controlvalvewhichcontainsit’s ownmainandport relief valves.Thiscircuit canbe set to operateat pressureslowerthanthe mainsystem,but it is a "LowFlow"circuit.

3. Breaker& ExtraKit - This kit combines both of the separatekits mentioned above.

4. Nibbler& BreakerKit ** - Thiskit is the mostversatile andmostpopularoneoffered.A) It providesthe ability to have Uni-directional(one-way) oil flow fromoneor bothpumps.

B) It alsoprovidesthe ability to haveBi-directional(two-way) oil flow fromoneor both pumps.It also usesthe hydraulic pilot operatedfoot pedal(as mentioned above),to control auxiliary control valve, whichcanoperateas singleor doubleacting. Thiscontrol valvealso containsit’s ownport relief valves, for circuit protection. System hasattachment flow selector (stop) valveslocatedon both sidesof arm(refer Figure8.13). ** This kit canbe set-upto operateBreakers,Tampers.

Shears.Nibblers,Thumbs.

Grapples,etc.

** This kit is explainedin this sectionbecause of the useof severalselector valvesnecessary to achievethe

I

variousoil flows. Theseselector valves mustbe set correctly to preventdamage to (and providethe proper performance of) the machine,andthe auxiliary equipment that is mounted.Pleaseread the set-up instructions carefully!

IREVISEDI 8-0

Section VIII-OPTIONAL

EQUIPMENT

8.1 SAFETYPRECAUTIONS Thefollowing Safety Precautionsshouldbe usedin conjunctionwith all other safety precautionsfound in this manual.

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATINGPROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATTACHMENT FIGURE8.1 A,

USE FOR INTENDEDPURPOSE-FIGURE 8.1 Usethe attachmentonly for its intendedpurpose.

If not usedin accordance with the manufacturers instructions, the excessivepressureexertedon the boom,armandframestructure of the machine will causeprematurefailure of the components.

PASSENGERS Never allow passengerson the attachment or machine.

i:

C. PROTECTIVEEQUIPMENT-FIGURE 8.2 Install protectiveguardson the machine andclose the all windows to protect the operatorfromflying debris. Also the operatorandall personellin the vicinity of the machine shouldwearprotectivegear suchas Safety shoes,HardHat, GlovesandFace Shield or Goggles.

FIGURE8.2

CYLINDERS-FIGURE8.3 Donot operateBoom,Armor Bucketcylinders to stroke ends whenusing a breaker attachment.

Doingthis cancauseunduestress on the cylinder rods and result in damage.

E. AVOIDCONTINUOUS OPERATIONFIGURE8.4 Operatethe Breakeror Nibbler in one(1) minute intervals. Operationfor longerthan one(1) minute at a time cancausehigh oil temperatures anddamagethe accumulators,cylinder seals andpossibly pump damage.

FIGURE8.3

FIGURE8.4

8-1

Section VIII-OPTIONAL EQUIPMENT F. HOSESURGE-FIGURE8.5 Shouldthe hydraulic hosesbeginto surge or vibrate abnormallyduring operationof a Breakeror Nibbler, immediately stop operationandcontactan Authorized KOBELCO Service dealer for assistance. This problemoften is a reesult in damaged accumulators andcanalso result in valvefailure.

FIGURE8.5

G. DO NOT USE DROPPNG FORCE- FIGURE 8.6 Neverusethe droppingforce of the attachmentto breakor drive objects. This will causeextensive damage to the attachmentand machinestructure.

FIGURE8.6 H. DO NOTUSE SWINGFORCE-FIGURE8.7 Neverusethe swingforce of the machine for pushing or sliding objects,this will causepremature failure of the attachmentand other machinecomponents.

FIGURE8.7 I. DONOTLIFT- FIGURE 8.8 Neverusean optional attachment to lift or transport objects or material. Doingso can causeextensive damage to the attachment, the machine structuresandcauseinjury or death.

FIGURE8.8 UNACCEPTABLEWORKRANGE

J. WORKING RANGES-FIGURE8.9 Neveroperate an optional attachmentover the sides of the machine.Only operateover the front or rear of the tracks.

A~~ABLE

UNACCEPTABLEWORKRANGE

FIGURE8.9

8-2

Section VIII-

OPTIONALEQUIPMENT

8.2 NIBBLER& BREAKER SYSTEM A. MACHINESET-UP FOR BREAKER OR TAMPER USE- UNI-DIRECTIONAL - (ONE-WAY FLOW) [ONE orTWO PUMPFLOW] ’~%!

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READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATIONPROCEDURES FOUNDINTHIS MANUALBEFOREOPERATING THE MACHINEOR ANY AI"rACHMENT. 1. Pilot Circuit SelectorValve a. Locatethe Pilot SelectorValvein front of the attachmentfilter housing.SeeFigure 8.10. b. Usea 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.10A. c. Usea spannerwrenchand turn the selector valve to align the arrowheads,stamped on the valve, as shownon Figure 8.10A,for twopump flow, or Figure 8.10Bfor one pumpflow. d. Reinstall the hexagonal headsafety bolt.

SeeFigure 8.10A.

FIGURE8.11 HAMMER& TAMPER RETURNOIL MUST GO THROUGH EXTERNAL FILTER

2. ReturnFlowSelector Valve a. Usea 19ramwrenchand removethe bolts that hold the panelabovethe MainControl Valve. Remove the panel andlocate the ReturnFlowSelector Valvebehindthe attachment filter housing.SeeFigure8.11. b. Use a 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.11. c. Usinga spannerwrench,turn the selector until the stampedarrowheadsare aligned as shownon Figure 8,11. d. Reinstall the hexagonalheadcapscrew andtighten it properly.

SET FOR TWO PUMP FLOW

FIGURE8.12A

3. Pump FlowSelector Valve a. Locatethe PumpFlow Selector Valve. See Figure8.12. b. Removethe Hexagonal HeadCapscrew with a 4ramallen wrench. c. Usinga spanner wrench,turn the selector until the stamped arrowsare aligned as shown on Figure8.12A,to select twopump flow, or as shownon Figure8.12B,to select onepump flow. [Checkflow requirementof attachmentbefore selecting two pumps !] d. Reinstall the hexagonalheadcapscrewand tightenit properly.

4. Attachment FlowSelector Valves a. Locatethe Att. FlowSelectorValveson both sides of the Arm.SeeFigure 8.13. b. Usinga spannerwrench,turn the selector valves until the stamped arrowsare aligned with the direction of the flow. Figure8.13 showthe valveson the lock position.

8-3

SET FOR ] ONE PUMP FLOW

FIGURE8.12B ! CAUTION !

MOST BREAKERS AND TAMPERS REQUIREONE PUMP FLOW ONLYZ

FIGURE8.13 Located onbothsidesof the armby the bucketend connection.

Section VIII-OPTIONAL EQUIPMENT B. BASIC OPERATION

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATIONPROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATTACHMENT. 1. Start Machineandplace the Safety LockLever in the "UNLOCKED" (Down)position. See Figure8.13. throttle controlto the "HI" idle position.

2. Move 3. UsingBoom,ArmandBucketcontrols set the Breakeror Tamper to desiredposition.

4. ReleaseControlPedalLockRod.SeeFigure8.14. is in desired 5. Makecertain Breaker/ Tamper position andagainstmaterialto be broken,or compacted.

6. PlaceRight foot on pedalanddepresswith toe to activate Breaker/Tamper.

SeeFigure 8.15.

7. OperateBreaker/Tamper for one(1) minutethen releasepedal.

FIGURE8.13

FIGURE8.14 OPERATIONOF BREAKER/TAMPER LONGER THANONE(1) MINUTEINTERVALSCOULD CAUSE PREMATUREWEAR OR DAMAGETOTHE ATTACHMENT ANDTHEMACHINE. IF MATERIAL IS NOTBREAKING, REPOSITION BREAKERAND REPEAT OPERATION IN ONE(1) MINUTEINTERVALS. operationis complete 8. After Breaker/ Tamper or operatoris requiredto leavethe machine, placepedallock rod in the lockedposition, see Figure8.16, positionattachment in hydraulicoil checkposition,move throttle controlto "LO"idle position andturn engine"OFF".

FIGURE8.15

NEVERLEAVETHE OPERATOR CAB WITH ENGINERUNNING. ALWAYSLOWERTHE ATTACHMENTSTO THE GROUNDBEFORELEAVING THE CAB.

FIGURE8.16

8-4

~r

Section VIII-

OPTIONALEQUIPMENT

8.3 NIBBLER& BREAKER SYSTEM (Cont.)

A. MACHINE SET-UPFORNIBBLERUSE SHEAR,THUMB, GRAPPLE,ETC. BI-DIRECTIONAL - .£TWO-WAY FLOW) [ONE orTWO PUMPFLOW] FIGURE8.17A

READ, UNDERSTAND ANDFOLLOWALL SAFETY PRECAUTIONSAND OPERATIONPROCEDURES FOUNDINTHIS MANUALBEFOREOPERATING THE MACHINEOR ANY ATTACHMENT.

GRAPPLE

1. Pilot CircuitSelectorValve a. Locatethe Pilot SelectorValvein front of the attachment filter housing.SeeFigure8.17. b. Usea 4 mmhexagonalwrenchand remove the safety bolt. SeeFigure8.17A. c. Usea spannerwrenchand turn the selector valve to align the arrowheads,stamped on the valve, as shownon Figure 8.17Afor two pumpflow, or Figure 8.17Bfor one pumpflow. d. Reinstall the hexagonal headsafety bolt.

SeeFigure 8.17A. 2. ReturnFlowSelector Valve a. Use a 19rnmwrenchand removethe bolts that hold the panelabovethe MainControl Valve. Remove the panel and locate the ReturnFlowSelector Valvebehindthe attachment filter housing.SeeFigure8.18. b. Use a 4 mmhexagonalwrench and remove the safety bolt. SeeFigure 8.11. c. Usinga spannerwrench,turn the selector until the stampedarrowheadsare aligned as shownon Figure 8.18. d. Reinstall the hexagonalheadcapscrew andtighten it properly.

3. Pump Flow Selector Valve a. Locatethe PumpFlow Selector Valve. See Figure8.19. b. Removethe Hexagonal HeadCapscrew with a 4ramallen wrench. c. Usinga spannerwrench,turn the selector until the stampedarrowsare aligned as shownon Figure 8.19A, to select two pump flow, or as shownon Figure8.19Bto select one pumpflow. d. Reinstall the hexagonalheadcapscrew andtighten it properly.

4. Attachment Flow Selector Valves a. Locatethe Att. FlowSelectorValveson both sides of the Arm.SeeFigure 8.20. b. Usinga spannerwrench,turn the selector valvesuntil the stamped arrowsare aligned with the direction of the flow. Figure8.20 showthe valveson the lock position.

8-5

FIGURE8.17B

FIGURE 8.18 J RETURNOIL MUST GO THROUGH AUXILIARY CONTROL VALVE

SET FOR TWO PUMP FLOW

FIGURE8.19A SET FOR ONE PUMP FLOW

FIGURE8.19B ! CAUTION! CHECK FLOW REQUIREMENT OF ATTACHMENT BEFORE SELECTING TWO PUMPS

FIGURE8.20 Located on bothsidesof the armby the bucketend connection.

Section VIII-

OPTIONALEQUIPMENT

B. BASIC OPERATION

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND OPERATIONPROCEDURES FOUNDIN THIS MANUALBEFOREOPERATING THE MACHINEOR ANY AI"rACHMENT. 1. Start Machineandplace the Safety LockLever in the "UNLOCKED" (Down)position. See Figure8.21.

2. Move throttle controlto the "HI" idle position.

3. Using Boom,ArmandBucketcontrols set the Attachment to desiredposition.

4. ReleaseControlPedalLockRod.SeeFigure8.22.

5. Usethe Boom,Armand BucketControls to position the attachment.

6. PlaceRight foot on pedalanddepresswith toe for onedirection of attachment operation,and depressbackof pedalwith heel for oppositedirectionof attachment operation.SeeFigure8.23. or operatoris re7. After operationis complete quired to leave the machine,placepedallock rod in the lockedposition, seeFigure8.24, position attachment in hydraulicoil checkposition, move throttle controlto "LO"idle position, and turn engine"OFF".

FIGURE8.21

FIGURE8.22

NEVER LEAVETHEOPERATORCABWITH ENGINERUNNING.MAKESURETOPLACEALL THE ATTACHMENTS ONTHEGROUNDBEFORE LEAVINGCAB. FIGURE8.23

FIGURE8.24

8-6

Section VIII-OPTIONAL EQUIPMENT 8.4 ADDITIONAL MAINTENANCE FOR BREAKER (OPTIONAL ATTACHMENT) to performthe followingmainteA. It is necessary nanceschedulein regardto HydraulicOil and Filters alongwith normalinspectionandmaintenanceas describedin SectionIV of this manual for the BreakerOptionalAttachment.

B. ADDITIONALHYDRAULICRETURNFILTER TheBreakeroptional attachmentincorporates an additional HydraulicReturnFilter mounted on an independent standto the R.H.side of the SwingMotor. SeeFigure 8.25.

FIGURE8.25

COMPONENT

LOCA~ON

REPLACEMENTSCHEDULE 1ST MAINTENANCE 2ND MAINTENANCE

REGULARMAINTENANCE EVERY600 HOURS

CHANGEHYDRAULICOIL HYDRAULICTANK RETURNFILTER

HYDRAULICTANK

25HOURS

100HOURS

EVERY200 HOURS

OPT. RETURNFILTER

BESIDESWINGMTR.

25HOURS

100 HOURS

EVERY200 HOURS

NOTE Contactyour KobelcoDealerto order the return filter elementfor the optional Breakerattachment, Part Number:2446U233S2

PLEASE NOTE Theabovefilter is for the genuine Kobelco HydraulicBreaker or Nibbler/BreakerKits. If your unit hasanotherbrand hydraulickit installed, it mayrequirea differentfilter element- pleasecheckwith your local Kobelcodealer.

8-7

Section

8.5

VIII-OPTIONAL

EQUIPMENT

VANDALISM GUARD Mark IV USA spec. Cab is A. The KOBELCO equipped with special studs to accommodate installation of the KOBELCO Vandalism Guard.

SeeFigure 8.26.

NOTE Contact your Kobelco Dealer to order the Vandalism Guard Kit P/N: KSP9120VKIT This kit contains the support bracket for the Vandalism Guardsand should be installed on the right side of the upper frame, below the fuel tank and hydraulic tank as shownin Figure 8.28. Contact the Service Department of your nearest KobelcoDealer for specific details on the installation of the support bracket.

FIGURE8.26

B. Whenmounting the Vandalism Guard to the machine,begin with Panel 1 and install to cab in sequence(1, 2, 3, etc.). SeeFigure 8.27.

14

C. Whenremoving guard from the cab, remove in reverseorder of installation (14, 13, 12, etc.).

SeeFigure 8.27.

13 12 11 10 FIGURE8.27

FIGURE8.28

8-8

NOTES

Section IX-

SPECIAL PROCEDURES

Table of Contents GENERAL ......................................................................................................................................................................

9-1 RELEASINGTRAVEL MOTOR BRAKES ........... , ................................................................................................

9-1 ~ 9-3 LOWERING ATTACHMENTWITH ENGINE FAILURE ................................................................................................

9-4 RELEASING SWING BRAKE ..............................................................................................................................

9-5 ~ 9-7

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i ,.,

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Im

READ, UNDERSTAND AND FOLLOWALL SAFETY PRECAUTIONSAND PROCEDURES FOUNDIN THIS MANUALBEFOREATTEMPTINGANY OPERATION,INSPECTION, MAINTENANCE OR REPAIR OFTHIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS,

9-0

Section

IX-

SPECIAL PROCEDURES

9.1 GENERAL The SK130(LC)machineincorporates automatically applied spring brake systemsin the travel motorsand swing motor. Thesesystemswill automatically engage the brakes whenthe engine is stopped making it impossible to movethe machine.This section contains the required proceduresfor releasing the travel motor brakes, the swing motor brake and lowering the attachment to the ground should suddenengine failure be experienced.

ATTACHMENT ON GROUND

---~ CHOCKBLOCKSAT FRONT AND REAR OF EACH TRACK

READ, UNDERSTANDAND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURESFOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION, MAINTENANCEOR REPAIR OFTHIS MACHINE, ATTACHMENTOR ANY OF ITS SYSTEMS.

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MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT FRONT AND REAR OF EACH TRACK BEFORE ATTEMPTING TO RELEASE BRAKES. NEVER STAND IN THE PATH OF THE TRACKS WHEN RELEASING BRAKES. FIGURE9.1

THE PROCEDURES FOUND IN THIS SECTION SHOULD BE PERFORMED BY A WELL TRAINED EXPERIENCEDSERVICE TECHNICIAN WHOIS FAMILIARWlTH THE KOBELCOSK130(LC) MACHINES. 9.2 RELEASINGTRAVELMOTORBRAKES A. Tools & EquipmentRequired 1. Four(4) ChockBlocks.

2. One(1) 19mm Socket HeadWrench.

3. One(1) 10mmHex-SocketHeadWrench.

4. Two(2) 3.8 Liter (1 Gal)capacitydrain pans.

5. TorqueWrench 5 ~ 6.5 kgfom(36 ~ 47ft. Ibs.) capacityor better.

6. Threadsealant. (For DrainandCheck/FillPlugs) 7. Rubberor Soft FacedMallet.

FIGURE9.2 BEFORE SHU’FrlNGOFFTHEENGINE,ALIGNTHEFILL ANDDRAIN PLUGSLINE PERPENDICULAR TO GROUND LEVEL ANDREMOVE CHECK/FILLPLUGWITH 10MMHEXAGONAL SOCKETWRENCH

B. Procedures NOTE Make sureto align the plugsonthe Final DriveCoversperpendicularto the ground,as shown on Figure9.3, before shuttingoff the engine.

1. PlaceChockBlocksat Front andRearof each track to prevent machinefrom movingwhen brakesare released.SeeFigure9.1.

2. Lowerattachmentsto ground.See"9.3 Lowering Attachment" for properprocedures,page 9-4.

3. Turn Key Switch "OFF"and removeKey. See Figure9.2.

4. Remove Check/Fill Plug from eachtravel motor using the 10mm hexagonalsocket headwrench.

SeeFigure9.3

FIGURE9.3

9-1

Section IX-SPECIAL PROCEDURES 5. Placea clean3.8 liter (1 Gallon)capacitydrain panundereachtravel motordrain plug andremovedrain plug using the 10mm hex-socket headwrench.SeeFigure 9.4.

6. After all of the gearoil hasdrained,coverthe drain pansto preventcontaminationandmove themto an area awayfrom the machine. the twelve plate mountingbolts from 7. Remove the travel motorreductionunit coverplates. See Figure9.5. the coversfrom both travel reduction 8. Remove units to exposethe planetarygears. See Figure9.6.

FIGURE9.4

Becareful not to damage lip of coverplate. Any damage to the lip couldresult in a gearoil leak.

FIGURE9.5 When removinganyinternal components, it will be necessary to havea cleanareafree of dirt andgrit to lay these components.

|Be awareof andprotect handsfrom pinch areas when | removingandinstalling planetarygearsor anyother component whichmaycausepersonalinjury.

FIGURE9.6

9-2

Section

IX-SPECIAL

PROCEDURES

9. UsingSnapRing Pliers, removethe retaining ring from the "SunGear"SeeFigure9.7. ,

Carefully remove "SunGear"fromthe planetary gear assemblyby handand lay it aside. See Figure9.8.

9. Install coverplates onto housingsandtighten all boltssecurely.

10. Install Fill andDrainPlugsinto coverplates andreplacegearoil into travel reductionunits throughFill/Checkport to properlevel.

11. After steps 4 through22 havebeenperformed on both travel reductionunits, the machine may be towedto an areawhererepairs canbe made.

FIGURE9.7

12. After repairsare made reinstall the "DriveGear" in reverseorder.Usethe followingtorquespecifications for bolts andplugs.

FIGURE9.8 TORQUESPECIFICATIONS COVER BOLTS5.5 ~ 6.5 kgf.m (40 ~ 47 ft. Ibs.) PLUGS5 ~ 6.5 kgf°m(36 ~ 47 ft. Ibs.) (Usethread Sealanton Plugs)

NOTE Referto Section4, page4-6 and4-7 for properoils specificationandcapacity.

NOTE Install newO-ringsealson CoverPlatesafter all repairs are completed.SeeFigure 9.9.

FIGURE9.9

9-3

Section

IX-SPECIAL

PROCEDURES

9.3 LoweringAttachmentWhenSuddenEngine Failure Occurs Shouldsudden enginefailure occur,follow the instructions belowto place the attachmenton the ground.

NOTE Rotationof the enginewith the Starter Motoris necessary in order to lower the attachmentto the ground.If rotationof the engineis not possible,contactan authorizedKOBELCO servicetechnicianfor serviceand assistance.

FIGURE9.10 MAKECERTAINTHE AREAAROUNDTHE MACHINEIS CLEAROF PEOPLEANDOBJECTS BEFOREATTEMPTINGTHESEPROCEDURES. 1. Locatethe EngineEmergency Stop Control at the lowerR.H.cornerof the seat baseandpull control out. SeeFigure9.10.

2. Placethe SafetyLockLeverin the "UNLOCKED" (Down)position. SeeFigure9.11.

3. Sound Hornto alert peoplein the areaof machine movement. posi4. Turnthe KeyswitchKeyto the "START" tion, usingstarter motorto rotate the engine.

Onlyoperatethe Starter Motorin 20 secondintervals andallow 3 ~ 5 minutesbetween intervals to allow the starter motorto cool.

5. Whileengineis rotating, slowlyandcarefully movethe R.H. Control Lever forward (Boom Down)and lower Boomcompletelyto ground.

SeeFigure 9.12. is completely down,operatethe Arm, 6. After Boom BucketandSwingControlsto releasehydraulic pressure in thesecircuits.

7. LocateHydraulicTankAir Breatheron top of hydraulic tank. Remove caPand depressstem until all internalhydraulictankpressure is released. (not necessaryto remove capon 2rid design.) SeeFigure9.13.

FIGURE 9.11

FIGURE9.12

(1st DESIGN) REMOVE

A’, USE CAUTIONWHENREMOVINGOR REPAIRING HYDRAULICCOMPONENTS AS HYDRAULIC PRESSURE MAYEXIST OR BETRAPPED IN CIRCUITS.

(2nd DESIGN)

FIGURE9.13

9-4

Section

IX- SPECIAL PROCEDURES

9.4 RELEASINGSWINGBRAKE

MAKECERTAINTHATTHEATTACHMENT IS ON THE GROUNDTO HELP PREVENTSUDDEN ROTATIONOF THE UPPERSTRUCTURE BEFORE ATTEMPTINGTO RELEASETHE SWINGBRAKE. REFERTO PAGES9-5 ~ 9-6 FORATTACHMENT LOWERINGPROCEDURES, A. Tools & Equipment Required 1. Handtools requiredfor removalof hydraulic tubes,hosesandfittings.

2, Plugsandcapsfor tubes, hosesandfittings.

3. 17rnmsocket headwrench.

4. 5mmsocket head wrench.

Lifting Devicecapableof lifting and 5. Overhead holding45 kg (100Ibs).

6. M12-1.75 X 20mm Lifting Eye. 7. Plentyof clean, dry shoprags.

8. Torquewrenches.

FIGURE9.14 INSTALL PROPER CAPS AND PLUGS ON HOSES, TUBES AND FITTINGS TO HELP PREVENT CONTAMINATION ENTERING THE SYSTEM

B. Procedures 1. Lowerattachmentto ground.Refer to pages 9-4 ~ 9-5 for properprocedures in loweringthe attachment.

2. Remove all hosesand tubes from the Swing MotorTopPlate andSwingValve to gain accessto the TopPlate MountingBolts. See Figure9.14.

3. Install the properplugsandcapsonto hoses, tubesandfittings to avoidthe possibilityof contaminationenteringthe hydraulicsystem.See Figure9.15.

FIGURE9,15

IUseonly plugs andcaps designedto properlyseal the

II specifichose,tubeor fitting theyareto benstaedon.I

FIGURE9.16

!

4. Thouroughly clean the top of the SwingMotor andSwingValveremoving all dirt anddebris.

X 20mm Lifting Eyeinto 5. Install the M12-1.75 the SwingMotorTopPlate. SeeFigure 9.16.

NOTE Placea large quantity of clean, dry shoprags aroundthe SwingMotorto help catch anyoverflowof hydraulic oil fromthe removalof the TopPlate.

6. Loosenthe four (4) TopPlate MountingBolts with the 17ramSocket HeadWrench.See Figure9.17.

FIGURE9.17

9-5

Section IX- SPECIALPROCEDURES two (2) TopPlate MountingBolts from 7. Remove cornersoppositeof eachother. SeeFigure9.18.

8. Attachoverhead lifting deviceto the lifting eye andremove mostof the slack fromthe cableor chain. the remainingtwo (2) bolts 9. Carefully remove fromthe TopMountingPlate.

NOTE TheTopPlate will raise fromspringpressureas the last two (2) bolts are removed.Some movement of the upper framemaybe experienced as the spring ¯tension is released.

FIGURE9.18

10. Usingthe overhead lifting device,carefullylift the SwingMotorTopPlate and SwingValve assemblyoff of and awayfrom the Swing Motor.

--

Donot allowanydirt or debristo enterthe swing motoror settle onthe top plate. all brakespringsandplace 11. Carefully remove in a container filled with fresh, cleanhydraulic oil. Then,seal the containerto preventcontamination.SeeFigure9.19.

12. Alignthe holesof the distributorplatein the swingmotoruntil they are locatedtowardthe front andbackof the swingmotorhousing.

SeeFigure 9.20.

13. Carefullyplacethe top plate over the Swing Motorandalign the dowelpins of the top plate with the holesin the distributor plate. See Figure9.21.

14. Carefullyandslowlylowerthe TopPlateinto positionon the SwingMotorandinstall, by hand,the four (4) TopPlateMounting Bolts.

FIGURE9.19

PLATE HOLES TOWARDSFRONT AND REAROF HOUSING

FIGURE9.20

Makecertainthe TopPlate DowelPins and the Distributor Plate Holesmeshtogether.

FIGURE 9.21

9-6

Section

IX-SPECIAL PROCEDURES

bolts 15. Securelytighten the top plate mounting in sequence.

Donot torqueat this point. the SwingValve Spool Housing 16. Remove MountingBolts with 5mmSocket Head Wrench.SeeFigure 9.22.

17. Carefully removethe SwingValveSpool. See Figure9.23. Placespoolin a containerfilled with fresh, cleanhydraulicoil andsealthe container to preventcontamination.

TheSwingSpoolmaybe underresidual hydraulic pressure.Pressurizedhydraulic oil cancausesevere injury. Usecare whenremovingspool. Wear approved Safety glassesor face shield andhardhat whenworkingon this equipment.

FIGURE9,22

18. Install the SwingValveSpoolHousingand securelytighten mounting bolts. Donot torque at this point.

NOTE Becareful not to damage the spool housing"O"-Ring.

SeeFigure 9.24.

19. After steps 1 ~ 18 havebeencompleted,attach a towingvehicleto the lowerframeof the disabledmachine andjog the lower frame until the attachment is in a positionto allow towingof the machine.

After the machine hasbeenpositionedfor tow20. ing, reinstall the SwingValveSpoolandBrake Springsin reverseorder.Thiswill lock the upperframeinto positionfor towing.

21. ReleaseTravel MotorBrakes,as described in Section9.2. Raiseor removeattachment, andtow machine to an area whererepairs can be made,or ontoa truck for transport.

FIGURE9.23

FIGURE9,24

9-7

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

SK1304RMMC2-1RNA April 04 Bur