Kobelco SK485LC-9 Tier 4 Hydraulic Excavator Operator's Manual PDF

OPERATOR’S MANUAL Hydraulic Excavator SK485LC-9 Tier 4

LS91Z00015P1 Issued August 2011

APPLICABLE: SK485LC-9 . . . . . . . . . . . . . YS12U-0800~

SK485LC-9 HYDRAULIC EXCAVATOR OPERATOR’S MANUAL

Part Number: LS91Z00015P1

Applicable PIN Number YS12U-0800 and higher

KOBELCO CONSTRUCTION TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or

serious injury. The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or

serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as

and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ● Is instructed in safe and proper use of the machine. ● Reads and understands the Manual(s) pertaining to the machine. ● Reads and understands ALL Safety Decals on the machine. ● Clears the area of other persons. ● Learns and practices safe use of machine controls in a safe, clear area before operating this

machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Kobelco Construction, LLC instructions on machine operation and maintenance.

WARNING_01_NA

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

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2010 Kobelco Construction, LLC All Rights Reserved Kobelco is a registered trademark of CNH America LLC

LS91Z00015P1NA Issued June 2011

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Operating Levers and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Use of Optional Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 250 hour maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 500 hour maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Periodical Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Maintenance for Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 I

Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SK485LC-9 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SK485LC-9 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION TO THE OWNER SK485LC-9 HYDRAULIC EXCAVATOR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the machine.

The standard attachments and tools of this machine are designed to carry out all kinds of earth moving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is equipped to carry out this kind of work. For this type of application, the machine must be equipped with safety valves, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your Kobelco Construction, LLC Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine's technical specifications and with prevailing safety requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial conformity with safety requirements.

The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your Kobelco Construction, LLC Dealer.

Before permitting a new operator on this machine, make sure: That the operator has received the necessary training on how to operate the machine correctly and safely.

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

Contact your dealer for operator manuals translated into Spanish or French Canadian.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your Kobelco Construction, LLC Dealer.

Your Kobelco Construction, LLC Dealer is available for any further information. They will also provide any after-sales service you may need, and genuine Kobelco Construction, LLC spare parts, your guarantee of quality and match.

1-1

CHAPTER 1 - GENERAL INFORMATION

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat when the cab is over the idler wheels.

Figure 1 below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the upper structure.

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

5. TRAVEL REDUCTION GEARS (TRAVEL MOTORS) 6. IDLER WHEELS

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

12

11 10

13

14 15

9

8

17

16

6

7

4

5

3

1 30

18

2 19

33

20

31

22 21

32

23

33

24 27

25

26

29

28

Figure 2

DC03H141

MACHINE COMPONENTS

1. ENGINE 2. HYDRAULIC PUMP 3. DIELSEL PARTICULATE FILTER 4. MAIN CONTROL VALVE 5. HYDRAULIC OIL TANK 6. FUEL TANK (MAIN) 7. SWING MOTOR 8. SWIVEL JOINT 9. BOOM CYLINDER

10. BOOM 11. ARM CYLINDER

19. TRACK IDLER 20. TRACK SPRING

28. RADIATOR 29. OIL COOLER

12. ARM

21. ENGINE AIR CLEANER

30. HOOD

13. BUCKET CYLINDER 14. IDLER LINK 15. BUCKET LINK 16. BUCKET 17. OPERATOR CAB 18. TRACK SHOE ASSEMBLY

22. LOWER ROLLER 23. TRACK GUIDE 24. UPPER ROLLER 25. SLEWING RING 26. TRAVEL MOTOR 27. BATTERY

31. COUNTERWEIGHT 32. INNER COOLER 33. SWING FLASHER

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

When ordering par ts, obtaining infor mation or a s s i s t a n c e , a l w ay s s u p p l y y o u r Ko b e l c o Construction, LLC Dealer with the type and serial number of your machine or accessories.

Write the following in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

RH11F020

Figure 4

ENGINE ➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump ➤ Swing Reduction Gear Figure 3

DC03H140

➤ Travel Reduction Gears

PRODUCT IDENTIFICATION PLATE

➤

➤

Travel Control Valve Model

➤

➤

Attachment Control Valve Serial Number

➤

Swing Control Valve Manufacturing Year

1-4

➤

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 FUEL HANDLING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 HAZARDOUS Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 emergency exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Counterweight Lifting Eyes - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Lifting Fuel Tank - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Pressurized Hot Oil - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Do Not Step On - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Stop Engine - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hot Coolant - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Handling Pilot Hoses - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Rotating Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Swing - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Use Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 EPA Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Hydraulic Oil Check Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Antifreeze Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Hydraulic Oil Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Grease Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Machines Equipped With Pattern Control Change Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Machines Equipped With Pattern Control Change Valve (Optional) - Danger . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Machines equipped with pattern control change valve (optional) - Warning . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Located inside cab, on right window glass lower corner - Part Number Lc20T01338P1 . . . . . . . . . . . . . . . . 2-22 Attachment Operation By Foot Pedal - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Nibbler and Breaker Hydraulic Oil Maintenance (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Machines Equipped with Pattern Control Change Valve (Optional) - Warning . . . . . . . . . . . . . . . . . . . . . . . 2-23 Operating Long Range Attachment (Optional) - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Work Mode Selection - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Do Not Pinch Your Hand(S) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Operator’s Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS Break Glass In Case Of Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Falling Front Window - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Control Lever Lock And Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Brake Release - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Nibbler and Breaker Operation (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Keep Clear Of Machine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Travel Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES WARNING This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

Failure to comply could result in death or serious injury.

M171C

NOTICE: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

PERSONAL SAFETY Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• The first panel indicates the nature of the Most accidents involving machine operating and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety signs on the machine before you operate or service the machine. See your dealer if you have any questions.

hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW Prohibition symbols such as used, are RED.

and STOP if

SAFETY AREA

1 1

Figure 1

RH11E108

2

1. OPERATOR’S MANUAL STORAGE SPACE Figure 2

BC02N198

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability, and load characteristics of this machine before you start to operate this machine.

1. WORKING AREA 2. SAFETY AREA

The safety area is the space necessar y for the machine to operate at the maximum range of the tool is a full 360 ° swing plus 6 feet (2 metres).

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

The safety information given in this manual does not replace safety codes, insurance needs, federal, state, or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

Additional safety messages are used in the text of the manual to show specific safety hazards.

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS UTILITY SAFETY Safety precaution MUST be followed when working near buried and overhead Utility Lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• Electrical Power Line • Gas Line • Water Line • Communication Line - Telephone or Cable Television

• Telephone or Cable Television NOTICE: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

NOTICE: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

RH99G001

Figure 3

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

2-4

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

aid kit and a working fire extinguisher with you and know how to use each.

points of support when getting on and off the machine. Keep steps and platform clean. Face the machine when climbing up and down.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of the type of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old or damaged hard hats may not provide the same level of protection as a new hard hat. Faded and soiled vest are no longer as highly visible as new vest.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• DO NOT OPERATE this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

• Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• DO NOT use the bucket or attachment to lift persons or carry riders on the machine.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

• Remove all loose object stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s seat.

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

• Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

• DO NOT OPERATE the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

• Before leaving the operator’s station, lower the equipment to the ground, shut off the engine and place the function safety lock into the locked or up position.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Remove the starter key or disconnect switch when leaving the machine parked or unattended.

OPERATING PRECAUTIONS

• Check brakes, steering and other machine control devices in accordance with the manufacturers instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a DO NOT OPERATE tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a DO NOT OPERATE tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

• Understand the machine limitations and keep the machine under control.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

• When roading a machine, know and use the signaling devices required on the machine.

Provide and escort for roading where required.

2-6

• On machines with independently operated wheel brakes, lock the brake pedals together when roading to provide equalized brake application.

• Use the recommended transport devices when roading the machine.

• Use the approved drawbar and / or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Before you operate at night, check that all lamps illuminate.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers and washers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. See the decal on the machine. Page 2-12.

You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

• If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• DO NOT OPERATE the machine if you do not feel well. This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or

MAINTENANCE PRECAUTIONS

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

earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

DC04E084

Figure 4

• Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operators console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will prevent accidental starting of the machine.

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking brake, place the equipment in a safe position, securely block the tracks and use extreme caution.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Use extreme caution when removing radiator

• Tighten the fuel tank cap securely. Should the fuel

caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

cap be lost, replace it only with the original manufacturers approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Release all pressure before working on systems which have an accumulator. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturers. recommendations.

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a tow bar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake. Avoid towing over long distances.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternate: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. Contact your dealer for the type and location of a fire extinguisher on this machine.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top. Allow room for expansion.

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

2-8

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HAZARDOUS Chemical Precautions

BURN PREVENTION

• If you are exposed to or come in contact with

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

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

Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

WARNING

hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

• Before you service your machine, check the MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

• Before you service this machine and before you

Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

• When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Check with your local environmental or recycling center or your dealer for correct disposal information.

TRANSPORTING PRECAUTIONS K now t he r ul es, l aws, an d s afe ty e qu i pm en t necessary for transporting this machine on a road or highway.

ROLL-OVER PROTECTIVE STRUCTURE (IF EQUIPPED) D o N OT m o d i f y t h e RO P S i n a n y m a n n e r.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SEAT BELT PRECAUTIONS

EMERGENCY EXIT HAMMER

1

2 Figure 5

DC04D529

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

1. Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat.

1. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

DC04D572

Figure 6

An emergency exit hammer is provided on the right side of cab. In case of emergency, take the life hammer, break the cab glass, and escape from the cab. In addition, the life hammer is equipped with a cutter on the lever side to cut seat belt, etc.

SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or tool as low as possible while moving the machine around the job site.

• Never smoke while refuelling.

WARNING

• Do not use tractive force of the machine for

Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

loading the bucket attachment nor to push or pull any objects.

• Do not use swinging force of the machine for operations.

• Do not perform “hammering” operation with the bucket.

• Do not use this machine for anything other than its intended purpose.

• DO NOT OPERATE bucket and arm cylinders to stroke end repeatedly.

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

• Do not use the long reach attachment for general construction work at any time.

2-10

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING Avoid injury!

An illegible or missing decal can have far-reaching consequences. Inspect decals daily.

Failure to comply could result in death or serious injury.

W0228A

WARNING Avoid injury!

Make sure decals are perfectly legible. Clean decals regularly. Replace all damaged, missing, painted over, or illegible decals. See your dealer for replacement decals. When replacing parts bearing decals, be sure to put new decals on each new part.

Failure to comply could result in death or serious injury.

W0229A

NOTICE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

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

NOTICE: Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED.

• WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW • Prohibition symbols such as and STOP if used, are RED.

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT LIFTING EYES - DANGER Located on top of counterweight (2 Required) - Part Number YN20T01221P1

YN20T01221P1

Figure 7

LIFTING FUEL TANK - WARNING Located on top of fuel tank (rear right corner) - Part Number YN20T01028P1

YN20T01028P1

2-12

Figure 8

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS PRESSURIZED HOT OIL - WARNING Located on top of hydraulic tank - Part Number YN20T01405P1

YN20T01405P1

Figure 9

HOT PARTS - CAUTION Located under engine cover - Part Number YN20T01352P1

YN20T01352P1

Figure 10

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT STEP ON - WARNING Located on top of engine cover - Part Number ZL11M0278

ZL11M0278

Figure 11

STOP ENGINE - WARNING Located on engine fan shroud - Part Number YN20T01009P1

YN20T01009P1

2-14

Figure 12

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT COOLANT - WARNING Located on top of engine fan shroud - Part Number YN20T01010P1

YN20T01010P1

Figure 13

BOOSTER CABLE - WARNING Located in Air Filter compartment on Relay Box Cover - Part Number YN20T01015P2

YN20T01015P2

Figure 14

BOOSTER CABLE - WARNING Located in Air Filter compartment on Relay Box Cover - Part Number YN20T01338P1

YN20T01338P1

Figure 15

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CALIFORNIA PROPOSITION 65 - WARNING Located in Air Filter compartment on Relay Box Cover - Part Number YN20T01495P1

YN20T01495P1

Figure 16

HANDLING PILOT HOSES - CAUTION Located on front panel inside the air cleaner compartment - Part Number YN20T01872P1

YN20T01872P1

2-16

Figure 17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ROTATING PARTS - CAUTION Located on opening side of the engine cover - Part Number YN20T01012P1

YN20T01012P1

Figure 18

SWING - DANGER Located on each side of the rear counterweight (2 Required) - Part Number YN20T01003P2

YN20T01003P2

Figure 19

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS USE DIESEL FUEL Located on side of fuel tank filler neck - Part Number PA20T01031P1

PA20T01031P1

EPA REGULATION Located on side of fuel tank filler neck - Part Number PV20T01100P1

PV20T01100P1

2-18

Figure 20

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HYDRAULIC OIL CHECK POSITION Located on back side of pump compartment door - Part Number YY20T01373P1

Y20T01373P1

Figure 21

ANTIFREEZE SOLUTION Located on back side of radiator compartment door - Part Number YN20T01832P1

YN20T01832P1

Figure 22

2-19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HYDRAULIC OIL USED Located on the back side of hydraulic tank - Part Number 2432T6573

BS06J013

Figure 23

GREASE SWING BEARING Located on upper frame lower right corner (below cab) - Part Number 2432P2689

DC03J078

Figure 24

SERIAL NUMBER PLATE Located on upper frame lower right corner (below cab)

DC03J079

2-20

Figure 25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) Located on front panel inside air cleaner compartment - Part Number YN20T01871P1

BS06J014 / BS06H241

Figure 26

MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) - DANGER Located on front panel inside air cleaner compartment - Part Number YN20T01214P1

BS06H451 / BS06H452

Figure 27

MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) - WARNING Located on front panel inside air cleaner compartment - Part Number YN20T01854P1

YN20T01854P1

Figure 28

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LOCATED INSIDE CAB, ON RIGHT WINDOW GLASS LOWER CORNER - PART NUMBER LC20T01338P1

LC20T01338P1

Figure 29

Figure 30 DANGER - ELECTRICAL POWER CONTACT WARNING - READ AND UNDERSTAND OPERATORS MANUAL WARNING - EXTREME HIGH PRESSURE IN TRACK ADJUSTMENT WARNING - MACHINE MAY MOVE SUDDENLY WARNING - CALIFORNIA PROPOSITION 65 WARNING - AUTOMATIC TWO SPEED TRAVEL

2-22

WARNING - TURNING OFF HEAVY LIFT SWITCH WARNING - RELEASING POWER BOOST SWITCH WARNING - DO NOT INSTALL ANY OBJECT ON HANDHOLD CAUTION - ATTACHMENT INTERFERENCE WITH CAB CAUTION - SLOW OR UNEXPECTED MOVEMENT NOTICE - STOPPING ENGINE WITHOUT COOL DOWN

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ATTACHMENT OPERATION BY FOOT PEDAL - CAUTION Located inside cab, on right window glass lower corner - Part Number PY20T01062P1

BS06J024 / BS06J025

Figure 31

NIBBLER AND BREAKER HYDRAULIC OIL MAINTENANCE (OPTIONAL) - CAUTION Located inside cab, on right window glass lower corner - Part Number YN20T01414P1

BS06J024 / BS06J026

Figure 32

MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) - WARNING Located inside cab on right window glass lower corner - Part Number YN20T01039P1

BS06J024

Figure 33

2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS OPERATING LONG RANGE ATTACHMENT (OPTIONAL) - WARNING Located inside cab, on right window glass lower corner - Part Number YN20T01238P1

BS06J024

Figure 34

WORK MODE SELECTION - CAUTION Located inside cab, on right window glass lower corner - Part Number YN20T01836P1

BS06J024 / BS006J027

2-24

Figure 35

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT PINCH YOUR HAND(S) - CAUTION Located inside cab, on right rear window and on left side of left console (2 Required) - Part Number YN20T01339

BS06J024 / BS06J028

Figure 36

OPERATOR’S CONTROL PATTERN Located inside of cab door - Part Number LC20T01333P1

LC20T01333P1

Figure 37

BREAK GLASS IN CASE OF EMERGENCY Located inside cab. on back window glass and on front window glass (2 Required) - Part Number PH20T01018P1

DC03J142

Figure 38

2-25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS FALLING FRONT WINDOW - CAUTION Located inside cab, on upper frame of front window - Part Number YN20T01416P1

BA06J093

Figure 39

CONTROL LEVER LOCK AND UNLOCK Located inside cab on left control console - Part Number YN20T01864P1

DC03J144

2-26

Figure 40

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SWING BRAKE RELEASE - CAUTION Located inside cab rear panel cover - Part Number YN20T01639P1

BS06J029 / BS06J030

Figure 41

NIBBLER AND BREAKER OPERATION (OPTIONAL) - CAUTION Located on Right Hand operator console - Part Number YT20T01054P1

BS06J024

Figure 42

KEEP CLEAR OF MACHINE - DANGER Located on both sides of the arm (2 Required) - Part Number YN20T01337P1

YN20T01337P1

Figure 43

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS NOTICE: When operating the machine, never attempt to carry out tasks calling for the control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

MOVE LOAD IN HORIZONTALLY

The following is a compilation of the Hand Signals to be used when a flagman is required for Excavator Operation. All personnel associated with the operation of the excavator should know these signals and their meaning before attempting to operate this machine.

RAISE LOAD VERTICALLY

DC04E040

Figure 46

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

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 44

Face Machine Operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

LOWER LOAD VERTICALLY

DC04E041

Figure 47

Face Machine Operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

RAISE BOOM

DC04E039

Figure 45

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

DC04E042

Figure 48

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with thumb up.

2-28

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LOWER BOOM

DC04E043

ARM IN

Figure 49

DC04E046

Figure 52

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with thumb down.

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

SWING LEFT

ARM OUT

DC04E044

Figure 50

DC04E047

Figure 53

Face machine operator, extend r ight ar m out horizontally from shoulder, make a fist with index finger pointing in swing direction.

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

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 51

Fa c e m a c h i ne o p e r a to r, ex t e n d l e f t a r m o u t horizontally from shoulder, make a fist with index finger pointing in swing direction.

DC04E048

Figure 54

Face machine Operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

2-29

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTER ROTATE RIGHT

DC04E049

CLOSE BUCKET (BUCKET IN OR DIG)

Figure 55

DC04E052

Figure 58

Face Machine Operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

Face machine operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

TRAVEL FORWARD

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 56

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

DC04E053

Figure 59

Face machine operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion.

TRAVEL REVERSE TURN LEFT

DC04E051

Figure 57

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

2-30

DC04E054

Figure 60

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

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS TURN RIGHT

DE04E055

STOP

Figure 61

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

DC04E058

Figure 64

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

EMERGENCY STOP

MOVE THIS MUCH

DC04E059 DC04E056

Figure 62

Figure 65

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

Fac e m ac hi ne ope rator, rais e bot h a r ms ou t horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY

STOP ENGINE

DC04E057

Figure 63

Face machine operator, raise left arm out horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

DC04E060

Figure 66

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

2-31

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

NOTES

2-32

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Opening and Closing Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Opening and Closing Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 document Storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Front and Rear Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 .Seat Back Reclining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Arm Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 control lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Engine Coolant Tank and Engine Air Cleaner Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Main Pump Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Right Hand Operator Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Buzzer Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Warning Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Buzzer Sounds (type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 LCD (Liquid Crystal Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Warning levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Warning Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Windshield Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Screen Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Screen Change Display Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Auto Accel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 LCD Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Monitor Time Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Pump Flow Rate Adjustment (Nibbler mode / Breaker mode)(Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Draining Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Power Boost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 24 Volt Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Location for Optional Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Cup Holder and Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Radio Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Climate Control - Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Air Outlet Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS basic Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Hydraulic Function Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Conflux/Single Flow Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Swing Parking Brake Release Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Twelve volt power suppy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 OPERATING LEVERS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Left Hand (LH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 Right Hand (RH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 Travel Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

1

1 Figure 3

DC04D505

Figure 1

DC04D503

1. DOOR LOCK

Use the key switch key to lock or unlock cab door.

Insert key into door lock and turn clockwise to unlock or turn counterclockwise to lock cab door.

CAB DOOR LATCH

1. DOOR RELEASE LEVER

2. Release door latch by pushing release lever down to release door from latch.

WARNING Never use the lever for door latch release as a handle to mount and/or dismount from the machine.

Failure to comply could result in death or serious injury.

R131B

1 Figure 2

DC04D504

1. DOOR LATCH

1. The cab door can be latch in an open position by opening door until it is locked open by the door latch located on the cab.

1 Figure 4

DC04D506

1. PULL RELEASE LEVER

3. Pull release lever located inside the door, and door opens from the inside of cab.

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS REMOVING AND STORING LOWER FRONT WINDOW

OPENING AND CLOSING WINDSHIELD Front window (upper) can be stored in ceiling.

NOTICE: Make sure to properly lock the window frame in place, or the wiper lock does not function, and consequently the wiper may be damaged because the wiper moves at the time when the wiper motor switch is turned on.

1

41 Figure 6

DC04D509

1. LOWER FRONT WINDOW

1. After placing upper front window in ceiling, and locking it in place, remove lower front window by hand from window frame.

Figure 5

RH11E110

1. LOCK LEVER

2. Securely store the removed lower front window in holder in the rear of cab, behind the operator’s seat.

1. Push the lock lever (1) on the upper center part of the window to the right and release the lock.

2. Hold handles on upper center and lower left sides of the front window. Lift the front window up and slide overhead all the way to the back. The window will automatically lock when in position.

1

3 2

WARNING

M1709

CAUTION Pinch hazard!

Make sure you correctly follow the instructions in this manual when handling the windshield. If you do not handle the windshield correctly, it could slip and injure your fingers or hands.

Failure to comply could result in minor or moderate injury.

C0045A

3-4

2

2

A falling window can cause injury to you or others.

Always make sure to properly lock the front window in place to avoid injury. Failure to comply could result in death or serious injury.

Figure 7

DC04D510

1. LOWER FRONT WINDOW 2. HOLDER 3. REAR WINDOW

3. To store it, insert the right and left sides of glass in holder, and support it with holder on the lower section of window frame.

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING DOOR GLASS WARNING: Make sure to secure front window with locks when placed in the upper position.

1

1

2

1

2

Figure 8

DC04D511

1. CAB DOOR UPPER GLASS 2. LOCK

1. Open cab door upper glass sliding it to front side after unlocking it.

2. Close the door glass sliding it to LOCK position, then lock it.

OPENING AND CLOSING SUNROOF

Figure 11

DC04D514

1. SUNROOF LOCK

2. Pull locks on right and left sides inward, and sunroof opens through the aid of gas spring.

Close sunroof pulling locks inward, and lock it.

CAB DOME LIGHT

ON

1 Figure 9

DC04D512

OFF

1. SUN ROOF IN CLOSED POSITION

1 Figure 12

RH11E112

1. CAB DOME LIGHT

1. Push the dome light switch up past the neutral (center) position to turn the dome light ON.

1

2. Place the dome light switch in the neutral (center) position and the light will be operated by the door switch. When door is opened the light will come ON and when the door is closed the light will turn OFF. Figure 10

DC04D513

3. Push the dome light switch down past the neutral (center) position to turn the dome light OFF.

1. SUN ROOF IN OPEN POSITION

1. Slide the sun visor backward.

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS DOCUMENT STORAGE COMPARTMENT

OPERATOR SEAT ADJUSTMENTS The operator seat incorporates several adjustment mechanisms to insure operator comfort, ease of operation and operator safety.

1

The adjustment areas are as follows: SEAT FRONT AND REAR HEIGHT ADJUSTMENT

RH11E108

Figure 13 1. DOCUMENT STORAGE COMPARTMENT

T h e O p e r a t o r a n d Pa r t s M a n u a l s t o r a g e compartment is a pouch located to the right of the operators seat. Keep the Operator and Parts Manual for this machine in this location at all times for quick, easy reference.

1 3

2

4 BS08173

Figure 14

1. SEAT WEIGHT ADJUSTMENT KNOB 2. SEAT HEIGHT ADJUSTMENT LEVER 3. RECLINING ADJUSTMENT LEVER 4. SEAT FORWARD - BACKWARD BAIL

• Rotate the weight adjustment knob (1) until weight close to operator’s weight is at the top end of the dial.

• Pull height adjustment lever (2) up to raise or lower rear of seat.

• Push height adjustment lever (2) down to raise or lower front of seat.

• Pull reclining adjustment lever (3) up to set desired reclining angle. Release the reclining adjustment lever to lock seat in position.

• Pull up on seat adjustment bail (4) and move seat forward or backward to desired position

3-6

CHAPTER 3 - INSTRUMENTS AND CONTROLS .SEAT BACK RECLINING ADJUSTMENT

ARM REST ADJUSTMENT

8

7

2

1

4 5

3

6 BS08B174

Figure 16

BS08175

Figure 15

5. ARM REST ADJUSTMENT 6. ARM REST CONTROL DIAL 7. LUMBAR SUPPORT 8. HEAD REST

• Lower arm rest (5) and turn adjustment wheel (6) until arm rest is in desired position.

1. SEAT ARMREST ADJUSTMENT WHEEL

To adjust the arm rest (4 inch): 1. Loosen knob (1) and move it forward slightly.

2. Adjust arm rest (2) to desired height and match to aligning hole of bracket (3).

3. Tighten knob (1).

• Adjust lumbar support (7) by turning the knob clockwise or counterclockwise to adjust support. to desired pressure.

• Move head rest (8) forward or backward to desired reclining angle. Raise or lower head rest (8) to desired height.

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

CONTROL LEVER ADJUSTMENT

2

1

B

A

2

C 1 BS08B476-01

Figure 17

1. To adjust the right/left control stand, remove bolt (1).

2. Adjust the height of hole on plate (2) to the desired position and tighten plate (2) securely with bolt (1).

3. Adjust height stand on both sides to desired position.

A. Low Position B. Middle Position C. High Position

Figure 18

DC04D529

1. BUCKLE 2. RED BUTTON

1. Sit on the operator’s seat and adjust the seat position so that the operator’s back closely contacts with the seat back.

2. Draw out the right side seat belt and fasten it to the buckle located on the left side.

NOTE: If the belt stops while you’re pulling it out, release the tension and continue pulling it out.

3. When the seat belt is used, draw it out moderately long and insert it in the buckle until rattling sound is heard. Release hands, and the length is automatically adjusted and the belt is locked.

4. After locking, the belt can be adjusted about 25 mm (1 in) to fit comfortably.

5. Press the red button of the buckle, and the belt is unfastened.

WARNING Equipment failure could cause accident or injury!

Always fasten seat belt securely before operating the machine. Inspect seat belt parts for wear and/or damage. To ensure operator safety, replace any and all damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

W0046A

NOTE: Replace the seat belt every three years regardless of appearance, and tag date of replacement on its support mount for reference.

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS ENGINE COOLANT TANK AND ENGINE AIR CLEANER ACCESS DOORS

3 2 1 Figure 19

DC04D592

1. ENGINE COOLANT TANK ACCESS DOOR 2. ENGINE COOLANT TANK 3. ENGINE AIR CLEANER

Located on the left side of the machine the engine coolant tank access door allows access to the engine coolant tank. It also holds the engine air cleaner access door closed.

IMPORTANT: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

Use the key switch key to lock and unlock the Engine coolant tank access door.

NOTICE: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

MAIN PUMP ACCESS DOOR .

1 Figure 20

DC04A037

1. MAIN PUMP ACCESS DOOR

Located on the right side of the machine this door allows access to the main pump.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL CAP

ENGINE COVER

1

Figure 21

RH11F021

1. FUEL TANK CAP

Stop engine and remove cap on fuel tank. Use key switch key to unlock cap if locked. Fill to desired level or to full capacity. See Chapter 5 for proper tank capacity.

1

WARNING WARNING: Make sure engine is OFF and keep battery cover and engine hood closed when fueling.

Failure to comply could result in death or serious injury.

M422B

Figure 22

BS06M270

1. ENGINE COVER

Open engine cover with key switch key (if locked) after stopping engine. Use stay to support it.

NOTICE: Always make sure to use the door stays to lock them open while performing inspection and/or maintenance.

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

Figure 23

RH11F022

COMPONENTS 1. LEFT HAND OPERATOR 7. HOUR METER CONTROL LEVER (HORN SWITCH) 2. SAFETY LOCK LEVER

8. GAUGE CLUSTER

3. LEFT TRAVEL PEDAL

9. CUP HOLDER

4. LEFT TRAVEL LEVER 5. RIGHT TRAVEL LEVER 6. RIGHT TRAVEL PEDAL

13. WORKING LIGHT SWITCH (BOOM, DECK) 14. PRESSURE RELEASE SWITCH 15. AIR CONDITIONER CONTROL PANEL

10. RIGHT HAND OPERATOR CONTROL LEVER 16. OPTIONAL SWITCHES (POWER BOOST SWITCH) 17. POTENTIOMETER FOR 11. STARTER KEY SWITCH EMERGENCY MODE 12. THROTTLE 18. SWING PARKING BRAKE POTENTIOMETER RELEASE SWITCH

19. FUSE AND RELAY BOX 20. OPERATOR SEAT 21. EMERGENCY HAMMER 22. DPF REGENERATION SWITCH 23. 12V SUPPLY

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR CAB NOMENCLATURE

Throttle Potentiometer

The Operator Cab Nomenclature points out locations of operator controls. Familiarize yourself with these controls and components.

The throttle potentiometer is located on the right hand operator console and controls engine RPM. When the throttle potentiometer is rotated to any position, it increases or decreases engine RPM and maintains engine at the programmed RPM for that particular position on the dial.

WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

RIGHT HAND OPERATOR CONSOLE AND MONITOR 1. Key Switch

NOTES: a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 1 second, and if the position of the throttle potentiometer is higher than 1050 rpm, the auto acceleration actuates automatically and engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto acceleration speed, the engine speed is maintained to the throttle potentiometer position.

Auto Accel/Decel Function: With the attachment, swing, travel control lever or control pedal operation, the engine speed returns to accel dial set position gradually according to the respective operating pilot valve movement.

Figure 24

BS06H116

1. KEY SWITCH 2. THROTTLE POTENTIOMETER

The Key Switch is located on the right hand operator console and has 4 operating functions.

“OFF” - When key is turned to this position, the en gi ne st op s a nd e l ec tr i c a l powe r t o th e machine’s electrical system is stopped after approximately 3seconds.

“ACC” - With key in the “ACC” position, only the cigarette lighter, tuner, and horn will have power.

“ON” - When Key is in the “ON” position, electrical power is supplied to all the machine’s electrical system.

“START” - When key is turned to this position, electr ical power is supplied to the star ter solenoid causing the starter to start the engine.

After engine starts key should be released to go back to the “ON” position.

3-12

NOTICE: The auto acceleration function can be activated by pressing the auto accel switch located on the monitor panel. When the auto acceleration function is active, the red light indicator above this switch is turned ON. Press the auto accel switch to cancel the auto acceleration function and the light will turn OFF.

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR

Figure 25

RH11F023

1. ENGINE COOLANT TEMPERATURE GAUGE 2. FUEL LEVEL GAUGE 3. SCREEN CHANGE SWITCH 4. BUZZER STOP SWITCH 5. MODE SELECT SWITCH 6. WASHER SWITCH

7. WIPER SWITCH 8. TRAVEL SPEED SELECT SWITCH 9. AUTO ACCEL SWITCH 10. MENU SWITCH 11. DIGGING SWITCH 12. NIBBLER SWITCH 13. BREAKER SWITCH

14. ARROW SWITCH a. UP b. DOWN c. NEXT d. BACK 15. LCD DISPLAY

When the engine star ts, it is set to “S” mode automatically. To select the proper work mode from the 3 modes shown below according to the work conditions. The work modes are “S”, “E”, and “H”.

WORK MODE SWITCH

“S” mode is for standard digging and loading operations.

“E” mode is for digging with lower fuel consumption.

“H” mode is for heavy duty digging which gives priority to the workload at high engine rpm’s.

RH11F024

Figure 26

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS NOTICE:

BUZZER STOP SWITCH

• Buzzer sounding due to engine overheating can not be stopped.

• The buzzer sounding, because the preheat complete and E/G oil pressure are displayed, stops by turning the key switch OFF. WARNING LEVEL 1. These may effect safety and the machine performance 2. These warn that the machine control mode is switched.

3. Equipment/system failure.

4. Normal priority warning.

5. Low priority message BUZZER SOUNDS (TYPE) RH11F025

Figure 27

1. Constant

When the engine coolant temperature is too high, or var ious sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently.

To stop the sound, press the Buzzer Stop button.

Can also be used to cancel travel alarm during traveling.

2. Beep ON 0.2 sec. OFF 0.3 sec.

LCD (LIQUID CRYSTAL DISPLAY)

The LCD is illustrated to the left and will display the icons listed in this section. Study these icons and their definitions so that possible problems will be quickly recognized and repairs made in a timely fashion.

RH11F030

3-14

Figure 28

3. Beep ON 0.5 sec. OFF 0.5 sec.

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING LEVELS

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING ICONS Icons (Priority A) Icon

Level

Description

Solution

1

Data from the controller is not received

Contact the dealer.

1

Swing brake disengage icon: displays when the parking brake release switch is moved into position RELEASE LOCK.

Put the machine in safe conditions and contact the dealer.

1

Engine cut-off icon: displays a few seconds after the engine oil low pressure icon. The engine is automatically cut-off

Contact the dealer

Level

Description

Solution

1

Wrong work mode icon: displays when the work mode selected does not correspond to the selected work mode.

Select the correct work mode.

2

Power Boost icon: displays when pressing the power button located on the right control lever.

2

Automatic warm up complete.

Wait for the icon to clear from the display screen.

2

Displayed when soot is deposited in the exhaust gas post-cleaning device and the device needs to regenerate.

Place the safety lock lever in the locked position. Regeneration starts after pushing the switch.

2

Displayed when the exhaust gas post-cleaning device has started combustion treatment (regeneration) automatically*

Key is turned on and place the safety lock lever in the locked position.

Wait until icon disappears.

2

Displayed when soot is deposited in the exhaust gas post-cleaning device.

This device needs to be regenerated and automatic regeneration has not been performed.

Place the safety lock lever in the locked position and push the manual regeneration switch to activate soot combustion regeneration.

2

Displayed when soot is deposited in the exhaust gas post-cleaning device. automatic regeneration has not been performed and the device cannot be regenerated.*

Contact your dealer.

2

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

Contact your dealer.

Icons (Priority B) Icon

*NOTE: When the regeneration icon displays while the machine is in operation, no action is required by the operator and machine operation can be continued. The regeneration icon displayed is an indication of the automatic soot combustion regeneration in process.

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3

Engine coolant temperature icon: displays when coolant temperature is raised to the specified temperature or higher

Reduce the engine speed to low idle and stop operating until the temperature of the coolant drops to normal operating values.

3

Engine coolant level icon: displays when the level of the engine coolant is insufficient.

Stop the engine, wait for the machine to cool off and top up the engine coolant level.

3

Water detected in the fuel prefilter icon: displays when there is a significant quantity of water in the fuel prefilter.

Drain water from the fuel prefilter.

3

Engine air filter icon: displays when the elements of the air filter are clogged and cannot provide an adequate supply of air to the engine.

Stop the engine and clean or replace the elements of the air filter.

3

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

Contact the dealer.

4

Battery recharge icon: displays when the battery recharge system does not operate properly.

Check the fuse and the battery recharge circuit.

4

Fuel level icon: displays when the fuel level in the tank is insufficient.

Stop the engine and increase the fuel level.

5

High hydraulic oil temperature icon: displays when the oil temperature is raised to a specified temperature or higher.

Contact the dealer.

5

Engine preheating icon: displays when the starter key is moved into position ON and the controller senses the coolant temperature is at a value that requires preheating of the engine.

Wait for the icon to clear the display.

5

Engine oil icon: displays every 500 hours of operation of the machine to remind of the periodic oil change.

Change the oil.

5

Icon displays when key switch is in position ON or START and the safety lock lever is in the unlocked position

Key switch in position ON, place safety lock lever in the locked position. Return key to position START.

5

Fuel filter Icon displays every 500 hours of machine operation to remind of the periodic fuel filter change.

Replace fuel filter with a new filter, specified for the machine.

5

Hydraulic oil filter icon displays every 1,000 hours of machine operation to remind of the periodic hydraulic oil filter change

Replace hydraulic oil filter with a new filter, specified for the machine.

5

Hydraulic oil icon displays every 5,000 hours of machine operation to remind of the periodic hydraulic oil change.

Replace hydraulic oil with new oil, specified for the machine.

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD WIPER AND WASHER SWITCH

• Press it once more - Wiper stops moving.

2: Washer Switch

• Press this switch, and washer fluid is sprayed while it is depressed.

2 1 1

Figure 30

BS06H101 RH11F026

1: Wiper Switch

• Press it once - Wiper moves intermittently.

• Press it again - Wiper moves continuously.

Figure 29

1. WASHER FLUID RESERVOIR

The washer fluid reservoir is located behind the cab, in the air cleaner compartment.

NOTICE: Make certain the Washer Reservoir has

SCREEN CHANGE SWITCH

RH11F027

Figure 31

SCREEN CHANGE DISPLAY SWITCH After turning the key switch on or starting the engine, the display screen (a) will show the rear view camera screen.

The display screen (a) is changed each time the display switch is pushed.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS AUTO ACCEL SWITCH

TRAVEL SPEED SELECT SWITCH

Figure 32

RH11F028

This switch is used to activate and cancel the auto accel function.

When the key switch is turned on, the auto-accel system activates. The auto-decel system reduces the en g i ne s p ee d t o t h e i d le l eve l r e d uc i n g f u el c o n s u m p t i o n a n d n o i s e u n d e r t h e fo l l ow i n g conditions.

1. The throttle control dial position is set over the auto decel idle level.

2. The control lever or pedals are not operated for 4 seconds or more.

Figure 33

RH11F029

The travel speed select switch is located on the gauge cluster switch panel. Each time engine is started, travel speed is automatically set to LOW 1st speed. The low speed icon (turtle) is indicated on the multi display. Press the travel speed switch on the gauge cluster, the speed is changed to the HIGH 2nd, the fast speed travel icon (rabbit) is indicated on the multi display.

Set to LOW when moving the machine on a rough or soft road, slope, or in narrow place, or when powerful tractive force is required.

When the control lever or pedals are operated, the engine speed goes back to the accel dial setting gradually.

Set to HIGH when moving the machine on flat, hard ground.

WARNING

WARNING

Never attempt to load or unload machine with the Auto Accel function activated. A sudden change of engine speed could be experienced. Failure to comply could result in death or serious injury.

Loss of control hazard!

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

Failure to comply could result in death or serious injury.

M1697

NOTICE: All Kobelco excavators will default to the auto acceleration function when the key switch is turned to the OFF position.

W0390A

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD CONTRAST ADJUSTMENT

1 2

RH11F031 / RH11F032

Figure 34

1. Turn key switch on and the main screen (a) is displayed. Press the Menu Switch (1) and the USER MENU (b) screen is displayed.

2. Move cursor to SCREEN SETTING. Press NEXT to select SCREEN SETTING display (d).

3. Move cursor to CONTRAST (d) on SCREEN SETTING display. Press NEXT to select desired value.

4. Using cursor, and get the desired values. Step of adjustable range is from 1 to 10.

5. Example: 1 (Faint) to 10 (Clear) 6. * Default is set to 5.

7. After adjustment, press the Menu Switch (1) and the adjusted values are stored as memory and CONTRAST setting is completed. Press the Screen Change Switch (2), and the display returns to main display (a).

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR TIME ADJUSTMENT

1 2

RH11F031 / RH11F033

Figure 35

1. Turn key switch on and the main screen (a) is displayed. Press the Menu Switch (1) and the USER MENU (b) screen is displayed.

2. Move cursor to the CLOCK SETTING. Press NEXT to select CLOCK SETTING (d).

3. Move the cursor up or down to select YEAR/MONTH/DAY/HOUR/MINUTE display. Press NEXT to select item to be changed.

4. Move the cursor up or down to get the desired value.

5. After adjustment, press Menu Switch (1). The adjusted values are stored as memory and the clock setting is completed. Press Screen Change Switch (2), and the display returns to main display (a).

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Auto Warm Up Use this feature to warm-up the engine oil and hydraulic oil in cold temperatures.

1 2 RH11F031 / RH11F034

Figure 36

1. Turn key switch on and the main screen (a) is displayed. Press Menu Switch (1) to display the USER MENU (b) screen.

2. Move the cursor down to to SWITCH STATUS. Press Next to display the SWITCH STATUS (c) screen.

3. Move the cursor down to AUTO WARM-UP, press Next to move cursor to OFF 4. Move the cursor down or up to change the status from OFF to ON. Press Menu Switch (1) to set the status.

5. Turn off the key to store the AUTO WARM-UP status.

6. When the engine is started in cold operations the warming of the engine automatically starts.

7. During the warmup of the engine and hydraulic oil, WARM-UP is indicated on the display.

8. When the warm up is complete, WARM-UP FINISHED is indicated on the display and the buzzer sounds for 5 seconds.

NOTICE: The Auto Warm UP System will not activate if the Ambient temperature is above 10°C (50°F).

NOTICE: If a pilot control lever is activated while the warm up system is active, the warm up system is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

NOTICE: In climate below -18°C (0°F) it may be necessary to use a coolant heater, fuel heater, engine heater jacket and/or additional battery power to aid in starting the engine.

NOTE: Once the auto-warm up status is initially turned ON during steps 1 through 4, it will become unecessary to repeat these steps since the status will be stored.

3-22

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Pump Flow Rate Adjustment (Nibbler mode / Breaker mode)(Option)

RH11F031 / RH11F035

Figure 37

1. Turn key switch on and the main screen (a) is displayed.

2. Change the attachment mode by selecting the Nibbler Mode or Breaker mode.The flow rate displays on the screen (b).

3. When the flow rate displays, press Menu Switch (1) to display the USER MENU screen (c).

4. Move the cursor down to OPTION SETTING and press Next to display the Nibber/Breaker Setting screen (e).

5. Move the cursor to the desired flow rate. Press Menu Switch (1) to set the target flow rate.

NOTE: The display will return to the main screen if there is no switch operation for 20 seconds.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS 2. Power Boost Switch

DRAINING HYDRAULIC SYSTEM PRESSURE A new convenient feature is now incorporated in the electro-hydraulic system to help the operator release the pressure in the hydraulic system directly from the operator’s cab for machine service or to switch auxiliary attachments.

1

Figure 40

DC04D547

1. POWER BOOST SWITCH

Located on the right hand control lever, this switch should only be used for increased break out force during digging.

NOTE: Use of power boost is prohibited when arms longer than standard are installed.

Figure 38

RH11F036

WARNING 1

Do not use Power Boost for lifting operations.

Instead use the Heavy Lift switch. Failure to comply could result in death or serious injury.

2

3. 24 Volt Cigarette Lighter

Figure 39

RH11F037

1. BREATHER TOP END CAP 2. VALVE HEAD

1

WARNING WARNING: Do not attempt to service the machine or switch auxiliary attachment without releasing the hydraulic system pressure. Failure to comply could result in death or serious injury.

M1121

3-24

Figure 41

BS06H093

1. CIGARETTE LIGHTER

The cigarette lighter is located on the right side control panel. To use the cigarette lighter the key switch must be in the ON position. Push the lighter in and wait approximately 30 seconds for it to “POP” out. Pull lighter from the socket to use. Replace lighter back into its socket after use.

Do not use the cigarette lighter as a power source for 12 volt accessories. It is a 24 volt outlet. Plugging a 12 volt accessory into volt connector may result in shortage and/or Fire.

CHAPTER 3 - INSTRUMENTS AND CONTROLS 4. Location for Optional Switches

5. Cup Holder and Ashtray

1 1

2

Figure 42

BS06H093

1. LOCATION FOR OPTIONAL SWITCHES

This additional switch panel is provided on the right side console for any machine customizing if desired.

Figure 43

BS06H094

1. CUP HOLDER 2. ASHTRAY

A cup holder is provided on the right side panel, below the monitor, and the ashtray is located on the right side console.

RADIO The radio is located on the right side control panel.

The LCD Display shows the radio station selected as well as its frequency band.

Figure 44

00RADIO

1. Power on/off 9. MD/LD Button (mode / loudness) 2. Volume up / down button: controls for bass / treble / balance / fader / initial 10. BD/ENT button (band/enter) volume / ct /ta vol / eon / rec mode / dsp 3. Function select button: controls for bass / treble / balance / fader / initial volume / ct / 11. Automatic or manual tuning bottons ta vol / eon / rec mode / dsp 4. Preset stations 5. AF function

17. Repeat button (for USB playback only) 18. Intro button (preview all tracks) (for USB playback only) 19. Random button (for USB playback only

20. Folder down (mp3 / wma files only) (for USB playback only) 13. SCAN/REC button (scan automatic tuning 21. Folder up (mp3 / wma files only (for USB control / record playback only) 12. A\PS button (auto seek search tuning)

6. TA function (traffic announcement) / End a 14. MU button (mute) / Answer a call function 22. USB port call function 7. PTY function (program type) 15. LCD 23. Front Aux in 8. DISP button (display) 16. Pause button (for usb playback only) 24. Not used 25. Reset

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO CONTROL SWITCHES POWER ON/OFF Press button (1) to turn unit on. Press and hold to turn off.

VOLUME Increase or decrease the volume by turning knob (2) right or left.

FUNCTION SELECT BUTTON To select other functions, press the knob (2) shortly unitl the desired functions are shown on the display ( BAS / TRE / BAL /FAD ). Turn knob right or left to adjust.

Press and hold knob (3) to adjust INIT VOL / CT / TA VOL / EON ON / REC MODE / DSP.

• IN VOL: adjust initial volume level using this mode.

• ADJ: adjust clock time. Turn knob (2) clockwise to set hours and counter clockwise to set minutes.

• TA VOL: adjust the volume level when traffic announcement (TA) is transmitted.

• EON: select EON condition, on or off.

• REC MP3: select rec mode (MP3 or WMA) • DSP: select DSP mode (CLASSIC, POP, ROCK, FLAT)

NEWS-AFFAIRS-INFO-SPORT-EDUCATE-DRAMA CULTURE- SCIENCE-VARIED-POP-ROCK-EASY M-LIGHT M - C L A S S I C - OT H E R M-WEATHER-FINANCE-CHILDREN-SOCIAL-RELI GION-PHONE IN-TRAVEL-LEISURE-JAZZ-COUNTRY-NATION. M-OLDIES-FOLK M-DOCUMENT-TEST-ALARM. DISP button (display) Press DISP button to switch between display information such as radio frequencies, clock, track and other information depending on the playing mode.

MD/LD button (Mode / Loudness) By pressing this key, user can select AUX / TUNER / USB / AD2P mode. By pressing this key longer than 2 s, you can select LOUDNESS mode.

BD BUTTON (Band) Each band is toggled cyclically by pressing this key: FM1-FM2-FM3-MW1-MW2-LW. AUTOMATIC OR MANUAL TUNING buttons RADIO MODE

• When pressed momentarily, these keys are operated as seek tuning mode. When pressed longer than 1 s, they are operated as manual tuning mode.

PRESET STATIONS buttons (1,2,3,4,5,6)

MP3/WMA PLAYER MODE

When pressed momentarily, these keys select a preset station directly. When pressed longer than 1 s, current station is stored in preset memory bank.

• When pressed momentarily, they are operated as

AF function (Alternative frequencies) When pressed momentarily, AF switching mode is selected. The radio checks the signal strength of the AF all the time. When pressed long, it is activated as regional mode on or off.

TA function (Traffic announcement) When pressed momentarily, it is activated as TA mode on or off. When TA mode is on and traffic announcement is transmitted. If the volume level was under the threshold point, it will be raised to the threshold point. When TP station is received, TP segment is turned on in LCD display.

track up or track down mode. When pressed longer than 1 s, they are operated as cue or review mode.

A/PS button (Auto seek search tuning) PS: by pressing shortly, the radio searches for each preset station. Each preset station will be played for 5 s.

AS: by pressing longer than 1 s, the 6 strongest stations are stored in the corresponding preset memory number. When Automatic Scan operation is finish, the radio executes the preset scan.

SCAN/REC button (automatic tuning control)

PTY function (Program type)

Press SCAN button to activate radio scan. The unit will search for every station and will play 5 s of each station found. To stop scanning, press the button once more.

When pressed momentarily, it is activated as PTY

MU button (mute)

ON/OFF function and start to search corresponding PTY information then stops if the corresponding PTY information is detected. By pressing this key longer than 2 s, you can select PTY mode by turning Volume knob as below.

Press MU button to turn off the sound. Press it again to return to the previous volume level.

3-26

LCD The Liquid Crystal Display will display the current state of the unit.

CHAPTER 3 - INSTRUMENTS AND CONTROLS PAUSE BUTTON

desired folder.

During PLAY, press PAU button to pause. Press it again to resume play.

• • Press “BD/ENT”, then the folder is fixed and the

REPEAT BUTTON

FRONT AUX IN

When this button is pressed, RPT ON indication is displayed and play of the selected track will be continually repeated until the track repeat mode is cancelled by pressing RPT button again.

AUX IN input jack allows easy connection of Portable Media.

INTRO BUTTON (Preview all Tracks) When this button is pressed, INT ON indication is displayed and the first several seconds of each track is played. Press again to stop intro and listen to track.

RANDOM BUTTON When this button is pressed, RDM ON indication is displayed and each track is played in random instead of normal progression. To cancel random mode, press RDM button again.

first file will be played.

RESET Reset button is placed on the housing. The reset button is to be activated for the following reason:

• Initial installation of the unit when all wiring is completed.

• All the function button do not operate.

• Error symbol on the display.

USB PORT Using USB cable to connect your portable digital MP3 player.

HOW TO SELECT MP3/WMA FILES Searching by Track:

• Press A/PS, then search track is activated.

• Turn knob (2) left or right, select first digit desired.

• Press knob (3), then the first digit is fixed and second digit will flash.

• Turn knob (2) left or right, select 2nd 3rd respectively.

• Press BD/ENT, the song selected will start.

Searching by Character:

• Press A/PS twice, then character search mode is activated.

• Turn knob (2) left or right and select the desired letter.

• Press knob (3), repeat steps above for 2nd 3rd character.

• The songs with the same character that you selected is displayed.

• Turn “VOL” knob to left or right, you can select the desired song.

• Press “BD/ENT”, then the song selected will start.

• Searching by File Name: • Press “A/PS” 3 times, then folder search is activated.

• Turn “VOL” knob to left or right, you can select the 3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS Climate Control - Air Conditioner The Air Conditioner Climate Control provides a comfor table indoor environment and adjustable control of cab temperature. It removes moisture from humid air and reduces window glass fogging.

2 2 1

The Climate Control - AC unit is installed behind the operator’s seat and send cold air or hot air into the cab.

AIR OUTLET DIFFUSER Select a preferable air diffuser direction that is most comfortable by moving the diffuser grill by hand.

2

2 2

Figure 45

RH11F038

1. AIR CONDITIONER CLIMATE CONTROL PANEL 2. AIR OUTLETS

CONTROL PANEL

Figure 46

RH11F039

1. AIR OUTLET MODE SELECTOR SWITCH 6. MAIN POWER SWITCH 2. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 7. FAN SPEED SELECTOR SWITCH 8. TEMPERATURE SETTING SWITCH AND °C / °F 3. LCD DISPLAY SELECTOR SWITCH 4. COMPRESSOR SWITCH 9. DEFROSTER SWITCH 5. AUTO CONTROL SWITCH

NOTICE: The LCD display indicates temperature, air outlet mode, compressor ON - OFF - AUTO, recirculate, fresh air, and fan speed.

The background of the control panel is illuminated whenever the A/C system is activated.

BASIC USE Before turning the Air Conditioner ON, close the door and windows to achieve the best performance.

3-28

a. Press the “AUTO” control switch to control air capacity and blower outlet automatically, and set the temperature in the range from 18.5°C (6 5.3°F ) to 31.5°C (88.7°F) . the AUTO indicator in the LCD display will come on.

The outlet temperature, outlet opening and fan speed are adjusted automatically so that indoor temperature of the cab comes closer to the set temperature.

CHAPTER 3 - INSTRUMENTS AND CONTROLS b. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF.

B. Auto Control Switch and Display

2 3

c. Select preferable fan speed manually through fan speed selector switch when fan speed, selected through auto control is not preferable.

The “AUTO” indicator in the LCFD display goes out. Press “AUTO” switch to return to automatic climate control.

CONTROL PANEL FUNCTIONS A. Main Power Switch and Display

1 2 Figure 48

RH11F040

1. MAIN POWER SWITCH 2. LCD DISPLAY 3. AUTO CONTROL SWITCH

a. Press the main power switch to activate the Climate Control-AC and the LCD display will illuminate.

1

Figure 47

b. Press control switch AUTO, and fan speed and air outlet are automatically controlled, and “AUTO” indicator lamp on LCD display is illuminated.

a. LCD display is illuminated when the Climate Control-AC is operating. When the Climate Control-AC is stopped, LCD will turned off.

c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power sw i t c h i s p r e s s e d a g a i n , t h e C l i m a t e Control-AC will come on in the auto control mode.

RH11F040

1. MAIN POWER SWITCH 2. LCD DISPLAY

b. Press main power switch, and all functions for the Climate Control-AC switch ON or OFF. Each time when this switch is pressed, the f u n c t i o n sw i t c h e s O N a n d O F F. W h e n switched ON, the Control Climate-AC starts operating at the point set before switching OFF (When it is set to AUTO, in auto mode; if NORMAL is selected, then in normal mode).

C. Temperature Setting Switch and Display

2

NOTICE: The key switch will switch air-conditioner OFF, but the operating condition just before switching off may not be restored when the key switch is turned ON.

1

Figure 49

RH11F040

1. TEMPERATURE SETTING SWITCH AND °C / °F SELECTOR SWITCH 2. LCD DISPLAY

a. The set temperature is indicated in digits on LCD display. Temperature set range is 18.5°C (65.3°F) to 31.5°C (88.7°F).

3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS b. Press the two temperature set switches simultaneously for 5 seconds to change the display from °C to °F or vice-versa in the LCD display.

E. Defroster Switch and Display

2

c. Press the temperature set switch Down or UP to change the set temperature. The temperature goes up or down by 0.5°C (0.9°F) in graduation. The set Temperature may be raised or lowered by continued pressing of the switch. d. The set temperature 18°C (64.4°F) is the lowest cooling temperature, and 32°C (89.6°F) is the highest heating temperature. Control beyond either of these limits is not possible.

D. Air Outlet Mode Selector Switch and Display

2

1 Figure 52

RH11F040

1. DEFROSTER SWITCH 2. LCD DISPLAY

a. Press Defroster Switch, the defroster indicator will be displayed.

1

b. Press Air Outlet Mode selector Switch, and it returns to air outlet mode just before pressing defroster switch. c. Press Defroster Switch in the condition where AUTO display is indicated, “AUTO” indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

F. Fresh and Recirculate Air Selector Switch and Display Figure 50

RH11F040

2

1. AIR OUTLET MODE SELECTOR SWITCH 2. LCD DISPLAY

1

a. Air outlet position is indicated by the arrow on LCD display. b. Press Air outlet Mode Switch in the condition where auto display light is on, and the display mode is fixed, “AUTO” indicator lamp on LCD display goes out, and “AUTO” control of the air outlet opening is released. Press it again, and the level is change to: VENT

BI-LEVEL

FOOT

FACE RH11F040

Figure 53

1. FRESH AND RECIRCULATE AIR SELECTOR SWITCH 2. LCD DISPLAY

a. Suction (fresh air intake) mode is indicated on LCD display. b. Each time Fresh and Recirculate Air Selector Switch is pressed, the mode is switched to either recirculate or fresh air intake.

DC04D551

3-30

Figure 51

CHAPTER 3 - INSTRUMENTS AND CONTROLS G. Compressor Switch and Display

2

1

1

Figure 56

DC04D552

Figure 54

RH11F040

1. COMPRESSOR SWITCH 2. LCD DISPLAY

a. Press the Compressor Switch, marked with the snow flake, and the snow flake icon will be indicated on LCD display.

Press UP or DOWN of fan speed selector switch, and auto control of fan speed is released, and the “AUTO” indicator lamp on LCD display goes out.

HORN SWITCH

b. Press it again, the compressor turns off, and its indicator icon on the LCD display goes out.

H. Fan Speed Selector Switch and Display

2 RH11F041

Figure 57 HORN SWITCH

The horn switch is located on the operator’s left control handle.

NOTE: Always sound horn before starting engine to alert personnel that the machine is going to be operated.

1 Figure 55

RH11F040

1. FAN SPEED SELECTOR SWITCH 2. LCD DISPLAY

When it is set to MANUAL mode, fan speed on LCD display is as follows.

Display

Fan Speed

LCD 4 bars are lit up.

MAX.

LCD 3 bars are lit up.

HIGH

LCD 2 bars are lit up

MEDIUM

LCD 1 bar is lit up.

LOW

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS CONFLUX/SINGLE FLOW CHANGE SWITCH

HYDRAULIC FUNCTION SAFETY LOCK

1

2

1 Figure 58

BS06H080

1. FUNCTION SAFETY LOCK IN LOCKED (UP) POSITION 2. FUNCTION SAFETY LOCK IN UNLOCK (DOWN) POSITION BS06H090

A hydraulic function safety lock is provided on the left control console to avoid activation of any unwanted hydraulic function. When the function safety lock is placed in the unlock (down) position, the alarm will sound intermittently for two (2) second and the hydraulic system becomes active. Always, before leaving the cab, shut down the engine, and place the function safety lock lever in the locked (up) position.

WARNING WARNING: Always place the hydraulic safety lock lever in the locked (up) position before leaving the cab. Never leave the machine unattended with engine running. Failure to comply could result in death or serious injury.

M1710

Figure 59

1. CONFLUX/SINGLE FLOW CHANGE SWITCH

Use this switch, located on the right hand control console, to select a single flow and conflux hydraulic circuit.

• Double Pump symbol mark (two marks side): With this portion of the rocker switch selected to this side auxiliary hydraulics will work with double pump flow. Example: (When carrying out the demolition work with the nibbler which requires the conflux flow).

• Single Pump symbol mark (one side): With this portion of the rocker switch selected to this side, auxiliary hydraulics will work with single pump flow. Example: (Select this side when the reduced flow rate of auxiliary hydraulics is required for the work with a breaker, etc.

NOTICE: Do not set this switch to conflux flow operation position when using breaker. If in doubt, contact Kobelco Construction Service representative.

3-32

CHAPTER 3 - INSTRUMENTS AND CONTROLS SWING PARKING BRAKE RELEASE SWITCH When ever the “CPU MECHATRO CONT. FAIL” is displayed on the LCD screen, use the brake release switch to override the computer control system. To release the parking brake, proceed as follows: a. Stop the engine.

TWELVE VOLT POWER SUPPY

2

1

1 Figure 61

BS06H105

1. 12V POWER SUPPLY 2. COVER

The 12 Volt power supply is located beside the right side switch panel.

BS06H097 / BS06H098

Figure 60

1. BRAKE RELEASE SWITCH

b. Locate the switch to release the Swing Parking Brake, located on the left side behind the seat and flip it to its release position. c. Start the engine and move the machine to a safe place.

NOTICE: Contact your Kobelco Construction dealer service department for repairs. d. Return brake release switch to normal operating position after repairs have been made.

For use of common auto accessories such as a fan or other accessories requiring 12 volt (DC) power.

Pull cover away from 12 volt power supply and insert 12 volt male socket into power supply. Replace cover after use.

MAXIMUM CONTINUOUS OUTPUT - 180 Watt NOTICE: Do not use the cigarette lighter as a power supply source for 12 volt accessories. It is a 24 volt outlet. Plugging a 12 volt accessory into a 24 volt connector may result in shorting and/or fire.

3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUSE BOX

HOUR METER

1

1 Figure 63

BS06H106

1. HOUR METER Figure 62

BS06H104

1. FUSE BOX COVER

The fuse box is located behind the operator’s seat. It contains all necessary fuses for the electrical circuits of the machine. Should it become necessary to inspect or change a fuse, remove the fuse box cover by pressing the locks on each end of the cover inward to unlock and lift up. Should a fuse require replacement, use a replacement fuse of the same type and amperage. Turn key switch “OFF” and wait for all electrical power to stop before removing or replacing a bad or blown fuse. The fuse cover incorporates a fuse puller to remove fuses. Refer to the Maintenance Section of this manual for a detailed diagram and description of fuse box.

3-34

The Hour Meter indicates the total time that the engine has run. It meters the time continuously as long as the engine is running.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATING LEVERS AND CONTROLS 1. L e f t H an d ( L H) O p e ra t o r C o n t ro l L ev er (ISO/SAE Pattern)

Figure 64

DC04D562

WARNING WARNING: Hydraulic controls are designed for and set to ISO operating pattern. Changing the control pattern will effect the operation of the machine controls. Failure to comply could result in death or serious injury.

M1716

The Left Hand Operator Control Lever is located at the top front of the LH operator console. Its purpose is to allow the operator to control operations of the swing and arm. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The left hand operator control lever has 4 basic operational functions.

2. Right Hand (RH) Operator Control Lever (ISO/SAE Pattern)

DC04D563

Figure 65

The Right Hand Operator Control Lever is located at the top front of the RH operator console. Its purpose is to allow the operator to control operations of the boom and bucket. Operating speed of function is variable from stop to full stroke depending on how far lever is operated. The right hand operator control has 4 basic operational functions.

• “FORWARD” - Variable Speed BOOM down.

• “BACKWARD” - Variable speed BOOM up.

• “LEFT” - Variable speed BUCKET in (Digging).

• “RIGHT” - Variable speed BUCKET out (Dump).

• “CENTER” - Neutral position.

• “FORWARD” - Variable speed ARM out.

• “BACKWARD” - Variable speed ARM in.

• “LEFT” - Variable speed left SWING. • “RIGHT” - Variable speed right SWING. • “CENTER” - Neutral position.

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS NOTE: An optional Pattern Control Change Valve is available. Contact your authorized dealer for more information. If your Excavator already has this valve installed follow the instructions (BHL Pattern) regarding its operation.

3. Pattern Control Change (BHL Pattern) A. To change the machine’s control pattern from ISO (SAE) to Back Hoe Loader (BHL) pattern, proceed as follows: 1. Place the attachment on the ground, throttle control in low idle, and turn the key switch off.

1 Figure 67

BS06H456

1 1. PATTERN CHANGER VALVE

3. Open the air cleaner compartment door, locate the pattern changer valve and change valve’s handle position from ISO/SAE to BHL. 4. Whenever a change is made to the machine’s control pattern, also change the pattern decal card in the operator’s cab to match the new pattern.

DC04C344

WARNING

Figure 66

1. HYDRAULIC FUNCTION SAFETY LOCK LEVER IN LOCKED (UP) POSITION

2. Place the hydraulic function safety lock lever in the lock (UP) position before leaving the cab.

WARNING: Confirm that the operating pattern of the levers conforms to the machine lever decal.

Unexpected movement could result if decal and lever pattern do not match. Replace the decal immediately. Failure to comply could result in death or serious injury.

M1713

1

Figure 68

DC04D565

1. ISO/SAE PATTERN DECAL CARD

3-36

CHAPTER 3 - INSTRUMENTS AND CONTROLS C. Left Hand Operator Control Lever (BHL Pattern)

1

Figure 69

DC04D566

1. BHL PATTERN DECAL CARD

DC04D567

Figure 71

Slowly operate Left Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

D. Right Hand Control Lever (BHL Pattern)

1 DC04A001

Figure 70

1. HYDRAULIC PATTERN DECAL CARD HOLDER

B. Make sure to place the BHL pattern decal card in its respective holder, located below the cab door handle. Make sure BHL patter n is showing.

DC04D568

Figure 72

Slowly operate Right Hand control to make sure it matches BHL pattern and to familiarize yourself with the new control pattern.

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS TRAVEL LEVERS AND PEDALS

3 2

4 5

1

6

Figure 73

BS06H089

1. LH FOOT REST 2. LH TRAVEL PEDAL 3. LH TRAVEL LEVER 4. RH TRAVEL LEVER 5. RH TRAVEL PEDAL 6. RH FOOT REST

The travel levers and pedals are located in front of operator seat. They are used to move the left or right track of the machine either forward or backward.

• “FORWARD” - Variable speed forward track movement.

• “BACKWARD” - Variable speed reverse track movement.

• “CENTER” - Neutral position.

3-38

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting and Stopping Machine Engine with Temperature above 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting and Stopping Machine Engine with Temperature below 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Machine Engine with Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 MACHINE WARM UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming of Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming of Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Safety lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Work Mode selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Switching the Attachment Mode (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Use of Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Turning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Machine Attachment and Swing - iso/sae pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Swing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Using Auto Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Operate Boom Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Bucket Teeth Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Maximum Digging Force position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Cleaning Sand and Soil from Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Stop Swing Motion Early . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Back Filling and Leveling with Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 Operating the Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operation in coastal areas or Salty Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 USE OF OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Selection of the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Before Operating the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Hydraulic Oil Level Check and Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Basic Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Nibbler and Breaker Combined (Conflux) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 Extra (Grapple, clamshell, etc.) and Extra and Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Securing Machine to Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 Lifting Machine With Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 Lifting Machine Without Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39 Overall specifications - counterweight 4-40 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE 8. Make sure that the engine hood and the side doors are properly closed and latched.

WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury CE-NA000

Before operating this machine, be sure to do the following: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids and lub r i ca nts ar e s uita bl e for pr evai lin g conditions. See Chapter 6.

2. Carry out the daily maintenance operations.

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or replace as necessary. See Chapter 6.

4. See Run-in period if the machine is new or if the engine has been reconditioned.

5. Check the track assemblies.

6. Clean the steps and access handles. Grease, oil, mud or ice (in winter) on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

9. Secure the cab door in either fully closed or fully opened position.

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

11. Check that no tools or other items have been left on the machine (be it on the undercarriage or the upperstructure) or in the operator's compartment.

12. Make sure no one is on or under the machine.

The operator must be alone on the machine.

13. Make sure nobody is standing in the machine working area.

14. Find out about current safety measures in use on the work site.

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over.

16. Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signaling equipment is fully operative.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 12. See Transporting The Machine in this chapter when driving the machine onto a trailer.

OPERATING THE MACHINE

WARNING

13. See Lifting Procedures for The Machine in this chapter when it is necessary to lift the machine.

Check all controls and safety devices in a safe, open area before starting work.

14. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine.

Driving hazard!

Failure to comply could result in death or serious injury.

W0248A

When operating the machine, be sure to do the following: 1. When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See Star ting The Engine in this chapter.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 5.

3. If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the ser vicing inter vals should be r educed accordingly.

4. Take note of the locations of pipes/cables before starting work.

5. Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the safest distances: See the decal on this machine for safe working distances.

6. When working on a public highway, use standard traffic signs and take into consideration the working range of the upperstructure and its attachments. Local regulations stipulate the number, type and location of reflector strips.

7. Never operate the working or travel controls unless you are properly seated in the operator's seat with the seat belt correctly fastened.

8. Modify your driving to suit the type of work and working conditions. See Operating instructions in the Job Site Operation section.

9. Do not allow anyone within the machine's operating radius. Stop all operations until everyone has moved away.

10. Operate all controls gradually to ensure smooth machine operation.

11. See Operating in water if the machine will be standing in water during use.

4-4

15. Never use the attachment for sweeping the ground to level out r ubble or push objects (transversal stress on the attachment).

16. Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

17. Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete stop until visibility has improved.

18. In the event of an operation problem or failure, move the machine to a safe place, lower the attachment to the ground, shut down the engine and remove the key switch. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

19. Do not stop the engine without taking prevailing weather conditions into consideration. See Stopping the engine.

20. See Parking the machine when you have to park the machine.

21. Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See Load handling.

22. When travelling with the hydraulic breaker (optional), make sure it is not too close and not pointing in the direction of the cab.

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING AND STOPPING MACHINE ENGINE WITH TEMPERATURE ABOVE 0°C (32°F) STARTING ENGINE

STOPPING ENGINE - NORMAL CONDITIONS

1. Move throttle control to “LO” position.

2. Insert key into key switch and turn to the “ON” position.

3. Sound horn to warn personnel that the machine is being started.

4. Turn key to the “START” position and release as soon as engine starts. Key will automatically return to the “ON” position.

NOTICE: Release key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

NOTICE: If engine fails to start after 3 attempts, inspect fuel system and correct any problem found.

When cranking engine, the absence of “blue” or “white” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

STARTING AND STOPPING MACHINE ENGINE WITH TEMPERATURE BELOW 0°C (32°F)

DC04B674

Figure 1

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

2. Move throttle to “LO” position. Allow engine to idle for 5 minutes.

3. Turn key switch to “OFF” position.

STOPPING ENGINE - NORMAL CONDITIONS

STARTING ENGINE 1. Move throttle control to “LO” position.

2. Turn the key switch to “ON” and preheat for 20 seconds to make star t-up easier. The E/G Preheat Icon will display.

3. Sound horn to warn personnel that the machine is being started.

4. Turn key to the “START” position and release as soon as engine starts. Key will automatically return to the “ON” position.

NOTICE: Release key after 20 seconds of cranking if engine does not start.

Wait at least 2 minutes before attempting to start engine again to allow starter motor to cool.

DC04B674

Figure 2

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position.

NOTICE:

2. Move throttle control to “LO” position. Allow engine to idle for 5 minutes.

• After starting the engine, use the auto warm up

3. Turn key switch to “OFF” position.

system described in Machine Warm Up in this chapter, and warm the engine and hydraulic oil.

• If engine fails to start after 3 attempts, inspect fuel system and correct any problem found.

• When cranking engine, the absence of “blue” or “white” smoke from the exhaust indicates no fuel is reaching the engine cylinders.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING MACHINE ENGINE WITH BOOSTER CABLE

WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

2

Failure to comply could result in death or serious injury.

1

W0353A

CONNECTING BOOSTER CABLE

Figure 3

DC04A035

1. POSITIVE (+) BATTERY CABLE 2. NEGATIVE (-) BATTERY CABLE

WARNING Explosion hazard!

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

Failure to comply could result in death or serious injury.

W0343A

1. Move vehicle or machine to be used for boosting as close to the batter y box of the disabled machine as possible.

NOTICE: Do not allow the vehicle or machine used for boosting to touch metal to metal with the disabled machine. This could short circuit electrical systems and cause extensive damage to the CPU and other components.

NOTICE: Use only vehicles or machines with 24V DC electrical system to boost starting this machine.

2. Make certain key switch of the disabled machine is in the “OFF” position before proceeding with booster cable connection.

WARNING Explosion hazard!

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

Failure to comply could result in death or serious injury.

W0343A

4-6

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

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

Failure to comply could result in death or serious injury.

W0111A

CHAPTER 4 - OPERATING INSTRUCTIONS DISCONNECTING BOOSTER CABLES

3

1

2

3

1

2

4 4 1

2

3

4

DC04D588

Figure 4

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY BEING USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY BEING USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

3. Locate and connect one end of the booster cable to the positive (+) terminal on the battery of the disabled machine.

4. Connect other end of positive booster cable to positive (+) terminal of battery being used for boosting.

5. Locate and connect second cable to the negative (- ) ter mi nal of the batter y being used for boosting.

6. Connect other end of negative (-) cable to the upper frame of disabled machine as far away from battery as possible.

STARTING BOOSTING MACHINE ENGINE 1. Start engine boosting machine in normal manner according to climate conditions.

2. Allow 5 minutes or more to provide partial charge to the discharged batteries.

STARTING DISABLED MACHINE ENGINE 1. Start engine of disabled machine in normal manner according to climate conditions.

4

3

2

1 Figure 5

DC04D588

1. POSITIVE (+) TERMINAL OF DISABLED MACHINE 2. POSITIVE (+) TERMINAL OF BATTERY USED FOR BOOSTING 3. NEGATIVE (-) TERMINAL OF BATTERY USED FOR BOOSTING 4. UPPER FRAME OF DISABLED MACHINE

After disabled machine engine is running, follow these steps to disconnect the cables.

1. Disconnect the negative (-) cable from disabled machine upper frame.

2. Disconnect negative (-) cable from battery used for boosting.

3. Disconnect positive (+) cable from battery used for boosting.

4. Disconnect positive (+) cable from terminal of disabled machine.

NOTICE: When using booster cables remember: 1. Connect positive (+) cable first.

2. Disconnect negative (-) cable first from frame of disabled machine.

WARNING The negative (-) cable, when connected to the upper frame of disabled machine may arc and create sparks. Sparks coming in contact with batteries could trigger an explosion. Never connect negative (-) terminal of disabled battery. Failure to comply could result in death or serious injury

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE WARM UP AUTO WARM UP NOTE: The Auto Warm Up System will not activate if the Ambient temperature is above 10°C (50°F).

1. Warming Up of Engine The “WARMING UP” is displayed on the multi display after operating the engine for 3 minutes at auto accel speed (1050 rpm). When the accel dial set value is the value for deceleration or lower, the engine speed returns to the speed set by the accel dial (throttle potentiometer).

2. Warming of Hydraulic Oil The warm up of hydraulic oil is performed as follows:

• Operation of pump max. flow rate at the engine speed 1050 rpm for 3 minutes.

• Pump max. flow rate with control valve closed at the engine speed 1600 rpm for 5 minutes.

• Pump max. flow rate with control valve fully open at the engine speed 1600 rpm for 5 minutes.

• Pump max. flow rate at the engine auto accel speed (1050 rpm) for 10 minutes.

“WARMING UP” is displayed on the multi-display during warming up operation.

3. Warming Up Complete After an elapsed time of about 26 minutes of warming of hydraulic oil, or when the hydraulic oil temperature switch turns OFF, the warming up indication “WARMING UP” on the multi-display disappears and concurrently buzzer sounds for 5 seconds. Turn the auto warm up switch OFF. NOTICE: 1. If a pilot control lever is activated while the warm up system is active, the war m up is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

2. If the auto warm up switch is pressed to the OFF position, the warm up system is disconnected.

3. In climate below -18°C (0°F) it may be necessary to use a coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid in starting the engine.

4-8

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions.

Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

Auto warm up should be utilized anytime machine is started in climate temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in death or serious injury.

M1716

MANUAL WARM UP 1. Warming Up of Engine a. Allow the engine to run for 5 minutes under no load conditions with Throttle Control at “LO” idle position. b. During warm up, visually and audibly inspect engine for abnor mal conditions such as unusual exhaust color, excessive vibrations and excessive or unusual noises. c. Should problem areas be noticed, stop engine, locate and repair problem areas before restating or operating the machine.

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Warming of Hydraulic Oil

DC04D595

Figure 6

NOTICE: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab. a. Move Throttle Control to half throttle to begin and after 5 to 10 minutes turn to “HI” idle position.

Figure 8

DC04D474

d. Operate the Boom and Arm controls for 5 to 10 minutes each.

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions.

Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

Auto warm up should be utilized anytime machine is started in climate temperatures below 10°C (50°F) to stabilize machine control response. Cold oil can cause erratic machine operation. Failure to comply could result in death or serious injury.

M1716

DC04D473

Figure 7

b. Perform bucket dig operation and hold over relief for 10 to 15 seconds, then operate bucket dump and hold over relief for 10 to 15 seconds. Repeat the operations for 5 to 10 minutes. c. Move throttle control to mid position.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL DECAL OPERATING PATTERN The operating and travel controls of this machine are factory set at ISO/SAE standard operating patterns.

OPERATING PATTERN DECAL Figure below is a representation of the “CONTROLS” decal located inside the right side window of the operator cab. Study this decal and understand the directions each control can be operated and the functions as sociated with eac h movement of particular control. Detailed instructions for each control and its functions are explained on the following pages of this Chapter. Should this decal become damage or missing, install a new decal.

BS06H096

4-10

WARNING If your machine is set to the BHL pattern control changer, make sure to remove the ISO/SAE operation pattern control decal inside the right side window and use the decal supplied for the optional BHL pattern control. This decal should be placed inside the door, below the handle. See Pattern Control Change (BHL pattern) in this manual for detail information on how to operate the pattern control changer. Failure to comply could result in death or serious injury.

M1717

Figure 9

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION OF HYDRAULIC CONTROLS The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of this instructions, and practice with a machine, will allow a given operator to become more efficient in the operation of this equipment.

SAFETY LOCK LEVER 1. Unlocked Position

2

1

Figure 11

BS06H080

1 Figure 10

DC04D475

1. UNLOCKED POSITION 2. LOCKED POSITION

Before any Hydraulic Operation is possible the Function safety lock lever must be placed in the “UNLOCKED” (down) position. Placing the Function safety lock lever in the “UNLOCKED” (down) position also positions the left hand Operator’s Console in its operating and lock position.

1. TRAVEL MOTOR

Always know the position of the travel motors.

WARNING Always know the location of travel motors before operating any hydraulic controls. Failure to comply could result in death or serious injury.

M1727

WARNING Check and make sure that operations pattern control matches the decal provided inside the right side window. Failure to comply could result in death or serious injury M1713

2. Locked Position Before leaving the operator cab, place the Function safety lock lever in the “LOCKED” (up) position by pulling lever up. With Function safety lock lever in the “LOCKED” (up) position, no hydraulic operation is possible and this allows easy access in and out of the operator seat.

WARNING Always place the safety lock lever in the Locked (up) position before leaving cab to prevent any operation of hydraulic controls. Failure to comply could result in death or serious injury.

M1710

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS Press the work mode selector switch, and modes “H,“E”, or “S” can be selected.

WORK MODE SWITCH

NOTICE: By default, all Kobelco standard excavators start in “S” mode; and all excavators equipped with long reach attachment start in “S” mode also.

NOTICE: When using “S” (standard) mode: The monitor display will show the operation control pattern after approximately 5 seconds of repetitive motion of the joystIck control levers.

During fine control operations, use the throttle potentiometer as needed, for better control of the attachment.

Select the effective work mode according to the work condition and working target from the table shown below.

RH11F024

Figure 12

WORK MODE SELECTION TABLE Distinction

Remarks

H - Heavy Mode

H will appear in upper left corner of LCD.

This mode senses the movement of control lever, and is suitable to carry out the heavy load work giving priority to the work load at high speed.

E - Fuel Economy Mode

E will appear in upper left corner of LCD.

Eco mode is the mode focusing on better fuel economy, allowing for normal digging operation with lower fuel consumption than S mode.

S - Standard Mode

S will appear in upper left corner of LCD.

Used for standard work and loading operations.

Control Mode

SWITCHING THE ATTACHMENT MODE (OPTION)

The attachment mode switch deter mines the attachment work mode.

1. Nibbler Mode - A nibbler requires a conflux flow circuit. Select conflux flow when in the nibbler mode.

2. Breaker Mode - A breaker requires a single flow circuit. Select single flow when in the breaker mode.

3. Digging Mode - Select when digging.

1

NOTICE: If using a breaker attachment and in a work mode other than the breaker mode, damage will occur to the hyrdaulic component and breaker.

3

2

Figure 13

RH11F030

1. NIBBLER 2. BREAKER 3. DIGGING

4-12

NOTICE: When the H or S of the fuel consumption mode is flickering, an improper attachment mode was selected.

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE TRAVEL CONTROLS

2. Use of Travel Speed Select Switch

This machine incorporates several Travel Controls for the convenience of the operator. Each track can be operated independently to turn the machine or simultaneously counter rotate the machine or to travel straight.

1. Operating Both Travel Levers Together With the travel motors positioned behind the cab:

RH11F029

DC04D477

Figure 14

a. Push both travel levers or press the pedals toward front of machine and machine will travel “FORWARD”.

Figure 16

a. For fast travel speed, depress and release the travel speed s elect switc h once befor e operating the travel controls. This puts the travel motors in HIGH (2nd) travel speed and the icon (rabbit) for HIGH (2nd) travel speed will display on the gauge cluster. b. To return to the slow travel speed, stop travel and depress and release travel speed select switch once. This puts the travel motors in LOW (1st) travel speed and the icon (turtle) for LOW (1st) travel speed will display on the gauge cluster.

NOTE: The travel speed is automatically set to low (1st) speed when the engine is started.

DC04D478

Figure 15

b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”.

NOTICE: Use “FAST” travel speed on firm, level surfaces only. Do not travel continuously for more than two hours. Stop for a period of 10 minutes at low idle speed before resuming travel.

3. Turning Machine

c. Return both travel levers to “NEUTRAL” (center) position and machine will stop travelling. Parking brakes are automatically applied when travel levers are in neutral position.

NOTICE: The distance travel levers are pushed or pulled determines travel speed of the machine.

EXAMPLE: Travel levers are pulled or pushed to full stroke machine will travel at top speed.

Travel levers are pulled or pushed to mid position machine will travel at 1/2 speed.

DC04D479

Figure 17

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS a. Push the left travel lever toward front of machine to turn machine to the RIGHT in forward motion.

4. Counter Rotating Machine

DC04D483 DC04D480

Figure 18

b. Pull the left travel lever back toward operator seat to turn machine to the LEFT in reverse motion.

a. Pull left travel lever BACK and push right travel lever FORWARD to counter rotate machine to the LEFT.

DC04D484 DC04D481

Figure 19

c. Push the right travel lever toward front of machine to tur n machine to the LEFT in forward motion.

Figure 21

Figure 22

b. Pull right travel lever BACK and push left travel lever FORWARD to counter rotate machine to the RIGHT. NOTICE: All functions explained with use of travel levers can also be performed using the travel pedals.

NOTICE: A. Depending on the shoe type and ground conditions, this machine has a maximum climbing ability of 35° (70% grade) max., limited by engine lubrication.

B. When approaching or descending a slope, operate the travel slowly.

C. For braking, slowly return travel levers or pedals to the neutral (center) position. Brakes are engaged automatically.

DC04D482

Figure 20

d. Pull right travel lever toward operator seat to turn machine to the RIGHT in reverse motion

4-14

D. The travel operation for 2 hours or more may cause the failure of the travel motors due to the rise of the operating temperature. Don’t travel continuously for more than 2 hours.

S t o p for 1 0 m i nu t e s a t l ow i d l e be fo r e resuming travel.

CHAPTER 4 - OPERATING INSTRUCTIONS E. During counter rotation machine may stall depending on shoe type and ground conditions.

F. In extremely cold conditions, below -20°C (-4°F), the travel lever or pedal action may be “heavier” than normal. This is due to the viscosity of the hydraulic oil in frigid climates.

5. Travel Safety a. Make certain the travel motor location is known before performing any travel operation. b. Travel on firm, level surfaces as much as possible. c. When traveling on rough terrain, travel in SLOW speed with engine at a low idle. d. Travel with the travel motors in the back of the machine for long distance travel. e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging.

If necessary to travel or operate machine in a river or other water, the bed must be firm and water current slow. Water must not be deeper than indicated in the chart.

DO NOT operate this machine in water or liquid which contains corrosive or abrasive materials in solution, suspension, or mixture.

NOTICE: If the machine is operated while the swing bearing is submerged in water, then the swing bearing, swing pinion, and the swivel joint may wear out prematurely. Immediately replacement of grease in grease bath and flushing of the swing bearing is required. See Maintenance Section.

MACHINE ATTACHMENT AND SWING - ISO/SAE PATTERN The following operation instruction are to be used with hoe bucket attachment only. If other attachment are being used, consult the operators manual for the particular attachment.

f. Keep a safe distance from stationary objects and electrical power lines. g. Be aware of load capacities of bridges and road shoulders. Reinforce if necessary. h. Use decking or planking to protect road surfaces as much as possible. Be careful when turning or counter rotating machine on asphalt pavement. i. Do not allow large or heavy objects to strike travel motors. j. Do not travel over large objects such as boulders, rock, etc. k. The machine can sink on soft ground or mud.

Avoid these areas.

WARNING Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

Failure to comply could result in death or serious injury.

M1087

1. Boom Operation Operation of the Boom is performed by pushing and p u l l i n g t h e Ri g h t C o n tr o l L eve r fo r war d a n d backward. Boom speed is determined by how far the lever is activated.

6. Operating the Machine in Water

DC04D485

Figure 24

a. Pulling right control lever BACK raises boom.

RH11F042

Figure 23

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS 3. Bucket Operation

DC04D486

Figure 25

b. Pushing right control lever FORWARD lowers boom. c. Returning right control lever to the neutral (center) position stops operation of the boom.

2. Arm Operation Operation of the Arm is performed by pushing or pulling the Left Control Lever forward and backward.

Arm speed is determined by how far the lever is activated.

DC04D487

Figure 26

a. Pushing the left control lever FORWARD moves the arm out.

DC04D488

Figure 27

b. Pulling the left control lever BACK brings arm in.

G. Returning the left control lever to the Neutral (center) position, stops operation of the arm.

4-16

BS06H081

Figure 28

NOTICE: Check clearance between bucket and cab before operation. Slowly cycle bucket, check for interference with arm and cab, particularly if a lifting eye is welded on bucket bottom. Exercise care when operating the bucket near the cab.

Operation of the Bucket is performed by moving the Right Control Lever to the right or left.

DC04D489

Figure 29

a. Moving the right control lever to the LEFT operates the bucket in (digging).

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 30

DC04D490

Figure 32

DC04D492

b. Moving the right control lever to the RIGHT operates the bucket out (dumping).

b. Moving the left control lever to the RIGHT swings the machine to the right.

c. Returning the right control lever to Neutral (center) position, stops operation of the bucket.

c. Returning control to the Neutral (center) position stops swing.

4. Swing Operation Swing operation is performed by moving the Left Control Lever to the right and left. Swing speed is determined by the amount the lever is moved.

WARNING

USING POWER BOOST The power boost switch is located on top of the right operator control. It is a momentary switch which is activated by depressing with the thumb. This system is designed for use during bucket digging operations when extra “Break-Out” power is required to allow the bucket to break through a dig.

Make certain area is clear of obstacles and persons before beginning swing operation of the machine.

Sound horn before beginning swing operation.

Failure to comply could result in death or serious injury.

M106F

NOTICE: Use operations.

swing

flashers

during

1

swing

Figure 33

DC04D493

1. POWER BOOST SWITCH

Operate the bucket in digging control. While bucket is digging, depress the power boost switch with right thumb. This will increase bucket digging power by approximately 10%.

DC04D491

Figure 31

NOTICE: If the power boost switch is depressed, the power boost icon will be displayed on the gauge cluster Display.

a. Moving the left control lever to the LEFT swing machine to the left.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS USING AUTO ACCELERATION

Auto Accel Operation and Control a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 4 seconds, if the position of the throttle potentiometer is higher than 1050 rpm, the auto decel/accel actuates automatically and the engine speed returns to 1050 rpm.

1

b. When the throttle potentiometer is positioned lower than the auto decel/accel speed, the engine speed is maintained to the throttle potentiometer position.

Figure 34

BS06H064

1. THROTTLE POTENTIOMETER

The throttle potentiometer is located on the right side operator console, and it is used to control the engine RPM. When the throttle potentiometer is rotated to any position, it increases or decreases engine RPM to maintain the engine speed for that particular position.

With the attachment, swing, travel control lever or control pedal operation, the engine speed returns to the accel dial set position gradually according to the respective operating pilot valve movement. Thus, m a k i n g t h e o p e r a t i o n e a s i e r, l o w e r i n g f u e l consumption, and reducing noise level.

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY Always point bucket teeth in the direction the machine will be digging to reduce digging resistance and the possibility of bucket teeth damage.

USE ARM IN ACTION

MAXIMUM DIGGING FORCE POSITION

DC04E074

Figure 35

Operate the bucket at shallow depths and use the arm in action to fill the bucket. Setting the bucket too deep will decrease the machine ‘s efficiency.

DC04E077

OPERATE BOOM SMOOTHLY

Figure 38

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

CLEANING SAND AND SOIL FROM BUCKET

DC04E075

Figure 36

Always begin and end boom operation slowly with smooth careful movement of the control lever. Do not perform sudden starts and stops of the boom as this creates unnecessary stress on the machine and its components.

DC04E078

Figure 39

Operate arm to a near level position and bring the bucket to a dumping position. If sand and soil do not fall out, move the bucket lever right and left a few times.

BUCKET TEETH DIRECTION

NOTICE: Avoid shaking out soil using the stops at the end of the bucket cylinder stroke.

DC04E076

Figure 37

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE SHOVEL

STOP SWING MOTION EARLY

DC04E079

Figure 40

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

BACK FILLING AND LEVELING WITH FRONT ATTACHMENT

DC04E081

Figure 42

Digging with the shovel differs slightly from digging with backhoe.

1. Using the arm cylinder, scrape the ground.

2. Scrape the ground at 2° ~ 3° to improve draining in areas near the groundwater level.

3. Be careful not to hit the cab with the reversed bucket.

4. The excavating power during shovel operations is less than that during backhoe operations.

5. If machine bucket is equipped with a lifting eye, check to make sure that the eye will clear arm with bucket cylinder in full extended (full dump) position.

DC04E080

Figure 41

For back filling and leveling work after digging, move the bucket back and forth horizontally.

NOTICE: Do not push or pull material with the bucket like a bulldozer when using the machine to level material.

1. In leveling ground toward machine, pull the arm gently, lift the boom a little and when the arm has passed the vertical point, lower the boom gently and manipulate the machine so the bucket moves horizontally.

2. For leveling ground away from machine, reverse operation in step 1 above.

3. In the above operation, bucket motion may be used together with the boom and arm for a slope facing operation.

4. Never travel with front attachment touching the ground. Severe structural damage could occur.

4-20

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS OPERATION IN EXTREME COLD 1. Follow procedures at the beginning of this Chapter as starting engine may be difficult due to extremely cold temperature.

2. Use an engine oil, hydraulic oil, and Diesel fuel d e s i g n e d fo r u s e i n c o l d c l i m a t e s . S e e Maintenance Section for reference. Also keep batteries fully charged.

3. Make certain to perform Machine Warm-Up procedures as described at the beginning of this Chapter to prevent premature wear or damage to pumps, motors, and other components.

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

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

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

5. Keep battery terminals free of ice and snow. Ice and snow could cause the terminals to short circuit and cause extensive damage to the machine system. Check the battery electrolyte (acid) level frequently and fill as necessary with distilled water. If the machine will be left outside overnight, it is recommended to remove the batteries and store in a warm area.

5. If the machine becomes overheated, idle the machine to help cool the engine, turn engine “OFF” and check coolant level. If after filling to proper level the machine continues to overheat, stop engine, allow to cool, drain and flush entire cooling system and refill with the proper mixture of fresh, clean coolant.

WARNING Do not drain the cooling system when the engine is hot. Allow time to cool all engine parts. Failure to comply could result in death or serious injury B121

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

7. Keep a close watch on the Cluster gauge for w a r n i n g i c o n s d u r i n g o p e r a t i o n . Av o i d unnecessary low speed running of the engine during operation.

OPERATION IN HIGH ALTITUDES 1. Due to low atmospheric pressure at high altitudes, a decrease in engine power will be experienced. Be aware of this fact when placing machine under heavy load in high altitudes climates.

2. Keep close watch on the engine temperature gauge to avoid overheating of the engine.

OPERATION IN SANDY AND DUSTY AREAS 1. Check the engine air cleaner elements frequently in sandy or dusty conditions.

2. When air cleaner restriction lamp is displayed. change filters immediately regardless of time intervals.

OPERATION IN EXTREME HEAT

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

1. Use an engine oil, hydraulic oil and fuel designed for use in hot climates. See Maintenance Section for reference. Also keep batteries fully charged.

4. Keep clean the radiator, oil cooler, inter-cooler, and air condition condenser.

2. Clean radiator, oil cooler and debris screen often to p r even t da m ag e or ove r he at in g o f th e machine.

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

3. Keep all belts properly tensioned.

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

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION IN COASTAL AREAS OR SALTY CLIMATES 1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electr ical components and cylinder rods.

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

OPERATION IN HUMID CLIMATE 1. In climates with high humidity, thoroughly wash the machine daily and coat all bare surfaces with an oil based lubricant to help prevent corrosion.

2. Operate the A/C with the cab doors and windows closed.

RECOMMENDATION FOR LONGER UNDERCARRIAGE LIFE Undercarriage life varies upon operation method.

Use the following guides to increase the life of the machine’s undercarriage.

1. Select the track shoe that best suits the machine’s application. If in doubt, consult with your Kobelco Construction distributor when selecting track shoes.

2. Do not allow the tracks to slip during operation. If this occurs, reduce load until slipping stops.

3. Avoid sudden starts, accelerations, abrupt speed changes, high speeds on rough terrains, sharp turns, and sudden stops.

4. Always operate machine in straight lines whenever possible. Avoid shor t radius when turning. Make turns with the largest possible radius.

5. Prior to operation, clear boulders and obstacles to prevent damage to track shoes.

6. Always operate machine parallel to the inclination of the slope. Operating machine across the inclination of the slope will not only shorten the machine’s undercarriage life, but the machine could unexpectedly slide down hill, and/or roll over.

7. Do not force the machine to carry out work that exceeds its working capability.

8. It is very important that inspections and maintenance must be carried put accordingly, as mentioned in the Maintenance Section. DO NOT OPERATE machine with loose track shoes, and maintain proper track tension adjustment at all times during operation.

BUCKET SELECTION GUIDE Bucket selec tion is ex tremel y imp or tant to a machine’s productivity, durability, and stability.

Choosing an excessively large bucket can reduce productivity due to slower than normal cycle times.

Using an oversized or overly wide bucket in severe conditions such as mining, will lead to durability problems for both the machine and bucket involved.

Stability will be adversely affected using a bucket that is unnecessarily large.

The Bucket Selection char ts listed in the SPECIFICATION’S Section are to be used as general guidelines.

If the buckets used locally vary in weight from these sample buckets, it will be necessary to adjust the bucket capacity accordingly. A heavier bucket must correspond to a reduced capacity.

If the material density (weight) exceeds guidelines specifications then the bucket capacity must be reduced.

4-22

If the machine is to continuously dig rock, wasted shale, river cobbel or other severe applications the narrowest bucket possible should be utilized. This will allow the greatest possible penetration and minimal twisting of the attachment (boom and arm). Bucket capacity is not to be the prime consideration for severe applications.

If a machine is used exclusively to load trucks at close radius then the bucket loads can be adjusted up 5% to 7% from the Lift Chart Values listed in the Specification’s Section, due to a close in dump radius.

If a machine is used in a spoil pile operation, which causes a large radius dump cycle, applicable loads may have to be adjusted down by 5% from the Lift Chart Values listed in the Specification’s Section or stability complaints may occur.

NOTICE: See the “Bucket Selection chart” in the Specification’s Section to select the appropriate bucket size according to the application for the SK485LC-9.

CHAPTER 4 - OPERATING INSTRUCTIONS

USE OF OPTIONAL ATTACHMENT EXAMPLE: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the lifting table accordingly.

1

2. If a bucket is changed for a larger bucket, which weight is 350 kg (770 lbs) more than the bucket indicated in the Lifting Chart, then you have to subtract this additional weight from every value indicated in the Lifting Chart accordingly.

3. If a bucket is changed for a smaller bucket, which weight is 350 kg (770 lbs) less than the bucket indicated in the Lifting Chart, then you can safely add 350 kg (770 lbs) to every value indicated in the Lifting chart accordingly.

Figure 43

DC04D574

1. BUCKET QUICK COUPLER

If a machine is equipped with optional attachments such as a bucket quick coupler, and/or thumbs (either hydraulic or mechanical), applicable bucket sizes and s u s p e n d e d l o a d s mu s t b e r e d u c e d i n d i r e c t proportion to the weight or combined weight of these attachments. Failure to consider the added weight of such attachments will cause stability complaints.

Additionally the weights of such attachments must be considered when the Lift Chart is referred to before lifting a load. See Lift Charts in the Specification’s Section.

Us e of qui ck c ou ple rs fo r bu cke t interchangeability will reduce effective arm digging force and particularly bucket breakout force due to an increase of tooth tip radius.

Example: Some couplers can increase tooth tip radius up to 12 inches. If this is used with 48” tooth tip radius, effective bucket breakout force can be reduced 25%, a 5% reduction in effective arm force, a reduction in lift capacities of up to 272 kg (600 lbs).

It is also impor tant to mention that some quick couplers offer a great advantage, particularly when lifting loads. Some quick couplers allow the operator to quickly remove the bucket for lifting purposes; therefore, increasing lifting capacity, height and visibility. Always follow coupler manufacturing instructions for safe operation.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine.

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC BREAKER

4. Basic Operation

1. Selection of the Hydraulic Breaker W h e n m o u n t i n g a B r e a ke r o n t h e H y d r a u l i c Excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each Breaker. To select H y d r a u l i c B r e a k e r s , c o n t a c t y o u r Ko b e l c o Construction Dealer or vendor source.

WARNING Before operating this machine, review and understand all Safety Precautions in the Safety Section of this manual. Failure to comply could result in death or serious injury.

2. Before Operating the Hydraulic Breaker Consult your Kobelco Construction Dealer for the piping needed for the Boom and Arm when installing a hydraulic breaker. Replace the hydraulic return filter according to the replacement schedule table listed on MAINTENANCE FOR NIBBLER/BREAKER in the MAINTENANCE AND ADJUSTMENT Section.

Thoroughly read the Hydraulic Breaker Operation Manual and SAFETY PRECAUTIONS from this Section, as well as the Safety Precaution’s Section on this Manual to avoid damaging the machine or hydraulic breaker during operation. Select the appropriate hydraulic flow for the breaker by following the instruction detailed in the NIBBLER/BREAKER BASIC MACHINE OPERATION in this section.

3. Hydraulic Oil Level Check and Contamination Prevention When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the Arm-Bucket end and the hose end on the on the hydraulic breaker side to prevent dust and water from entering into piping.

M1416

1

Figure 44

BS06H080

1. FUNCTION SAFETY LOCK LEVER

a. Start machine and place the hydraulic function safety lock lever in “UNLOCKED” (down) position.

Before starting operation, check the cap screws on the tube fixing clamps for looseness, and the connection of the tubes and hoses for oil leakage.

RH11F044 / RH11F045 /RH11F031

Figure 45

b. Make sure to select the Breaker Mode. Move throttle control to HI idle position. c. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

4-24

CHAPTER 4 - OPERATING INSTRUCTIONS NIBBLER/BREAKER

1

WARNING

A

Before operating this machine, review and understand all Safety Precautions in the Safety Section of this manual. Failure to comply could result in death or serious injury.

B

M1416

MACHINE SET-UP A. Setting return flow Selector Valve.

Figure 46

RH11043

1. PIN A. LOCKED B. UNLOCKED

d. Move pin (1) forward to unlock (B) the pedal. e. Make certain breaker or nibbler is in desired position and against material to be broken. f. Place right foot on pedal and depress with toe to activate breaker or nibbler.

a. Use a 5 mm allen type wrench to loosen and remove the socket head capscrew. b. Use a 24 mm wrench to turn the selector valve to the proper position. c. After the valve is set in the proper position, install the 5 mm socket head capscrew and tighten it.

B. Setting Stop Valve

g. Operate breaker or nibbler at one (1) minute intervals.

NOTICE: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute intervals.

WARNING Always set the pedal lock to the LOCKED position when the Nibbler or Breaker is not in use. Failure to do so could result in death or serious injury.

1 Figure 47

DC04D498

1. NIBBLER AND BREAKER STOP VALVE

NOTE: Make sure to relieve hydraulic system and tank pressure as instructed in RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE in Section 6. a. Locate the stop valves on both sides of the Arm. b. Use a 24 mm wrench to turn the stop valve to the proper position.

NOTE: Make sure to switch the position of the stop valves to the “CLOSED” position before removing the attachment.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS Each time the work mode is pressed, the work mode indicator will show in the upper left side of the LCD in order of “H”, “E” or “S”.

5. Basic Machine Operation

Adjustment of maximum flow rate:

• Turn key switch on and the main screen is displayed.

1

• Change the attachment mode by selecting the Nibbler Mode or Breaker mode. The flow rate displays on the screen.

• When the flow rate displays, press Menu Switch to display the USER MENU screen.

• Move the cursor down to OPTION SETTING and press Next to display the Nibber/Breaker Setting screen.

• Move the cursor to the desired flow rate. Press Menu Switch to set the target flow rate.

BS06H093 / BS06H090

Figure 48

1. CONFLUX/SINGLE FLOW CHANGE SWITCH

The standar d S K485LC-9 is equipped with a bi-directional auxiliary hydraulic valve. The double pump flow switch is provided on the right side control panel to select a single or double pump flow to the auxiliary system.

• The display will return to the main screen if there is no switch operation for 20 seconds.Turn key switch on. b. CONTROL PEDAL Hydraulic Breaker Single Circuit

• Press it Forward when using the nibbler for demolition work.

A

• Press it Backward when using the breaker.

NOTICE: Never turn switch on bi-directional flow (two pump flow) to operate Breaker. It may cause damage to the machine. a. BREAKER MODE

B

DC04E083

Figure 50

Release pedal lock on the right front side of driver’s seat to operate pedal.

RH11F044 / RH11F045

Figure 49

In case of optional attachment such a breaker, etc. are us ed, the flow rate c an be automati cally controlled.

Adjust the maximum flow rate by the following procedure:

4-26

IMPORTANT: Pedal operation varies upon specifications. Make sure to read the operator’s manual carefully before operating optional attachment.

CHAPTER 4 - OPERATING INSTRUCTIONS NIBBLER AND BREAKER COMBINED (CONFLUX)

Pedal Operation - Breaker Only Foot Pedal Depressing Section

Operating Condition

Depress toe section

Breaker starts operation

Pedal in neutral position

Breaker stops operating

2 1

3

Figure 51

RH11F046

DC04E083

1. BREAKER SWITCH 2. SLIDING SWITCH 3. POWER BOOST SWITCH

Figure 52

Release pedal lock on the right front side of driver’s seat to operate pedal.

Pedal Operation - Breaker

If the machine is equipped with optional hand control grip levers, follow the procedure below.

Foot Pedal Depressing Section

Operating Condition

• Depress the Breaker switch (1) to start breaker

Pedal in neutral position

Breaker stops operating

Depress heel section

Breaker starts operation

operation.

• Release the Breaker Switch (1) to stop breaker operation.

• Slide the Switch (2) to the left to start breaker operation.

NOTE: It is recommended to use Breaker Switch (1) as much as possible and the use of the Sliding Switch (2) should be minimal.

Pedal operation - Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

2 1

3

Figure 53

RH11F046

1. BREAKER SWITCH 2. SLIDING SWITCH 3. POWER BOOST SWITCH

If the machine is equipped with optional control grip levers, follow the procedure below.

• Move the Sliding Switch (2) to the right to open the nibbler.

• Move the Sliding Switch (2) to the left to close the nibbler.

• NOTICE: The Breaker Switch (1) must not be touched while operating the nibbler.

NOTICE: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute Intervals.

WARNING Never leave the operator cab with engine running.Failure to comply could result in death or serious injury.

M1416

4-28

CHAPTER 4 - OPERATING INSTRUCTIONS SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with other safety precautions found in this manual.

WARNING Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

Failure to comply could result in death or serious injury.

When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close all windows to protect the operator from flying debris.

Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

D. CYLINDERS

M1087

A. USE FOR INTENDED PURPOSE

DC04E063

Figure 56

DO NOT OPERATE boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

DC04E061

Figure 54

E. AVOID CONTINUOUS OPERATION

Use the attachment only for its intended purpose. If not used in accordance with the manufacturer’s instructions, the excessive pressure exerted on the boom. arm and frame structure of the machine will cause premature failure of the components.

B. PASSENGERS Never allow passengers on the attachment or machine.

C. PROTECTIVE EQUIPMENT

DC04E064

Figure 57

Operate the Nibbler/Breaker in one (1) minute intervals. Operation for longer than one (1) minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

DC04E062

Figure 55

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS Never use the swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

F. HOSE SURGE

I. DO NOT LIFT

DC04E065

Figure 58

Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an a u t h o r i z e d Ko b e l c o C o n s t r u c t i o n d e a l e r fo r assis tance. T hi s problem often is a r esult of damaged accumulators and can also result in valve failure.

G. DO NOT USE DROPPING FORCE

DC04E068

Figure 61

Never use optional attachment to lift or transport objects or materials. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

J. WORKING RANGES

DC04E066

Figure 59

Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

H. DO NOT USE SWING FORCE

DC04E067

4-30

Figure 60

DC04E069

Figure 62

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

CHAPTER 4 - OPERATING INSTRUCTIONS GETTING THE MOST OUT OF YOUR BREAKER

WARNING Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

Failure to comply could result in death or serious injury.

M1087

A. BREAKER PROPER POSITIONING

DC03M065

When the excavator boom is lowered, it normally follows a curved path, which changes the original perpendicular position of the breaker. therefore, it is very impor tant to keep adjusting the operator’s controls to maintain constant per pendicularity between the breaker and the surface of the material being broken. In addition, the applied pressure should be sufficient to avoid the breaker tool from bouncing on the rock rather than transmitting the shock wave into it. The applied pressure should not lift the machine high off the ground, since the excavator can drop suddenly, as the breaker breaks through the material, and harmful shock loads will be transmitted through the entire machine.

Figure 63

Always position the Breaker perpendicular to the material you intend to break. The Breaker can be vertical, horizontal, or anywhere in between, as long as the tool is perpendicular to the surface and the pressure applied is in the same direction of the tool.

B. APPLIED PRESSURE ON BREAKER The Breaker must have sufficient pressure between the tool and the surface of the material intended to break to allow the shock wave to flow through the tool and to the material being broken. The applied pressure has to be constantly adjusted by combining the boom, arm, and bucket functions so that the breaker follows the tool at all times during breaker operation.

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS E. EXCAVATING AND TRENCHING

C. BREAKING OVERSIZE ROCKS

DC03M066

Figure 64

Do not attempt breaking oversize boulders from the center. It is much more efficient to break these type of rocks from the edges. Also, do not break into smaller pieces than necessary. There is a direct relationship between the size of the boulders and the size of the breaker. It is inefficient to break large rocks with small breakers and vice versa.

D. SURFACE ROCK DEMOLITION

DC03M068

Figure 66

Lay back side walls a bit at the time so that they do not interfere with the breaker housing. To lessen the opportunity for side loading, approach each wall from the opposite side by positioning the excavator perpendicular to the trench.

F. RULES TO REMEMBER Use the following rules for correct breaker operation: 1. Make sure to adjust the proper hydraulic flow according to the breaker specifications.

2. Place tool against material to be broken at 90° angle to work surface.

3. Use the boom, arm, and bucket controls to press firmly against surface, keeping perpendicularity while operating the breaker.

4. As material breaks, stop breaker quickly to prevent idle strokes.

DC03M067

Figure 65

Use the breaker just as if it were a hand held breaker, or a plain hammer and chisel. Adjust the breaker’s position according to the work to be done, and take small bites at a time. The only difference between a hand held breaker and the hydraulic excavator breaker is the size of the rocks that can be broken.

Do not try to break too much at one time.

4-32

5. Reposition breaker if material does not break after 15 seconds of operation.

6. Do not bend or pry with the breaker tool while operating.

7. DO NOT OPERATE breaker with attachment cylinders at full extension.

8. DO NOT OPERATE breaker submerged in water.

CHAPTER 4 - OPERATING INSTRUCTIONS 9. DO NOT OPERATE breaker for more than a minute at a time.

B. Setting Attachment Selector Valves

10. Lubricate breaker every 30 minutes. Keep tool lubricated at all times.

EXTRA (GRAPPLE, CLAMSHELL, ETC.) AND EXTRA AND BREAKER 1. Machine Set-Up

WARNING Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

Failure to comply could result in death or serious injury.

M1087

A. Setting Boom Selector Valves

DC03M070

Figure 68

a. Locate the two (2) selector valves on the arm. b. Use a 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until stamped letter “E” is aligned with the socket head cap screw mounting hole. d. Reinstall the 5 mm socket head cap screw and tighten securely.

NOTICE: All selector valves MUST be turned to the “E” position or the EXTRA ATTACHMENT WILL NOT FUNCTION PROPERLY.

DC03M069

Figure 67

a. Locate the two (2) selector valves on the boom. b. Use 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until the stamped letter “E” is aligned with the socket head cap screw mounting hole. d. Reinstall the 5 mm socket head cap screw and tighten securely.

4-33

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Basic Operation

WARNING Read, understand and follow all safety precautions and operation procedures found in this manual before operating the machine or any attachment.

Failure to comply could result in death or serious injury.

M1087

1

Figure 69

BS06H080

1. FUNCTION SAFETY LOCK LEVER

a. Start machine and place the hydraulic function safety lock lever in the “UNLOCKED’ (down) position. b. Move throttle control to the HI idle position.

Figure 71

BS06H214 / BS06H216

e. Unlock pedal and place right foot on pedal.

Depress with toe to close attachment and depress back of pedal with heel to open attachment. f. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, operate the attachment in hydraulic oil check position, move throttle control to LO idle position, and place the Nibbler/Breaker selector switch in the neutral position.

1 WARNING BS06H088

Figure 70

1. NIBBLER/BREAKER SELECTOR SWITCH

c. Place the Nibbler/Breaker selector switch, located on the RH control console, to the operating position being performed. d. Use the boom, arm, and bucket controls to position the attachment.

4-34

Set the pedal lock to the “LOCKED” position while the breaker or nibbler is not used. Unexpected contact with the pedal in the “UNLOCKED” position may cause serious injury or death. Failure to comply could result in death or serious injury.

M1603

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION GROUND TRANSPORTATION 1. Machine Preparation a. Know the total weight, length, width and height of the machine being transported. b. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route.

c. Obtain any permits required from proper g o v e r n m e n t a g e n c i e s fo r m a c h i n e transportation. d. Use only a trailer with a rated capacity sufficient to transport the machine. e. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

Figure 72

RH11F047

2. Loading the Machine

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury. Failure to comply could result in death or serious injury.

CM113A

a. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine. b. Lower ramps of trailer. c. Start the machine. d. Set travel speed to LOW 1st speed. e. Move throttle control to low idle position.

DC03K083

Figure 73

g. Raise the attachment and slowly travel machine up trailer ramps and over rear axles of trailer. h. Slowly travel machine completely onto trailer until in proper transport position. i. Slowly swing machine 180° until attachment is toward rear of trailer.

f. Put Auto Accel function OFF.

4-35

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 74

DC03K084

j. Slowly lower boom until attachment rest on trailer bed.

DC04D580

1

Prior to transpor ting a long reach attachment equipped machine, the arm must be fully retracted and attachment lowered. Make sure the link between the boom and arm is properly installed to prevent damaging the arm and the arm cylinder during transportation.

Figure 75

DC04C344

1. FUNCTION SAFETY LOCK LEVER

k. Place hydraulic function safety lock lever in the “LOCKED” (up) position. l. Turn machine “OFF”, remove key and lock all doors, filler caps and access panels.

NOTICE: Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine, and possible turbo damage.

4-36

Figure 76

CHAPTER 4 - OPERATING INSTRUCTIONS 3. Securing Machine to Trailer

LIFTING MACHINE The following procedures are for lifting the machine, as built by Kobelco Construction. These procedure do not take into account modifications made to the machine that affect machine weight or center of gravity.

1. Lifting Machine With Attachment Installed

WARNING Always use proper lifting equipment and devices.

Use of improper lifting equipment could allow the load to shift or fall . Failure to comply could result in death or serious injury.

CM113A

a. Locate lifting locations at the front and rear of each crawler frame. b. Attach cables or wire ropes with a capacity rating sufficient to lift the machine, at lifting locations.

1 Figure 78

DC04D582

1. HARDWOOD OR STEEL BLOCK

DC04D581

Figure 77

NOTICE: Place a hardwood or steel block between cables and crawler frame to prevent damage to the tracks from cables during lifting.

a. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer. Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer. Also, make sure to secure front and rear of each track. b. Securely fasten all loose parts, as well as removed parts from the machine to the trailer or transporting platform.

4-37

CHAPTER 4 - OPERATING INSTRUCTIONS NOTICE: It may be necessary to place reinforced spreader bars between lifting cables to prevent damage to the machine during lifting.

Figure 79

RH11F048

WARNING Do not use counter weight lifting eyes to lift machine. using counter weight lifting eyes may cause machine to fall Failure to comply could result in death or serious injury.

CM113A

4-38

c. Bring loose ends of cable together at machine center of gravity and attach to an overhead lifting device with a rated lifting capacity sufficient to lift the machine.

CHAPTER 4 - OPERATING INSTRUCTIONS 2. Lifting Machine Without Attachment

WARNING WARNING: Always use proper lifting equipment and devices. Use of improper lifting equipment could allow the load to shift or fall causing severe damage, serious injury or death.

Pass the cables through the lifting points on the crawlers as indicated in 4-37 and bring loose ends of cables together at machine center of gravity and attach to an overhead lifting device with rated capacity sufficient to lift the machine.

WARNING

M1087

Do not use counter weight lifting eyes to lift machine. using counter weight lifting eyes may cause machine to fall Failure to comply could result in death or serious injury.

CM113A

Figure 80

RH11F049

Without Arm and bucket

Shoe Width A: (mm)

Total Length L: (mm)

Total Height H: (mm)

Total Width W: (mm)

Weight kg

900

10,660

3,370

3,650

46,500

RH11F050

Without Arm, Bucket and Counterweight

Figure 81

Shoe Width A: (mm)

Total Length L: (mm)

Total Height H: (mm)

Total Width W: (mm)

Weight kg

900

10,440

3,370

3,650

36,200

4-39

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 82

RH11F051

Without Boom, Arm, Bucket and Counterweight

Shoe Width A: (mm)

Total Length L: (mm)

Total Height H: (mm)

Total Width W: (mm)

Weight kg

900

6,210

3,370

3,650

31,600

Overall specifications - counterweight

Figure 83

RH11F052

Counterweight

4-40

Total Length L: (mm)

Total Height H: (mm)

Total Width W: (mm)

Weight kg

2,980

1,260

810

10,300

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE PREPARE MACHINE Perform the following procedure to prepare the machine for long term storage.

1. Perform all inspection and maintenance pro cedu res as des cr ibe d in Main tenanc e Section.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

1

IMPORTANT: Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank. Make sure to use an anti-algae additive in the fuel tank.

4. Move machine to an indoor location for storage.

2 2

2 Figure 84

DC04D586

1. MACHINE IN STORAGE POSITION 2. CYLINDER RODS HEAVILY GREASE TO PREVENT CORROSION DURING STORAGE

5. Operate bucket and arm completely “IN” extending cylinders. then lower boom until attachment is resting on the floor.

6. Coat cylinder rods with heavy coat of grease to prevent corrosion during storage.

7. Remove batteries and store in a well ventilated, warm area.

CARE DURING STORAGE 1. Every 30 days during storage, it will be necessar y to star t and run the machine to circulate the fluids through the systems. Before starting, clean cylinder rods and after running, re-grease cylinder rods.

REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in the Maintenance Section before bringing machine out of storage for normal operation.

2. Remove drain plugs from the travel motors and swing gear reduction units to drain off any moisture which may have accumulated during storage.

3. Carefully and closely inspect all hydraulic hoses after long per io ds of s torage fo r s igns of deterioration. Replace all hoses showing these signs.

NOTICE: Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

4-41

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-42

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Motor Reduction UnitS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Upper Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Lower Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operating Lever Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Ring Gear Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Transmission Component Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Use of Bio-degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Biodiesel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES ENGINE

Capacity ------------- 160 cc (5.41 Fluid Oz.) Each x 16 NOTICE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

Type of Oil ------------------------ Engine Oil SAE 15W40 Capacity:

TRACK IDLERS

Engine Oil Pan (H Level) -----35.0 liters (9.2 gal)

Type of Oil ------------------------ Engine Oil SAE 15W40

Engine Oil Pan (L level) ----- 27.0 liters (7.1 gal)

Capacity -------------- 200 cc (6.76 Fluid Oz.) Each x 2

Filter Capacity ------------------- 1.1 liters (0.3 gal)

NOTICE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

Residual --------------------------- 4.9 liters (1.3 gal) Total Engine Oil Volume --- 42.5 liters (11.2 gal) IMPORTANT: Must comply with requirements of API CJ4 or better.

OPERATING LEVER JOINT

NOTICE: See ENGINE OIL LEVEL in Chapter 6 for proper oil filling and/or checking engine oil level.

Capacity ------------------------- As required in each joint

HYDRAULIC

NOTICE: See CONTROL LEVER JOINT LUBRICATION in chapter 6 for proper lubrications.

Type of Oil -------------------------------- EP Grease EP/2

Type of Oil ----------------------------Hydraulic Oil AW 46 Capacity: Hydraulic Tank -----------------300 liters (79.0 gal) Hydraulic System ------------555 liters (147.0 gal) NOTICE: See HYDRAULIC OIL LEVEL in Chapter 6 for proper filling and/or checking hydraulic oil level.

UPPER ATTACHMENT PINS Type of Oil -------------------------------- EP Grease EP/2 Capacity -------------------------- As required in each pin NOTICE: See ATTACHMENT LUBRICATION in Chapter 6 for proper lubrications.

SWING MOTOR REDUCTION UNITS Type of Oil ------------------------- SAE 90 GL4 Gear Oil

SWING BEARING

Capacity -------------------------------14.0 liters (3.6 gal)

Type of Oil -------------------------------- EP Grease EP/2

NOTICE: See SWING MOTOR REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

Capacity --------- As required (1 place - swing 90° x 4) NOTICE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

TRAVEL MOTOR REDUCTION UNIT Type of Oil ------------------------- SAE 90 GL4 Gear Oil

TRACK TENSION ADJUSTMENT

Capacity ------------------ 15.0 liters (4.0 gal) Each x 2

Type of Oil -------------------------------- EP Grease EP/2

NOTICE: See TRAVEL MOTORS REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

Capacity ---------------------------- As required (2 places) NOTICE: See TRACK TENSION in Chapter 6 for proper procedures in injecting grease.

TRACK UPPER ROLLERS Type of Oil ------------------------ Engine Oil SAE 15W40

SWING RING GEAR BATH

Capacity ---------------- 50 cc (1.69 Fluid Oz.) Each x 4

Type of Oil ------------ Lithium base grease with MOS2

NOTICE: See MAINTENANCE ON ROLLERS AND IDLERS in Chapter 6 for proper oil filling.

Capacity-----------------------------------22.0 Kg (48.5 lbs)

TRACK LOWER ROLLERS

NOTICE: See SWING RING GEAR LUBRICATION in Chapter 6 for proper lubrications.

Type of Oil ------------------------ Engine Oil SAE 15W40 5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS RADIATOR

REQUIRED FILTERS

Coolant --------------- Ethylene-glycol Coolant Solution

NOTICE: Refer to the Parts Manual for the correct part numbers to order.

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

HYDRAULIC

• Return Filter Element for Standard Machine • Return Filter Element for Breaker and Nand B • Tank Suction Strainer

Capacity: Radiator --------------------------18.5 liters (4.9 gal)

• Tank Breather Filler Element

Cooling System ---------------41.0 liters (10.8 gal)

• Pilot Line Filter

NOTICE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

ENGINE

• Engine Oil Filter FUEL TANK Type of Fuel --------------------- Diesel Fuel grade No. 2 Capacity --------------- Fuel Tank - 650 liters (172 gal) NOTICE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

• Air Cleaner Inner Element • Air Cleaner Outer Element FUEL

• Engine Fuel Filter • Priming Pump Gauze Filter OPERATOR CAB

• A/C Fresh Air Filter • A/C Recirculate Air Filter NOTICE: Refer to MAINTENANCE AND ADJUSTMENT Chapter 6 in this Manual for the Locations and proper procedures in replacing filters.

5-4

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climate and certain conditions.

CLIMATE ZONE

LUBRICANT HYDRAULIC OIL (ANTI-WEAR, ANTIOXIDANT, AND NON-FOAMING)

FRIGID -30°C~15°C (-22°F~59°F)

FRIGID -20°C~30°C (-4°F~86°F)

FRIGID-WARM -25°C~40°C (-13°F~104°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 5°C~55°C (41°F~131°F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT ENGINE OIL A.P.I. CLASSIFICATION FOR "SERVICE CD")

FRIGID -30°C~30°C (-22°F~86°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 30°C and Above (86°F and Above)

SAE10W30

SAE15W40*

SAE15W50

*Note: All engines shipped from factory with SAE15W40 engine oil.

CLIMATE ZONE

LUBRICANT

FUEL

FRIGID -15°C ~ -25°C (5°F ~ -13°F)

WARM -5°C ~ -15°C (23°F ~ 5°F)

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

WINTERIZED ASTM D975 No.1

ASTM D975 No.2

ASTM D975 No.2

LUBRICANT

For ROLLERS and IDLERS

ENGINE OIL A.P.I. Classification for "Service CJ4 - SAE15W40

(For General Purpose Lubrication)

LUBRICANT

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL (For General Purpose Lubrication)

A.P.I. Classification for "Service CD" - SAE15W40

LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

Extreme Pressure Multi Purpose Grease No.2 EP Type Grease

N.L.G.I. No. 2 Lithium Base with MOS2 Grease

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ANTIFREEZE (LLC) -34°C (-29.2°F)

FLUID ENGINE COOLANT (50% MIXTURE)

Mixture ratio should protect to 5°C (9°F) lower than the coldest temperature the machine will experience. Take into consideration Wind Chill Factors.

USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. You are recommended to use the synthetic based type, because the vegetable based oil has a maximum usage temperature of 80°C (176°F). Because of this, the degradation of vegetable based oil occurs more rapidly, and causes reduced service life.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. In the case that you would like to use BIO OIL, it is required to flush the hydraulic system that was filled with mineral oil twice, before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

5-6

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Coolant Solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l ea k ag e. D o n ot us e no n- a p pr ove d a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

HYDRAULIC FLUID Use hydraulic fluid specifically designed for high pressure applications. Your dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions.

GREASE The type of grease to use depends on ambient temperature. Use a quality extreme pressure multipurpose No. 2 grease.

ENGINE OIL CI-4 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, flush the hydraulic system that was filled with mineral oil twice. This is a requirement before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

ENVIRONMENT Before you service this machine and dispose of oil, fl ui ds, an d lu br i c an ts, a l way s r em em ber th e environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

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

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

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

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

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

FUEL STORAGE

NOTICE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out with approved lubricants.

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

USE OF BIO-DEGRADABLE OILS

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

When using Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

5-8

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hot Surface and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Warm Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 “Tag-Out” Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Releasing Hydraulic System and Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Guidelines to Replace Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Special Considerations for Hand Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 DPF (Diesel Particulate Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 DAILY INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Machine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Steps and handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Boom AND Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 50 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Fuel Tank Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Radiator, Oil Cooler and Debris Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Engine Accessory Belt Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Swing Ring Gear and Swing Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Swing Ring Gear Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Swing Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 Checking Swing Gear Attaching Bolts for Proper Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Check Swivel Valve for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Oil Level in Swing and Travel Reduction UnitS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Inspecting Counterweight Attaching Bolts for Proper Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Control Lever Joint Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Swing Motor Reduction Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Travel Motors Reduction Unit Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Engine Accessory Belt Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Climatizer - AC Unit Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Recirculate Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Checking the Radiator Cap and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 500 HOUR MAINTENANCE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Replacing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Bleeding Air From Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Change Oil in Travel Motor Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Change Oil in Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Checking and Cleaning Fuel Tank and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 Checking the Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Checking the Air Conditioning Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Engine Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 cleaning suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Maintenance on Rollers and Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Change Swing Ring Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 PERIODICAL INSPECTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Dust Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Bucket, Arm, and Link Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Reversing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Removing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Installing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Bucket Teeth and Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Windshield Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Hydraulic Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Boom Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Arm Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Bucket Cylinder and Nibbler/Breaker Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Fuel Lines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Hydraulic Suction Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Rear View Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 MAINTENANCE FOR NIBBLER/BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 Counterweight (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Travel Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69 6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Releasing Travel Motor Brakes Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Lowering Attachment When Sudden Engine Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72 Releasing Swing Brake Manually With Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Releasing Swing Brake Manually Without Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Bleeding the Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION

WARNING Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

DC04B668

Figure 1

1. It is recommended by Kobelco Construction that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition.

2. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection a n d m a i n t e n a n c e a s t h ey w i l l g u i d e t h e technician step by step for each procedure. Also, refer to the inspection and maintenace charts for general service interval recommendations.

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

3. Use only oils, fluids, lubricants, filters and r e p l a c e m e n t p a r t s s u p p l i e d b y Ko b e l c o Constr uction to keep machine in optimum operating condition.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL SAFETY DISPOSAL OF HAZARDOUS WASTE

WARM ENGINE OIL

Dispose waste oils, fluids, lubricants, filters, and other hazardous waste properly.

Engine should have a temperature between 20°C ~ 40°C (68°F ~ 104°F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature.

IMPORTANT: Dispose of all hazardous waste in accordance with government environmental regulations, laws, and codes.

“TAG-OUT” MACHINE

KEEP MACHINE CLEAN

DC04B671 DC04B669

Figure 2

Thoroughly clean machine before perfor ming inspection and maintenace procedures. It is easier and safer to locate problems, perform maintenance a n d a l s o r e d u c e r i s k o f hy d r a u l i c s y s t e m contamination when machine is clean.

Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operators console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine.

INSPECT WASTE OILS AND FILTERS

HOT SURFACE AND FLUIDS

DC04B672 DC04B670

Figure 3

Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool down before performing maintenance procedure.

6-6

Figure 4

Figure 5

Before disposal, inspect all waste oils, fluids, and f i l t e r s fo r d e b r i s a n d fo r e i g n m a t e r i a l . I t i s recommended to cut open the oil filters to determine any abnormal wear.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WELDING SAFETY

PREVENT CONTAMINATION

1. Turn key switch to “OFF” position.

1 Figure 6

DC04B673

Always cap or plug lines when hydraulic components are removed to help prevent hydraulic system contamination that can be caused by dirt, dust, and debris entering a line or port.

NOTICE: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

SEALS AND O-RINGS Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

Figure 7

BS06H238

1. NEGATIVE (-) BATTERY CABLE

2. Remove negative (-) cable from battery terminal 3. Attach the welder ground cable within 1 m (3’ 3”) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

STOP ENGINE Never attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool.

WEAR SAFETY EQUIPMENT Wear hard hat, safety goggles or face shield, work gloves, safety shoes, and well fitting work clothes when perfor ming inspection and maintenance procedures on this machine.

CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

WARNING Improper use of solvents can result in fire or explosion. Do not use gasoline or low flash point solvents. Clean only in a well ventilated area away from sources of sparks or flame, including any appliances with a pilot light. Failure to comply could result in death or serious injury.

M1629

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

Figure 10

BS06H208

5. Shift the right and left travel control levers forward and backward, also operate the right and left control levers to full strokes several times.

NOTE: Must be put into Hydraulic Drain to release pressures in attachments.

Figure 8

DC04B674

1. Move the machine to firm level ground and place the attachments on the ground in the oil check position.

1

2. Stop the engine.

2

3. Turn the key switch to “ON”.

Figure 11

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

6. Remove the cap on the hydraulic tank breather and push the air release button down to release the pressure in the hydraulic tank.

7. Carry out the inspection and/or maintenance of hydraulic system.

1 WARNING DC04A001

Figure 9 1. FUNCTION SAFETY LOCK LEVER

4. Lower the function safety lock lever to unlock the hydraulic system.

Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

6-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GUIDELINES TO REPLACE GROUND TOOLS

GUIDELINES FOR ATTACHMENT LUBRICATION

It is very important to keep bucket teeth and side cutters properly tighten. Loose or missing bolts will increase loads and eventually cause tool failure.

Extended operation with loose hardware can cause the bolts to stretch and wear on the support mounting holes. Heating of hardware and support mounting holes will cause the same effect. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters.

Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubr ication inter vals are based on a standard excavator (see Specifications Section for the definition of Standard Excavator) working in an average duty cycle. Average duty cycle is defined as “Most typical digging application, road construction in natural bed clay, digging 50% ~ 60% of the daily work schedule”.

• When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

1

• Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT.

• When installing end bits, start at the center and work toward the outside edges.

• Always torque bolts according to specifications.

• For best results, strike all head bolts with a heavy hammer to seat them properly before final torque.

3

2 DC04C280

Figure 12

1. BUSHING 2. PIN 3. ROUGH SURFACE REQUIRING BREAK-IN.

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

• When new parts are used, the mating surfaces will seat more uniformly and the bolts torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

• Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

• When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mount hole if needed. Torque bolts according to specifications.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points.

Because of these high spots, it is recommended that the front attachment or the repair ed area be lubricated a minimum of once every eight (8) hours for the first one hundred (100) hours for a standard machine working in an average duty cycle. All other machine should be lubricated every 4 hours for the first twenty (20) hours and every eight (8) hours for the next eighty (80) hours of operation. T his lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SPECIAL CONSIDERATIONS FOR HAND LUBRICATION

3

1

4

2

Figure 13

DC04C281

1. BUSHING 2. PIN 3. HAND LUBE FILL 4. LOAD AREA

While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand operated grease dispenser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standar d l ubr ication procedure is modified. See the pin load and grease cavity illustration shown above. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. Therefore, to avoid this situation, the front attachment has to be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

6-10

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DPF (DIESEL PARTICULATE FILTER) DPF is an acronym for diesel particulate filter. A DPF works in conjunction with the an oxidation catalyst and an EGR valve (Exhaust Gas Recirculation) to remove a majority of the NOx, particulate matter and unburned hydrocarbons from burned diesel fuel.

Soot is a natural by-product from the combustion of diesel fuel. Inside the DPF is a porous structure that catches the soot as it passes through. After the soot builds up over time, the on board computer controls fuel injection to allow unburned fuel to enter the filter at measured inter vals where it flares off and generates increased temperatures that incinerate the accumulated soot.

Check to make certain engine oil level in the oil pan is at a nor mal level. Should the oil level r ise abnormally, check the injection system.

Make certain there is no exhaust leakage.

Check the cover for damage, missing clips.

Check hoses of the differential pressure sensor for any deterioration. Replace hoses every two years.

See the procedure below for inspection.

Normal working

Carry into service shop

Connection of Hino-DX

<Error code is checked by Hino-DX.>

1. First check in service shop

Checking for previous trouble DPF condition is checked by monitor

2. Diagnosis

(When the previous engine trouble is found, firstly check the engine, and check DPF.)

3. Service the forcible regeneration (To control the gauge cluster, use a personal computer.)

Engine check

<To operate manual forcible regeneration, use a personal computer.> Operate forcible regeneration manually.

4. Judgment of forcible regeneration completion

5. Diagnosis

(Regeneration does not complete.) ¨ Cleaning of filter Error code "PXXXX" is indicated on gauge cluster.

6. Measurement of differential pressure (To control gauge cluster, use a acceleration and personal computer.)

7. Diagnosis

ULCX3404036E01

Cleaning of filter

<Raise the engine speed to maximum under no load, and check differential pressure value.> Monitor differential pressure value of differential pressure sensor.

Monitor engine speed.

(Differential pressure value is beyond the limit of allowable value.) ¨ Cleaning of filter

Cleaning of filter

Figure 14

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Service intervals

As Required (AR)

Every 8 hours

Every 50 hours

Every 250 hours

Every 500 hours

Every 1000 hours

6-12

page

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

Service points

Intervals in hours

clean

check

6-33

Fan and air conditioning drive belt

6-42

Air filter

AR

6-25

Fuel tank filter

AR

6-19

Steel track shoe bolt torque

AR

6-13

Engine oil level

8

6-13

Coolant level

8

6-16

Hydraulic reservoir level

8

6-25

Radiator and oil cooler

8 8

replace

lubricate

drain

AR

6-33

Fan/alternator belt tension

6-22

Attachment

6-24

Drain fuel tank sediment

6-57

Hydraulic system lines

6-43

Hydraulic return filter

6-19

Track shoe bolt torque

Run-in

8-16

Bolt and nut torque

Run-in

6-27

Battery check

50

6-28

Swing reduction gear

120

6-31

Travel reduction gears

120

6-20

Idler wheel and rollers

250

6-46

Hydraulic Breaker return filter

6-35

Radiator hoses and clamps

250

6-19

Track shoe bolt torque

250

8-16

Bolt and nut torque

6-28

Fan/alternator belt tensioner

AR

50 50 50 50 50 50

250

250 50

250

6-27

Battery electrolyte level

6-23

Engine oil

50

250 500

6-23

Engine oil filters

50

500

6-22

Machine Grease Points

6-29

Turntable bearing

6-29

Swing reduction gear

Run-in

6-32

Travel reduction gears

Run-in

6-36

Fuel filter

500

6-36

Fuel pre-filter

500

6-22

Attachment

6-46

Hydraulic fluid condition

6-46

Reservoir breather filter

6-43

Hydraulic return filters

6-42

Primary air filter element

250

6-42

Secondary air filter element

250

SM

Tappet clearances

500 500 500 500

1000 1000 1000 1000 1000 1000 1000

Service intervals

Every 2000 hours

page

Service points

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Intervals in hours

clean

check

replace

lubricate

drain

6-46

Hydraulic Fluid

2000

6-31

Swing reduction gear

6-48

Pilot Filter

6-37

Travel reduction gears

2000

6-44

Draining and filling cooling system

2000

6-47

Suction Strainer

2000 2000

2000

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTICE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen to serve as a reminder that service work is due. See “Systems display and control panel” in the “Controls/Instruments/Accessories” Section.

NOTICE: RM = See Repair Manual or contact Authorized Dealer.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

ENGINE COOLANT LEVEL

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

1

M1070

ENGINE OIL LEVEL 1. Raise the engine cover.

1

Figure 16

BS06H211

1. ENGINE COOLANT RESERVOIR

2

1. Open left rear compartment cover and inspect coolant level in engine coolant reservoir.

2. Proper coolant level is between “FULL” and “LOW” marks.

3. If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

Figure 15

BS07M101

1. ENGINE OIL DIPSTICK 2. OIL FILL CAP Figure 17

BS07M117

2. Pull engine dipstick, clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again to visually inspect the engine oil level on dipstick.

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

NOTICE: After adding oil, check oil level again, replace filler cap and dipstick and close engine cover.

4. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then refill reservoir to proper level.

WARNING Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

6-14

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE FLUID LEAKS 1. Inspect complete engine for signs of fluid leaks.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Failure to comply could result in death or serious injury.

M1725

FUEL LEVEL Figure 18

DC04C286

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard.

Figure 21

RH11F053

Figure 19

DC04C287

1. Turn “ON” the key from key switch and the fuel gauge in the cluster will indicate the fuel tank level.

WARNING: Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury.

ENGINE ELECTRICAL

2

1 Figure 22

DC04C294

1. FUEL TANK CAP 2. FUEL TANK CAP LOCK

DC04C292

Figure 20

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

2. To refuel the machine, use the key from key switch to unlock the cap (if locked) and remove the fuel tank cap. Do not remove the fuel screen for fueling. Refill fuel tank to full mark to reduce air volume (condensation). Failure to do so could create problems such as r usting and fuel freezing, as well as other associated problems.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. To add hydraulic oil, proceed as follows:

HYDRAULIC OIL LEVEL

1 2 Figure 23

DC04B674

Figure 25

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1. Place the machine in the oil check position on a firm level surface.

A. Depress air release button hydraulic tank pressure.

to

release

1 2 3

Figure 24

DC04C297

2. Check the sight glass through the opening of the hydraulic tank side cover.

WARNING For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. DO NOT OPERATE machines on inclined surfaces with a slope greater than 35°.

Failure to comply could result in death or serious injury.

M1718

Figure 26

BS06M157

1. CAP SCREW 2. RETURN FILTER COVER PLATE 3. O-RING

B. Slowly remove the six mounting bolts from the hydraulic return filter cover plate.

WARNING

C. Add hydraulic oil, filling hydraulic tank to the proper level.

Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

D. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic oil and install the O-ring.

M1295

6-16

E. Install cover plate, cap screws and washers.

Tighten the cap screws to torque specification.

Refer to Torque Specification Table in the Specifications Section.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEAKS

WARNING Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1716

IMPORTANT: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

HYDRAULIC FUNCTIONS

Figure 28

DC04C287

WARNING Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury. Failure to comply could result in death or serious injury.

M1736

Figure 27

BS06H208

Check all hydraulic controls for proper functionality before operating the machine.

1. Check complete hydraulic system for leaks. Use a small piece of cardboard when checking areas with high pressure.

2. Check all hoses and lines for signs of damage.

3. Repair or replace damaged hoses and lines before allowing any operation.

WARNING Never operate the machine with faulty control or function. Make all necessary repairs before allowing any operation. Failure to comply could result in death or serious injury.

M1726

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS STEPS AND HANDHOLDS

MACHINE ELECTRICAL 1. Check all switches for proper operation.

2. Visually check all wiring and connectors for signs of damage, corrosion, etc.

3. Repair or replace all damaged or faulty electrical components before allowing any operation of the machine.

DC04A040

Figure 30

1. Inspect daily all mounting steps, hand holds, and mirrors on the machine to make sure they are clean and in safe working condition.

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

Figure 29

RH11F053

4. Check all gauges and L.C.D. display on the gauge cluster for proper operation.

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Failure to comply could result in death or serious injury.

M1725

6-18

NOTICE: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FRAME STRUCTURE

TRACKS AND COMPONENTS

1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

1. Track Shoes

1

Figure 32

DC04A040 DC03K221

Figure 31

NOTE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding is required, consult an authorized Kobelco Construction Service Dealer for proper procedures. Use only certified welding personnel familiar with str uctural welding methods to perform repairs requiring welding.

Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

1. TRACK SHOES

A. Visually inspect track shoes for signs of excessive wear or damage.

B. Have all repair or replacement work done by an authorized Kobelco Construction Service Dealer.

C. Check tightness of shoe mounting bolts and nuts. If loose, remove bolt, clean thread, apply engine oil and torque to 853 ± 27 N-m (628 ± 36 ft-lbs).

2. Track Links

NOTICE: Disconnect batteries before welding on this machine. Connect welder ground cable within 1 m (3’ 3”) of area to be welded

1

Figure 33

DC04C300

1. TRACK LINK

A. Inspect link for signs of excessive wear or damage.

B. Have all repair or replacement work done by an authorized Kobelco Construction Service Dealer.

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. Idlers

3. Sprockets

1 1

2

Figure 34

DC04C301

Figure 35

DC04C302

1. SPROCKET 2. SPROCKET BOLT

1. IDLER

A. Inspect Idlers for excessive wear and damage.

A. Inspect sprockets for excessive wear and damage.

B. Should the sprockets require service, contact an authorized Kobelco Construction Service Dealer.

C. Check and make sure all sprocket bolts are properly torqued.

NOTICE: If any sprocket bolt is loose, proceed as follow:

B. Should the Idlers require service, contact an authorized Kobelco Construction Service Dealer.

NOTICE: Every 8 hours of operation, make sure to check Idlers and Rollers for leakage and repair as needed. Contact your Kobelco Construction dealer’s Service Department for any assistance.

NOTICE: Change oil in Idlers and Rollers every 2000 hours of operation. See 2000 hour maintenance in this section for specific details.

C1 - Remove bolt and clean threads.

C2 - Apply Loctite #262 to the bolt.

5. Rollers

C3 - Torque to 55 kgf·m (397 lbs-ft)

1 Figure 36

DC04C303

1. ROLLERS

A. Inspect Rollers for excessive wear and damage.

B. Should the Rollers require service, contact an authorized Kobelco Construction Service Department for assistance.

6-20

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK TENSION

WARNING Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

M1720

5. Tighten grease fitting to 6 kgf·m (45 lbf-ft) torque.

6. Keep others away from machine start engine and operate the travel motor for the track being adjusted, back and forth. Recheck track tension and adjust if needed.

7. Keep others away, start and lower machine to the ground.

8. Perform steps 1 through 6 on the opposite track if needed.

Figure 37

DC04C304

1. On a firm level surface operate swing, arm, bucket, and boom controls until machine is set up as shown. Stop the engine.

BOOM AND ARM 1. Inspect Boom and Arm structures for signs of excessive wear and damage.

WARNING Support lower frame with suitable blocks. Failure to comply could result in death or serious injury.

M1288

2. Measure the sag in the center of the track, between the bottom of the track frame and the track shoe surface.

Figure 39

DC03K221

NOTE: Remove any excessive grease from the attachment pin connecting areas for inspection.

2. Should repair or replacement be necessary, contact an authorized Dealer for assistance.

DC04C307

Figure 38

3. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting with a grease gun until proper tension is reach.

4. To decrease track tension, carefully loosen grease fitting 3/4 of a turn to allow grease to escape.

NOTICE: Visually check every eight (8) hours for excessive lateral play between boom and arm, and arm and bucket connections. Measure clearances every fifty (50) hours. Refer to shop manual for details regarding attachment lateral clearance.

WARNING Disconnect batteries before welding on this machine.

Connect welder ground cable within 1 m (3’ 3”) of area to be welded. Failure to comply could result in death or serious injury.

M1067

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 50 HOUR MAINTENANCE: ATTACHMENT LUBRICATION

1

3 2 1 Figure 40

DC04C305

Figure 42

DC04C308

1. ARM TO BOOM PIN 2. ARM CYLINDER ROD PIN 3. BUCKET CYLINDER HEAD PIN

1. BOOM CYLINDER HEAD

1. Boom cylinder head pins.

5. Arm to boom pin.

6. Arm cylinder rod pin.

4

7. Bucket cylinder head pin.

3

5

2 1

4 1

3 2 Figure 41

DC04C306

1. BOOM FOOT 2. BOOM FOOT PIN (EACH SIDE) 3. ARM CYLINDER HEAD PIN 4. BOOM CYLINDER ROD PINS

Figure 43

DC04C309

1. BUCKET CYLINDER ROD END 2. TOP BUCKET LINK PIN 3. BOTTOM BUCKET LINK PIN 4. ARM TO BUCKET PIN 5. IDLER LINK TO ARM PIN

2. Boom foot pin.

3. Arm cylinder head pin.

8. Bucket cylinder rod pin.

4. Boom cylinder rod pins.

9. Top bucket link pin.

10. Bottom bucket link pin.

11. Arm to bucket pin.

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

6-22

12. Idler link to arm pin.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE ENGINE OIL AND FILTER ELEMENT Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation.

NOTICE: One new oil filter is shipped with the machine in the support kit. This is to be used at the 50 hour oil and filter change.

2

1 Figure 46

DC04C310

1. BELLY PAN COVER 2. BELLY PAN COVER BOLTS

3. Remove bolts and engine belly pan covers

Figure 44

DC04B674

1. Move the machine to a firm, level surface, and run engine for 5 minutes to warm the oil.

4. Locate the engine oil drain valve and place an empty oil container [42.5 L (11.2 Gal) capacity] under the engine.

5. Remove engine oil drain valve and let the engine oil drain out completely.

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

1 1 Figure 47

BS07M102

1. ENGINE OIL DRAIN VALVE

Figure 45

BS07M117

1. ENGINE OIL FILLER CAP

2. Raise the engine cover and secure it open.

Remove the oil filler cap.

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

Figure 48

BD06H022

6. Use a filter wrench and turn counter clockwise to remove the oil filter.

7. To install the oil filter, apply a thin coat of engine oil to the gasket of the new oil filter, fill the filter partially with engine oil and then secure the filter by tightening 3/4 ~ 1 complete turn by hand after the gasket comes in contact with the oil filter head.

NOTICE: Check the waste oil. If there are metal flakes in the oil, contact your Kobelco Construction Service Dealer. Do not reuse the oil filter.

8. Clean oil drain plug and install it. Tighten securely.

9. Refer to LUBRICATION, FILTERS, and FLUIDS Section for the proper oil to use and fill engine oil to proper level.

Figure 50

BS07M101

1. ENGINE OIL DIPSTICK

13. Check oil level and close engine cover.

14. Reinstall engine belly pan covers and tighten bolts to 83.3 N-m (38 Ft-lbs).

FUEL TANK DRAIN Drain the fuel tank every 50 hours or weekly.

1 1 Figure 49

BS06K465

1. ENGINE OIL FILLER CAP

10. Add oil and install oil filler cap. Clean up all spilled oil.

11. Keep others away from machine, start engine, run for 5 minutes. While running, check for oil leaks.

12. Should any oil leaks be found, stop engine, check for the source of leakage, and repair immediately and refill with proper oil.

6-24

Figure 51

BS07M103

1. FUEL TANK DRAIN VALVES

1. Stop the engine. Place an empty container below the fuel tank drain valves.

2. Locate and open fuel tank drain valves on bottom of fuel tank.

3. Drain water and sediment from fuel tank into a waste container, then close the drain valves.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WATER SEPARATOR The water separator isolates water that mixes in with the fuel.

1

2

1 1

Figure 53

BS06M264

2

1. HOSE CLAMPS

2. AIR HOSE

Figure 52 1. FUEL FILTER 2. DRAIN VALVE

1. Stop the engine. Open the engine cover, secured it open, and inspect all hoses for damage.

Tighten all hose clamps.

1. The fuel filter is located in front of counterweight on the right rear side of the machine.

2. Replace any damaged hose before allowing any operation of the machine.

2. Stop the engine. Open right side door and place container under drain hose to collect water.

RADIATOR, OIL COOLER AND DEBRIS SCREEN

BS06H084

3. Loosen drain plug and air bleeder plug to drain water in fuel filter.

Clean radiator after every 50 hours of operation using pressurized air.

4. After draining, tighten drain plug and air bleeder plug securely.

2 1

WARNING Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1209

3 4

AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system, including turbo charger and intercooler, on a new machine after the first 50 hours of operation. Inspect the air intake hose at after 120 hours. Then at every 500 hours of engine operation.

5 Figure 54

BS07M117

1. RADIATOR 2. OIL COOLER 3. A/C CONDENSER

4. INTER COOLER 5. FUEL COOLER

1. Stop the engine. Open radiator compartment door and engine cover and secure them open to clean the radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler.

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS NOTE: When working in extremely dusty environments, it is recommended to check the radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler at the end of the working shift and clean regardless of working hours.

1 Figure 55

BS07M110

1. RADIATOR LOWER ACCESS COVER

2. Remove radiator lower access cover from bottom of machine.

3. Rinse all dirt and debris from engine compar tment. Reinstall debris screen and radiator lower access cover.

NOTICE: Be careful not to bend or damage cooling fins of the radiator, A/C condenser, oil cooler, inter cooler, or fuel cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler.

6-26

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE BATTERIES

.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

M144C

Figure 57

BS06H237

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

WARNING

BS06H238

Figure 56

1. Stop the engine. Open the battery access door and secure it open.

Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

84-109

NOTICE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

ENGINE ACCESSORY BELT WEAR AND TENSION

NOTE: Use hydrometer manufacturer’s instruction.

Inspect belt wear and tension on a new machine after the first 50 hours of engine operation. Then, every 250 hours.

according

to

its

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

4.

1.

2.

1.

3.

Figure 58

BS06H238

1. POSITIVE (+) BATTERY CABLE 2. NEGATIVE (-) BATTERY CABLE

7. When disconnecting batteries, remove the negative (-) cable first. W hen connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level, and reinstall caps before charging. d. Connect charger leads to the proper battery terminals.

2.

Figure 59

BS07M106/BS07M105

1. ALTERNATOR 2. FAN BELT

3. CRANK PULLEY 4. A/C COMPRESSOR BELT

Measure belt tension on longest span of belt. Apply a 30 Nm (22 lbf) on the Alternator and Fan belts, and 8 Nm (6.1 lbf) on the Air Conditioner belt. Measure the belt deflection and compare to the Belt Deflection table.

BELT

DEFLECTION

Alternator Belt

15 mm ~ 17 mm (0.59”~ 0.67“)

Fan Belt

12 mm ~ 14 mm (0.47”~0.55”)

Air Conditioner Belt

4 mm ~ 5 mm (0.16”~0.20”)

NOTICE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

6-28

NOTICE: Be very careful when moving the alternator. Do not damage the stator coil section located between the alternator’s front and rear housing.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SWING RING GEAR AND SWING BEARING LUBRICATION 1. Swing Ring Gear Lubrication Check the grease level and condition of the swing ring gear grease bath on a new machine after the first 50 hours of engine operation. Then, check every 250 hours. Replace the grease in the swing ring gear b a t h ev e r y 2 , 0 0 0 h o u r s ( S e e 2 , 0 0 0 h o u r maintenance in this section for details).

NOTICE: Do not overfill sump bath. If overfilled, sump bath grease could be pumped into swing motor reduction unit and cause severe damage. Use only N.L.G.I. lithium base with MOS2 grease in swing ring gear sump bath.

If the swing ring ever becomes submerged in water, it is mandatory that the sump bath grease be changed.

Refer to 2,000 Hour Maintenance for specific instruction.

2. Swing Bearing Lubrication Lubricate the swing bearing on a new machine after the first 50 hours of engine operation. Then, lubricate every 500 hours, or as conditions dictate.

1.

DC04C329

Figure 60 1. SWING RING GREASE INSPECTION COVER

a. Stop the engine. Locate the swing ring grease i ns p e c ti o n c over b e twe en th e to o l b ox compartment and the boom support frame.

Remove bolts and inspection cover plate.

1.

Figure 62

DC04C331

1. SWING BEARING GREASE FITTING

a. Stop the engine. Locate the grease fitting at the front of the swing bearing. b. Using a grease gun filled with general purpose EP grease, lubricate swing bearing with several pumps from grease gun. c. Keep others clear of machine, swing machine 90° right, and repeat step 2. See label on frame. d. Repeat the process at 90° increments and lubricate swing bearing until ring has been completely greased. e. Check and make sure the swing bearing seal is in good condition. It is nor mal to see excessive grease come out of the seal.

DC04C330

Figure 61

b. If water is present, remove the lower plate (drain plate). c. Keep others away from machine, start the engine and slowly rotate the upper structure to inspect the swing gear. d. Should any grease be needed, add N.L.G.I. No. 2 Lithium base with MOS2 grease only.

6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING SWING GEAR ATTACHING BOLTS FOR PROPER TORQUE

NOTICE: Make sure to inspect the upper and lower side of the Swivel Valve. Repair any leakage as needed.

OIL LEVEL IN SWING AND TRAVEL REDUCTION UNITS

1.

2.

2.

1.

1.

Figure 63

DC04C331

1. SWING GEAR ATTACHING BOLTS

Stop the engine. Check the swing ring bolts torque on a new machine after the first 50 hours of engine operation. Then, Check every 500 hours. Check the swing ring bolts for proper torque across each other and in sequence. If bolts are loose, remove one bolt at a time, clean it and apply Loctite #262 and torque accordingly.

Figure 65

BS07M112

1. FILL PLUG

2. DIPSTICK

Before starting the engine check the oil level on swing motor reduction unit on a new machine after the first 50 hours of engine operation then check every 120 hours.

SWING RING TORQUE SPECIFICATIONS SK485LC-9

2.

Inner Race: 57.5 ± 5.8 kgf-m (415 ± 42 ft-lbs) Outer Race: 40.0 ± 4.0 kgf-m (289 ± 29 ft-lbs) CHECK SWIVEL VALVE FOR LEAKAGE

1.

Figure 66

DC04C334

1. DRAIN PLUG 2. FILL/LEVEL PLUG

Stop the engine. Check the oil level on travel motor reduction unit on a new machine after the first 50 hours of engine operation then check every 250 hours.

DC04C332

Figure 64

Stop the engine. Check the swivel valve for leakage on a new machine after the first 50 hours of engine operation. Then, every 250 hours. If needed, contact your Kobelco Construction Ser vice Dealer for assistance.

6-30

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR PROPER TORQUE.

Stop the engine. Remove the rubber boots from the control levers and lubricate the universal joint and the top of the sliding area every 250 hours.

SWING MOTOR REDUCTION UNIT OIL

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

1 Figure 67

DC04C335

Check the oil level of the swing motor reduction unit on a new machine after the first 50 hours of engine operation. Then, check every 120 hours.

1. COUNTERWEIGHT BOLTS

1

2

2

Stop the engine. Check bolts and nuts for proper torque.

1

NOTICE: Striking counterweight against obstruction may cause loosening of bolts. Check bolts for loosening after the first 50 hours of engine operation.

Then, every 250 hours.

NOTICE: If a counterweight bolt is found loose, remove it, clean threads, apply Loctite #262 before installing it. See Specification Section for torque reference.

WARNING

Figure 69

BS07M112

Always wear eye and face protection when using compressed air or water. Failure to comply could result in death or serious injury M1611

1. FILL PLUG

2. DIPSTICK

1. Locate the dipstick on the side of the swing motor. Pull dipstick, wipe clean and reinsert all the way in.

2. Pull dipstick and read oil level.

CONTROL LEVER JOINT LUBRICATION

3. If necessary to add oil, remove plug from oil fill port and fill to full level with proper oil. Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper oil specifications.

1

2 DC04C336

Figure 68 1. UNIVERSAL JOINT 2. TOP OF THE SLIDING AREA

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL MOTORS REDUCTION UNIT OIL Inspect oil level of travel motor reduction unit on a new machine after the first 50 hours of engine operation. Then, check every 120 hours.

1 2

2 Figure 70

DC04C337

1. VENT HOLE

2. FULL MARK

4. Check and make sure the vent hole on dipstick is clean.

1 Figure 73

DC04C334

5. To drain oil from the swing motor reduction unit:

1. DRAIN PLUG 2. FILL/LEVEL PLUG

1. Move machine to a firm, level surface. Operate travel until “DRAIN” plug is positioned at 6:00 o’clock. Oil “FILL/LEVEL” plug should be on the top side at about 10:00 o’clock.

1 Figure 71

BS07M112

1. DRAIN PORTS

a. Locate drain port under the center opening of the lower frame. b. Place an empty container under drain ports and remove plugs allowing excess oil to drain into container.

NOTICE: Total volume for the SK485LC-9 swing reduction unit is 14.0 l (3.6 gal). c. Replace plugs and tighten securely after all oil is drained. d. Fill through fill port using proper oil. e. Recheck oil level and make sure it is within specifications.

Figure 72

6-32

DC03N026

Figure 74

2. Stop engine and remove the travel motor reduction unit oil LEVEL plug. If oil just seeps from the port, oil level is correct.

3. To add oil, add oil in the FILL/LEVEL port until it just begins to flow out of the port.

4. Use teflon tape on the plug for better sealing.

Install plug and tighten securely.

NOTICE: Capacity of SK485LC-9 Travel Reduction Unit is 15.0 liter (8.0 gal).

NOTICE: Perform all pre-start (every 8 Hour and 50 Hour) inspection and maintenance procedures along with the 250 Hour inspection and maintenance procedures.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE ACCESSORY BELT WEAR AND TENSION

4

Inspect belts and tensioner assembly on a new machine after the first 50 hours of engine operation.

Then, every 250 hours.

2

With the engine off, measure belt tension on longest span of belt. Apply a 10 kgf m (72 lbf-ft) on the belts and measure the belt deflection and compare to the Belt Deflection table.

1 4 3 2 6 5 1

Figure 76

BS07M107

2 3 Figure 75

BS07M105/BS07M106

1. ALTERNATOR 2. IDLER PULLEY

3. CRANK PULLEY 4. A/C COMPRESSOR

Measure belt tension on longest span of belt. Apply a 30 Nm (22 lbf) on the Alternator and Fan belts, and 8 Nm (6.1 lbf) on the Air Conditioner belt. Measure the belt deflection and compare to the Belt Deflection table.

BELT

1. ALTERNATOR 2. ADJUSTING BOLT 3. ADJUSTING NUT

4. MOUNTING CAP SCREW 5. IDLER PULLEY NUT 6. IDLER PULLEY

a. Loosen mounting cap screw and adjusting nut on the alternator. b. Loosen or tighten adjusting bolt to adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut properly.

TIGHTENING TORQUES Mounting Cap Screw: 83 Nm (61 lbf-ft) Adjusting Nut: 51 Nm (38 lbf-ft) c. After adjustment, start engine and run it at low idle for 5 minutes. Then recheck belt tension.

DEFLECTION

Alternator

15 mm ~ 17 mm (0.59”~ 0.67 “)

Fan

12 mm ~ 14 mm (0.47”~0.55”)

Air Conditioner

4 mm ~ 5 mm (0.16”~0.20”)

1. Fan Belts Check fan belts for excessive wear and cracks and replace them if needed. When replacing a twin type V-belt, replace them both. If only one belt is replaced, it may fail due to the excessive loading. To adjust the fan belts, proceed as follows: 6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Air Conditioning Compressor Belt

Removing the Climatizer - AC unit filters:

Check belt for excessive wear and cracks and replace as needed. To adjust the AC compressor belt, proceed as follows:

1. Fresh Air Filter a. Remove cover on the left rear side of operator seat and pull up.

4 1

1 Figure 78

BD06H019

3

2

1. COVER Figure 77

BS07M106

1. IDLER PULLEY 2. ADJUSTING BOLT

3. IDLER PULLEY NUT 4. A/C COMPRESSOR

a. Loosen the idler pulley nut. b. Loosen or tighten adjusting bolt. c. Tighten idler pulley nut 4.0~5.5 kgf·m (29~40 lbf-ft).

1

d. After adjustment, start engine and run it at low idle for about 5 minutes with AC turned ON. Then recheck belt tension.

CLIMATIZER - AC UNIT FILTER INSPECTION Inspect the fresh air filter every 250 hours of engine operation and the recirculate air filter every 500 hours of engine operation.

2

NOTICE:

• If the working environment is extremely dusty, it is recommended to reduce the inspection schedule to at least half of the above specified working hours.

• The fresh air filter is a paper filter. DO NOT WASH. Wear safety glasses. Clean with air only. Do not clean more than 10 times or replace it every 2 years.

• Wear safety glasses. Clean the recirculate air filter with compressed air or by washing and rinsing.

• Do not wash the recirculate air filter with any organic solvent, such as: gasoline, trichlene, paint thinner, etc.

6-34

BS06H207

1. RECIRCULATE AIR FILTER

Figure 79 2. FRESH AIR FILTER

b. With handle remove the fresh air filter (2) for inspection and cleaning or replacement. c. After cleaning or replacement, use this procedure in reverse for assembling.

2. Recirculate Air Filter a. Move floor mat on left front side of operator seat. b. Pull out recirculating air filter. c. After cleaning or replacement, use this procedure in reverse for assembling.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE RADIATOR CAP AND HOSES Inspect the radiator cap and hoses every 250 hours of engine operation.

b. Locate the radiator lower cover. Remove bolts and cover to obtain access to the radiator drain hose and lower hose.

3 2

1 1 Figure 80

BS07M108

1. RADIATOR HOSE CLAMP 2. RADIATOR CAP

Figure 82

BS07M109

3. RADIATOR HOSE

1. Stop the engine. Raise the engine cover and secure it open.

1. RADIATOR DRAIN VALVE

c. Place an empty clean container under the radiator drain hose. Do not contaminate coolant mixture drained, since it can be reused. d. Turn drain valve counter clockwise to drain coolant.

WARNING Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

2. Check the hoses for leakage due to loose clamps, or crack and worn hoses.

3. Tighten any loose clamps.

4. Should you need to replace any cracked or worn hoses, proceed as follows: a. Place a rag or paper towel on the radiator cap and slowly remove it to release the pressure.

e. Loosen the hose clamp and remove radiator hose. f. Clean the areas where the new hose will be connected. g. Remove the clamps (if reusing old clamps) from the old hose and install them to the new hose. h. Coat the inside ends of the new radiator hose with grease and install it. Tighten clamps properly. i. Fill radiator with coolant drained in step “c” if reusing old coolant mixture. j. Install radiator cap, start engine, and bring engine temperature to about 90°C (194°F). k. Run engine at low idle, check for leakages and repair as needed. l. Install radiator lower cover and close engine cover.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

5. Inspect radiator cap for proper operation and replace if needed.

1 Figure 81

BS07M109

1. RADIATOR LOWER HOSE

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE: FUEL FILTERS NOTICE: To replace the fuel filter and fuel pre-filter, perform the following instructions with the engine off.

1. Replacing Fuel Filter a. Place an empty container below fuel filters.

q. Lubricate O-ring for fuel filter bowl and attach to new fuel filter. r. Lubricate the O-ring seal with diesel fuel and install filter by hand (do not use wrench), and tighten 3/4 ~ 1 turn after the O-ring seal has made contact with support mount surface. s. Open fuel shutoff valve. t. Open air bleeder plug on top of filter support housing and use primer pump to fill filter with clean fuel.

1

2. Replacing Pre-Filter

2 1 2

Figure 83

BS06H084

1. FUEL FILTER

2. FUEL SHUTOFF

b. Close fuel shutoff valve.

Figure 85

BS06H084

m.Use a filter wrench and turn counter clockwise to remove the fuel filter. n. Remove O-ring seal from the filter support mount.

1. FUEL PRE-FILTER

2. FUEL SHUTOFF

a. Close fuel shutoff valve. b. Loosen air bleeder plug and drain valve and drain fuel from fuel pre-filter. c. Use filter wrench and turn counter clockwise to remove filter. d. With a clean, dry cloth, clean the filter support mount surface. e. Lubricate the O-ring with diesel fuel and install filter by hand, (do not use wrench), and tighten 3/4 to 1 turn after O-ring has made contact with support mount surface.

2 1

f. Tighten drain valve.

2

g. Open fuel shutoff valve. h. Open air bleeder plug on top of filter support housing and use primer pump to fill filter with fuel.

3

BS06H086

Figure 84 1. FUEL FILTER 2. O-RING

3. FUEL FILTER BOWL

o. Remove fuel filter bowl from bottom of filter. p. With a clean, dry cloth, clean the filter support mount surface.

6-36

WARNING Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1302

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Bleeding Air From Fuel System If air contaminates the fuel system, the engine may become hard to start or malfunction. Bleed the air whenever the water separator is drained, or the fuel filter elements are replaced.

CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS Change the travel reduction units oil on a new machine after the first 500 hours of engine operation.

Then change every 2000 hours.

WARNING

4

2

Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

WARNING 1 Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

3

M1302

1 Figure 86

BS06H087

1. FUEL FILTER 2. PRIMING PUMP

3. DRAIN VALVE 4. AIR PLUG

a. Loosen the air plug located on top of the fuel filter support mount. b. Push button by hand to supply fuel until air bubbles stop coming out of the air plug.

NOTICE: Use paper towel or rags to contain any fuel spill. c. Tighten the air plug when no more bubbles are present.

2 Figure 87

DC04C334

1. FILL/LEVEL PLUG

2. DRAIN PLUG

d. Continue pumping even after tightening the air plug. Stop pumping with the handle in the lower position and tighten the knob completely.

1. Move machine to a firm, level surface. Operate travel until “DRAIN” plug is positioned at 6:00 o’clock. Oil “FILL/LEVEL” plug should be on the top side at about 10:00 o’clock.

NOTICE: The air in the injection pump will automatically be forced out when the engine starts.

2. Stop engine and place an empty container under the drain plug.

e. Run engine at low idle for 5 minutes to check and make sure there is no fuel leakage.

WARNING Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE OIL IN SWING REDUCTION UNIT Change the Swing Reduction Unit oil on a new machine after the first 500 hours of engine operation.

Then, change every 2000 hours.

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

WARNING Figure 88

DC03N027

3. Remove oil “FILL/LEVEL”, and “DRAIN” plugs to drain oil into the container.

4. After oil has been drained out completely, clean “DRAIN” plug. Use teflon tape on “DRAIN” plug for additional sealing and install plug. Tighten securely.

Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1302

1. Move machine to a firm, level surface and place attachment on the ground. Stop the engine.

1 Figure 89

DC04C388

5. Add SAE 90W Gear oil through the oil “FILL/LEVEL” opening until oil starts flowing out of the port.

6. Clean oil “FILL/LEVEL plug. Use teflon tape on plug for additional sealing and install plug.

Tighten plug securely.

TRAVEL REDUCTION UNIT CAPACITY SK485LC-9: 15.0 liters (4.0 gal)

6-38

Figure 90

BS07M112

1. DRAIN PORTS

2. Locate drain ports under the center opening of the lower frame. Place an empty container under drain ports and remove plugs allowing oil to drain into container 3. Clean the drain plugs. Use teflon tape on plugs for additional sealing and install it. Tighten securely.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. Using the dipstick, confirm that the oil level is within the designated range.

1

6. Clean the fill plug. Use teflon tape on plug for additional sealing and install it. Tighten securely.

CHECKING AND CLEANING FUEL TANK AND STRAINER

Figure 91

BS07M112

1. DIPSTICKS

4. Remove the dipstick and fill the unit with oil.

NOTE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper capacities and oil specifications.

Swing Reduction Unit Capacity

DC04C387

Figure 93

1. Stop the engine. Use key switch and remove the fuel tank cap.

2. Check the cap seal and replace it if needed.

SK485LC-9: 7.0 liters (1.8 gal) x 2

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

WARNING Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1302

DC04C337

DC04C386

Figure 94

3. Remove the fuel tank strainer and clean it.

Replace the strainer if it is damaged.

4. Install fuel tank strainer and use the key switch to install the cap.

Figure 92

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE ENGINE RPM

4

3

1

Figure 97

DC04C384

RH11F028

2. Keep others clear of machine. Start the engine and set the engine to the High Idle position.

DC04C398

1. TEMPERATURE SETTING SWITCH 2. MAIN POWER SWITCH 3. COMPRESSOR SWITCH 4. AIR CAPACITY SELECTOR SWITCH

Figure 95

1. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system by pressing the switch located on the monitor.

2

3. Set machine to the conditions shown when checking the refrigerant.

• Air Conditioner ---------- ON • Fan Switch --------------- HI position (Max.) • Temp. Adjustment Switch -- Lower Temp • Door/window ------------ Close • Compressor Switch --- ON (The lamp lit up)

Figure 96

3. Press the Monitor’s display screen change switch ONCE to switch to the Tachometer Mode display.

4. Compare RPM value displayed on the LCD to the machine specifications. If RPM value differs from specification, contact your Kobelco Construction Dealer’s Service Department for assistance.

NOTICE: See SPECIFICATIONS Section for proper engine RPM specifications.

CHECKING THE AIR CONDITIONING REFRIGERANT 1. Keep others clear of machine. Start the engine.

2. Set the engine speed to the Middle speed position.

6-40

DC04C383

Figure 98

4. Check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver-dryer.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

Figure 99

BS07M100

1. SIGHT GLASS

a. Figure (A) shows that the refrigerant volume is proper. b. Figure (B) shows that the refrigerant is over charged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system. c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your Kobelco Construction Dealer.

NOTICE:

• New Refrigerant HFC-134a is used in this machine. Do not mix HFC-134a with CFC-12.

• Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

• Air Conditioning Unit should only be serviced by a qualified technician.

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE ENGINE VALVE CLEARANCE Check and adjust the engine valve clearance every 1000 hours of the engine operation. Contact your Kobelco Construction Dealer’s Service Department for assistance.

1

AIR CLEANER NOTE: The air restriction indicator will not signal if the element is torn or if the air cleaner compartment is not sealed properly. If “CLOGGED AIR FLTR” icon is displayed, inspect, clean, and/or replace the air cleaner elements.

1. Stop the engine. Open engine air cleaner access door. If door is locked use key switch key to unlock it.

2

Figure 102

DC04C290

1. WING NUT 2. AIR CLEANER INNER ELEMENT

4. Remove the wing nut and air cleaner inner element from the housing. ]

1

Figure 100

BD06H021

1. AIR CLEANER COVER

2. Remove air cleaner cover.

Figure 103

DC04C291

5. To clean the outer element, use compressed air less than 2.8 bar (40 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

WARNING Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

1

DC04C289

Figure 101 1. AIR CLEANER OUTER ELEMENT

3. Remove the air cleaner outer element from the housing.

6-42

6. After cleaning, use light to check the inside of the element for tear ing, pinholes, or cracking.

Replace with new element if necessary.

7. Assemble elements in the reverse order of disassembly.

NOTICE: Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element.

Failure to do so could cause engine damage.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER Change the hydraulic tank return filter on a new machine after the first 50 hours of engine operation then change every 1000 hours.

NOTICE: If Breaker is used replace return filter every 250 hours.

1 Figure 106

DC04B340

1. MOUNTING BOLTS Figure 104

DC04B674

1. Place the machine in the oil check position on a firm level surface.

NOTICE: Slowly remove the mounting bolts. The filter cover plate is under spring tension.

3. Remove the six mounting bolts from the hydraulic return cover plate.

WARNING Never change oil or filters on a machine that has just finished working. Allow sufficient time for the machine to cool down before performing any maintenance. Failure to comply could result in death or serious injury.

1 4 2

5 3 3 6

1 2 Figure 107

BS06H083

Figure 105

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

2. Stop the engine. Depress air release button to release hydraulic tank pressure.

1. BOLT 2. COVER PLATE 3. O-RING 4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

4. Remove O-ring, Spring, Bypass Valve, and Return Filters.

5. Install the new Return filters.

6. Install the Bypass Valve and spring.

7. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install the O-ring.

8. Install Cover Plate, Bolts, and Lock Washers.

Tighten the Bolts to torque Specification.

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE ENGINE COOLANT CHANGE WARNING: Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine.

Allow sufficient time for the engine to cool down before changing fluids.

Figure 110

BS07M110

3. Locate the lower cover beneath the radiator.

Figure 108

DC04B674

1. Move the machine to a firm level area and place the attachment on the ground and shut off the engine.

1 Figure 111

BS07M109

1

1. RADIATOR DRAIN VALVE

4. Remove cover to obtain access to the radiator drain hose. Place an empty container, with sufficient capacity for engine coolant, below the radiator drain hose. Turn valve counter clockwise to open drain.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

BS07M108

Figure 109 1. RADIATOR CAP

2. Stop the engine. Raise the engine cover, secure it open, and place a rag or paper towel on the radiator cap. Slowly remove the cap. The system could be under pressure.

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

6-44

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 11. Prepare a mixture of radiator detergent according to the manufacturing specs. and pour the solution into the radiator.

12. Repeat step 8 and start the engine, but run it at low idle for 30 minutes before draining and flushing.

13. After flushing is completed, use teflon tape on the engine drain plug for additional sealing.

Install plug and tighten securely.

14. Close the radiator drain valve.

1 Figure 112

DC04C310

15. Add a mixture of engine coolant according to specifications indicated in the ENGINE C O O L A N T M I X T U R E t a b l e . R e fe r t o LUBRICATION, FILTERS, AND FLUIDS section for proper system capacity.

1. BELLY PAN COVERS

ENGINE COOLANT MIXTURE

5. Remove the engine lower covers.

6. Locate the engine coolant drain plug. Remove it to drain coolant. Use a funnel with hose attached t o d i r e c t t h e d r a i n e d c o o l a n t t owa r d t h e container.

7. After draining, close the drain valve and install the drain plug. Fill cooling system with fresh water, preferable with hot water.

Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

• Change contaminated and foamy coolant with new coolant mixture as soon as possible.

• Cooling water other than long life coolant should be changed two times a year, in Autumn and Spring.

16. Install radiator cap. Start engine and run it at low idle for 5 minutes. Check and make sure there is no leakage.

17. Install engine and radiator lower covers. See Specification section for proper torque values.

18. Repeat steps 8, start the engine and run engine at high idle for 5 minutes to bleed out any air from the cooling system.

1

RH11F028

1

Figure 113

8. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system (1) by pressing the switch located on the lower side of monitor.

9. Keep others away from the machine. Start the engine and bring engine cooling temperature to about 90°C (194°F). Then run engine at low idle.

Remove engine drain plug, open radiator drain plug, and simultaneously feed fresh water into radiator until draining water comes out clear (about 10 minutes flushing is sufficient).

10. When flushing is completed, stop engine and also stop water feeding. Drain engine cooling system completely. Close drain valve and install drain plug.

BS06H211

Figure 114 1. ENGINE COOLANT RESERVOIR

19. Return throttle to low idle and stop engine. Wait about 3 minutes and check engine coolant reservoir for proper level.

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE HYDRAULIC OIL NOTICE: The following procedures are to be used for a normal oil change for the hydraulic tank oil only.

NOTICE: If it is necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure, or change main pump, contact an authorized Dealer’s.

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

M587

Figure 115

DC04B674

1. Move the machine to a firm, level surface with the attachment in the hydraulic oil check position.

Lower the attachment to the ground.

NOTICE: Warm up changing hydraulic oil.

hydraulic

system

before

2. Shut off the engine.

3. Turn the key switch to the ON position.

Figure 117

BS06H208

6. Move the attachment control levers several times.

4. DO NOT START THE ENGINE.

1

1

2 DC04A001

Figure 116 1. FUNCTION SAFETY LOCK LEVER

5. Make sure the function safety lock lever is in the unlock (down) position.

Figure 118

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

7. Depress air release button to release hydraulic tank pressure.

6-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

1

Figure 119

DC04B340

Figure 121

DC04C374

1. MOUNTING BOLTS

1. DRAIN PLUG

8. Slowly remove the six retaining bolts from the suction strainer cover plate.

11. Place a 300 liter (79 gal) empty container under the hydraulic tank drain plug. Remove plug and allow all oil from hydraulic tank to drain into container.

CLEANING SUCTION STRAINER

12. Remove return filters. See Figure 107, page 6-43.

1

3

13. After all oil has drained, carefully and thoroughly clean inside of hydraulic tank.

2 4

5

14. Install hydraulic tank drain plug and tighten securely.

15. Inspect return filter and oil for signs of abnormal wear.

16. Clean hydraulic tank covers, spring, and bypass valve.

17. Install new return filter elements along with the bypass valve and spring. See Figure 107, page 6-43.

6

NOTICE: Make sure to install the correct filter element for a Standard Excavator and for an Excavator with Nibbler and Breaker attachment.

Check Parts Catalog.

Figure 120

DC04C376

1. BOLT 2. LOCK WASHER 3. COVER

9. Remove cover, hydraulic tank.

4. O-RING 5. SUCTION STRAINER 6. STRAINER O-RING

O-ring,

and

strainer

from

10. Remove the O-ring from the bottom of the strainer.

DC04C373

Figure 122

18. Clean and inspect suction strainer for damage.

Replace strainer if needed.

6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

NOTICE: Use the same viscosity oil in the hydraulic tank as it was drained. Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper hydraulic oil.

3 2 4

5

NOTICE: Always use clean hydraulic oil. Avoid contamination during filling.

PILOT LINE FILTER Clean the pilot system filter/screen on a new machine after the first 50 hours of engine operations.

Then clean it every 2000 hours.

WARNING 6

Figure 123

DC04C376

1. BOLT 2. LOCK WASHER 3. COVER

WARNING: Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

4. O-RING 5. SUCTION STRAINER 6. STRAINER O-RING

19. Install a new O-ring seal on the strainer.

Lubricate seal with hydraulic oil and install strainer assembly onto suction tube.

20. Install a new O-ring on cover plate mount surface groove, lubricate seal with hydraulic oil.

1 2 Figure 125

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1. Depress air release button to release hydraulic tank pressure.

DC04C297

Figure 124

21. Fill hydraulic tank to proper level with fresh clean hydraulic oil through return filter cover.

22. Install suction strainer cover. Tighten the bolts.

Refer to SPECIFICATIONS Section in this manual for proper torque values.

23. Install new O-ring seal, lubricate it with hydraulic oil and install cover for hydraulic tank return filter e l e m e n t . T i g h t e n t h e b o l t s . R e fe r t o SPECIFICATIONS section in this manual for proper torque values.

6-48

1

BS07M111

1. PILOT SYSTEM FILTER

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Open side door on pump side of machine.

MAINTENANCE ON ROLLERS AND IDLERS

3. Remove hose from pilot line filter.

Change the oil in all rollers and idlers every 2000 hours of machine operation.

4. Clean filter with light oil.

NOTICE: Refer to the machine’s Service Manual for specific instruction regarding removing and installing the undercarriage rollers and idlers. Contact your Kobelco Construction Dealer’s Service Department for assistance if necessary.

5. Re-connect pilot line filter.

HYDRAULIC TANK BREATHER

1 2 Figure 126

DC04B339

DC04C371

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

1. Remove cap of the hydraulic tank breather and depress air release button to release hydraulic tank pressure.

Figure 128

1. Remove rollers and idlers as indicated in the Service Manual.

2. Remove side plugs from upper rollers cover plate and drain the oil into an empty container.

3. Remove plugs from track rollers center flanges and drain the oil into an empty container.

1 2 3 4 5 6 Figure 127

DC04C372

1. CAP 2. SEAL

3. COVER 4. FILTER

5. VALVE BODY 6. GASKET

2. Remove breather filter cover.

3. Remove old filter. Clean mounting surfaces and install new filter.

NOTICE: Refer to the Parts Catalog for the correct Filter Part Number.

4. Install breather filter cover.

5. Install cap and tighten securely.

DC04C370

Figure 129

4. Remove idlers and remove side plugs from idler h o u s i n g . D ra i n t h e o i l o u t i n t o a n e m p t y container.

5. Refill the upper rollers, track rollers, and idlers with clean oil and install the plugs.

6. Install rollers and idlers and torque properly.

Refer to SPECIFICATIONS Section for proper torque values.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper oil and capacity information.

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations. Failure to comply could result in death or serious injury.

1 1

CHANGE SWING RING GREASE

1

Figure 131

BS07M112

1. SWING MOTOR ASSEMBLY

Figure 130

DC04C369

1. SWING RING GREASE

Change the Swing Ring grease every 2000 hours of machine operation. To properly replace the grease, it is necessary to remove the upper frame. Refer to the Service Manual or Machine’s Shop Manual and/or contact your Kobelco Construction Dealer’s Service Department for assistance. Proper tools have to be used and specific instructions must be followed to disassemble the machine upper structure from the lower structure.

NOTICE: If the Swing Ring ever becomes submerged in water, it is mandatory that the swing ring grease be changed.

REFER TO LUBRICATION, FILTERS, AND FLUIDS SECTION FOR PROPER GREASE AND CAPACITY INFORMATION

6-50

If the machine is in the field and can’t be brought to a shop to replace the Swing Ring grease, proceed to remove the swing motor assembly. Use eye bolts on top cover of the swing motor and a proper lifting device to remove the Swing Motor Assembly. Use proper caps and plugs for lines and hoses that need to be removed during this process.

WARNING Lower and block attachment properly before removing swing motor reduction unit.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

PERIODICAL INSPECTION ITEMS Inspect dust seals in all pin connections frequently.

The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear.

DUST SEALS

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

1

7

6

8

5

9

2

4

3 Figure 132

DC04C367

1. BOOM FOOT DUST SEALS (2 PCS) 2. ARM TO BOOM DUST SEALS (2 PCS) 3. ARM TO IDLER LINK DUST SEALS (2 PCS) 4. BUCKET CYLINDER TO BUCKET LINK DUST SEALS (4 PCS) 5. ARM TO BUCKET DUST SEALS (2 PCS)

6. BOOM CYLINDER HEAD DUST SEALS (2 PCS) 7. BOOM CYLINDER ROD DUST SEALS (2 PCS) 8. ARM CYLINDER HEAD AND ROD DUST SEALS (4 PCS) 9. BUCKET LINK (AT BUCKET) DUST SEALS (2 PCS)

NOTICE: Refer to the Parts Catalog for replacement Dust Seals Part Number.

3

If excessive wear is found, refer to the Machine’s Sh op M anual or S er vi c e Ma nua l for sp ec if ic instructions in regards to disassembly and assembly.

Contact your Kobelco Construction Dealer’s Service Department for assistance if necessary.

Install the seals as shown. Make certain that the pin surface and tapered end are smooth and free from burrs or imperfections that could cause damage to the new seals.

1

2 DC04C366

1. DUST SEAL

Figure 133 2. BUSHING

3. BOSS

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BUCKET

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

1. Bucket, Arm, and Link Clearance Frequently check clearance between Bucket and Bucket Link and/or between Arm and Bucket to make sure it is within specifications. If clearance is greater than 1.2 mm (0.05”) adjust clearance. Proceed as follows to correct excessive play:

Figure 136

DC03K235

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove the load from pins. d. Carefully slide out, partially, main pins mounting arm and bucket link to bucket. e. Insert shims as needed to correct any excessive play. Refer to Parts Catalog for proper Part Numbers. f. Align the shims with pin holes and insert pins into position. Be careful not to damage the seals.

Figure 134

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

2 1 Figure 137

DC04C364

1. O-RING SEAL 2. RETAINING BOLT, NUT, AND JAM NUT

g. Install retaining bolt with nut and jam nut.

2 1 Figure 135

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, AND JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nut, nuts, and retaining bolt.

6-52

h. Roll O-ring onto the grooves between Bucket/Arm, and Bucket/Bucket Link.

NOTICE: Inspect O-rings for damage or excessive wear. If worn or damaged replace with new parts to protect the seals, pins, and surfaces from dirt and debris which can cause premature failure.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Reversing Bucket

Figure 140

DC03K232

Figure 138

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

f. Rotate bucket 180° or move machine.

1 2

2 1

Figure 141

DC03K233

1. ARM PIN FOR FRONT BUCKET OPERATION 2. ARM PIN FOR BACK HOE BUCKET OPERATION Figure 139

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, AND JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nuts, nuts and retaining bolts from both pins.

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

d. Carefully slide out main pins mounting arm and bucket link to bucket.

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove load from pins. e. Clean pins and pin holes, and apply grease on pins and holes surfaces.

g. Install arm and bucket link in their respective positions. h. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage the seals. i. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin. Be careful not to damage the seals.

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Removing the Bucket

2 1 Figure 142

DC04C364

Figure 144

DC04C363

1. O-RING SEAL 2. RETAINING BOLT, NUT, AND JAM NUT

j. Install retaining bolts with nuts and jam nuts on both pins.

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

k. Roll O-rings onto grooves between bucket/arm, and bucket/bucket cylinder link.

NOTICE: Slowly cycle bucket, check for interference with arm, particularly if a lifting eye is welded on bucket bottom. Be careful not to confuse the bucket shoveling operation with that of the backhoe.

2 1 Figure 145

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, RETAINING NUT, AND JAM NUT

b. Roll O-rings onto bucket bosses. c. Remove jam nuts, retaining bolts.

BS06H081

retaining

nuts,

and

Figure 143

NOTICE: Bucket can contact and damage cab when machine is equipped with certain attachments.

Check clearance between bucket and cab before operation. Exercise care when operating a bucket near cab.

DC03K235

Figure 146

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove load from pins.

6-54

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS d. Carefully remove main pins mounting arm and bucket link to bucket. Be careful not to damage the dust seals.

4. Installing the Bucket a. Make certain that the bucket is stable on firm level ground. b. Install O-rings onto bucket bosses. c. Clean pins and pin holes, and apply grease on pin and holes surfaces.

1

e. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin carefully to avoid damaging the seals. f. Install retaining bolts with nuts and jam nuts on both pins, leaving 1 mm gap between the nut and pin boss. g. Roll O-rings onto grooves between bucket/arm and bucket/bucket link. h. Apply sufficient grease to the bucket pin connections.

5. Bucket Teeth and Side Cutters Frequently, check bucket tooth points and side cutters for wear and looseness. The life of the bucket teeth and side cutters can not be determined by wor king hours, but rather by application and operating conditions.

WARNING

Figure 147

DC04C361

1. BUCKET LINK

To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

WARNING

a. Parts Description.

Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

6

B020A

d. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage seals.

1

4

7

3

1

2

5

Figure 149

DC03K237

3

1. ADAPTER NOSE 2. TOOTH POINT 3. RUBBER LOCK PIN 4. LOCKING PIN

2 Figure 148

DC03K236

5. SIDE CUTTER 6. CAP SCREW 7. NUT

NOTICE: Contact your Kobelco Construction Dealer for assistance in regards to parts for the specific bucket installed on your machine.

1. ARM 2. BUCKET 3. PIN

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS b. Replace the bucket teeth when their cutting edge and/or when hole for retaining pin on tooth are excessively worn.

c. Replacing the side cutters.

1 DC03K239

Figure 150

DC03K238

Figure 151

c.1 - Remove all sand and soil adhered around the side cutters capscrews. c.2 - Use an impact wrench to remove the capscrews, then remove the side cutters.

1. WOOD BLOCK

b.1 - Place a wood block under the bucket teeth support lip and remove all sand and soil adhered to the teeth pin connection areas. b.2 - Use a hammer and a punching tool to hammer out the locking pin. Be careful not to damage the rubber lock pin. b.3 - Inspect the locking pin and rubber lock pin. Replace them if the locking pin is too shor t or the rubber lock pin is in poor condition. b.4 - Clean the surface of the adapter nose with putty knife. b.5 - Fit tooth point onto adapter nose. b.6 - Push the rubber lock pin into the hole of the adapter nose. b.7 - Hammer the locking pin until it is aligned with the point surface.

6-56

DC03K240

Figure 152

c.3 - Clean the mounting surface and install a new side cutter with new cap screws and nuts. c.4 - Torque the cap screws with nuts to 100 ± 5 kgf·m (722 ± 36 ft-lbs).

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WINDSHIELD WASHER FLUID RESERVOIR

HYDRAULIC LINES, TUBES, AND HOSES

Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

S i n c e t h e r e i s n o d e f i n i t e t i m e t a bl e fo r t h e replacement of hydraulic lines, tubes, and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes, and hoses with new parts. Refer to the Parts Catalog for correct part numbers. when ordering.

1

BS06H101

Figure 153

1. WINDSHIELD WASHER FLUID RESERVOIR

1. Open engine air cleaner access door to locate washer fluid reservoir.

2. Pull cap off and fill with proper windshield washer fluid.

3. Replace cap and reposition engine air cleaner access door.

Do not bend, strike or damage high pressure lines.

Do not install bent or damaged lines, tubes, or hoses.

Replace all damaged lines, tubes, and hoses immediately to avoid any fire hazard.

Tighten all loose fittings and connections to the proper torque value.

Clean up all fuel and oil spills immediately to prevent fires, slipping, accidents, attachment dropping, etc.

Never use hands to check for leaks.

Carefully inspect all lines, tubes, and hoses for: 1. Fittings and connections damaged or 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 worn or damaged.

6. Loose fittings and connections.

Make certain all clamps, guards, and heat shields are in place and secured. This will help prevent vibration, excessive wear of components and excessive heat during operation.

1. Heater Hoses Inspect the heater hose between heater and engine for signs of damage and wear.

2. Boom Cylinder Hoses and Tubes

1 Figure 154

DC04C359

1. BOOM CYLINDER HOSES

Inspect boom cylinder head and rod hoses and tubes for damage, wear and loose connections

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Hydraulic Suction Tubes and Hoses

3. Arm Cylinder Hoses and Tubes

1

1 Figure 155

DC04C358

Figure 157

DC04C356

1. ARM CYLINDER TUBE AND HOSES

1. SUCTION HOSE

Inspect arm cylinder head and rod hoses and tubes for damage, wear and loose connections.

Inspect all hydraulic tubes and hoses for damage, wear and loose connections.

4. Bucket Cylinder and Nibbler/Breaker Hoses and Tubes

7. Rear View Mirrors.

1

2 Figure 156

DC04C357

1. BUCKET CYLINDER TUBE AND HOSES 2. NIBBLER/BREAKER TUBE AND HOSES

Inspect bucket cylinder head and rod hoses and tubes for damage, wear and loose connections.

Inspect also the Nibbler/Breaker tubes and hoses if equipped.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

6-58

DC04A040

Figure 158

Inspect the rear view mirror. Make certain both sides rear view mirrors and internal rear view mirror are in place, proper ly adjus ted, clean, and in good condition. If loose tighten the mounting hardware.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE FOR NIBBLER/BREAKER It is necessary to perform the following maintenance schedule in regard to Hydraulic Oil and Filters along with the normal inspection and maintenance.

2. Depress air release button to release hydraulic tank pressure.

REPLACEMENT SCHEDULE Item

Location

1st 2nd Regular Maintenance Maintenance Maintenance

Hyd. Oil Hyd. Tank

-

-

Every 600 Hours

Return Hyd. Tank Filter

50 Hours

250 Hours

Every 250 Hours

1

WARNING Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic components. Failure to comply could result in death or serious injury.

Figure 161

DC04B340

1. COVER MOUNTING BOLTS

WARNING Slowly remove the mounting bolts. The filter cover plate is under spring tension. Failure to comply could result in death or serious injury.

3. Remove the six mounting bolts from the hydraulic return cover plate.

Figure 159

DC04B674

1. Move machine to firm level ground and place attachment in oil level check position.

1 DC04B339

Figure 160 1. AIR RELEASE BUTTON

6-59

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1 4 2

5 3 3 6

Figure 162

BS06H083

1. CAP SCREW 2. COVER PLATE 3. O-RING

4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

4. Remove O-ring, spring, bypass valve, and return filter.

NOTICE: Make sure to use the correct return filter on machine using breaker. Refer to Parts Manual for correct part number when ordering parts.

5. Install the new return filter.

6. Install the bypass valve and spring.

7. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install O-ring.

8. Install cover plate, cap screws, and lock washers.

Tighten the cap screws to torque specification.

6-60

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL PROCEDURES COUNTERWEIGHT (OPTIONAL)

WARNING WARNING Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass. Failure to comply could result in death or serious injury.

Improper operation of the counterweight removal system can result in serious injury or death. Do not operate this system unless you have read and understand these instructions. If you have any doubt about your ability to perform these instructions, consult your authorized dealer.

W0038A

W0037A

COUNTERWEIGHT REMOVAL

1 Figure 164

DC04A001

1. SAFETY LOCK LEVER DC04B674

Figure 163

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground, and place the front attachments on the ground, the throttle control in low idle. Shut off the engine.

Place a Do Not Operate tag on the machine controls in a visible position.

2. Place the safety lock lever in the lock (UP) position before leaving the cab.

NOTICE: COUNTERWEIGHT MASS: 22,050 LBS. (10,002 KB).

6-61

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WARNING Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass. Failure to comply could result in death or serious injury.

W0037A

Figure 167

DMG1961

5. Open the pump compartment locate the connection for the remote controller cable. This is located below the solenoids. Remove the cover, and install the controller cable. Pass the cable beneath the door.

Figure 165

CTWBOLTS

3. Loosen the four bolts that hold the counterweight. Remove the bolts and store in a safe place. Start the engine and run at low idle.

4 IMG0189

Figure 168

6. Close all doors and access panels to prevent damage to doors when removing or installing the counterweight. Use care when closing rear door not to damage controller cable.

WARNING CTWSWITCH

Figure 166

4. Press the top of the counterweight removal installation switch. Located on the right console panel, this switch will activate the counterweight system. Make certain the safety lock lever is in the lock (UP) position, before leaving the cab.

NOTICE: Excavator functions are disabled when the counterweight switch is in the ON position.

Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

W0012A

WARNING Falling parts! Keep fingers and hands clear of mating surfaces of structure during counterweight removal and installation. Failure to comply could result in death or serious injury.

D0005A

6-62

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

2 3

2

Figure 171

CTWSWITCH2

Figure 169

CTWLOWER

1. EXTERNAL CONTROLLER 2. COUNTERWEIGHT TILT ROCKER SWITCH 3. COUNTERWEIGHT LIFT/HOIST SWITCH

9. Change the position of the Lift/Hoist Switch (3) to the tilt position and press the bottom of the Tilt Rocker Switch (2).

7. Using the external controller for the lifting system, change the position of the lift/hoist switch to the hoist position. Depress the top of the rocker switch to lift the counterweight cylinders.

Figure 172

DSCN1963

Figure 170

DSCN1964

8. Lift the counterweight all the way up until the lift cylinders reach their maximum height.

10. This will allow the counterweight cylinders to tilt down and separate the counterweight from the back of the machine. Make cer tain the tilt cylinder is fully retracted before lowering the counterweight.

WARNING 2

Falling parts! Keep fingers and hands clear of mating surfaces of structure during counterweight removal and installation. Failure to comply could result in death or serious injury.

D0005A

CTWSWITCHUP

Figure 173

11. Change the position of the of the Lift/Hoist switch to the down position and press the bottom of the rocker switch (2) in order to lower the counterweight.

6-63

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

4

DSCN1965

Figure 174

12. Lower the counterweight to the ground or transporting bed. Disconnect the counterweight by removing pins from the counterweight chain.

Install the pins back into the chain.

13. Use the external controller to reposition the cylinders and chain. Remove the exter nal controller and store securely in the compartment behind the operator’s seat. Close and secure the compartment access door.

WARNING WARNING: Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

W0012A

6-64

Figure 175

CTWSWITCH2

14. Deactivate the counterweight removal system by pressing on the bottom of the counterweight removal switch (4) located on the right console.

Turn the engine off.

WARNING Improper operation of the counterweight removal system can result in serious injury or death. Do not operate this system unless you have read and understand these instructions. If you have any doubt about your ability to perform these instructions, consult your authorized dealer.

W0038A

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS COUNTERWEIGHT INSTALLATION

WARNING Improper operation of the counterweight removal system can result in serious injury or death. Do not operate this system unless you have read and understand these instructions. If you have any doubt about your ability to perform these instructions, consult your authorized dealer.

W0038A

4 Figure 176

DC04B674

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground, and place the front attachments on the ground, the throttle control in low idle. Shut off the engine.

Place a Do Not Operate tag on the machine controls in a visible position.

CTWSWITCH2

Figure 178

3. Press the counterweight removal installation switch. Located on the right console panel, this switch will activate the counterweight system.

Make certain the safety lock lever is in the lock (UP) position, before leaving the cab.

NOTICE: Excavator functions are disabled when the counterweight switch is in the ON position.

1 Figure 177

DC04A001

1. FUNCTION SAFETY LOCK LEVER

2. Place the function safety lock lever in the lock (UP) position before leaving the cab.

WARNING Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass. Failure to comply could result in death or serious injury.

W0037A

DMG1961

Figure 179

4. Open the pump compartment locate the connection for the remote controller cable. This is located below the solenoids. Remove the cover, and install the controller cable. Pass the cable beneath the door.

NOTICE: COUNTERWEIGHT MASS: 22,050 LBS. (10,002 KB).

6-65

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2

3

Figure 180

IMG0189

5. Close all doors and access panels to prevent damage to doors when removing or installing the counterweight. Use care when closing rear door not to damage controller cable.

Figure 182

CTWSWITCH2

7. Change the position of the Lift/Hoist Switch (3) and press the bottom of the Tilt Rocker Switch (2) to tilt the counterweight cylinders all the way down.

WARNING WARNING: Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

2

W0012A

1

CTWSWITCHUP

2

CTWLOWER

Figure 181

1. EXTERNAL CONTROLLER 2. COUNTERWEIGHT TILT ROCKER SWITCH 3. COUNTERWEIGHT LIFT/HOIST SWITCH

6. Using the external controller for the lifting system, change the position of the lift/hoist switch to the tilt position. Depress the top of the rocker switch to lift the counterweight cylinders.

6-66

Figure 183

8. Lower the chains until they reach the counterweight lifting brackets. Change the position of the Lift/Hoist switch to the hoist position and press the lower side of the rocker sw i t c h ( 2 ) u n t i l t h e c h a i n s r e a c h t h e counterweight lifting brackets.

3

9. Install the chains to the counterweight lifting brackets and proceed to lift the counterweight up by depressing the upper side of the rocker switch.

10. Change the position of the Lift/Hoist switch to the tilt position and press the upper side of the rocker switch to tilt the counterweight cylinders back.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2

Figure 186

CTWBOLTS

Figure 184

CTWSWITCHUP

11. Change the position of the Lift/Hoist switch to the hoist position and press the lower side of the r ocke r sw itc h to l owe r t he c ou nte rwei gh t cylinders. Stop when the counterweight bottom levels with the upper sides of machines.

13. Clean the counterweight bolt threads and apply Loctite 242. Install the bolts and torque to 400 ± 40 kfg (2890 ± 290 ft lbs).

4

2

CTWSWITCH2

CTWSWITCHUP

Figure 185

12. Change the position of the Lift/Hoist switch to the hoist position and press the lower side of the rocker switch to lower the counterweight down until it sits securely on the upper frame of the machine.

Figure 187

14. Deactivate the counterweight removal system by pressing on the bottom of the counterweight removal switch (4). Turn the engine off. Remove the external hand control cable and store in the s torag e co mpa r tm ent lo c ated b ehi nd th e operator’s seat.

6-67

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MAINTENANCE

DSCN1963 DSCN1966

Figure 188

Al way s kee p th e c oun ter wei ght r emoval an d installation cylinders, pins, and bushings properly lubricated. Lubricate the counterweight cylinder pins and bushings each 500 hours of operation. Use extreme pressure multipurpose grease Number 2 to lubricate each pivot point (1-4).

6-68

Figure 189

Lubricate chains with a spray lubricant each 250 hours or monthly and each time the counterweight is installed. To lubricate the chains, raise the lift cylinders as directed in the removal/installation procedures, leaving some slack in the chains. Coat the chains with spray lubricant.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS B. Procedures

TRAVEL MOTOR BRAKES GENERAL The SK485LC-9 machine incorporate automatically applied spring brake systems in the travel motors and swing motor. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine. These sections contain the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachments to the ground should sudden engine failure be experienced.

1

WARNING

1 Figure 190

DC04C354

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

M1087

WARNING The procedures found in this section should be performed by a well trained experienced service technician who is familiar with machine. Failure to comply could result in death or serious injury.

M1087

RELEASING TRAVEL MOTOR BRAKES MANUALLY

1. CHOCK BLOCK

1. Position travel motors with drain plug down.

2. Lower attachment to ground. Refer to LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS in this section for proper procedures.

WARNING 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 Failure to comply could result in death or serious injury.

M110B.

A. Tools and Equipment Required

2. One (1) 14 mm Allen type socket wrench.

3. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

3. One (1) 8 mm Allen type socket wrench.

4. Turn key switch to OFF position and remove key.

4. Two (2) 15.0 liter (4.0 gal) capacity drain pans.

5. Place a clean 15.0 liter (4.0 gal) capacity drain pan under each travel motor drain plug.

1. Four (4) chock blocks.

5. Two (2) M10-1.5 x 30 mm lifting eyes.

6. Two (2) M12-1.75 x 20 mm Lifting eyes.

7. Overhead lifting device capable of lifting and holding 45 Kg (100 lbs).

8. Torque wrench 10~16 kgf·m (72~116 ft-lbs) capacity or better.

9. Thread sealant (for drain and check/fill plugs), and loctite #515 for cover bolts.

10. Rubber or soft face mallet.

DC03N027

Figure 191

6. Remove oil “FILL/LEVEL” and “DRAIN” plugs to drain oil into the container.

6-69

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS NOTICE: If the Reduction Unit drain plug is not at its lowest point (6:00 o’clock) for draining, drain as much oil as possible through the plug orifices, then:

1

2

3

1. CARRIER #2 2. SUN GEAR #2 3. SUN GEAR #1

Figure 192

• Loosen all cover bolts. Remove all but the top two bolts leaving them installed half way to keep the cover in place.

5 Figure 194

DC03M071

DC04C353

4

4. CARRIER #1 5. THRUST PLATE

9. Identify the internal parts of the Travel Reduction Unit.

1 Figure 195

DC04C351 DC04C352

Figure 193 1. THRUST PLATE

• Install the two (2) M10-1.5 x 30 mm threaded lift eyes into the holes provided.

• Attach the overhead lifting device to the lifting

10. Use the tip of a screw driver and remove the thrust plate.

eyes and remove most of the slack from the chain or cable.

• Remove the two cover bolts. Use a rubber mallet to strike the edge of the cover plate gently to help release it from the housing, until oil starts draining.

7. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine.

8. Remove the bolts holding the Reduction Unit cover and remove the cover. Be careful not to damage the cover plate seal or its surface lip.

1

DC04C350

Figure 196 1. CARRIER #1

6-70

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 11. Install the M10 eye bolt onto the Carrier #1 assembly and use the crane or lifting device hook on the eye bolt to pull out the carrier.

Remove most of the slack from the cable or chain. Work the carrier by hand to remove it.

1

WARNING Protect your hands from pinching at all times when removing or installing planetary gears. Failure to comply could result in death or serious injury.

2

M1087 DC04C347

Figure 199 1. SUN GEAR #1

1

2. CARRIER #1

If the Sun Gear can not be removed due to the loaded condition, remove it together with Carrier # 1.

Then remove the Sun Gear # 2 and Sun Gear # 1 respectively.

1 2 DC04C349

Figure 197 1. SUN GEAR #1

2. SUN GEAR #2

12. Remove the Sun Gear #1.

1 Figure 200

DC04C346

1. SUN GEAR COUPLING

2 Figure 198

DC04C348

1. SUN GEAR #2

2. CARRIER #1

1 Figure 201

DC04C345

1. SUN GEAR # 2

13. Make sure the gear coupling for Sun Gear # 1 and Sun Gear # 2 are properly installed

6-71

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 14. Reinstall Carrier # 1 assembly (DO NOT INSTALL SUN GEAR # 1) into reduction unit.

Remove the special eye bolt from the carrier assembly. Use plenty of grease on the thrust plate to hold it in place during assembly.

15. Install the cover plate onto reduction unit housing and tighten all bolts securely.

16. Install drain plug and refill reduction unit with drained oil.

17. Install the fill/level plugs.

18. Repeat steps 4~16 on the opposite travel reduction unit to prepare machine for towing.

19. After all repairs are made, reinstall Sun Gear # 1 on both reduction units in reverse order of removal. Make sure to use fresh gear oil. Refer to LUBRICATIO N, F ILTER, AND F LUIDS Chapter 5 for Oil specifications and Capacities.

NOTICE: Apply loctite 515 on cover bolts and torque to 7.5 kgf·m (54 lbf-ft). Use teflon tape on plugs and torque to 16 kgf·m (116 ft-lbs).

NOTICE: Avoid oil spills. Use containers, rags, and/or paper towel to contain any leakage. Dispose all waste oils, fluids, lubricants and other hazardous waste properly, according to government regulations.

1 Figure 202

DC04A001

1. FUNCTION SAFETY LOCK LEVER

20. Place the function safety lock lever in the UNLOCKED (down) position.

21. Sound horn to alert people in the area of machine movement.

22. Turn key switch to START position to use starter motor to rotate the engine.

NOTICE: Operate the Starter Motor in 20 second intervals and allow 3~5 minutes between intervals to allow the Starter Motor to cool.

LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS S h o u l d s u d d e n e n g i n e fa i l u r e o c c u r, fo l l o w procedures to place the attachment on the ground.

NOTICE: Rotation of the engine with the starter motor is necessary in order to lower the attachment to the ground. If rotation of the engine is not possible, contact an authorized Kobelco Construction service technician for service and assistance.

WARNING DC04C343

Make certain the area around the machine is clear of people and objects before attempting these procedures.

M1420

Figure 203

23. While engine is rotating, slowly and carefully move the RH control lever forward (boom down) and lower boom completely to the ground.

24. After Boom is completely down, leave the key switch in ON position, operate the arm, bucket and swing controls to release hydraulic pressure in these circuits. Turn key switch off.

6-72

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2

1 2 Figure 204

DC04B339

1

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

25. Locate hydraulic tank air breather on top of the hydraulic tank. Remove cap and depress air release button until all internal hydraulic tank pressure is released.

WARNING Use caution when removing or repairing hydraulic components as hydraulic pressure may exist or be trapped in circuits. Failure to comply could result in injury or death.

M1420

Figure 205

DC04C342

RELEASING SWING BRAKE MANUALLY WITH HYDRAULIC HAND PUMP

WARNING WARNING: Make certain that the attachment is on the ground to help prevent sudden rotation of the upper structure before attempting to release the swing brake. Refer to “Lowering Attachment When Sudden Engine Failure Occurs” in this section.

Failure to comply could result in injury or death.

1. SWING SHOCKLESS VALVE

Code

Name

Size

Torque Nm (kgf-m)

ft lbs

A, B

Main Port

2 - PF 3/4

167 (17)

123

M

Make-up Port

PF 3/4

167 (17)

123

DB

Drain Port

PF 3/8

74 (7.5)

55

PA, PB

Gauge Port

PF 1/4

36 (3.7)

27

PG

Brake Release Port

PF1/4

36 (3.7)

27

L

Gear Oil Level Port

PT 1/2

65 (6.6)

48

IP

Gear Oil Level Port

PT 3/4

98 (10)

72

M1420

Kobelco Construction highly recommends the use of a hydraulic hand pump to release the swing brake manually when the engine fails to start.

2. LIFTING BOLT HOLES

Remove the hose and install the proper connector on PG port.

Install the hydraulic hand pump to the PG port and apply 29 kgf/cm2 (413 psi) pressure.

6-73

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING SWING BRAKE MANUALLY WITHOUT HYDRAULIC HAND PUMP If a hydraulic hand pump is not available, and the contamination can be controlled easily, then proceed with the following procedures.

NOTICE: In highly contaminated environments it is recommended to remove the whole swing motor assembly. When the Swing Motor is removed, make sure to use caps and plugs on hoses, tubes, and fittings to protect the hydraulic system from any contamination. Also, a cover must be used to protect the Swing Gear compartment. If this approach is taken, and the swing gear grease bath becomes contaminated, make sure to flush and clean the swing gear compartment. Refer to LUBRICATIONS, FILTERS, AND FLUIDS Chapter 5 for proper grease and component capacity. Contact your Kobelco Construction Dealer’s Service Department for assistance.

A. Tools and Equipment Required 1. Hand tools required for removal of hydraulic tubes, hoses and fittings.

2. Plugs and caps for tubes, hoses and fittings.

3. 12 mm Allen type socket head wrench.

4. 5 mm allen type socket head wrench.

5. Two 20 M12-1.75 x 24 mm Lifting Eye. 6. Overhead lifting device capable of lifting and holding 100 kg (220 lbs).

7. Plenty of clean, dry shop rags and/or paper towels.

8. 17 mm Allen type socket head wrench.

9. 45 kgf·m (325 ft-lb) torque wrench.

6-74

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS B. Procedures 1. Lower attachment to ground and block to avoid sudden movement. Refer to previous pages for proper procedures in lowering the attachment.

1

1 2 Figure 208

DC03M072

1. LIFTING EYES

Figure 206

DC04C333

2. COVER BOLTS

4. Remove the two (2) plugs on top of the swing motor cover and install 2 x M12-1.75 x 24 mm eye bolts, and place a reference mark between top cover and housing.

1. SWING SHOCKLESS VALVE

2. Remove all hoses and tubes from the swing motor top plate and swing shock valves to gain access to the top mounting bolts.

NOTICE: Place a large quantity of clean, dry shop rags around the swing motor to help catch any overflow of hydraulic oil from the removal of the Top Plate.

5. Carefully loosen the four (4) top plate mounting bolts with the 17 mm socket head wrench.

6. Remove two (2) top plate mounting bolts from corners opposite of each other.

7. Attach overhead lifting device to the lifting eyes and remove most of the slack from the cable or chain.

8. Carefully remove the remaining two (2) bolts from the top mounting plate.

DC04B673

Figure 207

3. Install the proper plugs and caps onto hoses. tubes and fittings to avoid the possibility of contamination entering the hydraulic system.

NOTICE: The top plate will raise from spring pressure as the last two (2) bolts are removes. Some movement of the upper frame may be experienced as the spring tension is released.

NOTICE: Use only plugs and caps designed to properly seal the specific hose, tube or fitting they are to be installed on.

NOTICE: Do not allow any dirt or debris to enter the swing motor or settle on the top plate.

DC03M073

Figure 209

9. Using the overhead lifting device, carefully lift the swing motor top cover with swing shock valve assembly and away from the swing motor.

6-75

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 12. Carefully place the top plate over the swing motor and align the dowel pins of the top plate with the holes in the distributor plate. Slowly lower the top plate into position on the swing motor and install by hand the four (4) top plate mounting bolts

Figure 210

DC03M074

10. Carefully remove all brakes springs and place in a container filled with fresh, clean hydraulic oil.

T h e n , s e a l t h e c o n t a i n e r t o p r ev e n t contamination.

Figure 213

DC03M074

13. After the machine upper structure is positioned for towing, remove the swing motor cover again and reinstall the swing brakes springs.

1

1

2 Figure 211

DC03M075

1. DOWEL PINS

2. GREASE

11. Align the holes of the distributor plate in the swing motor until they are located toward the front and back of the swing motor housing. Use grease to hold the distributor plate on the top cover, aligned with dowel pins, before installing.

2

Figure 214

DC03M077

1. DOWEL PINS

2. GREASE

14. Repeat Steps 11~13 to lock the upper frame into position for proper transportation. Make sure to use grease to hold the distributor plate on top cover before installing.

NOTICE: Make certain the top plate dowel pins and the distributor plate holes mesh together.

DC03M076

6-76

Figure 212

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BLEEDING THE PILOT SYSTEM Whenever the hydraulic system is opened for repairs, pilot line change, etc., it is highly recommended that you bleed the pilot system to prevent erratic or delayed operation of the machine functions.

1

A. Tools and Equipment Required 1. A set of 1/2” drive metric sockets and wrenches including sizes 13~22 mm.

2. A 1/2” drive ratchet wrench.

3. Sufficient rags and paper towels.

B. Bleeding Procedure Figure 217

DC04C341

1. MAIN CONTROL VALVE COVER

3. Use a 19 mm wrench and remove the main control valve cover.

4. Make sure that the throttle control is positioned in LOW idle and sound horn before starting.

5. Start the engine and let run at low idle for about 10 minutes.

NOTICE: Use a rag or paper towels on the pilot connections to protect yourself from spraying during bleeding.

Figure 215

DC04B674

1. Place the machine on firm level ground and the attachment in oil level check position.

1

DC04B339

Figure 216 1. AIR RELEASE BUTTON

2. Depress air release button to release hydraulic tank pressure.

DC04C339

Figure 218

6. With the engine running at low idle, loosen the pilot lines from the top side of the spools in the Control Valve, one at a time, and operate the function for the spool being bled to bleed the air out of the pilot system. Make sure to bleed each one of the spools indicated in the figure. Tighten hose connections to 50 Nm (37 ft-lb) after bleeding each line.

7. Make sure hydraulic oil level is within specifications, and clean up any oil spilled.

Check all connections, repair any leakage and reinstall control valve top cover.

6-77

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-78

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL COMPONENTS ALTERNATOR Ask your Dealer to check the Alternator.

1

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

FUSES NOTICE: Fuses are also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Follow this procedure to replace “blown” or “faulty” fuses.

1. Move seat and seat base completely forward.

Figure 1

BS06H104

1. FUSE BOX COVER

2. The fuse box cover is located on the rear side of the operator’s seat. Loosen screws used to install the cover.

3. Remove the cover of the fuse box by pressing the lock of the cover inward to unlock then lift and remove cover.

4. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

WARNING Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

Failure to comply could result in death or serious injury.

M1728

5. Refer to fuse box cover or Figure 2 for fuse amperage and their functions.

7-3

CHAPTER 7 - ELECTRICAL

BS06H108

Figure 2

BS06H110

Figure 3

7-4

CHAPTER 7 - ELECTRICAL BATTERIES NOTICE: Batteries is also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

.

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

M144C

Figure 5

BS06H237

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

WARNING

BS06H238

Figure 4

1. Batteries are located on the left side of the machine in the air filter compartment.

Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

84-109

7-5

CHAPTER 7 - ELECTRICAL 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTICE: Use hydrometer manufacturer’s instruction.

according

to

its

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

2

1

BS06H238

Figure 6

1. POSITIVE (+) BATTERY CABLE 2. NEGATIVE (-) BATTERY CABLE

7. When disconnecting batteries, remove the negative (-) cable first. W hen connecting batteries, connect the negative (-) cable last.

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps. c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

NOTICE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

7-6

NOTICE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS SK485LC-9 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Working Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Digging Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Attachment Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Bucket Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 SK485LC-9 PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Travel Speed, Swing Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Standard Lift - Machine with 2.40 m Arm, 4.21 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-11 Heavy Lift - Machine with 2.40 m Arm, 4.21 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-11 Standard Lift - Machine with 3.00 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-12 Heavy Lift - Machine with 3.00 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-12 Standard Lift - Machine with 4.90 m Arm, 1.40 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-13 Heavy Lift - Machine with 4.90 m Arm, 1.40 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-13 Standard Lift - Machine with 4.04 m Arm, 1.40 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-14 Heavy Lift - Machine with 4.04 m Arm, 1.40 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-14 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-15 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-15 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Capscrews and Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Nuts and Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Torque Values For Most Common Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

CHAPTER 8 - SPECIFICATIONS

SK485LC-9 GENERAL SPECIFICATIONS The specifications found in this section are given on the Standard SK485LC-9 Hydraulic Excavator as manufactured by Kobelco Construction: Boom 7.0 m (23’ 0”), Arm 3.45 m (11’ 4”), and 1.8 m3 (2.35 yd3) SAE Bucket. No modification or options are taken into consideration in regard to these specifications. * Dimensions are not inlcuded in height of shoe lug.

MACHINE DIMENSIONS

Figure 1

RH11F054

Item

Unit

mm (ft-in)

A

Overall Length

12,040 (39-6)

B

Overall Height

3,600 (11-10)

C

Overall Width of Crawler

3,650 (11-12)

D

Width of Crawler Shoe

900 (35.4)

E

Height to top of Cab

3,370 (11-1)

F

Ground Clearance of Under Carriage

510* (20.1)

G

Radius of Rear End

3,700 (12-2)

H

Overall Length of Crawler

5,450 (17-11)

I

Center Distance of Tumblers

4,400 (14-5)

J

Ground Clearance of Rear End

1,340* (4-5)

WORKING WEIGHT Type Use

Grouser Shoes 900 mm (35.4”) For General Soil (Standard)

Working Weight - kg (lbs)

50,700 (111,790)

Ground Pressure - kpa (psi)

83 (12.0)

8-3

CHAPTER 8 - SPECIFICATIONS DIGGING FORCES ARM LENGTH SAE Rating

3.45 m (11’ 4”)

4.04 m (13’ 3”)

4.9 m (16’ 1”)

Bucket Digging Force

*255.8 kN (57,500 lbs)

233.5 kN (52,500 lbs)

233.5 kN (52,500 lbs)

Arm Crowding Force

*214.0 kN (48,100 lbs)

175.7 kN (39,500 lbs)

153.0 kN (34,400 lbs)

* Power boost engaged

ARM LENGTH 3.45 m (11’ 4”)

4.04 m (13’ 3”)

4.9 m (16’ 1”)

Bucket Digging Force

289 kN (64,998 lbs)

264 kN (59,346 lbs)

264 kN (59,346 lbs)

Arm Crowding Force

221 kN (49,687 lbs)

181.5 kN (40,804 lbs)

158.1 kN (35,535 lbs)

ISO Rating

* Power boost engaged

8-4

CHAPTER 8 - SPECIFICATIONS ATTACHMENT WORKING RANGES

Figure 2

RH11F055

ARM 11’ 4” (3.45 m) 2.48 yd 3 (1.9 m3)

Units: ft-in (m) Machine equipped with 2.48 yd3 (1.9 m3) Bucket WORKING RANGES (SK485LC-9) A

Maximum digging reach

A’

Maximum digging reach at ground level

38’ 10” (11.84 m)

*B

Maximum digging depth

25’ 7.5” (7.81 m)

*C

Maximum digging height

35’ 10” (10.93 m)

*D

Maximum dumping clearance

24’ 10.4” (7.58 m)

*E

Minimum dumping clearance

9’ 1” (2.77 m)

*F

Maximum vertical wall digging depth

23’ 4” (7.12 m)

G

Minimum front swing radius

16’ 10” (5.14 m)

*H

Height at minimum swing radius

29’ 8” (9.05 m)

*J

Digging depth for 8’ (2.4 m) flat bottom

25’ 2” (7.66 m)

K L

Stroke

20’ (6.10 m)

Minimum

9’ 10” (3.0 m)

Horizontal digging stroke at ground level

8-5

CHAPTER 8 - SPECIFICATIONS BUCKET SELECTION CHART SK485LC-9 Bucket Selection Chart

Application

General Purpose

Heavy Duty

Severe Duty

Capacity yrd3 (m3)

Width inches (m)

Weight lbs (kg)

1.5 (1.146)

30 (0.762)

2.0 (1.529)

36 (0.914)

2.375 (1.815)

Arm 3.47 m (11’ 4”)

4.05 m (13’ 3”)

4.90 m (16’ 1”)

3,640 (1,651)

H

H

H

2,825 (1,281)

H

H

M

42 (1.066)

3,035 (1,377)

H

H

L

2.75 (2.102)

48 (1.219)

3,225 (1,643)

H

M

X

3.125 (2.389)

54 (1.37)

3,380 (1,533

M

L

X

3.5 (2.675)

60 (1.52)

3,625 (1,644)

L

X

X

1.5 (1.146)

30 (0.762)

2,840 (1,288)

H

H

H

2.0 (1.529)

36 (0.914)

3,040 (1,379)

H

H

M

2.375 (1.815)

42 (1.066)

3,265 (1,481)

H

M

L

2.75 (2.102)

48 (1.219)

3,470 (1,574)

H

L

X

3.125 (2.389)

54 (1.37)

3,635 (1,649)

M

X

X

3.50 (2.675)

60 (1.52)

3,895 (1,767)

L

X

X

1.5 (1.146)

33 (0.838)

3,155 (1,431)

H

H

M

1.75 (1.337)

36 (0.914)

3,300 (1,497)

H

M

L

2.125 (1.624)

42 (1.066)

3,640 (1,651)

H

L

X

2.5 (1.911)

48 (1.219)

3,950 (1,792)

M

X

X

3.0 (2.293)

58 (1.473)

4,475 (2,030)

L

X

X

H - Used with material weight up to 1,780 kg/m3 (3,000 lb/yrd 3).

M - Used with material weight up to 1,483 kg/m3 (2,500 lb/yrd3).

L - Used with material weight up to 1,186 kg/m3 (2,000 lb/yrd3).

X - Not recommended.

ARM

DC04B663

BUCKET

Figure 3

Figure 4

DC04B664

3

3

Standard Arm is 3.45 m (11’ 4”)

Standard Bucket is 1.90 m (2.48 yrd )

A - Total length is 4.71 m (15’ 5”)

A - Length is 1.85 m (6’ 1”)

B - Total height is 1.60 m (5’ 3”)

B - Height is 1.49 m (4’ 9”)

C - Width is 0.65 m (2’ 1”)

D - Width with side cutters is 1.67 m (5’ 5”)

Weight - Approximately 2,610 kg (5,754 lbs)

Weight - Approximately 1,510 kg (3,329 lbs)

8-6

CHAPTER 8 - SPECIFICATIONS BOOM

SHOES

1 2

Figure 5

DC04B662

1. ARM CYLINDER BOSS

2. GROUND LEVEL

Standard Boom is 7.0 m (23’ 0”) A - Length is 7.0 m (23’ 0”)

DC03K215

Figure 6

1. Standard Shoes for SK485LC-9 are 35.4” (900 mm) triple grouser.

Height of grouser: 1.18” (30 mm).

Center line to center line of pins.

B - Height is 1,190 mm (78.3”) From center line of boom end to center line of arm cylinder boss.

C - Width is 930 mm (36.6”) From edge to edge of boom foot.

Weight - Approximately 4,650 kg(10,251 lbs)

8-7

CHAPTER 8 - SPECIFICATIONS

SK485LC-9 PERFORMANCE SPECIFICATIONS The following performance specifications are based on the standard machine with standard attachment.

TRAVEL SPEED, SWING SPEED AND GRADEABILITY SK485LC-9 Travel Speed

5.4 km/hr (3.5 mph) in high speed 3.4 km/hr (2.2 mph) in low speed

Swing Speed

9 RPM in M-Mode/High Idle

Gradeability

70% (35°) Limited by engine lubrication

Drawbar Force

403 kN (90,600 Lbf)

ENGINE Engine Make

HINO

Model

P11C-VC

Type

Diesel - 4 cycle, water cooled, direct injection with intercooler and turbocharger

No. of Cylinder - Bore x Stroke

6 cyl. - 122 mm x 150 mm (4.80” x 5.90”)

Displacement

10.520 Liters (642 cu. in)

Output Rating

257 kW (345 HP) @ 2,000 rpm

Maximum Torque

1400 N·m (1032 Lb-ft) @ 1,400 rpm

Cooling System

Circulating by a centrifugal pump.

Lubrication System

Pressurized oil fed by a gear pump.

Air Cleaner

Dry type with safety element

Electric System

24 V DC

Starting Motor

24 V - 5.0 kW

Alternator

24 V - 60Amps

Batteries

2 x 12V - (136 AmpHr)

Cold Start Assist

Electric Type

Engine Dry Weight

1150 kg (2,535 lbs)

Cooling Fan Drive Method

Suction type - 6 blades 850 mm Dia. (33” dia). Drive pulley ratio: 1.0

ENGINE SPEED ENGINE SPEED Low Idle

1,600 RPM

High Idle

2,100 RPM

8-8

CHAPTER 8 - SPECIFICATIONS

HYDRAULIC COMPONENTS Hydraulic Pumps

2 x 370 l/min. (2 x 97.7 gpm) Tandem, variable displacement axial piston pump with 30.0 l/min. (7.9 gpm) Pilot Gear Pump at 4.9 MPa (710 psi).

Swing Motor

Axial piston, fixed displacement 179 l/min. (47 gpm) @ 27.9 MPa (4,050 psi)

Travel Motors

Axial piston, variable displacement. Max. displacement of 210 l/min (55 gpm) at 35.8 MPa (5,200 psi), 32.8 rpm in high speed and 48.8 rpm in low speed.

Control Valve

6 spools in the main control valve

Cylinders (All)

Double action

Oil Filtration

Hydraulic oil filtration is performed through a replaceable element and a suction strainer.

Oil Cooler

Air forced ventilation through finned tubbing.

OPERATING PRESSURES Pilot System

50 (710)

Implement

314 (4550)

Swing

255 (3700)

Travel

343 (4980) 343 (4980)

Power Boost/Heavy Lift Units: kgf/cm2 (psi)

8-9

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radius and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

5. Capacities apply to the machine as originally manufactured and normally equipped by Kobelco Construction.

Lifting Capacities Chart Legends:

A - Reach swing center line to bucket hook (Load Radius).

B - Bucket hook height above/below ground.

C - Lifting capacities in pounds (lb) and kilograms (kg).

Front Lifting.

8-10

Side Lifting.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. example: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the Lifting Chart accordingly.

2. If a bucket is changed for a larger bucket, which weight is 350 kg (770 lbs) more than the bucket indicated in the Lifting Chart, then you have to subtract this additional weight from every value indicated in the Lifting Chart accordingly.

3. If a bucket is changed for a smaller bucket, which weight is 350 kg (770 lbs) less than the bucket indicated in the Lifting Chart, then you can add 350 kg (770 lbs) to every value indicated in the Lifting Chart accordingly.

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 2.40 M ARM, 4.21 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

HEAVY LIFT - MACHINE WITH 2.40 M ARM, 4.21 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-11

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 3.00 M ARM, 1.91 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

HEAVY LIFT - MACHINE WITH 3.00 M ARM, 1.91 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-12

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 4.90 M ARM, 1.40 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

HEAVY LIFT - MACHINE WITH 4.90 M ARM, 1.40 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-13

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 4.04 M ARM, 1.40 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

HEAVY LIFT - MACHINE WITH 4.04 M ARM, 1.40 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-14

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 3.45 M ARM, 1.91 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

HEAVY LIFT - MACHINE WITH 3.45 M ARM, 1.91 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-15

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

CAPSCREWS AND NUT METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES Make certain to tighten all Capscrews and Nuts to proper torque values.

Metric Coarse Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

1.77 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (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 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 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)

23 ± 2 (166 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50.5 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

TORQUE VALUE UNIT: kgf-m (ft-lbs)

8-16

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES Tighten all Capscrews and Nuts to proper torque values.

Metric Fine Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M8

P=1

1.15 0.11 (8.3 ± 0.8)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190)

212 ± 21 (1530 ± 150)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ±43 (3090 ± 310)

357 ± 36 (2580 ± 260)

TORQUE VALUE UNIT: kgf-m (ft-lbs)

ORS JOINT (O-RING SEALING TYPE) ORS Joint (O-ring Sealing Type)

Hose mouth ring and Coupling

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf-m (ft.-lbs)

1 - 14 UNS

30 - 32

14 ± 1.4 (101 ± 10)

1 - 3/16 12 UN

36 - 41

18 ± 1.8 (130 ± 13)

1 - 7/16 12 UN

41 - 46

21 ± 2.1 (152 ± 15)

WORKING PRESSURE kgf/cm2 (psi) 350 (4980) 385 (5475) Power Boost

8-17

CHAPTER 8 - SPECIFICATIONS NUTS AND SLEEVES Nuts and Sleeves

MANUFACTURER’S NAME

WORKING PRESSURE kgf/cm2 (psi)

350 (4980) Travel line only

NIPPON A.M.C.

350 (4980) Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS Flare Type Fitting Joints

TUBE SIZE O.D. X THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE kgf-m (ft.-lbs)

10 X 1.5 (0.394 X 0.059)

19

4.5 ± 0.5 (33 ± 4)

15 X 2.0 (0.591 X 0.079)

27

15 ± 2 (108 ± 14)

18 X 2.5 (0.709 X 0.098)

32

18 ± 2 (130 ± 14)

22 X 3.0 (0.866 X 0.118)

36

22 ± 2 (159 ± 14)

28 X 4.0 (1.10 X 0.157)

41

28 ± 3 (203 ± 22)

35 X 5.0 (1.38 X 0.20)

55

35 ± 4.5 (253 ± 29)

N2 (NYLON) TUBE FITTING JOINTS N2 (Nylon) Tube Fitting Joints

Overtightening of flare type (Union Nut Type) metal joints may cause damage to nuts, seat surfaces, and prevent optimum sealing resulting in oil leaks.

NOMINAL SIZE (PIPE THREAD)

TORQUE VALUE

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”

14 ± 1.4 (101 ± 10)

1-1/4”

17 ± 1.7 (123 ± 12)

1-1/2”

21 ± 2.1 (152 ± 15)

2”

42 ± 4.2 (304 ± 30) Unit: kgf-m (ft.-lbs)

8-18

1. Clean Tube and make sure certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

CHAPTER 8 - SPECIFICATIONS TORQUE VALUES FOR MOST COMMON BOLTS [Bolt Size] Units: kgf-m (ft-lbs) Location

Qty

SK485LC-9

5

Fuel Tank sending unit mounting

[M5] 0.2 ± 0.01 (1.4 ± 0.1)

6

A/C condenser mounting

[M6x50] 0.46 (3.3)

1

Hyd. tank sending unit mounting

15 ± 2 (108 ± 14)

6

A/C pulley mounting on damper

[M8x16] 4 (29)

4

Coolant reservoir mounting

1.1 ± 0.1 (8 ± 0.7)

4

A/C compressor mounting

[M8x100] 1.1 ± 0.1 (8 ± 0.7)

1

A/C idler pulley nut

[M10] 4 - 5.5 (29 - 40)

2

Pilot pump mounting bolts

[M10] 4 ± 0.4 (29 ± 3) Apply Loctite # 262

8

Hydraulic oil tank cover mounting

[M10] 4.7 ± 0.6 (34 ± 4)

2

Swing grease bath inspection cover mounting

[M10} 3 ± 0.6 (22 ± 4)

8

Swivel joint dust cover mounting

[M10} 1.5 ± 0.3 (11 ± 2)

6

Muffler support bracket mounting

[M10] 4 ± 0.4 (30 ± 3)

16

Engine mounting (engine body side)

[M10] 6.6 ± 0.4 (48 ± 3) Apply Loctite # 262

4

Travel lever mounting

[M10] 2.4 ± 0.3 (17 ± 2)

3

Stepping motor mounting

[M10] 1.9 (14) Apply Loctite # 242

12

Hydraulic pump housing to engine block mounting

[M10] 6.6 ± 0.6 (48 ± 4) Apply Loctite # 262

35

Lower cover mounting

[M10] 5.3 ± 0.6 (38 ± 4)

2

A/C compressor cover mounting

[M10x45] 6.2 (45)

10

Travel motor cover mounting

8.4 ± 0.8 (61 ± 6) Apply Loctite # 262

16

Cab support mounting bolts

4.7 (34)

3

Swivel joint mounting

11 ± 1 (79 ± 7) Apply Loctite # 262

4

Nuts for cab mounts

19 (137)

4

Idler and idler adjuster connection

[M16] 28.5 ± 3 (206 ± 22) Apply Loctite #262

4

Hydraulic oil tank and fuel tank mounting

[M16] 22 ± 2 (159 ± 14) Apply Loctite # 262

4

Radiator bottom support mounting

[M12] 12.3 ± 1.2 (89 ± 9)

1

Swivel joint locking nut

[M16] 15.9 ± 2 (115 ± 14)

8

Hydraulic pump coupling mounting

[M16] 22 ± 1 (159 ± 7) Apply Loctite # 262

8

track guide mounting

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Engine mounting (Upper frame side)

[M18] 23 ± 2 (166 ± 14) Apply Loctite # 271

44

Sprocket mounting

[M18] 40.4 ± 4(292 ± 29) Apply Loctite # 262

56

Lower roller caps

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Hydraulic pump mounting

[M20] 44 ± 4 (318 ± 29) Apply Loctite # 262

12

Swing reduction unit mounting

[M20] 55 ± 6 (397 ± 43) Apply Loctite # 262

36

Swing bearing inner race mounting

[M20] 57.4 ± 5.8 (415 ± 42) Apply Loctite # 262

33

Swing bearing outer race mounting

[M20] 40 ± 4 (289 ± 29) Apply Loctite # 262

184

Shoe bolt mounting

[M20] 86.8 ± 5 (628 ± 36)

4

Upper roller mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

34

Travel motor mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

4

Counterweight mounting

130 ± 13 (939 ± 94) Apply Loctite # 242

8

Side cutter mounting

[M24] 95 - 105 (686 - 758)

8-19

CHAPTER 8 - SPECIFICATIONS [Bolt Size] Units: kgf-m (ft-lbs) Location

Qty

SK485LC-9

2

Idler adjuster grease fitting mounting

[5/8”-18UNF] 5.9 ± 1 (43 ± 7)

2

Connector for heater hoses

2.5 (18) Apply three bond # 1110B

1

Nut on breather valve

1 - 1.4 (7 - 10)

4

Breather mounting bolts

0.48 (3.5)

1

Hydraulic tank plug

16.5 (119) Apply teflon tape

4

Top nuts for U-bolts muffler mounting

1.1 ± 0.1(8 ± 1)

4

Bottom nuts for U-bolts muffler mounting

0.9 ± 0.1 (6.5 ± 1)

1

Engine temperature sensor

2.5 ± 0.6 (18 ± 4) Apply three bond # 1110B

2

A/C hose connection on Compressor

2.4 ± 0.2 (17 ± 1.4)

2

A/C hose connection on Condenser

1.0 ± 0.1 (7.2 ± 0.72)

4

Cover mounting on swing motor

[M20] 43.8 (317)

1

Swing reduction unit oil plug

5.7 (41) Apply teflon tape

2

Oil plugs on travel reduction unit cover

5.7 (41) Apply teflon tape

WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m 3

Wood chips

700

420

Peat, dry

750

440

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted and broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

Material (Loose Weight)

8-20

CHAPTER 8 - SPECIFICATIONS SOME CONVERSION UNITS

UNITS OF PRESSURE

UNITS OF WEIGHT

Units of Pressure Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm

2

Bars

UNITS OF LENGTH psi

From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

0.0703

Pa (Pascal)

6894.76

psi

145.04

kg/cm

Units of Length

0.06895 2

MPa (MegaPascal)

UNITS OF VOLUME

UNITS OF POWER

Units of Volume From

Units of Power

Into

Multiply by

From

Into

Multiply by

Gal (US Liquid)

0.264

HP

kW

0.7457

in3

61.02

kW

HP

1.341

yard 3

0.00131

quarts

1.0567

ounces (US)

33.81

m3

0.765

3

46656

ft3

27

cm3

764554.9

liters

764.555

Liters

UNITS OF FLOW Units of Flow Into

From

Lit/min Gal/min (US liquid)

Liter/min

Lit/sec

Multiply by

in

3.79 0.0631

cm3/min

3785.4

ft3/min

0.1337

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

Yard

3

UNITS OF TORQUE Units of Torque From

N-m

lbf-ft

Into

Multiply by

lbf-ft

0.738

kgf-m

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgf-m

0.1382552

N-m

1.35582

lbf-in

12

8-21

CHAPTER 8 - SPECIFICATIONS

NOTES

8-22

CHAPTER 9 - INDEX

Chapter 9

INDEX Symbols “Tag-Out” Machine .............................................. 6-6

A Air Cleaner ......................................................... 6-42 Air Conditioning Compressor Belt ..................... 6-34 Air Intake System .............................................. 6-25 Alternator ............................................................. 7-3 Arm ...................................................................... 8-6 Arm Cylinder Hoses and Tubes ......................... 6-58 Arm Operation ................................................... 4-16 Arm Rest Adjustment ........................................... 3-7 Attachment Lubrication ...................................... 6-22 Attachment Working Ranges ............................... 8-5 Auto Warm Up ..................................................... 4-8

Checking and Cleaning Fuel Tank and Strainer .6-39 Checking Swing Gear Attaching Bolts for Proper Torque ..........................................................6-30 Checking the Air Conditioning Refrigerant .........6-40 Checking the Engine RPM .................................6-40 Checking the Radiator Cap & Hoses ..................6-35 Cleaning Parts ......................................................6-7 Cleaning Sand & Soil from Bucket .....................4-19 Cleaning Suction Strainer ...................................6-47 Climatizer - AC Unit Filter Inspection .................6-34 Components & Controls Nomenclature ..............3-12 Connecting Booster Cable ...................................4-6 Control Decal ......................................................4-10 Control Lever Joint Lubrication ...........................6-31 Counter Rotating Machine ..................................4-14

B

D

Back Filling & Leveling with Front Attachment .. 4-20 Basic Operation of Hydraulic Controls ............... 4-11 Batteries ..................................................... 6-27, 7-5 Before Operating the Hydraulic Breaker ............ 4-24 Before Operating the Machine ............................. 4-3 Bleeding the Pilot System .................................. 6-77 Boom ................................................................... 8-7 Boom & Arm ...................................................... 6-21 Boom Cylinder Hoses and Tubes ...................... 6-57 Boom Operation ................................................ 4-15 Bucket ......................................................... 6-52, 8-6 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes 6-58 Bucket Operation ............................................... 4-16 Bucket Selection Chart ........................................ 8-6 Bucket Selection Guide ..................................... 4-22 Bucket Teeth and Side Cutters .......................... 6-55 Bucket Teeth Direction ...................................... 4-19 Bucket, Arm, & Link Clearance .......................... 6-52 Burn Prevention ................................................... 2-9 Buzzer Stop Switch ........................................... 3-14

Decals ................................................................2-11 Digging Forces .....................................................8-4 Disposal of Hazardous Waste ..............................6-6 Document Pouch ..................................................3-6 Dust Seals ..........................................................6-51

C Cab Dome Light ................................................... 3-5 Cab Door Latch ................................................... 3-3 Change Hydraulic Oil ......................................... 6-46 Change Oil in Swing Reduction Unit ................. 6-38 Change Oil in Travel Motor Reduction Units ..... 6-37 Change Swing Ring Grease Bath ...................... 6-50 Check Swivel Valve for Leakage ....................... 6-30

E Engine .......................................................... 1-4, 8-8 Engine Accessory Belt Wear and Tension 6-28, 6-33 Engine Coolant Change .....................................6-44 Engine Coolant Level .........................................6-14 Engine Coolant Tank & Engine Air Cleaner Access Doors .............................................................3-9 Engine Cover ......................................................3-10 Engine Electrical .................................................6-15 Engine Fluid Leaks .............................................6-15 Engine Oil and Filter Element .............................6-23 Engine Oil Level .................................................6-14 Engine Oil Type ....................................................5-7 Engine Speed .......................................................8-8 Engine Valve Clearance .....................................6-42 Environment .........................................................5-7 Extra (Grapple, clamshell, etc.) and Extra & Breaker 4-33

F Fan Belts ............................................................6-33 Fire Extinguisher ................................................2-10 Flare Type Fitting Joints .....................................8-18 Frame Structure .................................................6-19 9-1

CHAPTER 9 - INDEX Fresh Air Filter ................................................... 6-34 Fuel Cap ............................................................ 3-10 Fuel Filters ......................................................... 6-36 Fuel Handling Precautions .................................. 2-8 Fuel Level .......................................................... 6-15 Fuel Lines and Hoses ........................................ 6-58 Fuel Tank Drain ................................................. 6-24 Fuses ................................................................... 7-3

Lifting Capacities ................................................8-10 Lifting Machine ...................................................4-37 Lifting Machine With Attachment Installed .........4-37 Lifting Machine Without Attachment ...................4-39 Locking/Unlocking Cab Door ................................3-3 Lowering Attachment When Sudden Engine Failure Occurs .........................................................6-72

G

Machine Access Compartments and Doors .........3-9 Machine Attachment and Swing .........................4-15 Machine Components ..........................................1-3 Machine Dimensions ............................................8-3 Machine Electrical ..............................................6-18 Machine Operation in Adverse Weather Conditions .

4-21 Machine Storage ................................................4-41 Machine Travel Controls ....................................4-13 Machine Warm Up ................................................4-8 Main Pump Access Door ......................................3-9 Maintenance on Rollers and Idlers .....................6-49 Maintenance Precautions .....................................2-7 Manual Warm Up .................................................4-8 Maximum Digging Force position .......................4-19 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-16 Metric Fine Thread Standard Tightening Torque Values ..........................................................8-17 Model, Serial Number, and Year of Manufacture .1-4 Monitor ...............................................................3-13 Mounting and Dismounting Precautions ...............2-5

General Information ............................................. 1-1 Ground Transportation ...................................... 4-35 Guidelines for Attachment Lubrication ................. 6-9 Guidelines to Replace Ground Tools ................... 6-9

H Hand Signals ..................................................... 2-28 Hazardous Chemical Precautions ....................... 2-9 Heater Hoses ..................................................... 6-57 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 600 mm Triple Grouser Shoes ....... 8-11 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 800 mm Triple Grouser Shoes ....... 8-12 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes ....... 8-13 Hot Surface & Fluids ............................................ 6-6 How to Handle Life Hammer ............................. 2-10 Hydraulic Breaker .............................................. 4-24 Hydraulic Components ........................................ 8-9 Hydraulic Functions ........................................... 6-17 Hydraulic Lines, Tubes, and Hoses ................... 6-57 Hydraulic Oil Leaks ............................................ 6-17 Hydraulic Oil Level ............................................. 6-16 Hydraulic Return Filter ....................................... 6-43 Hydraulic Suction Tubes and Hoses ................. 6-58 Hydraulic Tank Breather .................................... 6-49

M

N N2 (Nylon) Tube Fitting Joints ............................8-18 Nibbler/Breaker ..................................................4-25 Nuts & Sleeves ...................................................8-18

I

O

Identification Numbers ......................................... 1-4 Idlers .................................................................. 6-20 Inspect Waste Oils and Filters ............................. 6-6 Inspecting Counterweight Attaching Bolts for Proper Torque ......................................................... 6-31 Installing the Bucket .......................................... 6-55

Oil Level in Swing and Travel Reduction Unit ....6-30 Opening and Closing Door Glass .........................3-5 Opening and Closing Sunroof ..............................3-5 Opening and Closing Windshield .........................3-4 Operate Boom Smoothly ....................................4-19 Operating Both Travel Levers Together .............4-13 Operating Pattern ...............................................4-10 Operating Pattern Decal .....................................4-10 Operating Precautions ..........................................2-6 Operating Pressures ............................................8-9 Operating the machine .........................................4-4 Operating the Machine in Water .........................4-15 Operating the Shovel ..........................................4-20

K Keep Machine Clean ........................................... 6-6 Key Switch ......................................................... 3-12

L L.C.D. Display .................................................... 3-20 9-2

CHAPTER 9 - INDEX Operation at Seashore or Salty Climate ............ 4-22 Operation in Extreme Cold ................................ 4-21 Operation in Extreme Heat ................................ 4-21 Operation in High Altitudes ................................ 4-21 Operation in Humid Climate .............................. 4-22 Operation in Sandy and Dusty Areas ................ 4-21 Operator Cab Nomenclature ............................. 3-12 Operator Precautions .......................................... 2-5 Operator Seat Adjustments ................................. 3-6 Operator’s Compartment Controls and Accessories .

3-11 ORS Joint (O-ring Sealing Type ........................ 8-17

P Personal Safety ................................................... 2-3 Pilot Line Filter ................................................... 6-48 Practices to Improve Efficiency ......................... 4-19 Prevent Contamination ........................................ 6-7 Pump Flow Rate Adjustment ............................. 3-23

R Radiator, Oil Cooler & Debris Screen ................ 6-25 Radio ................................................................. 3-25 Rear View Mirrors .............................................. 6-58 Recirculate Air Filter .......................................... 6-34 Recommendation for Longer Undercarriage Life ......

4-22 Releasing Hydraulic System and Tank Pressure 6-8 Releasing Swing Brake Manually With Hydraulic Hand Pump ................................................. 6-73 Releasing Swing Brake Manually Without Hydraulic Hand Pump ................................................. 6-74 Releasing Travel Motor Brakes Manually .......... 6-69 Removing and Storing Lower Front Window ....... 3-4 Removing Machine from Storage ...................... 4-41 Removing the Bucket ........................................ 6-54 Replacing Fuel Filter .......................................... 6-36 Required Filters ................................................... 5-4 Required Fluids/Lubricants and Capacities ......... 5-3 Reversing Bucket .............................................. 6-53 Right Hand Operator Console and Monitor ....... 3-12 Right, Left, Front, and Rear of the Machine ........ 1-2 Rollers ............................................................... 6-20 Roll-Over Protective Structure (If equipped) ........ 2-9

S Safety Area .......................................................... 2-3 Safety Rules ........................................................ 2-3 Screen Change Switch ...................................... 3-18 Seals & O-Rings .................................................. 6-7 Seat Belt .............................................................. 3-8

Seat Belt Precautions .........................................2-10 Seat Height Adjustment ........................................3-6 Seat Reclining Adjustment ...................................3-7 Securing Machine to Trailer ...............................4-37 Selection of the Hydraulic Breaker .....................4-24 Shoes ...................................................................8-7 SK350-8 Performance Specifications ...................8-8 Special Considerations for Hand Lubrication .....6-10 Specific Precautions to this Machine ..................2-10 Sprockets ...........................................................6-20 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 600 mm Triple Grouser Shoes ........8-11 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 800 mm Triple Grouser Shoes ........8-12 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes ........8-13 Starter Motor ........................................................7-3 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) .....................4-5 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) ......................4-5 Starting and Stopping Precautions .......................2-5 Starting Boosting Machine Engine .......................4-7 Starting Disabled Machine Engine .......................4-7 Starting Engine .....................................................4-5 Starting Machine Engine with Booster Cable .......4-6 Steps and Handrails ...........................................6-18 Stop Engine ..........................................................6-7 Stop Swing Motion Early ....................................4-20 Stopping Engine - Normal Conditions ..................4-5 Swing Bearing Lubrication ..................................6-29 Swing Motor Reduction Unit Oil .........................6-31 Swing Operation .................................................4-17 Swing Ring Gear and Swing Bearing Lubrication .....

6-29 Swing Ring Gear Lubrication ..............................6-29

T Throttle Potentiometer ........................................3-12 Torque Specifications .........................................8-16 Torque Values For Most Common Bolts ............8-19 Track Links .........................................................6-19 Track Shoes .......................................................6-19 Track Tension .....................................................6-21 Tracks and Components ....................................6-19 Transportation ....................................................4-35 Transporting Precautions .....................................2-9 Travel Motors Reduction Unit Oil .......................6-32 Travel Safety ......................................................4-15 Travel Speed, Swing Speed & Gradeability .........8-8

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CHAPTER 9 - INDEX

U Units of Flow ...................................................... 8-21 Units of Length .................................................. 8-21 Units of Power ................................................... 8-21 Units of Pressure ............................................... 8-21 Units of Torque .................................................. 8-21 Units of Volume ................................................. 8-21 Units of Weight .................................................. 8-21 Use Arm in Action .............................................. 4-19 Use of Optional Attachment ............................... 4-23 Use of Travel Speed Select Switch ................... 4-13 Using Power Boost ............................................ 4-17 Utility Safety ......................................................... 2-4

W Warm Engine Oil ................................................. 6-6 Warming of Hydraulic Oil .............................. 4-8, 4-9 Warming Up of Engine ........................................ 4-8 Washer Switch ................................................... 3-18 Water Separator ................................................ 6-25 Wear Safety Equipment ....................................... 6-7 Weight of Materials Table .................................. 8-20 Welding Safety .................................................... 6-7 Windshield Washer Fluid Reservoir .................. 6-57 Wiper Switch ...................................................... 3-18 Work Mode selection Table ............................... 4-12 Work Mode Switch .................................... 3-13, 4-12 Working Weight ................................................... 8-3

9-4

Dealer’s stamp

Kobelco Construction Machinery America, LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Kobelco dealer.

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