Kobelco SK55SRX Tier 4 Hydraulic Excavator Operator's Manual PDF

SK55SRX Tier 4

OPERATOR’S MANUAL Hydraulic Excavator SK55SRX Tier 4

S2PS00004ZE03 Issued March 2012

APPLICABLE: SK55SRX . . . . . . . . . . . . . PS02-00101~

SK55SRX COMPACT HYDRAULIC EXCAVATOR

OPERATOR’S MANUAL

KOBELCO 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, Repair 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 CNH America 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.

TABLE OF CONTENTS 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Handling of Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Check Machine Condition During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Precautions after Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Optional Attachments (Breaker, Nibbler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Angle Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Accelerated Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 CHAPTER 5 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Preparing for Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Loading/Unloading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Securing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubricant, Fuel and Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Accessory Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 I

Installing Hydraulic Hose and Pipe Joint Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Releasing Internal Pressure of Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Bleeding Air In Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Replacing the Rubber Crawler Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Inspection and Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 When Required Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Daily (8 Hour) Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 50 Hour (Weekly) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 1500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Inspection/Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Special Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

GENERAL INFORMATION TO THE OWNER SK55SRX KOBELCO COMPACT HYDRAULIC EXCAVATOR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. 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 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 authorized Kobelco Construction Dealer.

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permit.

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 authorized Kobelco Construction, LLC Dealer. Your Kobelco Construction Dealer is available for any further information. They will also provide any after sales service you may need, and genuine Kobelco spare parts, your guarantee of quality and match. Contact your dealer for operator manuals translated into Spanish or French Canadian.

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and current information from your dealer before you start any machine operation.

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.

A

The following illustration shows the machine in nor mal 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.

C

B

1

1 UPSX0102002B01

1. TRAVEL MOTOR A. FRONT

B. RIGHT C. LEFT

DESIGNATION OF OPERATION SLEWING RIGHT BOOM UP ARM OUT BOOM SWING RIGHT

ARM IN

SLEWING LEFT

BOOM DOWN TRAVELING FORWARD BOOM SWING LEFT

BUCKET OUT

DOZER UP BUCKET IN

TRAVELING REVERSE

DOZER DOWN

TRAVELING FORWARD

TRAVELING REVERSE XPX00200006E0

1-2

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 32

30

36

15

34

11

17 18

33

12

35

8 31 19

37

13 3

16

20

14 29

4 28 5 27 24 7

10

1 23

26

9 25

22

9

6

2 UPSX0102001B01

MACHINE COMPONENTS

1. ENGINE 11. SWING CYLINDER 21. SWIVEL JOINT 31. BOOM CYLINDER 2. OIL FILTER 12. CONTROL VALVE 22. TRAVEL MOTOR 32. ARM CYLINDER 3. RADIATOR 13. TRAVEL LEVER 23. SWING BEARING 33. WORK LAMP 4. RESERVOIR TANK14. SAFETY LOCK LEVER 24. IDLER ASSEMBLY 34. ARM 5. AIR CLEANER 15. CANOPY 25. LOWER ROLLER 35. LINK 6. MUFFLER 16. CONTROL LEVER 26. UPPER ROLLER 36. BUCKET CYLINDER 7. FUEL TANK 17. DOZER CONTROL LEVER 27. RUBBER CRAWLER BELT37. BUCKET 8. HYDRAULIC TANK 18. THROTTLE LEVER 28. DOZER BLADE 9. HYDRAULIC PUMP19. MONITOR PANEL (GAUGE CLUSTER) 29. DOZER CYLINDER 10. SWING MOTOR 20. BATTERY 30. BOOM

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE When ordering par ts, obtaining information or a s s i s t a n c e , a l w a y s s u p p l y y o u r Ko b e l c o Construction Dealer with the type and serial number of your machine or accessories.

Write the following in the Product Identification Plate below: The model number, serial number and year of manufacture of your machine, and hour meter reading. The hour meter is located under the seat.

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year ➤ Hour Meter Reading UPSX0400001E01

For future reference, record the serial numbers of the major components of the machine.

1

3

COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump ➤ Swing Reduction Gear ➤ Travel Reduction Gears ➤ Travel Control Valve ➤ Attachment Control Valve UPSX0500001E01

➤ Swing Control Valve

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HOUR METER

CHAPTER 1 - GENERAL INFORMATION ENGINE SERIAL NUMBER When ordering parts, obtaining information or assistance for the machine engine, always supply your Kobelco Construction Dealer with the type and serial number of the engine.

ENGINE ➤ Make and Model ➤ Serial Number

ATTENTION: The engine and fuel system on your machine is designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only.

BS07M603

ELECTRO-MAGNETIC INTERFERENCE (EMC) Interference may ar ise as a result of add-on equipment which may not necessarily meet the required standards.

A s s u c h i n t e r fe r e n c e c a n r e s u l t i n s e r i o u s ma lfun ctio n o f th e u nit an d/or crea te unsafe situations, you must observe the following:

 The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country.

 The electro-magnetic field generated by the add-on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

 The add-on equipment must not interfere with the functioning of the on board electronics.

Failure to comply with these rules will render the warranty null and void.

1-5

CHAPTER 1 - GENERAL INFORMATION FOPS, ROPS CERTIFICATION The machine is equipped with a ROPS (Roll-Over Protective Structure) and FOPS (Falling Objects Protective Structure) for the cab. The protective structure, the fitting supports and the fastening elements on the machine are an integral part of the structure.

In the case of work where there is a risk of frontal impact where objects could penetrate the cab, a front guard may be installed.

WARNING: DO NOT connect any device for lifting the cab to the protection structure. DO NOT weld, drill or attempt to straighten or repair protection structures. Any type of modification could influence the structural integrity of the safety system jeopardizing its effect, with serious consequences for the operator, in case of collision, falling objects or landslides.

After a fire, corrosion or collisions, any possible damage to the cab protection structure must be carefully evaluated by specialized and qualified personnel. In any case, all damaged parts must be replaced with genuine spare par ts so that the original conditions are reinstated. Contact your Dealer to verify the functionality of the cab structure or the requirement for the replacement of the entire structure or parts of it.

When ordering par ts, obtaining information or assistance, supply your Dealer with the make, m o d e l a n d s e r i a l nu m b e r o f Fa l l i n g O b j e c t Protection (FOPS) and Roll Over Protection (ROPS) for your machine.

FOPS (Falling Object Protection) ➤ Make and Model ➤ Serial Number

ROPS (Roll Over Protection) ➤ Make and Model ➤ Serial Number

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UPSX0500001E01_FOPS

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 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Emergency Exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Boom and Arm Movement - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hydraulic Oil Bleeding - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety Controls - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hot Surfaces - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Pressurized Fluids and Lubricants - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Engine Stop - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Counterweight Swing Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Engine Stop - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Track Tension Adjuster - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Keep Clear of Working Area - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Prevent Battery Explosions - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Handling Battery - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Selector Valve - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Safety Lock Lever - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Seat Belt - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Window Lock - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Hydraulic Oil Check Position - Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Stop Engine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Confirm Attachment Movement- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Do Not Operate This Machine- Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Hot Parts (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Correct Fuel Usage - EPA Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 OpeRation Of Nibbler and Breaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 HANDLING OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES PERSONAL SAFETY

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.

M171C

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.

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 used, are RED.

and STOP if

SAFETY AREA

1

SEAT

1 2 Figure 1

BC02N198 UPSX0100001E01

1. OPERATOR’S MANUAL STORAGE SPACE

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 necessary for the machine to operate at the maximum range of the tool. The area is a full 360  swing plus 6 feet (2 meters).

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.

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.

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS UTILITY SAFETY Safety precautions 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 Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

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

LINE VOLTAGE

MINIMUM DISTANCE M (FEET)

0 ~ 50,000

3.0M (10) OR MORE

50,000 ~ 200,000

4.5M (15) OR MORE

200,000 ~ 350,000

6.0M (20) OR MORE

350,000 ~ 500,000

7.5M (25) OR MORE

500,000 ~ 750,000

10.5M (35) OR MORE

750,000 ~ 1,000,000

13.5M (45) OR MORE

2-4

RH99G001

Figure 2

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 h o l e by h a n d a n d / o r w i t h a u t o m a t i c va c u u m equipment to the utility line to verify the location and depth of the line.

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.

 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

 Certain protective equipment should be replaced

 Walk around the machine and warn all personnel

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 vests are no longer as highly visible as new vests.

See the manufacturer’s recommendation.

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.

 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 have 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 objects stored in the machine.

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

 Walk around the machine’s 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 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 booster cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using booster cables. Make sure that using booster 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 lever 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 manufacturer’s 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.

 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

 Know and understand the job site traffic flow

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

patterns and obey signalmen, road signs and flagmen.

 If a part of the machine touches high voltage

 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 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 an escort for roading where required.

2-6

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

 Avoid lubrication or mechanical adjustments with

well. This can be dangerous for you and for the people around you.

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.

 You must make a judgment if weather, road, or 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.

MAINTENANCE PRECAUTIONS

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

 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.

 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.

 Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized 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 manufacturer’s 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.

DC04E084

Figure 3

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

 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.

 Wear protective glasses and other required safety

 Keep the brakes and steering systems in good

equipment when servicing or repairing the machine.

 Replace all missing, illegible or damaged safety

 Wear gloves to protect hands when handling cable.

operating condition. decals. Keep all decals and safety notice signs clean.

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

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

 When the battery electrolyte is frozen, the battery

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 contaminate 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.

 Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

 Never use fuel for cleaning purposes.  Use the correct fuel grade for the operating season.

 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.

HAZARDOUS CHEMICAL PRECAUTIONS

 If you are exposed to or come in contact with 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

BURN PREVENTION

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.

WARNING BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

M144B

WARNING BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in death or serious injury.

M422A

2-8

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

 Before you service this machine and before you 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 n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n 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 R O 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.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS EMERGENCY EXIT HAMMER

SEAT BELT PRECAUTIONS

1

1

2 Figure 4

UPSX0101001B01

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

An emergency exit hammer is provided on the right s i d e o f c a b. I n c a s e o f e m e r g e n c y, t a ke t h e emergency hammer, break the cab glass, and escape from the cab. In addition, the emergency hammer is equipped with a cutter on the lever side to cut seat belt, etc.

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

FIRE EXTINGUISHER

BC02N375

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

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.

WARNING Before starting the engine make certain seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system 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 refueling.  Do not use tractive force of the machine for 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.

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply could result in death or serious injury.

CE-NA000

WARNING Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply could result in death or serious injury.

CE-NA000

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.

2-10

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOM AND ARM MOVEMENT - CAUTION Located on seat stand cover - Part Number YN20T01013P1

UPSY0101009E01CC

HYDRAULIC OIL BLEEDING - WARNING Located on hydraulic tank- Part Number PW20T01007P1

UPSX0101009E01C//PX00100004E01

SAFETY CONTROLS - WARNING Located on seat stand cover - Part Number YN20T01016P1

UPSX0101009E01CC/UPX00100005E01

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT SURFACES - CAUTION Located on engine door hinge - Part Number YN20T01220P1

UPSX01010009E01E/UPX00100006E01

PRESSURIZED FLUIDS AND LUBRICANTS - WARNING Located on radiator duct - Part Number PW20T01094P1

UPSX0101009E010/UPX0010025E01

ENGINE STOP - CAUTION Located on hood support - Part Number YN20T01012P1

UPSX010100801C/UPX00100008E01

2-12

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS COUNTERWEIGHT SWING AREA - DANGER Located on radiator cover- Part Number PE2T01014P1

UPSX010100801C/UPW00100079E01

ENGINE STOP - WARNING Located on engine radiator- Part Number YN20T01009P1

UPSX0101009E01D/UPX00100010E01

BOOSTER CABLE - WARNING Located on battery box cover- Part Number YN20T01338P1

UPSX0101009E01CC/UPX00100011E01

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS TRACK TENSION ADJUSTER - WARNING Located on crawler frame - Part Number 243T6110

UPSX0101009E01A/UPSX0101005E01

KEEP CLEAR OF WORKING AREA - DANGER Located on both sides of arm- Part Number PE20T01012P1

UPSX0101010E01B/UPX00100013E01

PREVENT BATTERY EXPLOSIONS - WARNING Located on seat stand cover- Part Number LS20T01202P1

UPSX0101009E01/UPSX0101T004E01

2-14

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HANDLING BATTERY - WARNING Located on seat stand cover- Part Number YN20T01356P1

Y N 20T01356P 1

UPSX0101009E01/ULC00010006E01

NOTICE: • Batteries give off hydrogen gasses that can explode and cause personal injury.

• Keep sparks, open flames and cigarettes away from batteries.

• Keep metallic articles away from batteries.

• Keep all ventilation caps tightly secured.

• Do not check change by placing metal articles across battery terminals.

• Leave battery box open to improve ventilation when charging.

• There is always the danger of burn and loss of eyesight due to the splashing of dilute sulfuric acid of battery. If skin and eye are accidentally splashed with dilute sulfuric acid, wash them with clean water immediately and have treated by doctor.

ELECTRICAL LINE SAFETY - DANGER Located on seat stand cover- Part Number YN20T01006P1

BS08A058//BS07M654

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SELECTOR VALVE - CAUTION Located on seat stand cover- Part Number PE20T01016P1

UPSX0101009E01F/UPX00100022E01

SAFETY LOCK LEVER - WARNING Located on seat stand cover- Part Number PY20T01073P1

Machine may move suddenly and cause serious personal injury if a control lever is accidentaly touched, be sure the safety lever is disengaged and in the locked position before exiting the cab.

PY20T01073P1 UPSX0101009E01B/UPX00100017E01

SEAT BELT - WARNING Located on seat stand cover- Part Number PE20T01027P1

UPSX0101009E01CC/UPX00100019E01

2-16

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS WINDOW LOCK - CAUTION Located on inside front window- Part Number YN20T01416P1

UPSX0101010E01/UPX00100026E01

HYDRAULIC OIL CHECK POSITION - NOTICE Located on seat stand cover- Part Number 2432P3379

Lack of hydraulic oil will cause damage to main hydraulic pump.

Before starting operation : . Place machine on level ground. . Fully retract arm and bucket cyinders and lower boom to ground. . Check hydraulic oil level gauge for proper level.

2432P3379

UPSX0101009E0CC/UPX00100027E01

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP ENGINE BEFORE CHANGEOVER - DANGER Located on inside of side cover- Part Number YN20T01214P1

UPSX0101009E01F/UPX00100031E01

CONFIRM ATTACHMENT MOVEMENT- WARNING Located on inside of right window (cab). Located on ceiling (canopy) - Part Number YN20T01039P1

UPSX0101010E01/UPX00100032E01

2-18

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT OPERATE THIS MACHINE- WARNING Located on inside of right window (cab). Located on ceiling (canopy) - Part Number PE20T01028P1

UPSX0101010E01FF/UPW00100075E01

CALIFORNIA PROPOSITION 65 - WARNING Located on inside right window (cab). Located on ceiling (canopy) - Part Number 2432T6457

UPSX0101010E01FF/UPJ00010005E01

2-19

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CALIFORNIA PROPOSITION 65 - WARNING Located on inside right window (cab). Located on ceiling (canopy) - Part Number YN20T01495P1

BS07M656UPJ00010006E01

HOT PARTS (OPTIONAL) Located on the cooler tube - Part Number PH20T01102P1

UPSX0101010E01C/PH20T01102P1

2-20

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CORRECT FUEL USAGE - EPA REGULATIONS Located near the fuel fill cap - Part Number PV20T01068P1 for machines with PIN PS02-00101 - 00117 Part Number PV20T01100P1 for machines with PIN PS02-00118~

DETAIL A A

UPSX0101008E01B/UPVX3801001E01/UPSX0101008E01A/20T01068P1

OPERATION OF NIBBLER AND BREAKER (OPTION) Located on inside of right window - Part Number PY20T01205P1

PY20T01205P1

UPSX0501002E01_2127/UPSX0401003E01

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HANDLING OF ACCUMULATOR WARNING: Do not abuse or misuse the accumulator, as it may explode. The accumulator contains high pressure nitrogen gas which may cause serious injury.

Observe the following when handing accumulators: 1. Do not disassemble the accumulator.

2. Keep the accumulator away from fire.

3. Do not drill or weld on the accumulator.

4. Do not knock, roll over, or give the accumulator a shock.

5. Remove gas from the accumulator before disposal.

Fo r f u r t h e r i n fo r m a t i o n a b o u t h a n d l i n g t h e accumulator, contact your dealer.

2-22

UPSX0801010B01

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS IMPORTANT: When operating the machine, never attempt to carry out tasks calling for the control of or to work in areas where visibility is poor or impaired without seeking the assistance of a signal person. Make certain that you and the signal person 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 7

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 5

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 8

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 6

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

DC04E042

Figure 9

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

LOWER BOOM 2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ARM IN

DC04E043

Figure 10

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

SWING LEFT

DC04E046

Figure 13

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

ARM OUT

DC04E044

Figure 11

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

SWING RIGHT

DC04E047

Figure 14

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

COUNTER ROTATE LEFT

DC04E045

Figure 12

Fa c e m a c h i n e o p e ra t o 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.

2-24

DC04E048

Figure 15

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.

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CLOSE BUCKET (BUCKET IN OR DIG)

COUNTER ROTATE RIGHT

DC04E049

Figure 16

DC04E052

Figure 19

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 17

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

DC04E053

Figure 20

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 18

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

DC04E054

Figure 21

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.

2-25

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP

TURN RIGHT

DE04E055

Figure 22

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 25

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 23

Figure 26

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

Fa c e m ac hi n e op e ra to r, ra i s e b ot h a r m s 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 24

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

2-26

DC04E060

Figure 27

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

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

NOTES

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

2-28

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 MACHINE ACCESS COMPARTMENTS AND DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Forward Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Left Hand Side Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Right Hand Side Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Radio (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Air Conditioner (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Ordinary Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Rapid Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Ordinary Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Periodic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB CAB (OPTION) WARNING: Avoid unexpected movement. When necessary to leave the operator’s seat, lock the safety lock lever. If the control lever is unexpectedly touched without the safety lock lever locked, it may cause a serious accident resulting in injury or death.

2

Locking the Cab Door

1

1. To lock the door in the “open” position push it against the catch (1) until it is secured.

2. To open the door, push down the door lever (2) on the left side of the operator seat until the catch releases.

UPSX0102010B01

1. DOOR CATCH 2. DOOR LEVER

3. When necessary to keep the door in the open position, be sure the door catch is secured.

WARNING: Avoid injury! In operation, lock the door securely, whether on the open or closed side. When not locked, the door may open unexpectedly and cause injury or machine failure.

Releasing Door Lock from Inside Cab To open the door from the inside of the cab, pull lever (3) by hand.

3

UPSX0102011B01

3. DOOR LEVER

Cab Dome Light 1. To turn the cab dome light ON, push the switch UPWARD. 2. To turn the cab dome light OFF, push the switch all the way DOWNWARD. The lamp does out at the NEUTRAL position.

ON

OFF

1

UPSX0102014B01

1. LIGHT SWITCH

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDOWS Opening and Closing Upper Front Window WARNING: 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. M1709

A

WARNING: When closing the upper front window, keep in mind that its weight will cause it to drop down very quickly. Hold it securely with both hands. When storing the front window, pull the safety lock lever up to the LOCKED position and stop the engine.

1. Park the machine on level ground, put the bucket on the ground and pull the safety lock lever UP to the LOCKED position. Stop the engine.

UYN0020094J01

A. LOCKED POSITION

2. To unlock the upper front window, push down the lock levers (1) located on the right and left sides of the window.

4

4

3. Hold the right and left handles of the front window and slide the front window overhead all the say to the back end of the ceiling until the window is locked.

4. To close the upper front window, follow the procedure descr ibed in Steps 2 and 3 in reverse.

UPSX0102012B01

A. LOCKED POSITION

Removing and Storing Lower Front Window 1. After placing the upper front window in the ceiling, hold the lower front window and remove it from the frame.

5

5

2. Store the removed lower front window in the holder in the rear of the cab b ehind the operator’s seat.

3. To store the window, insert the right and left sides of the glass into the holders (5) and support it with the holders (6) on the lower section of the window frame.

6 UPSX0102015B01

5. SIDE HOLDERS 6. LOWER HOLDERS

3-4

CHAPTER 3 - INSTRUMENTS AND CONTROLS Opening and Closing Right Window 1. To open the right window, release the lock (1) and move the slide glass.

2. To close the window, return the slide glass to its normal position and lock it.

1

UPSX0102016B01

1. LOCK

Window Washer Tank The window washer tank (1) is installed on the lower left of the operator’s seat. When the fluid level becomes low, remove the cap (2) and fill with washer fluid.

2

NOTICE: Do not operate the windshield washers when the tank is empty, as this may damage the washer tank motor.

1

UPSX0102017B01

1. WASHER TANK 2. CAP

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR SEAT Seat Adjustments To adjust the seat, pull the seat adjustment lever to the right. Move the seat forward or rearward to desired position. Release the lever to lock the seat in position.

LEVER UPSX0102020B01

Seat Belt

1

WARNING: Avoid Injury! Always wear seat belt while sitting in operator seat. Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure. Failure to comply could result in death or serious injury. M422B The seat belt has take-up motion which automatically adjusts its length to the size of the operator in the seat.

2

1. To fasten the seat belt, first check that it is not twisted and pull it out.

2. Pull the belt out a little longer than the required length and insert it in the buckle (1) until it locks securely in place. The length of the seat belt will automatically adjust to that of the seated operator.

3. After locking the buckle, the operator can adjust the seat belt another 25 mm (1 in) to fit comfortably.

1 DC04D529

1. BUCKLE 2. RED BUTTON

NOTICE: Replace the seat belt every three years regardless of appearance. Note date of replacement on support mount for reference.

4. To unfasten the seat belt, press the red button (2) and the buckle will unlock and release the belt.

Cup Holder The cup holder is located near the left rear of the operator’s seat. Press lock button (1) to open the cup holder.

1

UPSX0102005B01

1. CUP HOLDER

3-6

CHAPTER 3 - INSTRUMENTS AND CONTROLS Hour Meter The hour meter indicates the total time the engine has run. Even if the machine is not moving, the hour meter continues to count as long as the engine is running, regardless of speed. While the engine is running, the hour meter indicator flashes to show it is active. Use the hour meter to record operating time for maintenance.

UPSX0500001E01

Storage for Operator’s Manual

1

The operator’s manual can be stored in the back pocket of the door under the operator’s seat. Keep this Manual in the specified storage area at all times for quick reference.

SEAT

UPSX0102024E01

Storage for Tools and Accessories

1

Tools and accessories can be stored behind the door under the operator’s seat.

UPSX0102025E01

1

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE ACCESS COMPARTMENTS AND DOORS WARNING: AVOID INJURY! Stop the engine when the engine door or radiator cover is opened.

UNLOCK

(2) Engine Door Cover A lock is provided for the engine doors. Use the ignition key to open and lock the engine doors.

(3) (1)

RELEASE

LOCK

UPW0020008E01

To Open the Engine Door

1

1. Insert the key.

2. After releasing the lock, remove the key and open the cover.

3. Secure the cover in the open position with the rod.

1 1 UPSX010201B01

1. KEY CYLINDER

To Lock the Engine Door 1. Return the rod to the storage position by placing it into the holder.

2. Close the cover.

2

3. Insert the key and turn it, counter-clockwise direction to lock the cover. Then, remove the key.

NOTICE: Insert the key completely for proper operation; otherwise, damage may occur to the key or locking mechanism.

WARNING: Secure the engine doors in open position with strut when servicing. Failure to comply could result in death or serious injury. M1709 3 4 UPSX0103021B01

2. SIDE COVER (RIGHT HAND) 3. ENGINE DOOR 4. SIDE COVER (LEFT HAND)

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES 5

20

21

4

6

3

7

9 10 8

2

1 16 15 14 13 11 17

12

18

19

UPSX0102003B01

1. RIGHT OPERATING LEVER

8. BREAKER OPERATING SWITCH

15. DECELERATION SWITCH (OPTION)

2. LEFT OPERATING LEVER

9. OPTION SWITCH (NIBBLER AND BREAKER)

16. DOZER BLADE OPERATING LEVER

3. SAFETY LOCK LEVER

10 TRAVEL SPEED SELECT SWITCH

17. OPERATOR’S SEAT

4. RIGHT TRAVEL LEVER

11. MONITOR PANEL (GAUGE CLUSTER)

18. WIPER AND WASHER SWITCH

5. LEFT TRAVEL LEVER

12. WORK LIGHT SWITCH

19. HEATER SWITCH (OPTION)

6. BOOM SWING OPERATING PEDAL

13. THROTTLE LEVER

20. LEFT TRAVEL PEDAL

7. HORN SWITCH

14. STARTER SWITCH

21. RIGHT TRAVEL PEDAL

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

Controls and accessories in the operator’s compartment are described in the following pages.

They are organized according to their location within the operator’s compartment - forward controls, left-hand side controls, right-hand side controls, rearward controls and overhead controls.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS FORWARD CONTROLS Travel Speed Select Switch WARNING: Use low speed when operating on a slope or loading/unloading from a truck or trailer.

Sudden changes in ground level can cause accidents. Failure to comply could result in death or serious injury. SA130 The Travel Speed Select Switch is a button located on the right-hand travel speed lever. When the i g n i t i o n sw i t c h i s O F F, t h e t r ave l s p e e d i s automatically set to LOW (symbolized with the TURTLE icon).

UPW00200016J01

Low Speed (Turtle Icon) Select low speed when travelling on rough or soft terrains, slopes, narrow places, or whenever powerful tractive force is required. This speed should also be used when loading/unloading from a truck or trailer.

UPW00200055J01

High Speed (Rabbit Icon) Select high speed when travelling on flat, hard ground.

UPW00200056J01

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT HAND SIDE CONTROLS Horn Switch WARNING: Avoid injury! Sound the horn before starting the engine, travelling, swinging or operating the attachments.

The horn switch is located at the top of the left-hand control lever.

UPW00200016B01

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND SIDE CONTROLS Ignition Switch 1. The ignition switch is located on the right hand operator console. It is used to start or stop the engine, power the machine’s electrical system and activate pre-heating.

OFF - When key is turned to this position, the engine stops and electr ical power to the machine’s electrical system is stopped after approximately 3 seconds.

ON - When key is in the ON position, electrical power is supplied to all the machine’s electrical systems.

UPAX0602049B01

START - Turn the key to this position to start the engine and release it after the engine starts.

The key will automatically return to the ON position.

HEAT - When engine start-up is difficult due to cold temperatures, turn the key to this position to activate the pre-heat feature. Hold the key in this position for approximately 15 seconds and then turn the key to the START position to start the engine. Release the key after the engine starts.

Deceleration Selector Switch The deceleration selector switch is located next to the ignition switch on the right-hand console.

Press this switch while the engine is running to change the engine to LOW speed. Press the switch again to release the deceleration function. Or, turn the ignition switch from ON to OFF to automatically release the deceleration function.

Use of the deceleration selector switch can improve fuel efficiency and reduce noise.

UPW00200001E01

Work Lamp Switch The work lamp switch is located on the right-hand console. It is used to turn the work lights on and off on the boom and machine.

UPW00200019J01

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS Wiper and Washer Switch (Cab Option) NOTICE: Do not operate the washer for more than 20 seconds continuously or without washer fluid or the washer tank motor may be damaged.

The wiper and washer switch is located on the right-hand operator console. It is used to turn the windshield wipers on and off and to spray washer fluid on the windows.

It has four settings: WASH (left) - Sprays washer fluid OFF - Stops movement of windshield wipers

UPW00200021J01

ON - Starts movement of windshield wipers only WASH (right) - Sprays washer fluid and operates wipers simultaneously.

Breaker Operating Button The breaker operating button (2) is located on the grip of the right control lever (1). It is used to operate the breaker.

1

2

NOTICE: Make certain the selector valve is switched to the BREAKER mode. Working in the incorrect mode can cause malfunction or machine damage.

Before operating the breaker, first slide the option switch to the left. Then, use the breaker operating button to control the breaker.

Breaker Button Operation

UPW002000010B02

BREAKER BUTTON ACTION

OPERATING CONDITION

Hold down the button

Breaker starts operation

Release the button

Breaker stops operation

1. BREAKER OPERATING BUTTON 2. OPTION SWITCH

Option Switch (Nibbler and Breaker) The option switch (2) is located on the grip of the right control lever. It is used to control the breaker or nibbler.

To operate the breaker, first slide the option switch to the left, then use the breaker button to operate the breaker.

2

1

WARNING: Do not touch the breaker button while operating the nibbler.

To operate the nibbler, slide the option switch to the right or left.

OPTION SWITCH ACTION

OPERATING CONDITION

Slide switch to left

Nibbler closes

Slide switch to right

Nibbler opens

UPW00200017B01

1. OPTION SWITCH 2. BREAKER OPERATING BUTTON

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS GAUGE CLUSTER

BS07M673

A. GAUGES B. WARNING LAMPS C. INDICATOR LAMP 1. ENGINE COOLANT TEMPERATURE GAUGE 3. ENGINE OIL PRESSURE LAMP (RED) 8. HIGH (2ND) 2. FUEL LEVEL GAUGE 4. COOLANT TEMPERATURE LAMP (RED) TRAVEL SPEED LAMP (YELLOW) 5. BATTERY CHARGE LAMP (RED) 6. LOW FUEL WARNING LAMP (RED) 7. AIR CLEANER LAMP (RED)

GAUGES Engine Coolant Temperature Gauge Indicates the temperature of the engine coolant and operates when the ignition switch is turned to the ON position. The temperature is normal in the white range.

If the indicator enters the red range, let the engine low idle until the coolant temperature indicator moves back into the white range.

If the indicator is in the blue range, warm up engine and hydraulic oil.

BS07M674

1. BLUE - COLD CONDITION 2. WHITE - NORMAL OPERATING CONDITION 3. RED - POSSIBLE OVERHEATING CONDITION

Fuel Level Gauge Indicates the amount of fuel in tank. “F” indicates a FULL tank. Refuel with diesel fuel when the indicator approaches empty. DO NOT allow the machine to run out of fuel.

BS07M675

1. WHITE - OPERATING CONDITION 2. RED - REFILL WITH FUEL

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING LAMPS NOTICE: If warning lamps illuminate, change machine operating method immediately. If a warning lamp remains illuminated, stop the engine and determine the cause of the problem. See the Maintenance Section - Chapter 6 in this manual or contact your dealer.

Engine Oil Pressure Lamp (Red) The engine oil pressure lamp will illuminate if the engine oil pressure drops abnormally while the engine is running. Stop the engine immediately and check engine oil.

BS07M776

See the Maintenance Section - Chapter 6 for checking oil level.

NOTICE: The engine may suffer severe damage if the machine is operated with the engine oil pressure lamp illuminated.

Coolant Temperature Lamp (Red) If the coolant temperature rises abnormally, the coolant temperature lamp will illuminate. Run the machine at low idle until the coolant temperature drops to a normal range.

Reduce engine RPM to idle, and stop operation until engine coolant temperature reaches a safe operating temperature range.

See the Maintenance Section - Chapter 6 for checking coolant level.

NOTICE: The engine may suffer severe damage if the machine is operated with the coolant temperature lamp illuminated.

BS07M777

WARNING: Do not perform any maintenance on a hot engine. Allow the engine to cool before inspection or maintenance. Failure to comply could result in death or serious injury. M1393 Battery Charge Lamp (Red) The batter y charge lamp will illuminate if the charging system is experiencing a malfunction. This lamp will illuminate briefly when the engine is turned on and should turn off once the engine is running. Check the charging system if this indicator remains illuminated after the engine has started.

BS07M779

1

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS Low Fuel Warning Lamp (Red) If fuel is low, a warning lamp will illuminate. Stop the engine and add fuel. Do not allow the machine to run out of fuel.

BS07M780

Engine Air Filter Lamp (Red)

1

The engine air filter lamp will illuminate if the air cleaner filter is clogged. If the lamp illuminates, stop the machine immediately and clean or replace the air filter.

See Maintenance Section- Chapter 6 for additional information.

BS07M778

INDICATOR LAMP

1

High (2nd) Speed Travel Lamp (Yellow) The high speed indicator lamp will be illuminated when the travel speed is switched to high (2nd) speed. The travel speed selector switch is located on the grip of the right travel lever. The speed will automatically return to low (1st) speed when the ignition is switched off.

BS07M781

1

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEVERS AND PEDALS Your machine is equipped with a variety of levers and pedals to control machine functions. This diagram shows their locations.

6 3 1

3

2

2

5 4

UPSX0102007B01

1. SAFETY LOCK LEVER 2. RIGHT/LEFT CONTROL LEVERS 3. TRAVEL LEVERS WITH PEDALS

4. THROTTLE LEVERS 5. DOZER CONTROL LEVER 6. BOOM SWING OPERATING PEDAL

Safety Lock Lever The hydraulic function safety lock lever is located on the left control console. It can be used to avoid unwanted activation of any hydraulic function.

A

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 WARNING: When the safety lock lever is set in the locked (UP) position, functions for dozer and boom swing operations are still activated.

B

UPWX3402003E01

NOTICE: When the safety lock lever is set to LOCKED (up position, attachments and swing motor are locked simultaneously because they are part of the hydraulic system; however, their levers can still be moved. The travel levers are separately locked with their mechanical locking to lock the movement itself of the levers.

A. LOCKED (UP) POSITION

To shut down (lock) the hydraulic system, pull the safety lock lever UP (A).

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS To unlock the hydraulic system, pull the safety lock lever DOWN (B). All hydraulic systems will be active.

A

B

UPWX3402004E01

B. UNLOCKED (DOWN) POSITION

Right/Left Control Levers

A

E

The right/left control levers control the function of the boom and arm of the machine.

G

There are two control patterns - ISO and BHL. There will be a decal on the machine showing which control system is used.

H

D B

F

WARNING: Avoid injury! Inspect the work area or job site to make sure machine operation can be done safely. Confirm that the lever operation is the same as indicated on the labels. If not, immediately change the machine control pattern or the label displayed to match the machine control pattern. Do this immediately to avoid injury or death.

NOTICE: The operator’s control levers return to the neutral position when released and the operation of attachment is stopped. All functions can be stopped simultaneously.

C

4 1

G

H

B E

F 2 C D

A 3

UPW00200027B01

ISO OPERATING PATTERN ISO OPERATING PATTERN

LH CONTROL LEVER 2

4

E

Arm Out

F

Arm In

G

Swing Left

H

Swing Right

RH CONTROL LEVER 1

3

A

Boom Down

B

Boom Up

C

Bucket In

D

Bucket Out

UPW00100006E011

HYDRAULIC CONTROL LEVERS - ISO PATTERN

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS BHL OPERATING PATTERN

A

E

In the BHL multi-control shifting the boom and arm functions are opposite to the ISO system.

G

H

C

D

F

B

4 1

G

H

F A

B 2 C D

E 3

XPX00200004B01

BHL OPERATING PATTERN

BHL OPERATING PATTERN

LH CONTROL LEVER 2

4

E

Arm Out

F

Arm In

G

Swing Left

H

Swing Right

RH CONTROL LEVER 1

3

A

Boom Down

B

Boom Up

C

Bucket In

D

Bucket Out

BHL UPX00200006E01

HYDRAULIC CONTROL LEVERS - BHL PATTERN

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS Travel Control Levers

A

WARNING: Always know the position of excavator travel motors to prevent unexpected movement of the machine. Normal positioning for determining front, rear, forward, and reverse is with the travel motors located behind the operator's cab. Failure to comply could result in death or serious injury. M1726

N

A

B B

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

Travel Alarm (if equipped) The travel alarm (if equipped) sounds to aler t workers of machine movement whenever the travel levers are operated.

A

WARNING: Avoid injury! If the travel alarm (if equipped) does not sound after the travel lever is operated, stop the engine immediately and contact your dealer for repair.

2 1

B UPW00200028J01

A. FORWARD TRAVEL 1. TRAVEL MOTOR B. REARWARD TRAVEL 2. DOZER BLADE 1. NEUTRAL

The travel functions described below are with the travel motors located behind the operator’s cab.

Push both levers forward (or press the front of the pedals) to travel forward.

Pull both levers toward you (or press the near side of pedals) to move in reverse.

FRONT

REAR

CONTROL LEVER TRAVEL FORWARD TRAVEL REVERSE

Release both levers in the center position to stop movement and place the machine in neutral.

NOTICE: Refer to the Operating Instructions chapter in this manual for information on changing travel direction.

XPX00200005E01

Throttle Control Lever The throttle control lever is located to the right of the operator’s seat and is used to control engine speed.

A

B

(A) LOW (low idling) - Push the throttle fully forward to set the engine in low idle.

(B) HIGH (high idling) - Pull the throttle fully backward to set the engine in high idle.

UPW00200029J01

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS Dozer Control Lever Use the dozer control lever to move the dozer up or down.

D

C

(C) Dozer Up - Pull the lever back.

(D) Dozer Down - Push the lever forward.

When traveling, raise the dozer blade to its maximum height.

1

C

D UPW00200030J01

Boom Swing Operating Pedal Use this pedal to operate the swing motion of the boom.

To use the pedal, lift the pedal locking cover (1) up.

B

A

B

A 1

Right swing: push down right side of pedal Left swing: push down left side of pedal.

WARNING: Always lock the pedal if not using the boom swing operating function. Failure to comply could result in death or serious injury. M1491 UPSX0102009B01

A. RIGHT SWING B. LEFT SWING

1. PEDAL LOCKING COVER

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO (OPTIONAL) The radio (if equipped) is located on the right side control panel. The following describes the radio functions.

Power control key

10

Press the power control key (1) and the power switches from OFF to ON. After displaying the band AM or FM, the frequency or time is displayed.

AM/FM selector key Press the AM/FM selector key (2) to change the band from FM1 to FM2 to AM. When the band is switched, the station received before switching is selected.

1

Volume control key To turn up the volume level by 1, press the “+” side of the volume control key (3). To turn down the volume level by 1, press the “-” side of the volume control key. The volume level will be shown on the LCD display while operating the volume control key.

UPSX0102003B01RADIO

4.RADIO

DISP (Display) key Press the DISP key (6) to change the display from time to frequency. The band displays first, then the frequency.

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6

5

8

3

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1 UYN00020201J01

1. POWER CONTROL KEY 2. AM / FM SELECTOR KEY 3. VOLUME CONTROL KEY 4. UP / DOWN KEY

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5. PRESET KEY 6. DISPLAY CHANGE KEY 7. SOUND CONTROL KEY 8. TIME/FREQUENCY KEY

CHAPTER 3 - INSTRUMENTS AND CONTROLS Radio station selection The radio station can be selected three ways: 1. Manual tuning, 2. Auto selection, 3. Preset memory 1. Manual tuning Press the UP or DOWN keys to increase or decrease the frequency by one step.

1 step: AM 9kHz 1 step: PM 0.1MHz 2. Auto selection When pressing UP or DOWN keys for more than one second, the frequency increases or decreases. When radio waves are received during auto tuning, or while pressing the UP or DOWN key, the auto tuning is interrupted but the frequency stays the same.

UYN00020202J01

3. Preset memory The radio preset memory can be programmed automatically or manually.

Au t o P re s e t : T h e ra d i o d e t e c t s a n d c a n memorize the strongest frequencies.

A. Press the SOUND/AUTO PRESET key (7) for one or more seconds. The desired station starts the presetting.

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B. During presetting, the display “A” moves from left to right.

(Example of FM1 is selected) Press "SOUND" key (For 1 second or more)

C. After auto presetting, this function can receive the memorized station.

Frequency display

Repeat this procedure to preset the six strongest radio frequencies, using the six PRESET keys (5).

(After a certain time)

Auto presetting display (After a certain time)

(After a certain time)

Auto presetting display

(Auto preset end)

Auto presetting display

Frequency display UYN00020205E01

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Manual preset: Press one of the six PRESET keys (5) for one second or more. The currently received station is then memorized and stored for retrieval when you push that PRESET key.

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The display will show the number of the PRESET key, followed by the frequency.

(Example of FM1 is selected) Press "PRESET" key (No.1) (For 1 second or more)

Frequency display

(After 3 flickerings of preset No.)

Preset No. display

Frequency display UYN00020207E01

Preset memory: Press one of the six PRESET keys (5) for 0.5 second or less. The display will show the PRESET number, followed by the frequency.

(Example of FM1 is selected : The frequency 88.5 MHz is registered in advance) Press "PRESET" key (No.1) (For 0.5 second or less)

Frequency display

Preset No. display (After display of preset No. for 0.5 second)

Frequency display UYN00020208E01

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Sound/Auto Preset Key The SOUND/AUTO PRESET key can be used to adjust the sound balance, bass and treble of the right and left speakers. It is also used during auto presetting of station selection.

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Push the SOUND key to select the function you wish to control - BAL, TRE, and BAS will be highlighted on the display in sequence.

(Example of FM1 is selected)

BAL (balance control) TRE (treble control)

Frequency display "SOUND" key

BAS (bass control)

Sound control display (Balance) "SOUND" key

Sound control display (Treble) "SOUND" key

Sound control display (Bass) "SOUND" key Release sound control (To on-air display) UYN0002020218E01

Balance control To raise the volume of the left speaker, push the UP key (4) while BAL is displayed.

To raise the volume of the right speaker, push the DOWN (4) key while BAL is displayed.

"DOWN" key

Sound control display (Balance) "DOWN" key

Sound control display (Balance)

Sound control display (Balance)

"UP" key

Sound control display (Balance) "UP" key

Sound control display (Balance) UYN00020212E01

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Treble control To increase the treble, push the UP key (4) while TRE is displayed.

To decrease the treble, push the DOWN key (4) while TRE is displayed.

"UP" key

Sound control display (Treble)

"DOWN" key

Sound control display (Treble)

Sound control display (Treble)

"UP" key

"DOWN" key

Sound control display (Treble)

Sound control display (Treble) UYN00020217E01

Bass control To increase the bass, push the UP key (4) while BAS is displayed.

To decrease the bass, push the DOWN key (4) while BAS is displayed.

"UP" key

Sound control display (Bass)

"DOWN" key

Sound control display (Bass)

Sound control display (Bass)

"UP" key

"DOWN" key

Sound control display (Bass)

Sound control display (Bass) UYN00020207E01

CLOCK Setting the time

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1. Press the DISP key (6) for one second or more.

The HOUR display will flicker.

2. To increase HOUR, press the UP key (4).

To decrease HOUR, press the DOWN key (4).

3. Press the DISP key again and the MINUTE display will flicker.

4. To decrease MINUTE, press the UP key (4).

4 UYN00020216J01

5. Press DISP key again to complete time setting.

ANTENNA To prevent interference, retract the antenna before transporting or storing the machine.

UPSX0107006B01

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR CONDITIONER (OPTIONAL) The air conditioner (if equipped) is located to the right of the operator seat. It provides heating or cooling, removes moisture from humid air and reduces window glass fogging.

Three air outlets are located inside the cab (A), (B) and (C). The direction of air flow can be adjusted by hand.

NOTICE: Do not splash water on the control panel.

Water can cause unexpected failure.

CONTROL PANEL

NOTICE: Keep fire away from the air conditioner.

NOTICE: Adjust the air conditioner according to ambient temperature and weather conditions.

Optimum difference between ambient temperature and air temperature inside the cab is 5-6 degrees.

GRILL

(B) (A) (C)

UPSX0107010E01

A, B AND C = AIR OUTLETS

Control Panel Before turning on the climate control system/air conditioner, close the door and windows to achieve the best performance.

The Fan Speed Selector Dial (1) is used to change the fan speed and volume of air flow.

0 = OFF (Stop operation) 1 = Minimum fan speed/air flow 2 = Medium fan speed/air flow 3 = Maximum fan speed/air flow The Temperature Control Dial (2) is used to adjust the temperature. To lower the temperature, turn the dial to the LEFT to the COOL (blue) range. To raise the temperature, turn the dial to the RIGHT to the WARM (red) range.

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3 UPSX0107011E01

1. FAN SPEED SELECTOR DIAL 2. TEMPERATURE CONTROL DIAL 3. AIR CONDITIONER SWITCH

The Air Conditioner Switch (A/C Switch) (3) is used to turn the air compressor on or off.

NOTICE: Before turning the Air Conditioner Switch ON, first turn the Fan Selector Dial to 1, 2 or 3.

Press this switch to turn the air conditioning ON. A green lamp will illuminate when the air conditioning is ON. To turn the air conditioning OFF, press the switch again.

NOTICE: The Air Conditioner Switch not only cools but also removes moisture from the air. It can be used during cooling and heating of the cab. If the air inside the cab becomes too dry, causing soreness in the eyes, open the windows for ventilation.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS The Air Selector Lever (4) is used to switch between internal air recirculation and external fresh air intake.

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: Air recirculation : Fresh air intake NOTICE: When the air conditioner is operated for a long time, switch the Air Selector Lever to fresh air intake.

UPSX0107012B01

4. AIR SELECTOR LEVER (INTERNAL/EXTERNAL)

ORDINARY COOLING 1. Turn the Fan Speed Selector Dial ON to 1, 2 or 3 to select the preferred air volume.

2. Press the Air Conditioner Switch ON. Check that the green lamp illuminates.

3. To adjust the temperature, turn the Temperature Control Dial. To lower the temperature, turn the dial to the COOL (blue) range.

4. To intake fresh air, switch the Air Selector Lever from recirculation to fresh air intake.

RAPID COOLING NOTICE: When the air temperature inside the cab is very high, open the cab windows first to ventilate, then start the air conditioner.

1. Turn the Fan Selector Speed Dial to 3 (maximum).

2. Press the Air Conditioner Switch to ON and check to make sure the green lamp goes on.

3. Turn the Temperature Control Dial LEFT to the COOL (blue) range.

4. Switch the Air Selector Lever from fresh air intake to recirculation.

ORDINARY HEATING 1. Turn the Fan Speed Selector Dial to the preferred air volume.

2. To adjust the temperature, turn the Temperature Control Dial to the right to WARM (red.)

3. When it is too hot, turn the Fan Speed Selector Dial to the left to decrease air volume.

4. Switch the internal/external air selector lever from recirculation to fresh air intake.

5. During heating, if moisture condenses on the windows, press the Air Conditioner Switch. The air cond itioner will remove m oistur e an d dehumidify the cab during heating.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS PERIODIC SERVICE Maintain and service the air conditioner periodically to ensure ongoing heating and cooling performance. Check the items listed below in the chart and adjust the air conditioner belt regularly.

Item/Interval Refrigerant

Check

Air conditioner belt

Check/Adjust

Condenser

Check/Cleaning

Every 3 months or 250H

When required

Every 6 months or 500H

Once a year or 1000H

o o o o

Cleaning Filter

o

Replace

Adjusting the A/C belt WARNING: Rotating parts can cause injury. Keep away from the fan and belt when the engine is running. Stop the engine before servicing.

NOTICE: When wear or damage is found on the belt, replace it with a new one. Avoid oil adherence to new belt; it causes slipping and results in short service life of the belt.

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1. Pull up the safety lock lever to lock all controls and stop the engine.

2. Using the ignition key, unlock the hood and support it with stay.

3. Check the tension of the belt, using your thumb or a belt tension gauge. Apply 19 Nm (14 lb ft) force on the center of the belt between pulleys. If the deflection if 4 mm (0.157 inch) it is in normal tension.

UPSX010701401

1. CAP SCREW 2. ADJUSTING BOLT

4. To adjust the belt tension, loosen the cap screw (1) slightly on the idle pulley, then loosen or tighten the adjusting bolt (2).

5. Tighten the cap screw (1).

Tightening torque: 23 + 2.3 Nm (16.9 + 1.6 lb ft) 6. After adjustment run at low idle speed for about five minutes then check belt tension again.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Servicing the A/C filters WARNING: Flying debris from compressed air may cause accidents resulting in injury or death. Wear safety goggles and a respirator when servicing the air conditioning filters.

The air conditioning filters must be cleaned at least once a month to keep the air conditioner running efficiently. Using the air conditioner with dirty filters can cause damage to the equipment.

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2

Recommended Air Filter Service Interval

Clean internal/external filters

Every 250 hours

Replace internal/external filters

Every 1000 hours

NOTICE: The recommended service interval is for use in normal operations. For use in dusty/dirty environments, clean and replace air filters earlier than the recommended intervals.

UPSX0107015B01

1. KNOB 2. COVER

Removing the external (fresh air) filter 1. Loosen the knob (1) located on the right wall on the inside of the cab.

2. Remove the cover (2).

3. Hold the handle of the filter and pull it straight up.

Removing the internal (recirculation) filter 1. Remove the cover (2) on the wall of the inside of the cab.

2. Hold the handle of the recirculation air filter located on the back of the cover and draw the filter right beside.

Clean the filters using compressed air.

Reinstall the filters after cleaning, using the reverse of the procedures described above.

Checking the A/C refrigerant WARNING: Eye injury hazard! Wear protective goggles when using compressed air. Failure to comply could result in minor or moderate injury.

COO35A

NOTICE: When filling or changing refrigerant, confirm and use the specified type and quantity. See Specifications section. Use of unspecified refrigerant may cause damage to equipment.

UPSX0‘07017B01

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 1. Start the engine. Set engine speed to the middle position.

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UPSX0107016E01

1. TEMPERATURE CONTROL DIAL 2. FAN SPEED SELECTOR DIAL 3. AIR CONDITIONER SWITCH

2. Fill the A/C system with refrigerant to the proper volume. See table at right.

Turn the temperature control dial to C (maximum cooling.

Turn the fan speed selector dial to 3 (maximum speed).

Refrigerant volume

Description

(A) Proper After the air conditioner is turned ON, little bubbles appear. The refrigerant becomes transparent, then turns a light milky white.

(B) Overcharged

Turn the air conditioner switch ON. 3. Follow the procedure below and check the refrigerant volume by looking through the sight glass (inspection window) of the receiver dryer.

Figure A shows that the refrigerant volume is proper.

Figure B shows that the refrigerant is overcharged. This will make both high and low pressure extreme and exert a bad influence on the pressure switch operation and the air conditioning system.

Figure C shows that the refrigerant is insufficient. Contact our dealer/distributor for recharging refrigerant.

After the air conditioner is turned ON, no bubbles appear.

(C) Insufficient After the air conditioner is turned ON, bubbles appear continuously.

Bubbles......... Refrigerant gas is mixed with refrigerant fluid.

No Bubbles....Whole refrigerant becomes fluid and transparent.

Cloudy........... Refrigerant is separated from oil.

The fluid becomes a light milky white.

UYT00040099E01

NOTICE: To rotate the compressor, operate the air conditioner at least several minutes once a week regardless of season. When oil comes out from the pipe joint, contact your dealer/distributor because it is a sign of gas leaking.

WARNING: Do not release refrigerant which is sealed in this unit into the atmosphere. Recover the refrigerant before disposing of the unit.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 External Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Prior to Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Check Warning Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Stopping the Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Machine Warmup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Ditch Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Using the Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Offset Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Swinging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Operating in a Narrow Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 CHECK MACHINE CONDITION DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 PRECAUTIONS AFTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Avoid Sudden Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Machine Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Operation with Rubber Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Operation near Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 OPTIONAL ATTACHMENTS (BREAKER, NIBBLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Setting the Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Operating the Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Operating the Nibbler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Extra (Hand Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 ANGLE DOZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Dozer Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Dozer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Dozer Inspection and Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Do Not Allow Passengers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Wear Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Use for Intended Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Do Not Overstroke the Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Avoid Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 Stop Operation During Hose Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 Do Not Use Dropping Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 Do Not Use Swing Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 Do Not Pry and Break Forcibly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Do Not Operate Arm in Vertical Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Do Not Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Move Arm Slowly at Cylinder Stroke End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 ACCELERATED SERVICE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

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CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE 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 an d lubr ican ts ar e suita ble for p reva iling conditions. See Chapter 6 - Maintenance and Adjustments.

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 necessar y. See Chapter 6 Maintenance and Adjustments.

15. Work out a convenient means of escape from the machine (be proa ctive and deter mine an emergency exit) in the event of the cab door being jammed or the machine turning over. Cab models are equipped with an emergency hammer.

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

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.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

8. Make sure that the engine hood and the side doors are properly closed and latched.

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 (the undercarr iage 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.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE MACHINE WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in death or serious injury CE-NA000

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.

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.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See Chapter 6 - Maintenance and Adjustments.

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

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

4. Take note of the locations of hoses/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 signals 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.

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

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.

12. See Transporting the Machine in this chapter when driving the machine onto a trailer.

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

4-4

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, 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 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 the ground or the cab and not pointing in the direction of the cab.

CHAPTER 4 - OPERATING INSTRUCTIONS EXTERNAL VISUAL INSPECTION Before starting the engine, walk around the machine to check for loose nuts and bolts, oil, fuel or coolant leakage, and condition of the attachment and hydraulic system.

5

3 7

Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt, etc.).

Repair and clean as necessary.

1. Check the engine for oil, fuel or coolant leakage.

Repair as required.

2 6

4 1

2. Check the area around the engine and radiator for accumulated material, remove as required.

UPSX0103001B01

3. Check the hydraulic equipment, oil tank, hoses, and joints for oil leakage and repair as required.

4. Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the bolts for looseness.

1. ENGINE 2. AREA AROUND ENGINE 3. HYDRAULIC EQUIPMENT 4. TRAVEL SYSTEM

5. ATTACHMENTS 6. GUARDS 7. GAUGES

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the guards, steps and handrails for damage, and the bolts for looseness. Repair and tighten bolts as required.

7. Verify that the gauges and the monitor panel (gauge cluster) function properly.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS PRIOR TO STARTING THE ENGINE WARNING: AVOID INJURY! 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.

Check Coolant Level WARNING: AVOID INJURY! Do not remove radiator cap when engine is hot. Allow engine to cool down before removing radiator cap.

NOTICE: Engine coolant level is higher than normal when engine is warm. The coolant level will lower with engine temperature.

2

The radiator reservoir tank is located on the right side of the engine compartment.

1. Check the coolant level with cold engine.

2. Open engine reservoir tank. The coolant level should be between the lines of FULL and LOW. Maintain coolant level at the full mark with engine cold. Refer to Specifications section of this manual for engine coolant specifications.

1

3. Open radiator reservoir tank cap (1) to refill with proper coolant mixture. Check the radiator coolant level when the coolant level in the reservoir tank drops below the LOW level mark.

Check the engine cooling system for leakage and repair as needed, before resuming operation.

4. See Maintenance section of this manual for reference. Remove the radiator cap (2), and check for proper coolant level.

5. Refill radiator with proper coolant mixture. Install radiator cap (2) and tighten securely.

Check for Coolant Leakage If the coolant level in the radiator reservoir tank does not lower, but the coolant inside the radiator does, there is a possibility of air leakage in the cooling system. Make sure coolant level is to specifications and pressurize system to check for leakages.

Consult with the distributor for advise and/or repairs.

Repair any leaks before resuming operation.

4-6

UPSX0103002B01

1. RESERVOIR TANK CAP

2. RADIATOR CAP

CHAPTER 4 - OPERATING INSTRUCTIONS Check Engine Oil Level NOTICE: Park the machine on a firm, level surface before checking engine oil level. Make sure to check engine oil level before starting the engine. When checking the engine oil after operating the vehicle, wait at least 30 minutes after shutting off the engine.

1. Use the starter key switch to unlock and open engine doors. Secure engine door in open position using rod provided.

2

2. Pull out engine oil dipstick (1), clean it and insert it fully into its sleeve. Remove dipstick to check oil level. Oil level should be between the marks "H" and "L". If the oil is heavily contaminated or deteriorated, change it regardless of periodical schedule. Refer to Specifications section of this manual for oil specifications.

1

3. If needed, remove the filler cap (2) to refill. Check the oil level again after refilling.

H

4. Clean engine oil filler cap (2), before installing.

5. Close the engine door and secure it with key.

L

UPSX0103022B01

1. ENGINE OIL DIPSTICK 2. FILLER CAP

A. LOW FLUID LEVEL MARK B. HIGH FLUID LEVEL MARK

Check Hydraulic Oil Level WARNING: AVOID INJURY! Do not perform maintenance or inspection on a machine that has just finished operating. Allow enough time to the machine to cool off. Release hydraulic tank pressure before working with any hydraulic component.

XPX0030002E01

1. Move the machine to firm, level ground and position it as shown at right - bucket and dozer on the ground.

2. Check the hydraulic oil level through the sight level gauge on the side of the hydraulic tank. The oil level should be between H and L. Oil level will vary depending on the temperature.

1

2

L level - oil temperature should be between 10-30 degrees Centigrade (50-86 degrees Fahrenheit) H level - oil temperature should be between 50-80 degrees Centigrade (122 - 176 degrees Fahrenheit.

UPW00300004J01

1. BUCKET

2. DOZER

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS How to refill the hydraulic oil tank NOTICE: Refer to Specifications section for the recommended hydraulic oil.

1. Open the right side cover, and support it using the cover support rod.

2. Release the internal hydraulic pressure following the instructions in the Maintenance section of this manual under the heading, Releasing Inter nal Pressure of Hydraulic System.

UPSX0103023B01

3. Ensure that the internal pressure of the hydraulic oil tank is completely released, then loosen the bolts (1), remove the cover (2), and fill the reservoir to the proper level (A) with the specified hydraulic oil.

4. Check the O-ring (3) of the cover, and if wear or damage is recognized, replace it.

1 2

3

5. Install the cover (2) and fasten the bolts to the specified torque.

Tightening torque: 21.7~25.5 Nm (16~18.8 lb. ft.)

H

6. Start the engine and run it for 5 to 7 minutes at low idling speed. Operate each cylinder though its full travel and swing operation to remove any air from the hydraulic system.

A L 4

7. Return the machine to the hydraulic oil level check position.

8. Stop the engine and check the oil level and add oil as necessary.

9. Remove the cover support rod and return the cover to the normal position.

4-8

UPSX0103024B01

1. BOLTS 2. COVER 3. O-RING 4. LEVEL GAUGE

A. PROPER LEVEL

CHAPTER 4 - OPERATING INSTRUCTIONS Check Fuel Level WARNING: Avoid fuel related hazards! Stop engine before refilling. Refill with diesel fuel only. Do not overfill - it may cause oil spouting and damage the hydraulic system. Clean up all spilled fuel to prevent fire. Dispose of all hazardous waste in accordance with government environmental laws and regulations.

UPAX1003013B01

1. Turn the ignition switch (1) to "ON" position to illuminate the monitor panel and activate the fuel gauge.

2. Check the fuel gauge (2), and remove fuel cap (3) to refuel if needed. Refer to Specifications section of this manual for fuel specifications.

2

Fuel tank capacity: 38 liter (10.0 gal)

1 XPX00300004E01

1. IGNITION SWITCH

2. FUEL GAUGE

3. Do not remove fuel tank strainer (4) for refilling to avoid contamination.

4. After refueling, install fuel cap (3) and tighten securely.

5. Close the engine door and use key to lock it properly.

3

NOTICE: It is recommended to refuel at the end of the work shift. Refill to the FULL mark to reduce air volume due to condensation. Failure to do so could create rust or fuel freezing problems.

4

5 6 UPSX01030004B01

3. FUEL CAP 4. STRAINER

5. DRAIN PLUG 6. FUEL TANK

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS Check for Fuel Leakage Check and repair any fuel leakage. Do not operate a machine leaking fuel. Fuel leakage may be caused by faulty drain plug, crack on hose in fuel line, loosened hose clip, etc. Stop the engine immediately if any fuel leakage is found. Repair fuel leakage before resuming operation.

2 1

3 4 UPSX0103005B01

1. FUEL TANK 2. FUEL FILTER

3. WATER SEPARATOR 4. FUEL HOSE

Check Fan Belt WARNING: Avoid entanglement hazards! Rotating parts can cause injury. Keep away from fan and belt when engine is running. Stop engine before servicing.

XPX00100017E01

Check the fan belt for insufficient tension, wear, and damage. Insufficient belt tension may cause battery charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

Apply a force of 98 N (22 lb) to the center of belt between pulleys, and measure the belt deflection.

The table below shows normal condition.

2

3

NOTICE: A “used belt” is one which has been used on a running engine for five or more minutes.

1

NOTICE: See the 250 Hour Maintenance section in the Maintenance chapter of this manual for details on inspecting and adjusting the belt.

NEW BELT TENSION

USED BELT TENSION

8-12 MM (8/16 - 7/16 IN)

10-14 MM (3/8 - 1/2 IN)

4-10

UPSX0103006B01

1. MOUNTING/PIVOT BOLT 2. ADJUSTING BOLT

3. ADJUSTING BOLT

CHAPTER 4 - OPERATING INSTRUCTIONS CHECK WARNING LAMPS WARNING: AVOID INJURY OR DEATH! Careless movement of any control lever may cause unexpected movement of the machine. Set the safety lock lever to the "locked" (up) position before leaving the cab. Make sure the swing area of machine is clear of people and obstacles before operating. Know the position of the travel motors before starting traveling and sound horn before starting operation.

WARNING: Make sure all warning lamps and indicators function properly before operating the machine.

Before starting the engine, check the warning lamps and indicator lamps accordance with the following procedures:

1

2

RED: Warning Lamp YELLOW: Indication Lamp

3

4

5

6 UPWX3403002E01

1. ENGINE OIL PRESSURE 2. BATTERY CHARGE LAMP 3. ENGINE COOLANT TEMPERATURE LAMP

4. LOW FUEL WARNING 5. 2ND SPEED TRAVEL 6. AIR CLEANER CLOGGING LAMP

1. Make sure the safety lock lever is in the "LOCKED" (up) position.

2. Make sure all control "NEUTRAL" position.

levers

are

in

the

3. Use the starter key and the table (as reference) to check all warning lamps and indicators for proper functioning.

4. Do not operate the machine under faulty conditions. Consult with the distr ibutor if necessary. Refer to the section on warning lamps in the Instruments and Controls chapter and make sure all warning lamps and indicators function properly. Repair any malfunctioning lamps before resuming operation.

KEY OPERATION

OFF -> HEAT

OFF -> ON

START -> ON

FUNCTION

Pre-Heating

Before Start

Just After Start

1

Engine Oil Pressure Lamp

Light OFF

Light ON

Light OFF

2

Battery Charge Lamp

Light OFF

Light ON

Light OFF

3

Engine Coolant Temperature Lamp

Light OFF

Light OFF

Light OFF

4

Low Fuel Warning Lamp

Light OFF

Light OFF

Light OFF

5

2nd Speed Travel Lamp

Light OFF

Light OFF

Light OFF

6

Air Cleaning Clogging Lamp

Light OFF

Light OFF

Light OFF

Lamp

Check Work Lamp With the ignition switch in the ON position turn on the work lamps. If lamps do not light, replace the bulb. If they still do not light, check fuse and wiring and repair as necessary.

For fuse information, see sections on Fuses in this manual. For work lamp replacement, see section in this manual.

UPSX0102021B01

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING THE ENGINE WARNING: AVOID INJURY! Make sure the swing area of machine is clear of people and obstacles before operating. Know the position of the travel motors before starting traveling and sound horn before starting the engine.

NOTICE: Do not set the engine speed to high idle with cold engine. Do not hold the starter key switch in the START position for more than 15 seconds. If the engine does not start, return the starter key switch to the OFF position, wait 30 seconds, and then try again.

1. Make sure that the safety lock lever (1) is set to the LOCKED (UP) position.

A

B UPWX3403001B01

1. SAFETY LOCK LEVER A. LOCKED (UP) B. UNLOCKED (DOWN)

2. Make sure all control levers are set to the NEUTRAL position.

3. Slightly move the throttle control lever (2) from the low idling position.

2 3

UPW00300016J01

2. SAFETY LOCK LEVER 3. IGNITION SWITCH

5. turn ignition switch (3) to the START position and release as soon as the engine starts. Key will automatically return to the ON position.

OFF HEAT

ON START

3 UPAX1004004E01

3. IGNITION SWITCH

4-12

CHAPTER 4 - OPERATING INSTRUCTIONS STARTUP UNDER COLD CONDITIONS In cold weather, due to the increase in oil viscosity and decrease in battery performance, starting the engine may be difficult. Use the preheater to start the engine easily under these conditions.

1. Perform Steps 1-3 of Starting the Engine shown on the previous page.

2. Turn the ignition key (1) to the HEAT position and hold position or 15 seconds to preheat before starting.

WARNING: Do not hold the ignition key in the START position for more than 15 seconds. If the engine does not start, return the ignition switch to OFF, wait 30 seconds, then try again.

UPAX1004005E01

1. IGNITION KEY

3. Turn the key to the START position to start the engine.

4. Release the ignition key switch immediately after starting the engine. The key will return to the ON position by itself.

NOTICE: In cold weather, just after the engine starts, white exhaust gas may be emitted. This is not abnormal. After awhile, it will disappear.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS USING BOOSTER CABLES WARNING: AVOID BATTERY HAZARDS! Flammable gas (hydrogen gas) is generated in the battery. Do not allow sparks or flames to come in contact with batteries to avoid triggering an explosion.

WARNING: Do not allow the vehicle or machine used for boosting to touch metal to metal with the disabled machine.

WARNING: Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries.

UPAX1004006E01a

WARNING: Do not allow the booster cable clips to come in contact with each other once connected to a battery. The negative cable, when connected to the upper frame of disabled machine, may arc causing sparks.

WARNING: Connect the booster cable to a ground surface in the engine compartment as far as possible from the battery.

WARNING: If the battery fluid is frozen, do not attempt to start the disabled machine. Either allow batteries to thaw and then charge or replace the batteries.

UPAX1004006E01b

NOTICE: Select suitable size for the booster cables and clips according to the battery size.

2 1

NOTICE: Do not use booster cables that are damaged, i.e. broken insulation, damaged clamps or corroded.

UPAX1004006E01c

1. BATTERY

4-14

2. BOLT

CHAPTER 4 - OPERATING INSTRUCTIONS The electrical system of this machine is 12 V DC. 1. Turn the ignition key to the OFF position for both boost vehicle and disabled machine.

1

2. Remove the left side cover. Then open the cover under the operator's seat.

3. Remove the cover from the battery terminals.

2 UPSX0103008B01

1. BATTERY COVER

2. BATTERY

4. Connect the booster cable (red) clip to the positive (+) terminal on the battery of disabled machine.

5. Connect the clip from the other end of the positive (+) booster cable (red) to the positive (+) terminal on the battery of boost vehicle.

6. Connect the booster cable (black) clip to the negative (-) terminal on the battery of boost vehicle.

UPAX0602029B01

1. BATTERY

7. Finally, connect the clip from the other end of the negative (-) booster cable (black) to the upper frame of disabled machine, away from the battery.

2. BOLT

CABLE CONNECTING ORDER CABLE DISCONNECTING ORDER

8. Start the engine of boost vehicle, and run it for about 10 minutes at high idle.

(RED)

9. Start the engine of disabled machine.

10. After starting the engine of disabled machine, remove the booster cables in the reverse order of the above connection order.

11. Check and repair the cause of the problem of the charging system on the disabled machine.

BOOSTER BATTERY

DISCHARGED BATTERY

(BLACK) TO THE UPPER FRAME OF THE DISABLED MACHINE XPX00300005E01

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE MACHINE ENGINE NOTICE: Avoid damage to engine. Stopping the engine while running at high speed will cause damage from increased engine temperature affecting seals and oil.

1

1. Place the attachment on the ground before stopping the engine.

2. Place the safety lock lever in the "LOCKED" (up) position before leaving the cab.

3. Push the throttle lever (1) all the way forward to low speed position for 5 minutes to lower the coolant temperature.

UPW00300023J01

1. THROTTLE LEVER LOW IDLING POSITION

4. Turn the ignition switch (2) OFF to stop the engine.

5. Remove the ignition switch (2).

OFF HEAT

ON START

2 UPAX1004007E01

2. IGNITION KEY

4-16

CHAPTER 4 - OPERATING INSTRUCTIONS iNSPECTION AFTER STARTING ENGINE WARNING: Avoid injury or death! Careless movement of any control lever may cause unexpected movement of the machine. Set the safety lock lever to the LOCKED (UP) position before leaving the cab. Make sure the swing area of the machine is clear of people and obstacles before operating. Know the position of the travel motors before starting travel and sound the horn before starting operation.

NOTICE: Do not apply any heavy load on the new engine for the first 50 hours operation. Confirm the LIGHT-OFF for each warning lamp. Carefully listen for any abnormal sound. Check for oil and water leakage around the engine. At the first engine start-up of the day, operate the engine for about 5 minutes with no load to warm up the engine and circulate oil to every part of the engine.

EXHAUST GAS COLOR

SOUND

SMOKE

Check Exhaust Gas Color, Sounds and Smells 1. Check for abnormal exhaust gas color during engine operation. Avoid continuous operation if the engine exhaust is black. Black exhaust is an indication of an excessive rich fuel/air mixture.

Check and service the engine if this condition is present.

UPW003000010E01

2. Stop operation immediately when any abnormal sound exists during the machine operation.

Check the cause of the abnormal sound, and repair as needed.

3. Avoid the operation at the speed range with resonance. There may be a certain rotating speed range at which the vibration suddenly becomes excessive due to resonance. Avoid the operation at such speed range. Parts may be damaged due to vibration.

4. If burning smell or smoke is generated, stop the e n g i n e i m m e d i a t e l y. C h e c k fo r a n y abnormalities and repair as needed before resuming operation.

NOTE: When needed, contact your dealer for repairs.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS Check Switches and Levers After warming up the engine, check the operation of the following switches and levers.

WARNING: Avoid injury or death! If any improper operation is found, stop the engine immediately and contact your dealer to have the machine repaired and prevent any unexpected movements.

LOCKED

UNLOCKED

Safety Lock Lever (For Machines Equipped with Boom Swing Pedal Control) 1. With the engine running set the safety control lever to the LOCKED (UP) position.

2. Move the following controls: • Left control lever • Right control lever • Boom swing pedal • Travel control levers

UPSX0103009B01

3. Make sure the all functions do not actuate when the safety control lever is in the LOCKED (UP) position.

NOTICE: Dozer blade control function is live at all times, even with the safety lock lever in the LOCKED (UP) position.

Check Gauge Cluster

3

4

2

1

Check all gauges and warning lamps on the gauge cluster after starting the engine.

The red battery charge warning lamp (1) will light if the battery is not charging.

Check the electrical system.

The red engine oil pressure warning lamp (2) will light when engine oil pressure is low.

Confirm that the engine temperature gauge (3) and fuel level gauge (4) work properly.

4-18

XPX00300008E01

1. BATTERY CHARGE WARNING LAMP 2. ENGINE OIL PRESSURE WARNING LAMP 3. ENGINE TEMPERATURE GAUGE 4. FUEL LEVEL GAUGE

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE WARMUP Check all gauges and warning lamps on the monitor (gauge cluster) after starting the engine.

1

Engine Warmup WARNING: Avoid injury! When the engine is cold, avoid rapid increase of engine speed. Do not idle the engine for more than 20 minutes. Extended periods of idling will reduce the life of the engine.

Set the throttle lever in the MIDDLE position between low and high idle. Operate the engine for about five minutes with no load.

UPW00300009J01

1. MIDDLE SPEED POSITION

Hydraulic Oil Warmup NOTICE: Appropriate operation temperature range for hydraulic oil is 50 to 80 degrees Centigrade (122 to 176 degrees Fahrenheit). Avoid machine operation when the hydraulic oil temperature is below 20 degrees Centigrade (68 degrees Fahrenheit). Failure to do so will reduce the life of the hydraulic components.

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 when ever machine is started in 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. M1715

LEVER UNLOCK (DOWN)

2

BUCKET IN

BUCKET OUT

UPSX0103010E01

2. BUCKET CONTROL LEVER

1. Set the throttle lever (1) in the MIDDLE SPEED position.

2. Set the safety lock lever in the UNLOCKED (DOWN) position.

3. Operate the boom control lever to raise it all the way up.

4. Operate the bucket control lever (2) to retract or extend it completely against relief, see figure right. Hold this position for one minute, then release lever and wait for another minute before repeating process. Repeat this procedure at least 10 times or until the temperature of the pilot hydraulic oil is safe for smooth attachment operation.

5. After warming up hydraulic oil, slowly extend and retract each cylinder several times, and actuate travel and swing motors to complete the warm-up operation.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE OPERATION 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. M1416

A

WARNING: Avoid injury! Use a flagman when travelling on the shoulder of a road or in restricted work areas. Do not allow anyone to ride on the machine.

1. Confirm the location of the travel motor (1) before performing any travel operation. Travel with travel motors in the back of the machine for long distance travel.

1

UPW00100029J01

1. TRAVEL MOTOR

A. TRAVEL DIRECTION

2. Travel on flat and hard ground and in straight lines (or large angles) as much as possible.

When turning the machine, move forward and backward alternately as much as possible instead of making one sharp (pivot) turn.

3. Check the strength of bridges and road shoulders, and reinforce them if necessary.

4. Avoid contact with bridges or electrical power lines.

5. When traveling on rough ground, use low (1st) (C) speed to reduce the shock to the machine.

6. Do not allow large or heavy objects to strike travel motors (1). Likewise, do not travel over large objects such as rocks, stones, etc.

B

C

7. On a snowy or icy road, travel with slower speed avoiding any fast start, fast stop and fast slewing.

8. When loading/unloading for transport, remove any mud clogged in the crawler belts to prevent the machine from side skidding on the ramps.

Refer to Transportation chapter for the usage of ramps, etc.

4-20

UPW003000035J01

B. LOW IDLING POSITION

C. LOW (1ST) SPEED

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE TRAVEL The following instructions are aimed at providing an operator with the basic function of each hydraulic control. Use of these instructions and practice with a machine will allow the operator to become more efficient. Each operator must read and understand these basic instructions along with all safety precautions found in this manual and on the machine before operating the equipment.

WARNING: AVOID INJURY! Make sure the swing area of machine is clear of people and obstacles before operating. Sound horn before starting the engine. If any abnormality is found during the machine operation, immediately stop working.

Repair faulty conditions before resuming operation.

WARNING: Normal positioning of the machine for the purpose of determining front, rear, forward, reverse are with the travel motors located behind the operator’s cab. Always have the travel motor positioned correctly. Failure to comply could result in machine damage, injury or death. M1726 WARNING: Always know the location of travel motors before operating any hydraulic controls.Failure to comply could result in death or serious injury. M1727 Forward/Reverse Travel 1. Make sure the safety lock lever is in the UNLOCKED (DOWN) position (A). Operate the boom, arm, and bucket control levers to raise the attachments from the ground.

2. Pull the dozer control lever to raise the dozer blade.

A UPW00300029J01

A. UNLOCKED (DOWN)

3. To move the machine forward, push both (right and left) travel levers toward the front of machine. To move the machine in reverse, pull back both travel levers.

Travel speed changes depending on how far you push or pull the levers.

FORWARD

REVERSE

FORWARD

REVERSE

UPSX0103011E01

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS Pivot Turn To turn the machine RIGHT, push the left travel lever toward front of machine.

To turn the machine LEFT, push the right travel lever toward front of machine.

To turn the machine LEFT IN REVERSE, pull the left travel lever back.

To turn the machine RIGHT IN REVERSE, pull the right travel lever back to turn machine.

FORWARD

UPSX0103012E01

Spin Turn To counter rotate machine to the LEFT, pull left travel lever back and push right travel lever forward.

To counter rotate machine to the RIGHT, pull right travel lever back and push left travel lever forward.

REVERSE

FORWARD

UPSX0103013E01

Shifting Travel Speed (Low/High) For HIGH travel speed, depress and release the travel speed selector switch once before operating the travel controls. The rabbit marked lamp indicator (1) will illuminate in the gauge cluster.

Start the machine travel by operating the travel levers or pedals.

1

To return to SLOW travel speed, stop travel and depress and release the travel speed selector switch once.

NOTICE: Travel speed is always reset to LOW every time the ignition key is turned to the OFF position.

UPW003000033J01

1. RABBIT ICON = HIGH SPEED

To Stop Machine Travel WARNING: Avoid injury! Operating the attachment or swinging is not recommended while traveling. If necessary, operate the attachment or swing function slowly.

To stop machine travel, put the right and left travel levers in NEUTRAL position. Avoid stopping machine travel suddenly. Stop machine travel as slowly as possible.

STOP

STOP

STOP

STOP

UPSX0103014E01

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS Machine Operation on a Slope WARNING: Avoid rollover!

Operating the attachment or swinging is not recommended while traveling. If necessary, operate the attachment or swing function slowly.

WARNING: Do not change travel direction while traveling on or crossing a slope. The machine may roll over. Move the machine to a level area and proceed. Then travel up the slope to the new location.

WARNING: When the hydraulic oil is not warmed up sufficiently, the machine may not be able to deliver its full performance. Make sure the machine is sufficiently warmed up before climbing a slope.

The maximum grade ability of the machine is 58 percent (30 degrees).

UPW00300036J01

TO CHANGE TRAVEL DIRECTION ON A SLOPE, MOVE MACHINE TO LEVEL AREA THEN TRAVEL UP SLOPE

1. While moving down a slope, operate the travel levers slowly.

2. Travel on the slope in low (1st) speed.

3. Raise the bucket 30 to 40 cm (12-16 in) above the ground level while traveling.

4. If the engine stalls on a slope, place the bucket/attachment on the ground and make sure each operating lever is in the NEUTRAL position. Then, start the engine again.

5. If the machine starts to skid, immediately lower the bucket and apply the brake.

UPW00300091J01

BUCKET POSITION UP AND DOWN SLOPES

Swinging the machine on a slope may cause a rollover due to loss of balance. It is dangerous to swing to the downhill side of the slope with a full bucket.

When working on a slope is unavoidable, level an area on the slope to avoid machine rollover. Do not travel on a slope of more than 30 gradient.

UPW00100037J01

DO NOT SWING MACHINE ON A SLOPE

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS When parking the machine on a slope, even if it is for a short period of time, 1. Position the machine as shown in the figure.

2. Dig bucket teeth (2) into the ground.

2

3. Lower dozer blade (3) to the ground.

3

4. Put each operating lever in the neutral position.

5. Set the safety lock lever to the LOCKED (UP) position.

1

6. Block (1) the crawler belts/tracks.

UPW001000041J01

1. BLOCK CRAWLER BELTS/TRACKS 2. DIG BUCKET TEETH INTO GROUND 3. LOWER DOZER BLADE TO GROUND PARKING THE MACHINE ON A SLOPE

Machine Operation in Water WARNING: Be careful not to immerse the swing bearing, swing pinion and swivel joint into water or mud. If the machine is operated in water or mud, the swing bearing and other components may wear abnormally. If water or mud comes up to the swing bearing level, put fresh grease in the swing bearing unit until the old grease comes out. If water or mud goes higher than the upper frame level, contact your dealer for cleaning or repair.

1. The machine may be operated in water where the ground under the water is flat and the water flow is slow. The machine can be immersed in water at a depth (A) to the center of upper roller.

2. Operate the machine in water with care. Use the bucket to check for soft conditions at the bottom of river.

3

2

4

(A) 1 UPW00300037J01

A. WATER DEPTH 1. UPPER ROLLER 2. SWING BEARING 3. WATER SURFACE 4. RIVER BOTTOM

3. After operating in seawater, thoroughly wash the machine to remove salt.

4. Lubricate bucket pins and bushing every 4 hours if working with materials in wet conditions. Grease parts with a grease gun until grease comes out.

1

2

3 UPW00300038J01

1. GREASE POINT 2. GREASE POINT 3. GREASE POINT

4-24

CHAPTER 4 - OPERATING INSTRUCTIONS Machine Operation on Soft Ground When operating on soft ground, the machine may sink. Pay attention to the condition of the ground at all times while operating the machine to avoid getting stuck.

WARNING: Avoid injury! Attempting to free a machine that is stuck can be hazardous. Avoid operating on soft ground. The machine operator must be careful to avoid injury to himself and others while attempting to free the machine.

If possible, avoid travelling on soft ground. Avoid getting caught in the mud. In the event the machine gets stuck, follow these instructions: One Crawler Belt/Track Gets Caught in Mud When either side of crawler belts / tracks gets caught in the mud, 1. Lay logs or boards on the mud to form a base.

2. Operate the boom and arm to form an angle between boom and ar m of about 90-110 degrees.

3. Push on the ground with the bottom of the bucket to lift the machine body up to climb on the logs or boards.

UPW00300039J01

Both Crawler Belts/Tracks Get Caught in Mud When both sides of crawler belts / tracks get caught in mud and the machine does not move due to skidding, 1. Provide logs and boards, as described in the above section.

2. Using the bucket, dig into an area of the hard ground.

3. Then move the bucket control to pull the machine toward the hard ground. If this is not possible, get expert help to free the stuck machine.

UPW00300040J01

4. If the machine will not travel due to being stuck in mud, sand, gravel or on soft ground, lift each crawler belt / tracks off the ground by placing the bucket on the ground and pushing the boom and arm against the ground.

5. Raise the crawler belt / track a small distance off the ground.

6. Scrape the mud, sand, or gravel off the crawler belts / tracks. The stuck material may be cleared by rotating the crawler belts / tracks in forward and reverse with the crawler belt / track raised.

UPW00300041J01

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS Swing Operation WARNING: AVOID INJURY OR DEATH Operation of this machine on an incline or slope may cause it to become unstable or unbalanced.

UPW001000037J01

1. Make sure the area surrounding the machine is clear of people and obstacles before swinging the machine.

2. Work up and down incline or slope, never across. Do not swing or turn machine around on a slope. Build a level area on the slope for the machine to operate.

3. Operate control levers carefully to prevent sudden movements which may cause the machine to slide or rollover.

1 B

A

4. Use a flagman to guide the operator.

UPSX0103015B01

1. LEFT CONTROL LEVER 1. SWINGING RIGHT 2. SWINGING LEFT

4-26

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY WARNING AVOID INJURY! Swinging on a slope may cause the machine to become unstable or unbalanced. Do not swing down side of the slope with a full bucket. When working on slopes, build a level area for the machine to operate safely. Make sure the swing area of the machine is clear of people and obstacles before swinging.

NOTE: A wide range of machine applications are obtainable by means of using optional attachments. See section on Changing the Bucket in this manual.

DIGGING 1. Use Arm in Action - Operate the bucket at shallow depths using mainly the arm and the bucket control as required. Setting the bucket too deep will decrease digging efficiency.

2. Maximum Digging Force Position - The bucket will provide maximum digging force when the ar m and boom are at 90 - 110 degrees of each other. Operate slowly for maximum digging force.

B A UPW3303001B01

A. DIGGING DIRECTION

B. SHALLOW DEPTH

3. Direction of Bucket Teeth - Always point the bucket teeth in the direction the machine will be digging. Operate the bucket at shallow depths to reduce digging resistance and the possibility of damage to the bucket teeth.

UPW00300044J01

4. Operate Boom Slowly - Always begin and end boom operation slowly with smooth, careful movement of the control lever. Do not perform sudden starts and stops. Avoid making sudden stops while lowering the boom as this action places extreme stress on the machine and its components.

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

UPSX0103016B01

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS DITCH DIGGING For efficient ditch digging, position the machine parallel to the area to be dug and use smooth bucket and arm motions. To dig a wide ditch, dig both sides first, then dig the center portion.

UPW00300046J01

USING THE DOZER The dozer is used to push the soil back into the ditch or for ground levelling.

1. Scrape the soil laid on the ground at its upper or side face with the dozer.

2. Use the dozer blade to backfill the trench.

3. Adjust the height of the dozer with the dozer control lever to avoid overloading the engine.

UPW003000047J01

OFFSET DIGGING WARNING: AVOID INJURY OR DEATH! The excavator boom swing operating area is wide. When operating, note the surrounding conditions to avoid injuries and damage to properties, especially during offset digging operations near structures.

B

A

B

A

By depressing the left and right sides of the swing pedal alternatively, the boom swings in left and right directions, enabling offset digging in narrow spaces.

By depressing the left side of the swing pedal, the boom swings leftward and by pressing the right side the boom swings rightward.

The advantage of this function is that it enables offset digging work as shown in the illustration.

UPSX0103017B01

A. SWINGING RIGHT (RIGHT PUSHING DOWN) B. SWINGING LEFT (LEFT PUSHING DOWN)

4-28

CHAPTER 4 - OPERATING INSTRUCTIONS LOADING O p e r a t i n g e f f i c i e n c y m ay b e i m p r o v e d b y positioning the dump truck so that the swing distance is kept to a minimum. Be sure to maintain a good field of view when positioning.

It is recommended that truck loading be started at the front side of the dump body. Loading is easier and more soil can be loaded.

UPW00300049J01

SWINGING 1. Extend arm cylinder and bucket cylinder to maximum length and fold the bucket.

2. Extend the boom cylinder to maximum length.

3. Depress the left side of the swing pedal, then swing the boom by the left end of the swing.

4. Handle the operating lever to swing the upper frame.

NOTICE: Protect the damage due to impact.

bucket/attachment

from

UPSX0103018B01

BOOM IN FOLDED POSITION

OPERATING IN A NARROW SPACE Swinging may be done in narrow or limited operating space with the bucket folded in as shown in the illustration.

MINIMUM SWING RADIUS

TYPE BOOM

Canopy

Cab

Boom folded position

2,020 mm (6’ 7.5”) (Left 70 degree)

2,020 mm (6’ 7.5”) (Left 70 degree)

Boom forward position

2,420 mm (7’ 11.3”)

2,420 mm (7’ 11.3”)

UPSX0103019B01

BOOM IN FORWARD POSITION

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS

PARKING THE MACHINE WARNING AVOID INJURY! Always park the machine on a hard, level surface.

When parking on a slope is unavoidable, position the machine as shown in the illustration. Block the crawler belt/track (1), dig the bucket teeth into the ground (2), lower the dozer blade to the ground (3).

This will help prevent machine movement.

2

Set the safety lock lever to the LOCKED (UP) p o s i t i o n t o avo i d a ny u n ex p e c t e d m a c h i n e movement.

3 1

Stop the engine before leaving the cab/canopy.

If the machine is to be parked on a roadway, move the machine to the shoulder to allow passing of traffic. Also, post reflective warning signs and markers at a distance from the machine to safety warn motorists. Refer to local code and regulations regarding the posting of work area warnings and markers.

UPW00100041J01

1. CRAWLER BELT/TRACK 2. BUCKET TEETH 3. DOZER BLADE

1. Place both travel levers (4) into the NEUTRAL position.

2. Set the throttle lever (5) to LOW IDLING position.

6

4

3. Place the bucket (2) on the ground.

4. Place the dozer blade (3) on the ground.

5. Block the crawler belt/track.

5

UPSX0103020B01

4. TRAVEL LEVERS 5. THROTTLE LEVER

6. SAFETY LOCK LEVER

6. Set the safety lock lever (6) to the LOCKED (A) position.

A

B

UPW0030062J01

A. LOCKED (A) POSITION

4-30

B. UNLOCKED (B) POSITION

CHAPTER 4 - OPERATING INSTRUCTIONS

CHECK MACHINE CONDITION DURING OPERATION WARNING: Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in injury or death. M1088 Regularly check the monitor panel (gauge cluster) for warning lamps and indicators.

1. If the fuel level is low refill the tank with fuel after stopping the engine.

2. If the engine coolant temperature gauge is in the H range or the coolant temperature lamp is on, move the machine to a safe place. Run the engine at low engine speed to lower temperature. Refer to the INSPECTION & M A I N T E N A N C E C H A RT f o r d e t a i l s o n preventive maintenance.

XPX00300016E01

3. If the engine oil pressure lamp is on, move the machine to a safe place. Stop the engine Immediately and repair as necessary before resuming operation. Refer to the INSPECTION & MAINTENANCE CHART for details on preventive maintenance.

UPW00300064J01

PRECAUTIONS AFTER OPERATION 1. Move the machine to a firm, level surface.

Lower attachment to the ground.

2. Refill fuel to full mark to push out air and avoid condensation (moisture) in the tank. By doing this there will be less chance of freezing nor rusting in the fuel tank, which may cause troubles at time of start up.

3. Close and secure all the windows in place to prevent water or moisture getting into electronic components in the operator cabin.

4. Clean and inspect the machine thoroughly.

5. Lubricate / grease where necessary and repair or replace any problem areas before restarting the machine.

UPW001000042E01

6. When the machine is stored under cold weather conditions, it may be necessary to remove battery and store it in warm and well ventilated store area. This may increase battery life.

7. Remove key from key switch and lock all the doors and access panels.

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS AVOID SUDDEN ENGINE STOP Avoid stopping the engine when running at high idle. The engine is to be run for 5 minutes with no load before stopping. Continuously monitor the job site and machine for changing conditions to avoid sudden stop of the engine.

Pay attention to safety so that emergency stop of the engine will not be required.

If the sudden stop of engine is necessary due to changing conditions, hazardous situation or trouble with the machine, do the following to avoid injury or the damage to machine.

Do not restart the engine until its temperature is allowed to cool.

NOTICE: Sudden stop of the engine while operating at high speed causes a sudden rise of engine temperature resulting in deterioration of oil, damage to sealing components, etc.

1. If the engine stops operation, keep the safety lock lever in the "LOCKED" position.

2. If the engine has been stopped suddenly with the bucket or attachment off the ground, place blocks under the bucket/attachment and block crawler belts / tracks.

2 3

3. If the engine has been stopped suddenly on a slope block the crawler belts / tracks at the downhill side.

1

UPW00100041J01

1. CRAWLER BELT/TRACK 2. BUCKET TEETH 3. DOZER BLADE

4. Place a barrier around the machine while it is d o w n fo r r e p a i r s a n d p l a c e " D O N OT OPERATE" tag on the left control lever. Use "DO NOT OPERATE" tag P/N: LC20T01001P1.

5. Consult with the dealer/distributor for repairs if needed.

6. After an emergency stop, do not restart the engine until the temperature of the engine is allowed to cool.

1

1

UPW00300022E01

1. BLOCKS

4-32

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE SECURITY Use the ignition key to lock the engine door, cab door (if equipped), right and left side service doors, and fuel filter cap.

1 1 UPSX0102018B01

1. KEY CYLINDER

2

3 4 UPSX0103021B01

2. RIGHT HAND SIDE SERVICE DOOR 3. ENGINE DOOR 4. LEFT HAND SIDE SERVICE DOOR

OPERATION WITH RUBBER CRAWLER BELTS Rubber crawler belts offer features that iron crawler belts do not have. However, these advantages may not be realized if the rubber belts are used in the same way as iron crawler belts.

Although the rubber crawler belt displays many advantages because of its material properties, it has disadvantages in ter ms of strength. It is therefore necessary to get fully familiar with the characteristics of the rubber crawler belt and observe what actions are prohibited and cautioned against, in order to extend the service life of the rubber crawler belt and have it fulfill its advantages to the maximum possible extent. Read thoroughly "CAUTIONS ON USING RUBBER BELTS" before use.

Rubber belt

Iron shoe

Less vibration Smooth run Low noise Harmless for paved road Easy handling Not damageable Large traction force : Excellent

: Good

: Ordinary XPX00300017E01

COMPARISON OF RUBBER AND IRON CRAWLER BELTS

4-33

CHAPTER 4 - OPERATING INSTRUCTIONS WARRANTY OF RUBBER CRAWLER BELTS The machine warranty does not cover damage to t h e r u b b e r c r aw l e r b e l t s f r o m o p e r a t i o n i n improperly maintained job sites.

Prohibited Work Do not operate a machine equipped with rubber belts in the following conditions: 1. Do not operate or travel in gravel-mixed land, rugged and solid bedrock, ferroconcrete, iron scraps, edges of iron plates.

UPW003000067J01

2. Do not operate or travel in river beds with stones of various sizes. The rubber crawler belts may be damaged and come off the rollers.

Service life of the rubber belts will be reduced during dozer operation if they lose traction and slip.

UPW003000068J01

3. Avoid operation on surfaces contaminated with oil. Oil will damage the rubber crawler belts.

UPW003000069J01

4. Do not operate the machine near fire zones, steel plates exposed to the sun or in asphalt leveling operations. Heat will damage the rubber crawler belts.

5. When storing the machine for longer than three months, indoor storage is recommended. The rubber crawler belts can be damaged by exposure to environmental elements.

UPW003000070J01

4-34

CHAPTER 4 - OPERATING INSTRUCTIONS 6. Do not operate the rubber crawler belts in contact with the ground when one of the tracks is off the ground, as shown in illustration. The rubber crawler belt may come off the roller or could be damaged.

TRAVEL

UPW00300038E01

Precautions Be careful when operating a machine equipped with rubber belts in the following conditions: 1. Rubber belts slip easily on icy surfaces. Take the necessary safety precautions, such as not driving on snowy/icy slopes.

2. Avoid making a spin turn on a concrete road.

3. Avoid sudden changes in direction. This will cause early wear or chipping of the rubber crawler belts.

UPW00300072J01

4. Be careful not to damage the rubber crawler belt with the bucket or attachment during operation.

5. Do not apply side load force or side impact on the bucket or attachment during operation.

6. When the machine is raised bucket/attachment, lower it slowly.

by

the

UPW00300073J01

7. If the machine is operated in salty or corrosive conditions, the bonding of the rubber to the metal core can be damaged. Avoid using rubber crawler belts in corrosive conditions or thoroughly clean the belts after use. The normal temperature operating range for rubber crawler belts is between -25 deg.C to +55 deg.C {-13 deg.F to 131 deg.F}.

UPW00300074J01

4-35

CHAPTER 4 - OPERATING INSTRUCTIONS 8. The rubber belts should be used within -25 deg.C to +55 deg.C {-13 deg.F to 131 deg.F}, considering the physical properties of rubber.

NOTE: Use the rubber belts under proper tension to prevent them from coming off the rollers.

9. Avoid changing direction of the machine on ground with difference in level (20 cm {8 in} or more). When traveling over a place where there is a difference in level, do it at right angles to the difference in level.

UPW00300075J01

10. When climbing up a slope, avoid changing direction of the machine when at a point between level ground and the slope.

UPW00300076J01

11. If you travel on a slope or uneven surface with one side of the machine lifted, it will damage the rubber crawler belt. Always travel with both sides of the machine level.

UPW00300077J01

12. Do not change direction of the machine with the rubber crawler belt on ground with high spots, as shown in the figure. It will cause the rubber crawler belt to come off or be damaged.

UPW00300078J01

4-36

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS OPERATION IN EXTREME COLD NOTICE: When the temperature is extremely low, oil flow is reduced due to increased viscosity, making start-up difficult. Coolant may freeze, damaging radiator and/or engine.

1. Fuel and oil - Use fuel and oil of high quality and low viscosity for each system. See the section on Lubrication in the Maintenance chapter of this manual.

3. Battery - When the temperature becomes low, the charging ability goes down or the battery may freeze. Keep the battery charged as does to 100% as possible and cover the battery with insulation material.

 Perform test on the battery. We recommend the test be performed at room temperature for best results. Use a hydrometer to check the specific gravity of each cell and compare the readings with the table provided below.

2. Antifreeze/coolant - When operating or storing the machine in cold regions, the ratio of mixing antifreeze into the cooling system should c o n fo r m t o t h e l owe s t p r e d i c te d a m b i e n t temperature. If coolant freezes, the radiator, crankcase and cylinder head may be damaged.

Battery fluid temperature -20 degree C (-4 F)

1.31

1.29 1.28 1.27

 When shipped from the factory, the machine

0 degree C (32 F)

1.29

1.28 1.26 1.25

contains coolant mixed with all-season-type LONG LIFE COOLANT.

20 degree C (68 F)

1.28

1.26 1.25 1.24

 When operating or storing the machine in extreme cold, inspect the coolant to maintain proper concentration. The cooling system is filled with long life coolant LLC which is contained our genuine Antifreeze/Coolant specified for this machine. Our genuine Antifreeze/Coolant protects the cooling system from harmful corrosives while providing superior cooling performance necessary for emissions compliant engines for up to 1 year or 1000 hours of operation. Our genuine Antifreeze/Coolant also protects the engine from freezing in cold climate regions. Use of coolant other than our genuine Antifreeze/Coolant is not recommended and may result in poor machine performance and possible damage to the engine and cooling system. Our genuine Antifreeze/Coolant is specified for all machines operating in all regions including areas where cold temperatures or freezing is not normally expected.

NOTE: In extremely cold climates, covering the radiator is a method to aid the machine warm up. If necessary to maintain temperatures, cover the outer edges of the radiator, leaving an opening in the center part of the cover; thus, avoiding fan overloading. Keep a close watch on the gauge cluster for warning icons during operation. It may be necessary to use coolant heater, fuel heater, engine heater jacket, and/or additional battery power to aid engine starting. Likewise, mix coolant to a protection temperature of 5 degrees C (9 degrees F) lower than the machine will experience during operation, storage or transport.

Charging rate 100% 90% 80% 75%

NOTICE: Do not measure the specific gravity of battery fluid just after operation.

 Keep battery terminals free of ice and snow to avoid short circuits.

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

In extremely cold climates, remove the battery and store it overnight at room temperature.

4. After Operation in Extreme Cold - Mud and water adhering to the machine may freeze in cold we a t h e r i n t e r fe r i n g w i t h p r o p e r m a c h i n e operation. Use the following general guidelines as reference to prevent malfunctions:

 Clean off mud and dry off water adhering to the machine. Dry off water adhering to the travel system thoroughly and park on dry ground to prevent the travel system from freezing.

 Retract the cylinder rods to minimum length to reduce exposed areas. This will prevent frozen mud or water on the rod faces from damaging the seal.

OPERATION AT SEASHORE OR SALTY CLIMATE 1. Before Operation - Check all mounting hardware for proper tightness. Torque to proper value to aid in preventing salt from entering the machine systems. Apply grease to electrical equipment as required to prevent corrosion.

2. After Operation - Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods. Apply oil or grease as required to prevent corrosion.

4-37

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION NEAR WATER Electrical equipment is especially sensitive to water.

Be careful not to expose the electrical equipment to water when washing the machine or when it is raining. The electrical components (relays, fuses) are installed near the operator’s seat of the machine. Do not expose the operator’s seat to water.

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

2. Radiator - Clean the radiator on the machine regularly to prevent its core from becoming clogged with dust.

3. Fuel - Be careful not to let contamination in the fuel when refueling. Inspect the elements and filters at adequate intervals.

4. Electrical Equipment - Clean the starter and generator at adequate inter vals to prevent accumulation of dust. See section on Maintenance in this manual for details.

4-38

CHAPTER 4 - OPERATING INSTRUCTIONS

OPTIONAL ATTACHMENTS (BREAKER, NIBBLER) When mounting optional attachments, such as a hydraulic breaker or nibbler, on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and oil level for each attachment. To select proper attachments, contact your dealer/distributor.

Before installing a breaker or nibbler, consult with your dealer/distributor for hydraulic connection information.

Check the hydraulic return filter and if needed, replace it according to the specified replacement interval.

Thoroughly read the operator’s manual for the optional equipment and the safety precautions outlined in this section to avoid damaging the machine or breaker during operation.

While optional attachments are not installed, plug the hydraulic tubes on the bucket/arm end and hoses on the attachment end to prevent dust or water from entering the hydraulic system. Before operating the attachment, check the clamps on all hydraulic tubes and hoses for oil leakage and looseness and tighten as needed.

BASIC OPERATION WARNING: Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury. M1087 NOTICE: Continuous operation of the breaker or nibbler for longer than 30 seconds could cause premature wear or damage to the attachment and machine. If material is not breaking, reposition the breaker or nibbler and repeat the operation in 30 second intervals.

1. Start the machine and place the hydraulic function safety lock lever in UNLOCKED (down) position (B).

2. Move the throttle lever to the HI idle position.

3. Using the boom, arm and bucket controls, set the breaker or nibbler to the desired position.

4. Make sure the breaker or nibbler is in the desired position and against material to be broken.

BS06H080

A. LOCKED (UP) POSITION B. UNLOCKED (DOWN) POSITION

SETTING THE SELECTOR VALVE M a c h i n e s e q u i p p e d w i t h a n i b bl e r / b r e a ke r attachment must have the hydraulic system selector valve set to the correct position.

NOTICE: Operation of a nibbler or breaker with the selector valve in the wrong position will result in poor performance and may cause damage to the machine. Make sure the selector valve is positioned correctly for nibbler or breaker operation. To assure proper operation, change the selector valve position once a month.

1

UPSX0107002B01

1. SELECTOR VALVE

4-39

CHAPTER 4 - OPERATING INSTRUCTIONS NOTICE: Lower the attachment to the ground and stop the engine before switching the selector valve to avoid unexpected movement of the attachment or machine.

SELECTOR VALVE SHIFTING POSITION TO TANK

TO TANK

Selector valve markings are shown in the figure.

TO ATT

TO ATT

TO C/V

TO C/V

USE BREAKER

USE NIBBLER UPSX0107003E01

1. Use an Allen wrench (2) to loosen and remove the socket bolt (3).

2. Use a wrench (4) to turn the selector valve (1) to the desired position.

1

3. After the selector valve is in the desired position, tighten the socket bolt (3).

3 2

4 UPSX0107007B01

1. SELECTOR VALVE 3. SOCKET BOLT 2. ALLEN WRENCH 4. WRENCH

OPERATING THE BREAKER

1

WARNING: Check the function of the right control button before operating the machine.

The breaker operating button (2) is located on the grip of the right control lever handle. To operate the breaker, press the button. Operate the breaker in 30-second intervals. After 30 seconds, release the button to stop operation.

2

NOTICE: The breaker can be operated by sliding the option switch (1) to the left. When operating the breaker, it is recommended that the breaker operating button (2) should be used as much as possible.

WARNING: AVOID INJURY OR DEATH! Do not leave the machine with the engine running.

UPSX0107001B01

1. OPTION SWITCH 2. BREAKER OPERATING BUTTON

4-40

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE NIBBLER

1

WARNING: Check the function of the right control buttons before operating the machine.

To operate the nibbler, use the option switch (1) on the grip of the right control handle.

To open the nibbler, slide the option switch to the l e f t . T h e hy d r a u l i c f l o w r a t e w i l l i n c r e a s e proportionately as the switch is moved to the left.

2

To close the nibbler, slide the option switch to the r ight. The hydraulic flow ra te will decrease proportionately as the switch is moved to the right.

NOTICE: Do not touch the breaker operating button (2) when operating the nibbler.

WARNING: AVOID INJURY OR DEATH! Do not leave the machine with the engine running.

UPSX0107001B01

1. OPTION SWITCH 2. BREAKER OPERATING BUTTON

EXTRA (HAND CONTROL) WARNING: Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury. M1087

1

1. Start the machine and place the safety lock lever in the UNLOCKED (DOWN) position.

2. Move the throttle lever to the HI idle position.

3. Using the boom, arm and bucket controls, set the attachment to the desired position.

4. Use the boom, arm and bucket controls to position the attachment.

WARNING: Precaution for operation of switch on grip: the operation varies in the specifications so, before operating, read the operator’s manual carefully.

The Extra switch (1) is located on the grip of the left control handle. It is used to turn the attachment left or right by sliding the switch to the right or left.

UPSX0107008B01

1. EXTRA SWITCH

To turn the attachment to the left, slide the switch to the left.

To turn the attachment to the right, slide the switch to the right.

WARNING: Check the function of the left control handle extra switch before operating the machine.

NOTICE: Hydraulic flow will increase depending upon the slide distance of the switch (1).

4-41

CHAPTER 4 - OPERATING INSTRUCTIONS

ANGLE DOZER The angle dozer blade can move up, down, or change its angle with a single control lever.

1

UPSX0407003B01

1. DOZER CONTROL LEVER

DOZER CONTROL LEVER The angle dozer control lever (1) is located next to the right control stand. This lever can be used to move the dozer blade up or down, or change its angle right or left.

Release the lever and it returns to NEUTRAL position. The dozer blade remains in position.

2

UPSX0407002E01

4-42

CHAPTER 4 - OPERATING INSTRUCTIONS DOZER SPECIFICATIONS Unit: mm (in) 23

1,960 {6'5.2"}

23

400 {15.7"}

1,980 {6'5.9"} 1,960 {6'5.2"}

3,190 {10'5.6"}

345 {13.5"} 450 515 {17.7"} {20.2"}

6,190 {20'3.7"}

1,940 {6'4.4"}

UPSX0407006E01

ITEM

SPECIFICATIONS SK55SRX

Overall length when dozer is attached on the rear side

6,190 {20'3.7"}

Dozer overall width

1,960 {6'5.2"}

Dozer height

345 {13.5"}

Operating (angling) angle

23 deg. x 23 deg.

Dozer raising and lowering operating range

515 {20.2"} (UP) / 450 {17.7"} (LOW)

4-43

CHAPTER 4 - OPERATING INSTRUCTIONS

DOZER BLADE

SYSTEM

DOZER INSPECTION AND MAINTENANCE CHART

COMPONENT LOCATION

MAINTENANCE TO PERFORM

INTERVAL (Hour on Hourmeter) 8

Tightening of each capscrew

Dozer blade

O

Check on hydraulic hose, control valve and cylinder for oil leaking.

Hydraulic system & component

O

Check on cutting edge for wear and blade for damage.

Dozer blade

O

Check on angle frame for damage.

Dozer blade

Grease dozer blade & cylinder pins.

50

120

250

500

O

Dozer blade & Cylinder

O

O ••• Regular inspection & maintenance required.

UPSX0407004E01

MAINTENANCE PROCEDURE 1. Visually check the dozer blade for deformation and cracks. Repair damage immediately or replace the blade with a new one.

4

WARNING: Changing the set pressure of the relief valve on the dozer cylinder operating system is not allowed. Call your dealer for service.

2. Lubricate the dozer blade pins every 50 hours of engine operation. Use extreme pressure multi-purpose grease No. 2 EP type grease. To lubricate the dozer blade, place the bucket on t h e g r o u n d a n d b r i n g t h e d o ze r p i n s t o lubricating position.

3. Stop the engine.

1 3 2 3 1 2

4. Wipe clean all the grease nipples on the dozer cylinders (1) , dozer foot pins (2), angle cylinders (3), and blade/frame connection (4).

5. Replace any damaged grease nipples with new ones.

6. Using a grease gun, apply grease on the grease nipples until grease comes out.

7. After greasing clean all grease that comes out of the pins.

NOTICE: When digging under water, the submerged section must be lubricated before starting and finishing work.

NOTICE: When operating the machine after storage of one month or more, lubricate the dozer blade before starting operation.

4-44

UPSX0407005B01

1. DOZER CYLINDERS 3. ANGLE CYLINDERS 2. DOZER FOOT PINS 4. BLADE/FRAME CONNECTION

CHAPTER 4 - OPERATING INSTRUCTIONS

SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with other safety precautions found in this manual.

WARNING: Do not attempt to operate or service this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury. M1087 DO NOT ALLOW PASSENGERS This equipment is not intended or designed for the transportation of persons. Do not allow passengers to ride on the machine. Serious injury or death can result from allowing passengers on or in the machine.

UPW00100023J01

NO PASSENGERS

WEAR PROTECTIVE EQUIPMENT When operating attachments that produce flying debris, it is strongly recommended to purchase 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 area of the machine should wear protective gear, such as safety shoes, hard hat, gloves and face shield or goggles.

USE FOR INTENDED PURPOSE

UPW00100005J01

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.

UPW00700010J01

DO NOT OVERSTROKE THE CYLINDERS Do not operate the boom, arm or bucket cylinders at stroke ends when using a breaker attachment.

Doing that can put undue load on the cylinder rods and result in damage.

UPW0070009J01

4-45

CHAPTER 4 - OPERATING INSTRUCTIONS AVOID CONTINUOUS OPERATION Operate the nibbler/breaker in 30 second intervals.

Operation for longer than 30 seconds at a time can cause high oil temperatures that can cause damage to the accumulators, cylinder seals and pump.

UPW00700011J01

STOP OPERATION DURING HOSE SURGE Should the hydraulic hoses begin to surge or vibrate abnormally during operation of a breaker or nibbler, immediately stop operation and contact your dealer/distributor for assistance. Hose surge is often a result of damaged accumulators and can result in valve failure.

UPW00700012J01

DO NOT USE DROPPING FORCE Do not use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

UPW00700013J01

DO NOT USE SWING FORCE Do not use the swinging force of the machine for p u s h i n g t o s l i d i n g o b j e c t s. T h i s w i l l c a u s e premature failure of the attachment and other machine components.

UPW00700006J01

4-46

CHAPTER 4 - OPERATING INSTRUCTIONS DO NOT PRY AND BREAK FORCIBLY Do not use the breaker to pry and break rock and concrete. This may damage the hydraulic breaker and excavator boom, arm and hydraulic cylinders.

UPW00700007J01

DO NOT OPERATE ARM IN VERTICAL POSITION The arm should not be operated in the vertical position to prevent the hydraulic cylinders from vertical shocks that may damage the rod packings and pistons and cause oil to leak from those sections.

UPW00700008J01

DO NOT LIFT Do not use an optional attachment to lift or transport objects or material. 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.

UPW00700002E01

MOVE ARM SLOWLY AT CYLINDER STROKE END When lowering the arm rapidly, the cylinder rod reaches the stroke end rapidly and the impact can damage the arm cylinder. Operate the attachment slowly to avoid the abrupt approach to the stroke end of the arm cylinder.

UPW007000022J01

4-47

CHAPTER 4 - OPERATING INSTRUCTIONS WORKING RANGES WARNING: AVOID INJURY! Do not operate an optional attachment over the sides of the machine.

Only operate over the front or rear of the machine.

The balance of the machine becomes unstable at the positions shown in the right figure and there is the possibility of turning over the machine. Do not carry out breaker work in this position.

C B

A

C

UPW007000014J01

A. FRONT - OK B. REAR - OK C. LATERAL WORK PROHIBITED

4-48

CHAPTER 4 - OPERATING INSTRUCTIONS

ACCELERATED SERVICE INTERVAL WARNING: AVOID INJURY! Contamination and deterioration of hydraulic oil may cause function problems with control valves, early wear and possible seizure of the hydraulic pump leading to breakdown of the machine hydraulic system. Operation of the breaker accelerates the deterioration of the hydraulic oil, compared with normal earthmoving operation with a bucket.

Replace filters and hydraulic oil as indicated in the following table.

REPLACEMENT INTERVAL INSPECTION/MAINTENANCE

LOCATION

HYDRAULIC OIL RETURN FILTER

FIRST

2nd REPLACEMENT

REGULAR

Hydraulic tank

-

-

Every 1000 h

Hydraulic tank

50 h

200 h

Every 200 h

Prepare and update a maintenance record following the example provided.

DATE

HOURS

FILTER REPLACEMENT

HYDRAULIC OIL CHANGE

: : : :

4-49

CHAPTER 4 - OPERATING INSTRUCTIONS

4-50

CHAPTER 5 - TRANSPORTATION

CHAPTER 5

TRANSPORTATION TABLE OF CONTENTS PREPARING FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 LOADING/UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-1

CHAPTER 5 - TRANSPORTATION

NOTES

5-2

CHAPTER 5 - TRANSPORTATION

PREPARING FOR TRANSPORTATION When preparing to transport the machine, refer to the Specifications chapter for the total weight, height, width, length, traveling speed, ground pressure, etc. of the machine being transported.

Know route to be traveled. Investigate width of roads, bridges, overpasses, height of road signs, and road surface conditions on route.

Obtain any permits required from proper government agencies for machine transportation.

LOADING/UNLOADING 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. CM113A Use the following general guidelines for loading or unloading the machine to the transportation vehicle: UPW00100043E01

DO NOT USE BUCKET/ATTACHMENT TO LOAD/UNLOAD

1. Loading and unloading of the machine must be carried out on hard, leveled areas way from the road shoulder. Do not use the bucket/attachment to load or unload the machine from the trailer.

2. When needed, use a ramp capable of supporting the weight of the machine. The ramp slope should be 15 degrees or less. Check ramp width, length and thickness prior to loading/unloading. If the ramp structure bends excessively, support it with wood blocks or other suitable means.

UPW00100044E01

USE RAMP FOR LOADING/LOADING

5-3

CHAPTER 5 - TRANSPORTATION Use of Platform or Earth Banking The width and height of the loading area (earthen bank or loading platfor m ramp) must be high enough to match the trailer and wide enough to match the width of the machine and trailer. The ramp slope (A) should be 15 degrees or less.

The loading surface area must be able to support the weight of the machine to avoid a machine rollover. Make sure the loading area surface will suppor t the weight of the machine. Make improvements or repairs as necessary.

A

When loading the machine onto the truck: Machine with attachment - Drive onto the truck front first.

UPW0050002j01

A. RAMP SLOPE SHOULD BE 15 DEGREES OR LESS

Machine without attachment - Drive onto the truck rear first.

1. Position the machine on the truck/trailer for safe tiedown and weight distribution.

2. Remove any mud, oil, or grease from the ramp surface as well as from the crawler belts on the machine to prevent the machine from skidding.

3. Do not change traveling direction on the ramp.

Back up the machine, reposition and try again.

4. Always use low travel speed for loading or unloading the trailer.

SECURING THE MACHINE

B

After the machine is loaded and positioned on the truck/trailer, do the following:

2. Slowly position the bucket or attachment on the truck/trailer bed.

A

1. Lower the dozer blade.

3. Tie down the machine.

NOTICE: To protect the bucket (attachment) cylinder from damage during transport, place a wood block at the end of the bucket link to keep the cylinder from making contact with the truck bed.

4. Verify by measuring overall height and length to ensure compliance with legal regulations.

5-4

UPW00100084J11

A. HEIGHT B. OVERALL LENGTH OBSERVE LEGAL REGULATION

CHAPTER 5 - TRANSPORTATION 5. Move the safety lock lever to the LOCKED position (B).

B

6. Turn all switches off and remove the engine key.

Lock all covers and the cab door (if equipped).

7. Position blocks (A) at the front and rear of the crawler belts to secure them. This will prevent the machine from moving during transport.

1

A

1

A

UPSX0105003B01

1. WIRE ROPE/CHAIN

A. BLOCKS B. LOCKED POSITION (UP)

8. Position a block under the excavator arm to support it during shipping.

9. Tie down the machine using rigging sufficient for safe transport.

XPX00500001E01

LIFTING THE MACHINE WARNING: This machine/component is heavy. Use a suitable lifting and/or supporting device when lifting, moving or supporting the machine/component. Do not lift the machine/component higher than necessary.

Make sure all persons and pets are a safe distance from the machine/component when it is being lifted or moved. Failure to comply could result in death or serious injury. CM113A WARNING: Do not use the brackets (4 places) on the cab roof for lifting the machine. It causes damage to the cab.

UPSX0105001501

DO NOT USE CAB ROOF BRACKETS FOR LIFTING

WARNING: Do not use the fixing holes for transportation on the crawler frame for lifting. It causes damage to the crawler frame.

WARNING: When lifting the machine, operate the controls slowly and smoothly, avoiding any sudden or fast movements.

WARNING: When the machine is lifted with one or more workers, operation signals and communication must be understood by all involved to avoid injury or death.

UPSX0105002B01

DO NOT USE HOLES ON CRAWLER FRAME FOR LIFTING

5-5

CHAPTER 5 - TRANSPORTATION 1. Start the engine. Push DOWN the safety lock lever to unlock.

2. Operate the control lever to position each attachment as shown in the illustrations for the machine equipped with canopy or cab.

3. If the boom is swung, operate the swing pedal and turn the boom to the front of the machine.

CANOPY Rubber shoe 5,000 kg {11,025 lbs} Iron shoe 5,100 kg {11,246 lbs} 1800 5'11"

4500 14'9"

24 o 23o

5. Pull up the safety lock lever to lock.

(B)

4800mm {15'9"}

4. Lock the boom swing pedal.

6. Stop the engine and remove the ignition key.

Check the operator’s seat for loose items, tools, etc. that could fall or cause problems or injury while lifting the machine. Remove or stow these items.

(A)

7. To avoid interference between the machine and wire rope, use an iron bar of sufficient length.

Place wood blocks or heavy cloth between the machine and the wire rope to protect the machine from damage.

30mm {1.2"}

8. Install shackles in two lifting holes (A) provided at both ends of the dozer blade. Fasten the wire rope to the shackles as shown.

9. Install shackles on boom (B) and fasten the wire rope to the shackles as shown.

10. Lift the machine slightly and stop the lifting once to make sure the machine maintains balance.

Lift the machine slowly and in a horizontal position.

UPSX0105006E01

CAB Rubber shoe 5,130 kg {11,312 lbs} Iron shoe 5,230 kg {11,532 lbs} 1800 5'11"

4500 14'9"

24 o 23o 4800mm {15'9"}

(B)

(A)

30mm {1.2"} UPSX0105005E01

5-6

CHAPTER 5 - TRANSPORTATION

TOWING THE MACHINE If the machine should become stuck in soft soil areas it may be necessary to tow the machine.

WARNING: While towing, do not enter the area between the machine and the tow vehicle.

WARNING: Do not apply a shock load onto the towing rope. Keep the rope horizontal and perpendicular to the frame of the machine.

WARNING: Do not use the eyes on the lower frame of the machine for towing. Do not pull the machine using the brackets welded on the lower plates of the undercarriage. These brackets are provided for pulling lightweight objects.

1. Attach a wire rope or chain with the capacity to pull the machine out to the lower frame.

NOTICE: When towing the machine body, apply pads to the corner of the crawler frame to prevent the wire rope or chain from damaging the body.

2. Attach other end to the vehicle used to pull the machine. Operate the machine's travel lever in the proper direction while pulling with the other vehicle.

3. Tow the machine slowly in low speed mode.

UPW00100045E01

TOW MACHINE PROPERLY

5-7

CHAPTER 5 - TRANSPORTATION

5-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Read the Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Stop the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Tag Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Observe Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Hot Surfaces and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Warm Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Pressurized System Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Caution for Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Seals and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Use Support Equipment During Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Use Caution While Changing Bucket/Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Operation in Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Releasing Hydraulic Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Precaution Against Machine Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 LUBRICANT, FUEL AND COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Lubricant/Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Use of Bio-Degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 MAINTENANCE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 ACCESSORY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 INSTALLING HYDRAULIC HOSE AND PIPE JOINT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 O-Ring Seal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 BLEEDING AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 REPLACING THE RUBBER CRAWLER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Adjusting for More Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Adjusting for Less Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Removal of the Rubber Crawler Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Installation of the Rubber Crawler Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 INSPECTION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEN REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Check and Clean the Radiator Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Check and Replace the Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Check and Replace Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 Replace the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 Check and Replace Tooth Points and Side Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Replace the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Replace the Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Lubricate the Operating Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Check Electrical Wiring and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 DAILY (8 HOUR) INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Check for Fuel Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 Check Belt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45 Check the Warning Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Check Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Check Machine Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Check Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Check Cylinders, Piping and Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Check Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 Drain and Clean the Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 50 HOUR (WEEKLY) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Adjust the Crawler Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 Grease the Pins Around the Bucket/Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Drain the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Check the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Grease Attachment and Dozer Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Change the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Grease the Slewing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Adjust the Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Replace the Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Check the Radiator Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59 Check, Clean, Replace Air Cleaner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-60 Replace the Inner Air Cleaner Element (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Replace the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Change the Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-63 Replace the Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 Replace the Breather Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-67 Adjust the Engine Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-68 Check and Adjust the Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-68 1500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Check and Adjust Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 Clean the Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Clean the Pilot and Solenoid Valve Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Change the Oil in the Travel Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Change the Gear Oil in the Lower Roller, Idler and Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Change the Oil in the Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Change the Oil in the Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Grease the Swing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Check and Adjust the Contact Surfaces of the Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 INSPECTION/MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 SPECIAL MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 Changing the Pattern on the Rotary Multi-Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 Releasing Lock on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 Lowering Bucket/Attachment on Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL INFORMATION WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in death or serious injury.

M1087

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

NOTICE: For the adjustment, disassembly and repair of the engine, reduction gear and electronic equipment (controller, etc.) contact the dealer/distributor.

1. It is recommended 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.

U s e t h e s e p r o c e d u r e s w h e n p e r fo r m i n g inspection and maintenance as a guide. Also, refer to the inspection and maintenance charts for general service interval recommendations. If you doubt your ability to perform these tasks, contact your dealer for assistance.

DC04B668

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. Lubrication and maintenance intervals are determined by the hour meter. If performing lubrication and maintenance according to calendar time, the hour meter reading must correspond to the lubrication and maintenance period (8 Hours, 50 Hours, 250 Hours, 500 Hours, 1000 Hours, 2000 Hours, 5000 Hours etc.) in calendar time. Items for which service time cannot be specified are explained in the section “When Required.”

4. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition. Use the correct viscosity for the ambient temperature. Store appropriately.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL SAFETY NOTICE: Do not attempt any other inspection or maintenance procedures other than those specified in the manual.

Park the machine on flat, level ground before starting work. Do not attempt any maintenance with the engine running. Stop the engine and allow the machine to cool down before starting work.

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

KEEP MACHINE CLEAN Thoroughly clean machine before performing inspection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also reduce r is k of hydraulic sy stem contamination when machine is clean.

UPW00100058J01

READ THE HOUR METER Read the hour meter daily and check the maintenance schedule in this manual to ensure all maintenance is completed on schedule.

UPSX0104011B01

STOP THE ENGINE Do not attempt any maintenance with the engine running. There is the possibility of danger that your hand may be caught in the cooling fan or fan belt, resulting in injury.

Always stop the engine and allow the machine to cool to avoid injury.

If it is unavoidable to operate the engine for inspection or maintenance, carry out the work with two people. The person seated in the operator’s seat should be ready to stop the engine at any time while watching for a signal from the other person.

6-6

UPW00400002J01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TAG OUT MACHINE Before beginning any inspection or maintenance procedures, secure a DO NOT OPERATE tag (Part Number LC20T01001P1) to the operator’s 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.

UPW0010008E01

OBSERVE PRECAUTIONS Start the inspection and maintenance work fully understanding the contents of safety precautions indicated on the machine tables.

PV20T01005P1

ULC00040002E01

HOT SURFACES AND FLUIDS 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.

WARM ENGINE OIL 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.

UPW00400006J01

PRESSURIZED SYSTEM HAZARDS Release the internal pressure before removing the hydraulic system or fuel system, piping, or coupling of the cooing system or other related parts to which inter nal pressure is applied. See section on Hydraulic Tank Pressure for procedure to release internal pressure.

ULC000400013E01

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PREVENT CONTAMINATION A l w a y s c a p o r p l u g l i n e s w h e n hy d r a u l i c components are removed to help prevent hydraulic system contamination caused by dirt, dust and debris entering a port.

NOTICE: Do not allow hydraulic lines or components to become contaminated. This could cause severe system damage. Contact an authorized dealer/distributor to obtain the proper caps and plus to be used on this machine.

XPX00400002E01

INSPECT WASTE OILS AND FILTERS 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 t e r. I t i s recommended to cut open the oil filters to determine any abnormal wear.

UPW00400008J01

CAUTION FOR OIL FILLING When a strainer is provided on the filling port, do not remove it while refilling fuel, oil or fluid.

UPW00400009J01

DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly.

NOTICE: Dispose of all hazardous waste in accordance with government environmental laws and regulations.

UPW00400010J01

6-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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.

UPW004000011J01

USE SUPPORT EQUIPMENT DURING SERVICE When machine inspection or maintenance is done under the boom, arm or under the bucket/attachment, use proper equipment or blocks to secure the attachment.

UPW00400012J01

USE CAUTION WHILE CHANGING BUCKET/ATTACHMENT WARNING: Do not insert your finger, hand or arm into the pin bore. The alignment must be carried out visually or by using a tool.

XPX00400003E01

OPERATION IN DUSTY CONDITIONS When the machine is operated in dusty conditions, do the following: 1. Frequently check for air cleaner clogging.

2. Clean the air cleaner element ahead of the specified period.

3. Clean the radiator core ahead of the specified period.

4. Clean and replace the fuel filter element ahead of the specified period.

5. Clean the electric equipment, especially the starter and generator, to prevent dust deposits.

UYN00040078J01

CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

WARNING: Never use gasoline, diesel fuel or other flammable solvents to clean parts. Always clean parts in a well-ventilated area. Failure to comply could result in death or serious injury. M138A

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING HYDRAULIC 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 Always release the internal pressure of the hydraulic tank before performing inspection or maintenance procedures.

1. Push the rubber cap DOWN to release pressure in the reservoir.

UPSX0104012B01

WELDING SAFETY 1. Turn the ignition key switch to OFF position and wait four seconds for the electrical power to disconnect.

UPW00400023E01

2. Remove negative terminal.

(-)

cable

from

battery

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Make sure the welder ground is not located at a seal or bearing.

5. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

PRECAUTION AGAINST MACHINE WASHING When washing the machine, do not use high pressure water to wash the inside of the body (swivel joint area).

6-10

UPW00100079J01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS The following chart provides information on the specifications of oil, grease, fuel, and coolant to be used in various climates and working conditions.

Component / System

Hydraulic tank

Temperature Range Type

Capacity

Hydraulic oil

34 liters {9.0 gal} 61 liters {16.1 gal} hydraulic system

Specifications Genuine parts Long life hydraulic oil KW5046 (20 L) P/No. KAP YN01T01066D3 Genuine parts Long life hydraulic oil KW5032S (20 L) P/No. KAP YN01T01066D1

ISO VG 46 ISO VG 32 SAE 40

Engine *1

Engine oil

H level : 7.4 liters {2.0 gal} L level : 3.4 liters {0.9 gal}

SAE 30 SAE 10W

A.P.I. classification for "service CD"

SAE 10W-30 Fuel tank

Diesel fuel

Radiator *1

2.6 liters{0.69 gal} Antifreeze 6.0 liters{1.59 gal} /Coolant total system

Travel motor Gear oil Idlers Lower rollers Upper rollers

Belt/Track tension adjust see adjustment procedure in section Control levers & Pedals

0.9 liters{0.24gal} X 2

ASTM D-975 No.2 30% LLC mixture 50% LLC mixture

Engine oil

ASTM D-975 Grade 2-D L.L.C specification *2

EXTREME GEAR OIL SAE #90

Genuine parts A.P.I clssification for "service GL-4" P/No. KAPSP90020

SAE 30

A.P.I. classification for "service CD"

75 cc{4.6cu.in} X 2

Boom, Arm, Linkage, /attachment Dozer blade Cylinder Boom Swing Cylinder pin Slewing bearing Slewing gear

75 liters {19.8 gal}

110 cc{6.7cu.in} X 10 20 cc{1.2cu.in} X 2 12-places 6-places

Grease

2-places

Genuine parts

1-place

Extreme pressure multipurpose grease No.2* 3

3.6 kg

2-places

As needed disassembly is required

NOTE: *1 Machines are shipped from factory with * marked oil. *2 LLC means Long Life Coolant *3 Cartridge part number KAPG0420D1 (400 g x 20) Pail can part number KAPG1601D1

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICANT/HYDRAULIC OIL

BIODIESEL FUEL

When changing and replenishing hydraulic oil, make sure to use oil specified by the manufacturer. The use of unspecified hydraulic oil or mixed oil causes deterioration of oil.

Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

Be sure to select hydraulic oil adaptable to the ambient temperature.

Change the hydraulic oil after 5,000 hours of operation.

Specified oil: Shell Tellus Oil S46 or Shell Tellus Oil ST32 DIESEL FUEL This engine is equipped with an electronically controlled high pressure fuel injection system that provides fuel savings and reduced emissions. The system requires the use of high precision, well-lubricated parts. If low viscosity fuel with low lubrication ability is used, durability may be notably lowered.

Specified fuel: ASTM D-975 No. 2 NOTICE: When oil leakage or damage is found in the lower roller, upper roller and front idler, contact your dealer for repair.

ANTIFREEZE/COOLANT WARNING: Antifreeze/coolant is flammable. Direct contact with hot surfaces or flames may cause it to burn. Repair leaks immediately and dispose of used antifreeze or coolant promptly and in accordance with government environmental regulation.

The cooling system of the machine is filled with long life coolant (LLC) which protects the cooling system from harmful corrosives while providing superior cooling performance for emissions compliant engines for up to one year or 1000 hours of operation. The long life coolant also protects the engine from freezing in cold climates. Use of other types of coolant is not recommended and may result in poor machine performance and possible damage to the engine and cooling system. Long life coolant is specified for all machines operating in all regions including areas where cold temperatures or freezing is not normally expected.

6-12

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.

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.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

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.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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.

USE OF BIO-DEGRADABLE OILS When you use Bio-degradable Oil (BIO OIL), refer to the following information:

Potential oxidation and stability could be a problem with the fuel store in the machine.

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.

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 mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, it is required to flush the hydraulic system that was filled with mineral oil several times before adding bio oil.

DO NOT allow water to collect in the fuel or storage tanks. 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.

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: 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.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

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.

Recommended Brand: MOBIL EAL Envirosyn 46H Recommended Change Interval: The BIO oil change interval is 2,000 hours. For the changing procedure, refer to the Changing Hydraulic Oil section of this manual.

Flushing Procedure 1. Drain mineral oil from hydraulic tank completely.

2. Drain mineral oil from cylinder completely.

3. Fill hydraulic tank with new BIO OIL. 4. After starting the engine, move every cylinder 10 strokes.

5. Idle travel motor right and left for three minutes.

6. Repeat swing operation 10 rotations.

7. Drain BIO OIL from hydraulic tank completely.

8. Drain BIO OIL from each cylinder completely.

9. Fill hydraulic tank with new BIO OIL. Repeat steps 4 to 9 twice.

10. For hydraulic oil in final condition, analyze the hydraulic oil and be sure of amount of remaining mineral oil.

Fo r fu r t h e r i n fo r m a t i o n a b o u t r e c o m m e n d e d Bio-degradable oil, please contact local dealer.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE PARTS 4

8(Right)

7 8(Left)

9 3

2

1

6

5

UPSX0104050E01 1. RETURN FILTER 2. SUCTION STRAINER 3. AIR BREATHER ELEMENT (OUTER)

6-14

4. AIR CLEANER ELEMENT (INNER) 7. WATER SEPARATOR ELEMENT 5. ENGINE OIL FILTER CARTRIDGE 8. BUCKET SIDE CUTTERS 6. FUEL FILTER CARTRIDGE 9. BUCKET TEETH

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Device

Parts No.

Parts Name

Hydraulic oil tank

YR52V01004R400 (ZD11G11000)

Return filter element kit (O-ring)

Hydraulic oil tank

PW50V00015F1 (ZD11G11500)

Suction strainer (O-ring)

Air breather

Q'ty

Replacement Interval

1

After 50 hours (first change) Every 1000 hours (from 2nd change) (Breaker specification : Every 200 hours)

1

Every 2000 hours

YN57V00002S010

Element

1

Every 1000 hours Replacement of element a 1000 hours interval is a guideline.

If the machine is operated in very dusty conditions, change the oil filter at a reduced hour interval.

PM11P00012S005

Element (Outer)

1

After 6 times of cleaning or one year whichever comes first.

PH11P01039P1

Optional Element (Inner)

1

For machines equipped with W (double) element the inner element must be replaced together with the outer element.

Replace the inner element with new one.

Engine oil filter

119005-35160

Cartridge

1

After 50 hours (first change) Every 250 hours

Fuel filter

129004-55801

Cartridge

1

Every 500 hours

Water separator

119802-55710 (24321-000650)

Element (O-ring)

1

When required

Bucket

PH69B00003P1 PH69B00004P1 (ZS13C16040) (ZN13C16013)

Side Cutter (Right) Side Cutter (Left) (Cap Screw) (Nut)

1 1 6 6

When required

Bucket

YJ69B00002S001 YJ69B00002S002 YJ69B00002S003

Tooth Locking Pin Rubber Lock Pin

4 4 4

When required

Air cleaner

NOTE: Replace parts during periodic maintenance or before the end of service life. The machine can be used economically if parts are changed properly and timely. When you order parts, confirm the parts number using the parts catalog.

NOTE: Items in parentheses () are parts to be changed at the same time.

NOTICE: Before you service this machine and dispose of oil, fluids and lubricants, always remember the 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.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ACCESSORY TOOLS No.

TOOL NAME

PART No.

1

LABEL

LC20T01001P1

2

TOOL CASE

PW01T01005P1

3

WRENCH

YJ23H00001P1

REMARKS

If tools become lost or damaged, contact an dealer/distributor to order the tools.

6-16

For engine oil filter

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

INSTALLING HYDRAULIC HOSE AND PIPE JOINT FITTINGS WARNING: AVOID INJURY! When replacing hoses or seals, make sure the attachments are well-secured to avoid sudden movement of attachment. Slowly remove fittings to release any hydraulic pressure during disassembly.

Metal joint and o-ring type fittings are used on this machine.

Sealing is performed with metal compression of the connector opening (elbow) and hose. Use caution during disassembly and assembly to prevent damage on the seal surfaces.

Be careful not to damage the hose, pipe and O-ring groove face and seal face. Use of damaged parts causes oil leakage. Prevent contamination. Fittings contaminated with foreign matter leak. To prevent oil leakage, do not use fittings that are clogged with dirt, sand, etc.

A

1

3

2

B

C UPRX0040014J01

1. HOSE A. SEAL FACE 2. UNION NUT B SEAT (HOSE SIDE) 3. CONNECTOR C SEAT (CONNECTOR SIDE)

Hoses should not be twisted or bent sharply during installation as twisting or bending can decrease the useful life of the hose. Clean hose ends and fittings of any contamination. Remove remaining solvent or lubricant on the fitting threads and dr y par ts completely before reassembly.

O-RING SEAL FITTINGS

1

O-ring seal fittings are equipped with an O-ring which seals the connection. The tightening torque of the joint of each hydraulic hose is determined by the diameter of the hose fitting screws. If any leakage or damage is found, replace the fitting and hose immediately.

When servicing, replace O-rings with new ones. If any O-ring is found to be leaking due to a loose fitting, do not tighten it - install a new O-ring, check for proper fit, then tighten it to the required torque.

See Torque Charts in Specifications section.

Never install a damaged or worn O-ring. Check new O-rings for damage. Install O-rings that are in good condition. The material and hardness differs for each size of O-ring. Use O-rings that meet the specifications of this machine. See Specifications section or contact your dealer.

2 3

4

4 4

A UPW00400029J01

1. HOSE A. O-RING FITTING 2. UNION NUT 3. CONNECTOR 4. O-RING

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM WARNING: 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 To avoid injury, release the internal pressure of the hy d r a u l i c s y s t e m b e fo r e c a r r y i n g o u t a n y maintenance work.

The following procedure is the only way to release the internal pressure:

UPW00400030J01

HYDRAULIC OIL LEVEL CHECK POSITION

1. Place the machine in the position shown in the figure, Hydraulic Oil Level Check Position. Fully retract the arm and bucket cylinders, then lower the boom to place the bucket on the ground.

Lower the dozer blade to the ground.

2

1

2. Make sure the hydraulic oil temperature is below 40 degrees Centigrade (104 degrees Fahrenheit).

3. Stop the engine.

4. Immediately after the engine stops, shift the right-hand and left-hand travel control levers forward and backward. Operate the levers in full stroke several times. Operate the swing pedals several times and release the internal pressure remaining in the hydraulic system.

5. Open the right side cover (1) to the hydraulic tank and support it with stay.

6. Press the rubber cap (2) on the upper surface of the hydraulic tank several times (five to seven times).

7. Make sure the pressure in the hydraulic tank is released completely.

8. To maintain the system check it often.

6-18

UPSX0104014B01

1. RIGHT SIDE COVER 2. RUBBER CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BLEEDING AIR IN FUEL SYSTEM If air enters the fuel system, the engine may become hard to start or may malfunction. Bleed the air whenever the fuel tank is empty, the water separator is drained, or when the fuel filter element is replaced.

1

1. Set the safety lock lever to LOCKED position and stop the engine.

2. Fill the tank.

2

3. Confirm that the handle of the water separator is set to the OPEN position.

4. Loosen the air breather plug (3) on the upper part of the water separator. Using a screwdriver, turn it two or three turns.

5. Turn the ignition key to the START position to crank the engine. As the engine cranks, fuel is pumped into the injection system. As air is bled out of the system, the engine will start to run.

6. Tighten the air breather plug (3) when the fuel coming out through the air breather plug hole does not contain air bubbles.

3 C

B

A 4 D

5 UPSX0104015B01

1. FUEL FILTER A. IN 2. WATER SEPARATOR B OUT 3. FIR BREATHER PLUG C FUEL VALVE CLOSED 4. FUEL VALVE D FUEL VALVE OPEN 5. DRAIN VALVE

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REPLACING THE RUBBER CRAWLER BELT Since the abrasion on the rubber crawler belt varies depending on working conditions and the nature of the soil, a frequent check is required for wear and tension. New belts will initially stretch, so be sure to frequently check crawler tension during the first 30 hours on a new machine or after belt replacement.

UPW00400039J01

1. FUEL FILTER A. IN 2. WATER SEPARATOR B OUT 3. AIR BREATHER PLUG C FUEL VALVE CLOSED 4. FUEL VALVE D FUEL VALVE OPEN 5. DRAIN VALVE

WARNING: AVOID INJURY OR DEATH! This work must be done carefully by two people. The operator must operate the machine as instructed by the signals of the partner.

NOTICE: Operating the machine with loose or out of adjustment rubber crawler belts can cause belts to wear prematurely and come off the idler, rollers, or sprockets.

UPAX1004021B01

WARNING: The rubber crawler belt is changed by lifting one side of the machine at a time. Unexpected lowering or movement of the machine can result in serious injury or death.

WARNING: Do not operate the boom, arm or bucket/attachment while removing or installing a rubber crawler belt.

1

UPW00400041J01

1. SAFETY SUPPORT

6-20

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Move the rubber crawler belt so that the joining part (M mark) is in the upper center position.

2. Swing the upper structure to place it at 90 degree (right angle) to the crawler frame.

Operate the boom, arm and bucket/attachment, placing them on the gr ou nd . Slowly and gradually lower the boom to lift one side of the machine. Support the lower travel structure of the machine with a safety support (1).

M XPW00400040J01

3. Measure the clearance (A) between the lower face of the crawler frame and the upper face of the crawler belt at the center position of the crawler frame.

2

1

Rubber belt: 75 - 85 mm (2.95 - 3.35 in) Iron shoe: 130-150 mm (5.12 - 5.91 in) 4. If the tension is out of specification, adjust it.

4

3

UPSX010417B01

1. CRAWLER FRAME 2. LOWER ROLLER A. CLEARANCE

3. RUBBER BELT 4. IRON SHOE

WARNING: Grease in the track tensioning mechanism is under extreme pressure and can penetrate the skin, causing severe injury. Keep face and body away from the grease fitting area. Do not loosen the grease fitting more than one turn. If grease does not release after one turn of the fitting, contact your dealer for assistance.

XPX00100020E01

5. Before adjusting the tension of the crawler belt, take note of the operating conditions.

When working on gravel or stone, looser tension (upper limit range) is preferable.

When working on hard ground, tighter tension (lower limit range) is preferable.

1

UPW00400043J01

1. GREASE FITTING

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUSTING FOR MORE BELT TENSION WARNING: Grease in the track tensioning mechanism is under extreme pressure and can penetrate the skin, causing severe injury. Keep face and body away from the grease fitting area. Do not loosen the grease fitting more than one turn. If grease does not release after one turn of the fitting, contact your dealer for assistance.

1. Using a grease gun, feed grease to the grease fitting (1) until proper tension on the crawler belt is obtained.

UPW00400045J01

Rubber belt: 75 - 85 mm (2.95 - 3.35 in) Iron shoe: 130-150 mm (5.12 - 5.91 in)

B

2. Move the machine forward and backward to equalize tension on both the left and right crawler belts.

3. Check the tension on the belts and repeat the adjustment to obtain the proper tension on both belts.

NOTICE: If specified crawler track (rubber) tension adjustment cannot be maintained or loosened, the grease tension cylinder may need repair. Contact your dealer for repair.

2

1 A

UPW00400044J01

1. GREASE FITTING 2. GREASE CYLINDER

A. GREASE FILL B PRESSURE

ADJUSTING FOR LESS BELT TENSION WARNING: Grease in the track tensioning mechanism is under extreme pressure and can penetrate the skin, causing severe injury. Keep face and body away from the grease fitting area. Do not loosen the grease fitting more than one turn. If grease does not release after one turn of the fitting, contact your dealer for assistance.

1. Gradually loosen the grease fitting (1) to release grease under pressure. Do not loosen the grease fitting more than one turn.

1

A

UPW00400046J01

1. GREASE FITTING

2. Move the crawler belt forward and backward when the grease does not release adequately.

A. DETAIL (SEE BELOW)

1

3. Tighten the grease fitting.

Tightening torque: 58.8 - 88.2 Nm (43.4 - 65 lb ft) 4. Move the machine forward and backward to confirm the correct tension on the crawler belts.

5. Check the tension and if it is not correct, adjust again.

UPW00400047J01

1. GREASE FITTING DETAIL A (GREASE RELEASE)

6-22

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REMOVAL OF THE RUBBER CRAWLER BELT WARNING: Before removing the rubber crawler belt, confirm that the pressure inside the track tensioning cylinder has been completely released, then turn the sprocket. If the procedure for releasing the pressure in the track tensioning cylinder is not followed, grease can penetrate skin, causing severe injury. If the tension of the rubber crawler belt does not release, contact your dealer for service.

1

1. Move the machine to an area with a hard, level surface.

2. Operate the boom, arm and bucket to set the attachment on the ground. Slowly and gradually lower the boom to lift one side of the machine as shown in the figure.

UPW00400041J01

1. SAFETY SUPPORT

3. Support the lower travel structure of the machine with a safety support (1).

4. Slowly loosen the grease fitting (2) on the grease cylinder to allow discharge of the grease to release tension.

5. Slowly loosen the grease fitting (2) on the grease cylinder less than one turn. Grease will flow from the fitting and track tension will release.

2

UPSX0104001B01

2. GREASE CYLINDER

6. Insert three steel pipes into the bottom front rubber crawler belt, then slowly rotate the sprocket backward. When the rubber crawler belt separates from the idler wheel, stop the rotation. Shut off the engine. Slide the rubber crawler belt over the steel pipes to remove it.

A

A

B

3

UPSX0104002B01

3. STEEL PIPES

A. DIRECTION OF ROTATION B REMOVING DIRECTION

REMOVING CRAWLER BELT

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLATION OF THE RUBBER CRAWLER BELT 1. Start the engine.

2. Operate the boom, arm and bucket to set the attachment on the ground. Slowly and gradually lower the boom to lift one side of the machine as shown in the figure.

1

UPW00400041J01

1. SAFETY SUPPORT

3. Support the lower travel structure of the machine with a safety support (1).

A

A

C

4. Engage the rubber crawler belt with the sprocket and hang it on the idler.

5. Insert three steel pipes into the bottom front rubber crawler belt, then slowly rotate the sprocket backward. When the rubber crawler belt separates from the idler wheel, stop the rotation. Shut off the engine. Slide the rubber crawler belt over the steel pipes to remove it.

2 UPSX0104003B01

2. STEEL PIPES

A. DIRECTION OF ROTATION C. REMOVING DIRECTION

INSTALLING CRAWLER BELT

6. Stop the rotation of the sprocket to confirm that the rubber crawler belt (4) is securely engaged to the sprocket (5), idler (6), and lower roller (3).

See figure.

7. Check and adjust the tension on the rubber crawler belt. See sections on Adjusting for More Belt Tension and Adjusting for Less Tension in this chapter.

3

8

4

7

8. After confirming engagement of the rubber crawler belt to the sprocket, idler and lower roller, and checking the belt for proper tension, lower the machine to the ground.

6

9

5

UPSX0104018B01

3. LOWER ROLLER 7. LUG 4. RUBBER CRAWLER BELT 8. METAL CORE 5. SPROCKET 9. TRAVEL MOTOR 6. IDLER

6-24

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

INSPECTION AND MAINTENANCE CHART Follow the chart for recommended intervals for regular inspection and maintenance. Perform inspection and maintenance according to calendar time or operation time shown by the hourmeter, whichever comes first.

Symbols and their meanings : : Necessary regular inspection item to hour meter.

O : Only first replacing is performed.

Components

: Inspectantion and/or maintenance is needed.

Item

Interval

When Pre-

Every

Every

Every

Every

requi start

week

3

6

12

red

months months months 8H

Replacing

500H

1,000H

1,500 2,000 5,000 H

H

H

part)

Engine oil

O O

Engine oil filter

Cartridge

Water separator

Draining Cleaning

O

Element

Fuel filter

Replacing

O

Cartridge

O

Air cleaner Checking/Cleaning element Replacing

O

Radiator Coolant

Fan belt

Soft clean water

O

Checking leakage

O

Checking

O

Adjusting

(LLC)

O

Radiator core

O

Radiator cap

O

Hoses in cooling system Checking/Replacing

O

Checking the color, sound, smell of exhaust gas

O

Injection timing Checking/Adjusting

Element

O

Replacing

Valve clearance

Element O

Checking the level E ngi ne

250H

etc.

(Replacing

O

Checking the level Engine oil

50H

Lubricant

O O

NOTE: See Lubricant, Fuel and Coolant Specifications for detailed specifications for lubricants, coolants, and fuel.

LLC is Long Life Coolant.

NOTE: When the machine works in dusty locations, clean the filter and radiator core more often.

6-25

Fuel System

Engine

Components

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Item

Interval

When Pre-

Every

Every

Every

Every

requi start

week

3

6

12

red 50H

250H

Starter and generator Checking/Adjusting

Fuel tank

Upper frame

H

H

H

part)

O

Draining water and deposits

O

Checking leakage

Hydraulic tank

1,500 2,000 5,000

O

Fuel Checking/Adjusting

O O O

Suction Cleaning/ strainer Replacing

O

Hydraulic oil Strainer

O Return filter

(Breaker

O

Element

O

Element

attachment) (200H)

Air breather filter

Change

Checking oil leakage and damage of cylinders, etc.

Accumulator

Lower frame

1,000H

Check and adjustment for contact surface of intake and exhaust valve

O

Line filter In-line filter/Cleaning

O Change

O

Slewing bearing

EP grease

O

Grease in the Replacing slewing grease bath

O

EP grease

Travel reduction motor

O

Gear oil

Replacing

Checking/Adjusting for tension of rubber belt Checking wear and damage of rubber belt Lower roller Idler

O O

Checking

O

Checking oil leakage and wear of sprocket/travel reduction motor

Attachment

500H

etc.

(Replacing

O

Checking Hydrauli the level c oil Replacing Hydraulic system

months months months 8H

Lubricant

Greasing for pins

O O

Bucket Boom, Arm cylinder & Dozer

O (50H)

Replacement of bucket

O

Replacing/Adjusting mount gap

O

Checking wear and damage of the tooth and side cutters

O

6-26

EP grease

O

(50H)

O

EP grease

Components

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Item

Interval

Electrical equipment

Every

Every

Every

Every

requi start

week

3

6

12

red

months months months 8H

Checking damage of the electrical wirings

O

Checking the function of warning lamps

O

Checking switches/levers

O

O

Checking looseness and missing of the bolts and nuts

O

500H

1,000H

1,500 2,000 5,000 H

H

H

part)

Distilled water

O

Checking Lubrication

250H

etc.

(Replacing

12V 55W (Halogen lamp)

O

Checking abnormal deformation and damage of the machine exterior

Control lever

50H

Lubricant

O

Battery Checking the fluid level Measuring the specific gravity

Replacing work lamp (Lamp)

Others

When Pre-

O

EP grease

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

WHEN REQUIRED MAINTENANCE WARNING: Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in death or serious injury. M1087 WARNING: AVOID BURNS! Hot fluids and surfaces can burn. Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine.

XPX00300002E01

CHECK AND CLEAN THE RADIATOR CORES WARNING: To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure when hot. Allow enough time for the machine to cool before removing the radiator cap.

1. Open the right side cover and the cover under the radiator.

2. Check for clogged radiator fins.

3. Remove dust, mud and other material on the radiator cores and fins using compressed air.

NOTICE: To avoid damage of the fins, keep a distance between the spray nozzle of compressed air and the fins. If the fins are damaged, water leakage will occur.

UPSX0104019B01

CHECK AND REPLACE THE RADIATOR CAP WARNING: To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure when hot. Do not remove the radiator cap when the system is hot. Allow time for the machine to cool down before removing the radiator cap.

1. Allow the radiator cap and cooling system to cool down so it can be touched with a bare hand.

XPX00100018E01

2. Slowly loosen the radiator cap to release the pressure. After all pressure is released, remove the cap.

3. Check the cap for damage and contamination.

Clean and/or replace if necessary.

4. Securely tighten the cap.

UPW004000050J01

6-28

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK AND REPLACE WORK LAMP NOTICE: A 55 watt bulb is used for the work lamp.

WARNING: AVOID BURNS! Do not touch a bulb that is lit. Shut off the work lamp. Work lamp bulbs develop high temperature during operation. A bulb that has just been shut off can remain hot for some time. Allow time for the bulb to cool before handling.

Before replacing a burned out bulb, make sure the work lamp switch is in the off position.

UPW00400051J01

1. Place the attachment on the ground and set the safety lock lever to LOCKED position, then stop the engine.

1

4 3

2. Disconnect the connector, then remove the work lamp from the machine with a wrench.

NOTICE: Avoid breaking the lamp bulb lens when disassembling. While loosening the screw, hold the lamp bulb lens so it does not fall.

3. Remove the screw (1) (four pieces) then remove the rim (2) and lens (3) from the casing (4).

4. Remove the spring (6) for fixing the socket (5).

NOTICE: The service life of a work lamp bulb is shortened if oil or grease is on the bulb at the time of installation. When replacing the bulb, hold it at the flange area. Do not touch the bulb glass. If touched, clean the bulb with a clean cloth.

2

5

6

7

UPW00400052J01

1. SCREW 5. SOCKET 2. RIM 6. SPRING 3. LENS 7. PUMP 4. CASING

5. Remove the bulb (7) from the socket and replace it with a new one.

6. Assemble the work lamp using the reverse order of the above steps.

6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE BUCKET WARNING: AVOID INJURY! Replace the bucket on firm, flat ground. Pay close attention to safety. When aligning the pin bores, do not insert your finger into the bores. It may cause severe injury. Align the bores visually or try using a tool.

XPX00400010E01

Removing the bucket

7

1. Carefully operate the boom and the arm to remove load from the pins.

A 8

2. Roll O-rings (1) onto the bucket boss. After removing the pins, return the O-rings to the original position.

A

3. Remove the lock ring (2) and lock pin (3) then remove the pins (4) and (5) then remove bucket (6).

6 3

9

2

4

NOTICE: Keep the pins free from sand, dirt and other contaminants.

NOTICE: Be careful not to damage the dust seals (9) on both ends of the arm (7) and bucket/bucket link (8).

1

3

2 A-A

9

5 UPSX0104020B01

1. O-RINGS 2. LOCK RING

7. ARM

3. LOCK PIN

8. BUCKET/BUCKET LINK

4. PULL PIN

9. DUST SEALS

5. PULL PIN

6-30

6. BUCKET

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Reinstalling the bucket 1. Clean each pin and pin hole and grease sufficiently.

2. Move the bucket cylinder to match the pin bores of the bucket (6) and bucket link (8) with each other then insert the pin (4).

7 8 5 4

3. Raise the boom and slightly raise the bucket from the ground.

4. Align bucket (6) with the pin hole of the arm (7).

Move the arm then insert the pin (5).

6

6 UPW00400061J01

4. PIN 5. PIN 6. BUCKET

7. ARM 8. BUCKET LINK

5. Insert the pin (3) and fix retaining ring (2).

9 2

3

9

4 5 UPSX01040361B01

2. LOCK PIN 3. PIN 4. PIN

5. PIN 9. DUST SEALS

NOTICE: If the O-ring (1) is cracked or has lost elasticity, replace it with a new one.

6. Fit O-ring (1) to the normal position.

1

2

7. Apply grease on the grease nipples for the respective pins until the grease comes out through the gap between the pins and bore.

3

B-B

B

B

UPSX0104021B01

1. O-RING

B. DETAIL B-B 2. LOCK RING 3. PIN

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Inspecting the rubber crawler belt

1

Repair or replace the rubber crawler belt if it wears down, if the steel cord breaks, or if it cracks.

5

2

3 4 UPSX0104022B01

1. LOWER ROLLER 4. STEEL CORD 2. RUBBER CRAWLER BELT 5. METAL CORE 3. LUG

Height of lug If the height of lug (A) wears down, traction force decreases. Replace the belt with a new one if height (A) is below 5 mm (0.2 inches).

A

If the lug wears out and exposes the steel cord (4) in the belt over two or more links, replace the belt with a new one.

4 XPX00400024E01

A. HEIGHT 4. STEEL CORDS

Steel cords broken If the steel cords (B) of the rubber crawler belt are broken by more than one half of one side row, replace the belt with a new one.

B UPW00400066J01

B STEEL CORDS

Cracks and exposed steel cords If a crack (A) develops that is about 60 mm (2.4 inches) in length can be seen between the lug of the rubber belt, repair the belt.

If a small, short crack (B) develops that exposes the steel cord, repair the belt immediately.

NOTICE: For repairs or replacement of rubber crawler belts, contact your dealer.

A 4

B

XPX00400025E01

4. STEEL CORDS A. CRACK B SMALL SHORT CRACK

6-32

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Peeling of metal core on rubber crawler belt Depending on the usage of the rubber crawler belt, there occasionally may be peeling of the metal core (2). Peeling occurs on the inner side due to contact with the rollers (1), idlers and sprockets. The lug side (outer side of belt) may appear undamaged.

1 A 2 4

NOTICE: Prohibited operation of the machine can cause the metal core of the rubber crawler belt to come out of the track. Read and fully understand the prohibited usage of the rubber crawler belt described in this manual. Note that the warranty is not applicable for any damage due to the prohibited usage of the rubber crawler belt or use of it with improper tension.

5 3 UPW00400068J01

1. LOWER ROLLER 4. STEEL CORD 2. METAL CORE 5.

3. RUBBER A. INTERFERENCE WITH ROLLER

1. Cracked rubber belts showing metal core (2) must be replaced with new belts.

2

XPX00400026E01

2. METAL CORE

2. It is not necessary to repair a rubber crawler belt with cracks (A) on the portion of the belt that makes contact with the metal core and roller.

NOTICE: The metal core starts to come out of track during prohibited usage of the rubber crawler belt.

Read and fully understand prohibited usage of the rubber crawler belt. For more details, see Operation with Rubber Crawler Belts in this manual.

A

UPW00400071J01

2. CRACKS

6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK AND REPLACE TOOTH POINTS AND SIDE CUTTER NOTICE: When replacing the tooth points and side cutters, place a safety block (A) to the bottom face of the bucket.

A

1. Check the teeth points of the bucket for wear and looseness.

Tooth point life cannot be determined only by the number of operating hours; operating conditions must also be considered.

UYN00040002B02

A. SAFETY BLOCK

8~10mm

2~3mm

UPWC0400053J01

TOOTH POINTS

4

3

1 2

5 UPW0040054J01

1. ADAPTER 5. ADAPTER NOSE 2. TOOTH POINT 6. SAFETY BLOCK 3. RUBBER LOCK PIN 7. HAMMER 4. LOCKING PIN 8. PUNCHING TOOL

6-34

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE TOOTH POINTS 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

7

Replace the bucket teeth:

 When small holes appear on the teeth points,

8

 When the edges of the teeth points are worn.

6 2 UPW00400055J01

2. TOOTH POINT 6. SAFETY BLOCK 7. HAMMER 8. PUNCHING TOOL

1. Using a hammer and punching tool, hammer out the locking pin. Be careful not to damage the rubber lock pin (3).

2. Inspect the locking pin (4) and rubber lock pin (3). Replace them if the locking pin (4) is too shor t or the rubber lock pin (3) is in poor condition.

3. Clean the surface of the adapter nose (1) with a putty knife to remove adhered soil.

4. Fit the tooth point (2) onto the adapter note (1).

4 3 5 2 4 6

5. Push the rubber lock pin (3) in the holes of the adapter nose (1).

6. Hammer the locking pin (4) until it is aligned with the point surface.

UPW00400056J01

2. TOOTH POINT 6. SAFETY BLOCK 7. HAMMER 8. PUNCHING TOOL

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE SIDE CUTTERS NOTICE: Early replacement of the side cutter is recommended, as a delay in replacement could cause damage to the bucket.

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 1. Remove all sand and soil adhering around the bolts. Use an acetylene torch to cut off the bolts then remove the side cutters.

UPW000400057J01

A. SAFETY BLOCK

2. Clean the mounting face and install a new side cutter. When replacing the side cutter, also replace the bolts and nuts with new ones.

2

Tightening torque: 249.6 to 308.4 Nm (184.1 to 227.5 lb.ft.)

2

3. After tightening, spot weld the nuts.

1

4 3 UPW000400058J01

1. NUTS 2. SIDE CUTTER

6-36

3. BOLT 4. TOOTH POINT

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICATE THE OPERATING LEVERS When any operating levers require more effort to operate or do not move smoothly, apply grease to the sliding and rotating portion (A) and the top portion (B) of the universal joint.

2 1

UPW00400072J01

1. CONTROL LEVER 2. RUBBER BOOT

1. Move the machine to firm and level ground, set the attachment on the ground, place the safety lock lever to the LOCKED position and stop the engine.

2. Carefully raise up the rubber boot on the troubled control lever by hand, paying attention not to damage it.

3. Apply grease to the sliding and four rotating por tions (A) and the top por tion (B) of the universal joint.

A 3 B

4

4. Return the rubber boot to its original position.

5. Check for looseness of the pilot valve. If loose, retighten the socket bolts.

6. For additional service, contact your dealer.

UPW00400073J01

A. ROTATING PORTION 3. UNIVERSAL JOINT B TOP PORTION 4. SOCKET BOLT

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ELECTRICAL WIRING AND FUSES WARNING: AVOID FIRES! When fuses require frequent replacement or when there is short circuiting on the electrical wiring, contact your dealer. Short circuiting may cause fire.

WARNING: Before checking the electrical system, disconnect the negative (-) side of the battery cable.

NOTICE: For fuse replacement, refer to the fuse diagram in Chapter 7 Electrical.

XPX00400012E01

6-38

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY (8 HOUR) INSPECTION AND MAINTENANCE The following procedures are to be performed every 8 hours or daily, before starting the machine.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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

Before starting the engine, walk around the machine to check for any loose nuts and bolts, any oil, fuel or coolant leakage, and the condition of attachment and hydraulic system.

Check for any looseness in the electrical wiring and for any accumulated material (leaves, dirt, etc.). Repair and clean as necessary.

WARNING: The deposit of combustible, fuel leakage and oil leakage in heated area around the engine, muffler and battery may cause fire of machine. Check the area sufficiently, and if the abnormality is found, repair it or contact our dealer/distributor.

1. Check the engine for any oil, fuel or coolant leakage. Repair as required.

2. Check the area around the engine and radiator for any accumulated material and remove as required.

3. Check the hydraulic equipment, hydraulic oil tank, hoses, and joints for oil leakage, and repair as required.

4. Check the travel system, such as the crawler, idlers, and sprockets, for any damage or wear, and the bolts for looseness.

5. Check the attachments, cylinders, linkages and hoses for any cracks, wear or looseness and repair as required.

6. Check the door, cover, steps and handrails for damage, and the bolts for looseness. Repair and tighten bolts as required.

7. Verify that the gauges and the monitor panel (gauge cluster) function properly.

8. Check rear view mirror for abnormality, and if abnormality is found, repair it.

9. Clean the surface of mirror and adjust the angle so that the rear sight is visible from the operator seat.

10. Check seat belt and attaching metal for possible damage and if damaged, replace it with new one.

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK COOLANT LEVEL 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 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 1. Allow the engine to cool down before checking the coolant level. Engine coolant level is higher than normal when the engine is warm.

2

2. Open engine reservoir tank and check the coolant level. The coolant level should be between the lines of FULL and LOW. Maintain coolant level at the FULL mark with the engine cold. Refer to Specifications chapter for engine coolant specifications.

1

NOTICE: If the coolant level in the reservoir tank has dropped below the LOW level mark, check the engine cooling system for leakage and repair as necessary before resuming operation.

NOTICE: If the coolant level in the reservoir tank does not lower but the coolant inside the radiator does, there is the possibility of air leakage in the engine cooling system. Make sure the coolant is to specification and pressurize the system to check for leakage. Contact your dealer for advice and/or repairs. Repair any leakage before resuming operation.

3. Remove the engine reservoir tank cap (1) and refill the tank with the specified coolant.

4. Remove the radiator cap (2) and check for proper coolant level.

NOTICE: If the radiator cap is dirty or damaged, clean or replace it as needed. See section on Cleaning or Replacement of Radiator Cap in the Maintenance chapter for reference.

5. Refill radiator with specified coolant if needed.

6. Install the radiator cap and tighten securely.

6-40

UPSX0103002B01

1. RESERVOIR TANK CAP 2. RADIATOR CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ENGINE OIL LEVEL 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

2

WARNING: When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury. M1303 1. Make sure the machine is on firm, level ground and that the engine is cool. It is best to check the engine oil level before starting the engine.

When checking the oil level after operating the machine, wait at least 30 minutes after shutting off the engine.

1 H L

2. Use the ignition key to unlock and open the engine door. Secure the door in the open position using rod provided.

3. Pull out the engine oil dipstick (1) and insert it fully into its sleeve. Remove dipstick to check the oil level. The oil level should be in the range between the marks “L” and “H” on the oil level gauge (G).

UPSX0103022B01

1. ENGINE OIL DIPSTICK H. OIL LEVEL HIGH 2. FILLER CAP L. OIL LEVEL LOW

NOTICE: If the oil is contaminated and deteriorated, change it ahead of schedule.

4. Refill if needed. To refill, remove the filler cap (2). Refill with the specified engine oil. Refer to Specifications chapter in this manual.

5. Check the oil level again after refilling.

6. Clean the filler cap before reinstalling.

7. Close the engine door and secure with key.

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK FUEL LEVEL WARNING: Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious bodily injury. M1394 NOTICE: Dispose of all hazardous waste in accordance with government environmental laws and regulations.

UPAX1003013B01

1. Turn ignition key (1) to ON position to illuminate the monitor panel and activate the fuel gauge.

2. Check the fuel gauge (2) and remove the fuel cap (3) to refuel if necessary.

NOTICE: It is recommended to refuel at the end of the work shift. Refill to the FULL mark to reduce air volume and condensation. Failure do to so could cause rusting and fuel freezing and other problems.

2

1 XPX00300004E01

1. IGNITION KEY 2. FUEL GAUGE

3. Refill with specified fuel. For fuel specifications, see the Specifications section in this manual.

Fuel tank capacity: 38 liters (10 gallons) 4. Do not remove the fuel tank strainer (4) when adding fuel. This helps avoid contamination.

3

5. After refueling, install fuel cap (3) and tighten securely. Close the engine door and use key to lock it.

4

5 6 UPSX0103004B01

3. FUEL CAP 5. DRAIN PLUG 4. FUEL TANK STRAINER 6. FUEL TANK

CHECK FOR FUEL LEAKAGE Check and repair any fuel leakage. Do operate a machine leaking fuel. Fuel leakage may be cause by a faulty drain plug, cracked hose, loose hose clip, etc.

2 1

Stop the engine immediately if any fuel leakage is found and repair it before resuming operation.

3 4 UPSX0103005B01

1. FUEL TANK 2. FUEL FILTER

6-42

3. WATER SEPARATOR 4. FUEL HOSE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK HYDRAULIC OIL LEVEL WARNING: AVOID INJURY! Do not perform maintenance or inspection on a machine that has just finished operating. Allow enough time for the machine to cool off. Release hydraulic tank pressure before working with any hydraulic component.

WARNING: Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic 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, seek medical attention immediately.

Failure to comply could result in death or serious injury. M587A

XPX00300002E01

1. Move the machine to firm, level ground and set it in the Hydraulic Oil Level Check position as shown.

2. Check the oil level through sight level gauge provided on the side of the hydraulic tank.

Hydraulic oil level should be between H and L. Oil level varies depending on oil temperature.

Check the oil level referring to the following: • Before starting: "L" level oil temperature 10 to 30 C degrees (50 to 86 F degrees) • Normal operation: "H" level oil temperature 50 to 80 C degrees (122 to 176 F degrees)

1

2

UPW00300004J01

1. BUCKET 2. DOZER HYDRAULIC OIL LEVEL CHECK POSITION

3. Refill with specified oil when the level is below the L mark. Refer to Specifications section.

4. To refill, open the right side cover and support it using the cover support rod.

5. Release the internal pressure of the tank. See Releasing Inter nal Pressure of Hydraulic System in the Maintenance chapter of this manual.

UPSX0103023B01

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Ensure that the internal pressure of the hydraulic oil tank is completely released.

Loosen the bolts (1). Remove the cover (2) and fill the reservoir to the proper level with the specified hydraulic oil.

7. Check the O-ring (3) on the cover and if it is worn or damaged, replace it.

1 2

3

8. Install the cover (2) and fasten the bolts to the specified torque: 21.7 to 25.5 Nm (16 to 18.8 lb ft) 9. Start the engine and run it for 5 to 7 minutes at low idle. Operate each cylinder to full extension and operate the swing mechanism to remove any air in the hydraulic system. Return the machine to the Hydraulic Oil Level Check Position.

10. Stop the engine and check the oil level and add oil as necessary.

11. Remove the cover support rod and return the cover to its normal position.

6-44

H A L 4

UPSX0103024B01

1. BOLTS A. PROPER LEVEL 2. COVER 3. O-RING 4. LEVEL GAUGE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK BELT CONDITION

WARNING Stay clear of rotating machine parts and keep shields installed to help protect from clothing entanglement and injury. Wear close-fitted clothing.

Failure to comply could result in death or serious injury.

M223A

NOTICE: The term, “used belt” refers to a belt which has been used on a running engine for five or more minutes.

XPX001000017E01

1. Check the fan belt for insufficient tension, wear, and damage. Insufficient belt tension may cause batter y charge failure, engine overheating, or abnormal belt wear. If too much tension is applied to the belt, the bearings or belt may be damaged prematurely.

2. Apply a force of 98 N (22 lb) to the center of belt b e t w e e n p u l l ey s, a n d m e a s u r e t h e b e l t deflection. The table below shows normal condition.

NEW BELT TENSION

USED BELT TENSION

8 to 12 mm (8/16 to 7/16 in)

10 to 14 mm (3/8 to 1/2 in)

NOTICE: See the section on 250 HOUR MAINTENANCE in the Maintenance chapter of this manual for details on the inspection and adjustment procedure for the belt.

2

3

1

UPSX01030006B01

1. MOUNTING/PIVOT BOLT 2. ADJUSTING BOLT 3. ADJUSTING BOLT

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE WARNING LAMPS WARNING: AVOID INJURY OR DEATH! Careless movement of any control levers may cause unexpected movement of the machine. Make sure the swing area of the machine is clear of people and obstacles before operating. Know the position of the travel motors before starting travel and sound the horn before operating the machine.

Before starting the engine, check the warning and indicator lamps.

1. Make sure the safety lock lever is in the LOCKED (up) position.

2. Make sure all control levers are in the neutral position.

1

2

RED: Warning Lamp YELLOW: Indication Lamp

3

4

5

6 UPWX3403002E01

1. ENGINE OIL PRESSURE 2. BATTERY CHARGE 3. ENGINE COOLANT TEMP

4. LOW FUEL 5. SECOND SPEED TRAVEL 6. AIR CLEANER CLOGGING

3. Use the ignition key and the Key Operation Table as a reference to check the function of all warning lamps and indicators.

4. Do not operate the machine under faulty conditions. Consult with your dealer if necessary. Refer to the Warning Lamps section of the Gauge Cluster description in Chapter 3 of this manual.

Key Operation Lamp

OFF-->HEAT Pre-Heating

OFF-->ON Before Start

START-->ON Just After Start

1

Engine Oil Pressure Lamp

Light OFF

Light ON

Light OFF

2

Battery Charge Lamp

Light OFF

Light ON

Light OFF

3

Engine Coolant Temp. Lamp

Light OFF

Light OFF

Light OFF

4

Low Fuel Warning Lamp

Light OFF

Light OFF

Light OFF

5

2nd Speed Travel Lamp

Light OFF

Light OFF

Light OFF

6

Air Cleaner Clogging Lamp

Light OFF

Light OFF

Light OFF

CHECK WORK LIGHT 1. With the ignition key in the ON position, turn on the work light. If it does illuminate, replace the bulb.

2. If the work light does not go on, check the fuse and wir ing and repair as necessar y. See Chapter 7 Electrical for fuse information. See C h a p t e r 6 M a i n t e n a n c e fo r w o r k l i g h t replacement.

UPSX010201B01

6-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK MACHINE EXTERIOR Before operating the machine, check the exterior for damage. Keep in mind that a dent or distortion which does not appear to be severe may cause abnormal contact with internal parts or hydraulic hoses. Consult with your dealer for repairs.

CHECK BOLTS AND NUTS Check the machine for missing bolts and nuts and replace as needed. Make sure all bolts and nuts are properly tightened. Check all hose clamps for tightness. Any abnormal machine sound during operation may indicate a cause or leakage or fire.

UPW00400075J01

CHECK CYLINDERS, PIPING AND HOSE WARNING: AVOID INJURY! Do not perform maintenance or inspection on a machine that has just finished operating. Allow enough time for the machine to cool off. Release hydraulic tank pressure before working with any hydraulic component.

WARNING: Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic 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, seek medical attention immediately.

Failure to comply could result in death or serious injury. M587A Hydraulic oil leakage will affect machine performance. To check for leakage in hydraulic cylinders, piping and hoses:

XPX003000003E01

1

2

1. Move the machine to firm, level ground, place the attachment in the oil check position and stop the engine.

2. Set the safety lock lever to the LOCKED position and stop the engine.

3. To check for leakage, allow the temperature of each portion of the machine to cool down to 40 degrees Centigrade (104 degrees Fahrenheit).

4. Wear protective glasses and gloves.

UPSX0104037B01

1. HYDRAULIC TANK 2. AIR BREATHER

5. Open right side cover and support it with stay.

6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. Press the breather valve with rubber cap on the upper surface of the hydraulic tank several (five to seven) times and release the pressure in the hydraulic tank.

NOTICE: If problems with the machine occur during operation, stop the machine immediately and contact your dealer for repairs. If there is any engine oil, engine coolant, hydraulic oil or fuel leakage on the machine, or any system warning lamp is illuminated, contact your dealer for repairs.

CHECK TRAVEL SYSTEM 1. Check the lower roller, idler and travel motor for leakage.

2. Check the lower roller, idler and sprocket for abnormal wear and loose bolts.

1

3. Slowly move the machine and listen for any abnormal sounds.

2

4. Consult your dealer for advice/repairs as needed.

3 4

5

6

UPWX3404006E01

1. TRAVEL MOTOR 2. SPROCKET 3. LOWER ROLLER

4. CRAWLER BELT 5. UPPER ROLLER 6. IDLER

DRAIN AND CLEAN THE WATER SEPARATOR WARNING: AVOID FIRES! Wipe up any spilled fuel.

Do not use gasoline to clean filter elements. Dispose of waste fuel promptly in accordance with governmental environmental regulation.

If the red ring (5) in the water separator sinks to the bottom of the case (8), no water is mixed in. When the ring is floating, water is mixed in up to the level of the ring.

1 C

B

A 2 D

If water is mixed in, loosen the drain valve (3) and drain the water using the following procedure:

3

1. Set the safety lock lever to the LOCKED (up) position and stop the engine.

4

2. Open the engine door. After allowing the engine to cool, push the handle (2) of the water separator UPWARD to the CLOSED position (C).

5 8 6

UPSX0104023B01

A. IN 1. AIR BREATHER PLUG B OUT 2. HANDLE (FUEL VALVE) C FUEL VALVE CLOSED 3. DRAIN VALVE D FUEL VALVE OPEN 4. ELEMENT 5. RING (RED) 6. SPRING 8. CASE

6-48

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Loosen the ring (9) to remove the case (8) and drain the water.

NOTICE: Be careful not to lose the red ring (8) and spring (6).

2 7 4

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

5

8

6 9 UPW00400079J01

2. HANDLE (FUEL VALVE) 6. AIR SPRING 3. DRAIN VALVE 7. O-RING 4. ELEMENT 8. CASE 5. RING (RED) 9. RING

4. Check the drained water for contamination. If it is dirty, clean the element (4) and inside the case (8).

5. Remove the element (4) and clean it.

6. Replace the O-ring (7) with a new one.

7. Set the O-ring (7) to the case (8) then tighten it with the ring (9).

8. Push the handle (2) DOWNWARD to the OPEN position (D).

9. After draining the water and cleaning, make sure to bleed out the air in the fuel system. See Bleeding Air in Fuel System section in this chapter.

UPW00400080J01

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR (WEEKLY) MAINTENANCE Perform the following procedures after 50 hours of operation along with the Daily Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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 ADJUST THE CRAWLER TENSION Proper adjustment of the rubber crawler belt tension is essential for extending the service life of the crawler belt and the travel system. It also prevents the crawler belt from coming off due to insufficient tension.

WARNING: AVOID INJURY OR DEATH! The check and adjustment of tension for the rubber crawler belt is done with a track lifted off the ground one side at a time. Unexpected lowering or movement of the machine can result in serious injury or death. Do not operate the boom, arm or bucket/attachment while adjusting the rubber crawler belt. Follow the instructions provided. This work must be done carefully by two people. The operator must operate the machine as instructed by the signals of the partner.

XPX00100020E01

To check and adjust the tension of the rubber crawler belts, see Check and Adjust Tension of Rubber Crawler Belt in this chapter.

UPW00400039J01

RUBBER CRAWLER BELT

6-50

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GREASE THE PINS AROUND THE BUCKET/ATTACHMENT NOTICE: In the case of a new machine, grease the pins around the bucket/attachment every 8 hours for the first 50 hours of operation.

1. Park the machine on a firm, level surface in the “Greasing Position” with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

2. Clean the grease fittings before greasing.

Replace any damaged grease fitting.

UPW00400030J01

NOTICE: The grease gun is located on the inside of the side door on the left side of machine.

GREASING POSITION

3. Lubricate with a grease gun through the grease fittings shown at right (A, B, C, D) until the grease comes out through the gap of pin. Wipe o f f a ny g r e a s e t h a t l e a k s o u t o f t h e p i n connection.

NOTICE: Dispose of all waste in accordance with environmental regulations.

C

D

A B UPW00400124J01

A. BUCKET CYLINDER ROD PIN B IDLER LINK/ARM CONNECTING PIN C BUCKET LINK PIN D ARM/BUCKET CONNECTING PIN

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DRAIN THE FUEL TANK WARNING: Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious bodily injury. M1394

2

NOTICE: It is most effective to drain the fuel tank before starting the engine in the morning, since the water and sediment have time to settle after the machine has stopped operating for the night.

1. Park the machine on a firm, level surface with both attachments resting on the ground.

2. Swing the upper structure of the machine so that the drain valve (1) under the fuel tank comes to midway between the crawler shoes.

3. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

1 UPSX0104024B01

4. Place an empty container under the drain valve to catch the discharged fuel.

1. FUEL TANK 2. DRAIN PLUG

4. Loosen the drain valve (1) and drain water and sediment. When clean fuel begins to flow, tighten the drain plug. Check for fuel leakage after tightening drain plug. If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

NOTICE: Check for fuel leakage after tightening the drain plug. If fuel leaks, stop the engine and consult your dealer for repair.

CHECK THE BATTERY During the summer, the volume of the battery fluid decreases easily in high temperatures. Check the fluid level in the morning before starting operation.

Continuous use of the battery with a low fluid level decreases battery performance. Check the fluid level periodically and, if insufficient, refill the battery with distilled water before engine star t-up and before charging the battery.

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 6-52

XPX00400014E01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Check indicator (A) on the battery and ensure it is BLUE in color. RED and WHITE in color means insufficient battery fluid and charging.

(H)

C

(I)

D

(J)

E

2. Set the safety lock lever to the LOCKED (UP) position and stop the engine.

3. Wear face protection.

D

4. Refer to Guard with Locking Device and Covers in this manual and remove the floor mat and battery cover.

3

E

D

2

5. Remove the caps (1) on each cell and check the fluid level.

6. If the battery fluid is low, refill the cell with distilled water to the specified level (10 - 15 mm/0.4 - 0.6 in above the polar plate).

7. Make sure the air vent holes in the caps (1) are clean. Securely tighten them.

8. If the terminals (2) are dirty, wash them with warm water then reinstall, applying grease or rust preventive solution. If the terminals are oxidized, polish them with a wire brush or emery paper.

1 B A UPW00400007JS1

1. CAP 2. TERMINAL 3. TERMINAL COVER A. INDICATORS B AIR VENT HOLD C BLUE D RED

E F G H I J

WHITE UPPER LIMIT LOWER LIMIT GOOD CONDITION REFILLING REQUIRED CHARGING REQUIRED

NOTICE: When it is difficult to obtain enough cranking speed at engine start-up, measure the specific gravity of the battery fluid using a gravimeter. The measured value will vary depending on the ambient temperature. Standard specific gravity for battery fluid is 1:28 (at 20 degrees Centigrade/68 degrees Fahrenheit). For the specific gravity of battery fluid in cold climate conditions, refer to the Machine Operation in Adverse Climate Conditions in Chapter 4 of this manual. Make the charging rate around 100%.

NOTICE: If engine start-up is difficult even after recharging the battery, replace the battery with a new one.

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE Perform the following procedures after 250 hours of operation along with the Daily and 50 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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 GREASE ATTACHMENT AND DOZER PINS When to apply grease:

 During the first 50 hours of machine operation, grease the lubrication points (4 through 14) of the attachment every 8 hours.

 After the first 50 hours of machine, grease the lubrication points every 250 hours.

 When operating the machine with a special

UPW00400030J01

attachment, apply grease every day before starting work.

GREASING POSITION

 For underwater digging operations, apply grease

7

to the areas to be immersed in water every day before and after work.

 When the machine is stored for more than one

10

month, apply grease before starting work.

9 5

4

8 11

6 UPSX100401B01

4. BOOM FOOT PIN 8. ARM CYLINDER ROD PIN 5. BOOM CYLINDER FOOT 9. BOOM/ARM CONNECTING PIN PIN 6. BOOM CYLINDER ROD 10. BUCKET CYLINDER FOOT PIN PIN 7. ARM CYLINDER FOOT 11. BUCKET CYLINDER ROD PIN PIN BOOM, ARM AND ATTACHMENT GREASE POINTS

6-54

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Park the machine on a firm, level surface in the “Greasing Position” with both attachments resting on the ground. Turn the engine off. Keep all unauthorized personnel clear of the area.

2. Clean the grease fittings before greasing.

Replace any damaged grease fittings.

12

14

13

UPSX1004011B01

12. SWING CYLINDER FOOT PIN 13. SWING CYLINDER ROD PIN 14. SWING BRACKET/FRAME CONNECTING PIN BOOM SWING GREASE POINTS

3. Lubricate with a grease gun through the grease fittings shown in the GREASING POINTS figures until the grease comes out through the gap of pin.

1 2 3

4. Wipe off any grease that leaks out of the pin connection.

NOTICE: The dozer foot pin (3) is supported by an iron bushing. If the dozer blade is used often, grease the bushing.

UPAX1004052BJ01

1. DOZER CYLINDER ROD PIN 2. DOZER CYLINDER FOOT PIN 3. DOZER CYLINDER ROD PIN DOZER GREASING POINTS

CHANGE THE ENGINE OIL WARNING: AVOID BURNS! Do not change oil immediately after stopping the engine. The engine and other parts are very hot. To avoid burns, allow the engine to cool before changing the engine oil.

NOTICE: The first oil change must be done at 50 hours for a new machine engine.

UPWX3404008E01

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Place an empty container to receive the drain oil under the drain plug (1) located at the bottom of the engine.

4

2. Remove the bottom cover (2) under the drain plug.

3. Slowly loosen the drain plug so that the oil does not splash. Contain any oil spillage.

4. Check the drained oil for contaminants, such as metal particles and foreign materials. If the oil contains contaminants, consult your dealer for repairs.

5. Securely tighten the drain plug (1).

6. Open the engine guard and remove the yellow filler port cap (4). Refill the engine with the specified oil. Refer to Specifications section.

1

2 UPSX0104043B01

1. DRAIN PLUG 2. COVER 4. CAP (YELLOW)

7. Start the engine, idle it for several minutes then stop the engine. Check the oil level - it should be between the H and L marks on the dipstick (3).

See Check Engine Oil Level section in this manual.

3

H L UPWX3404008E01

3. DIPSTICK

GREASE THE SLEWING BEARING WARNING: AVOID INJURY! Do not slew or swing the machine while adding grease to the slewing bearing.

Only one grease nipple is provided for the slewing bearing.

1. Feed grease to the swing bearing, slewing the machine and placing it in four different positions, 90 degrees apart, until the grease oozes out.

2. Wipe off any grease that oozes out around the swing bearing seal.

UPSX0104025B01

6-56

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUST THE BELT TENSION WARNING: AVOID INJURY! Stop the engine during machine inspection and maintenance to prevent fingers and hands from being entangled in the engine fan or belt.

Check the fan belt for wear and proper adjustment.

Replace the belt if it shows excessive wear or damage. Adjust the belt if necessary, following the steps below:

UPAX1004035B01

1. When the adjustment of the fan belt tension is necessary, loosen bolts (2) from the center cover (1) and open the center cover.

1

2 4

2. Slightly loosen the attaching bolt (3) and adjusting bolt (4).

3. Loosen the adjusting bolt (5) and adjust the fan belt to the specified tension, then tighten attaching bolt (3) and adjusting bolt (4).

NEW BELT TENSION

USED BELT TENSION

8 TO12 MM (8/16 TO 7/16 IN)

10 TO 14 MM (3/8 TO 1/2 IN)

NOTICE: A “used” belt is one which has been used on a running engine for five or more minutes.

4. After adjustment, start engine and run it at low speed for about 5 minutes, then check the belt tension.

5

3

UPSX0104026B01

1. CENTER COVER 4. ADJUSTING BOLT 2. BOLTS 5. ADJUSTING BOLT 3. ATTACHING BOLT

5. Close the center cover (1) and tighten bolts (2).

REPLACE THE ENGINE OIL FILTER WARNING: AVOID BURNS! The engine and muffler are hot after the engine stops. To avoid being burned, allow enough time for the engine to cool before inspection or maintenance.

NOTICE: The engine oil filter is not serviceable.

Replace it with a new filter.

NOTICE: For a new machine, replace the oil filter after the first 50 hours of operation.

NOTICE: An oil filter wrench is provided with the machine to remove the filter.

XPX00300002E01

NOTICE: If the machine is operated in very dusty conditions, change the oil filter sooner than specified.

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Stop the engine, open the engine door and remove the lower cover.

2. Place the filter wrench (2) on the filter cartridge (1) and turn counterclockwise with the wrench to remove it.

3. Wipe off any dirt on the seal face of the filter base and avoid contamination.

1 NOTICE: If metal particles or foreign material are noticed in the oil filter, contact your dealer.

2

UPSX0104038B01

1. FILTER CARTRIDGE 2. FILTER WRENCH

4. Apply a thin coating of engine oil to the seal of the new oil filter. Install and tighten by hand, turning about 2/3 or a turn after the seal contact the engine.

A

5. Start and run the engine at low idle for five minutes to check for leaks.

6. Close the engine door and install the cover under the engine.

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

6-58

UPW00400090J01

A. SEAL

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE RADIATOR HOSE Replacement of radiator hoses is a good maintenance practice, as it reduces cost and the unexpected interruption of work.

1. Open engine hood and support it with stay.

2. Check the hoses for water leakage due to loose clamps or cracked and worn hoses.

3. Tighten any loose clamps and replace any cracked or worn hoses. See next section for replacement procedure.

NOTICE: Immediately replace a hose if it is cracked, worn, or water is leaking from it. This will prevent serious problems, such as engine overheating.

UPAX1004040B01

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

1

1. Slowly loosen the radiator cap (1). Ensure that pressure has been released.

2. Remove the radiator cap by pushing it down and holding while turning.

4

3. Remove the cover located under the radiator and loosen the drain plug (2). Drain the coolant into a suitable container.

4. Loosen the hose clamp and disconnect the damage hose. Replace with a new one.

3

5. Install the drain plug.

6. Fill the radiator (3) with coolant, then fill the re ser vo ir tan k (4 ) with co olan t. Re fer to Checking the Coolant Level in this chapter.

7. After filling, tighten the radiator cap securely.

8. Reinstall the cover to its original position.

2 UPSX0104027B01

1. RADIATOR CAP 3. RADIATOR 2. DRAIN PLUG 4. RESERVOIR

6-59

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK, CLEAN, REPLACE AIR CLEANER ELEMENTS NOTICE: When replacing the element, cover the engine intake port to prevent dust from entering.

NOTICE: The air cleaner clogging lamp will not illuminate if the element is torn or if the air cleaner housing is not sealed properly. If the AIR CLEANER CLOGGING lamp is illuminated, inspect, clean and/or replace the air cleaner element.

NOTICE: Maintenance intervals are for reference in dusty areas, clean and replace earlier than the specified times.

XPX0040017E02

The air cleaner elements should be cleaned every 250 hours and replaced after 6 cleanings. The inner air element is optional. See next section for cleaning and replacement of the inner element.

1. Release three clamps (2) from the air cleaner cover.

3 1 2

2. Remove the air cleaner outer element (1) from the housing.

3. Clean the inside of the air cleaner casing.

NOTICE: Avoid water getting inside the engine.

Make sure the O-ring seal is positioned correctly.

UPSX0104044B01

1. OUTER ELEMENT 2. CLAMPS 3. INNER ELEMENT (OPTIONAL)

4. To clean the outer element (1), blow compressed air (less than 0.3 MPa (43 psi) up and down along the folds of the filter element inter ior to remove clogged dust or other contaminants.

5. After cleaning, use a light to check the inside of the element for tearing, pinholes, or packing d a m a g e. R e p la c e w i t h a n ew e l e m e n t i f necessary.

6. Set the outer element (1) in the casing.

7. Install the cover on three clamp (2) positions, directing the mark, “TOP”, on the cover to the inlet side.

8. Check the element for tearing, pinholes or packing damage. Even if the damage is found within six times of cleaning, replace the element with a new one.

6-60

UPW004000094J01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE INNER AIR CLEANER ELEMENT (IF EQUIPPED)

3 1 2

NOTICE: The air cleaner inner element is an optional part. It is not serviceable. Replace if necessary. For machines equipped with the “W” (double” element, the inner element must be replaced together with the outer element.

NOTICE: When replacing the element, cover the engine intake port to prevent dust from entering.

Remove the inner element (3).

Install the new inner (3) and outer (1) elements then replace the cover.

UPSX0104044B01

1. OUTER ELEMENT 2. CLAMPS 3. INNER ELEMENT (OPTIONAL)

6-61

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE Perform the following procedures after 500 hours of operation along with the Daily, 50 Hour, and 250 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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 REPLACE THE FUEL FILTER The fuel filter is not serviceable. Replace it with a new one.

WARNING: When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely. Spilled fuel could ignite and cause a fire.

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

UPAX1004039B01

1. Stop the engine, open the engine door and remove the lower cover.

2. ‘Place the filter wrench on the filter cartridge (1) and turn the wrench counterclockwise (A) to remove it.

1

3. Wipe off any dirt on the seal face (B) of the filter base to avoid contamination.

A UPW00400096J01

1. FILTER CARTRIDGE

4. ‘Apply a thin coat of grease to the seal of the new oil filter. Install and tighten by hand, turning 2/3 of a turn after the seal contacts the engine.

B

5. Start and run the engine at idle for five minutes to check for leaks.

UPSX0104007B01

B SEAL FACE

6-62

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE Perform the following procedures after 1000 hours of operation along with the Daily, 50 Hour, 250 Hour and 500 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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

CHANGE THE ENGINE COOLANT 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 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

XPX00400018E01

To prevent the system from rusting or freezing, use specified coolant. Refer to Specifications chapter.

To prevent the system from rusting or freezing, a mix of 50 percent or more is recommended. Adjust the mixture to the lowest expected ambient/outdoor operating temperature.

6-63

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 1. Stop the engine. Open the engine door. Wait for the cooling system to cool before servicing.

1

2. Loosen the radiator cap (1) slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove.

3. Drain the coolant through a hose into an empty container.

4. After draining, install the drain plug (2). Then fill the cooling system with the mixture of water and system cleaner.

4

3

2 UYN00040060J01

1. RADIATOR CAP 2. DRAIN PLUG

5. Operate the engine at a speed slightly faster than low idling (5) to raise the coolant temperature to 80 degrees Centigrade (176 degrees Fahrenheit) or within the white range o n t h e t e m p e r a t u r e g a u g e fo r c o o l a n t t e m p e r a t u r e . O p e r a t e t h e e n g i n e fo r approximately 10 minutes.

5

6. Stop the engine. Allow the system to cool.

Loosen the radiator cap slowly. After ensuring that the pressure has been released, push the cap down and hold it down while turning to remove. Loosen the radiator drain plug (2).

Flush the radiator (3) with clean water until the draining water runs clear.

7. Install the radiator drain plug (2). Fill the radiator with a mix of 50 percent clean water and 50 percent Long Lift Coolant. Start and run the engine for awhile to fully release air from the cooling system.

8. Stop the engine. Allow the engine to cool.

Check the coolant level in the reservoir tank (4) - it should be between FULL and LOW. Refer to Checking the Coolant Level in this manual.

Adjust level to specifications.

9. Check the system for leaks. Repair all leaks.

Close the engine door.

6-64

3. RADIATOR 4. RESERVOIR TANK

UPSX0104008E01

5.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE HYDRAULIC RETURN FILTER The return filter needs special servicing because it plays an important role in removing contaminants from the hydraulic system. This prevents damage and prolongs the life of the equipment.

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 WARNING: 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. M1295

UPAX1004039B01

1. Park the machine on firm, level ground and place the attachment in the oil check position.

Stop the engine.

2. Open the right side cover and support it with stay.

3. Clean dirt from the filter area to avoid contaminating the hydraulic system.

UPW00400019E01

6-65

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 4. Press the valve (4) and breather cap (6) together several times (five to seven times) and bleed the hydraulic oil tank of the remaining pressure.

1 2 3

5. Remove bolt (1) and cover (2) from the upper surface of the tank.

4

6. Take out the spring (3), valve (4) and element assembly (A) from tank.

7. Remove O-ring (5) fitted on the face of cover (2).

8. Clean the parts taken out with light oil.

9. Install element assembly (A) using the reverse procedure described in steps 5 and 6.

B Element assy A

C B 6

5

10. Install cover (2).

Tightening torque: 22.7 to 25.3 Nm (15.3 to 18.7 lb ft) 11. Start and run the engine at idle, moving the machine controls to remove air from the system.

Then, place the machine in piston to check the oil level. Stop the engine and check the oil level, adding oil if needed.

(5) (B)

12. Close the cover on the hydraulic oil tank and lock it.

(C) (B)

NOTICE: Use of a breaker attachment on the machine reduced the life of the hydraulic oil. Service the return filters earlier than the specified service interval. See Maintenance Specifications.

ELEMENT KIT UPSX0104029E01

A. ELEMENT ASSEMBLY B C

6-66

(A)

1. BOLT 2. COVER 3. SPRING 4. VALVE 5. O-RING 6. BREATHER CAP

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE THE BREATHER ELEMENT 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 To keep the hydraulic oil clean and extend the life of hydraulic components, replace the filter element at regular intervals. Replacement of the filter element at 1000 hour intervals is a guideline. If the machine is operated in very dusty conditions, change the element earlier.

UPDX0104009B01

1. Park the machine on firm and level ground.

Extend the bucket cylinder, retract the arm cylinder and lower the bucket to the ground as shown in the right figure. Place the dozer blade on the ground and shut off the machine engine.

2

1

2. Open the right side cover (1) and support it with stay.

3. Remove the guard (2)

UPSX0104030B01

1. RIGHT SIDE COVER 2. GUARD

4. To release the inner pressure of the hydraulic oil tank, press the rubber cap (3) on the upper surface of the hydraulic tank several times (5 to 7 times).

3 4

5. After removing the rubber cap (3), remove the nut (4).

5

6. Rotate the cover (5) counterclockwise and remove it, then remove the element (6).

6

7. Install the new element (6) and install the cover (5) along the groove.

7

8. Do not allow water or dirt to enter into the air intake and exhaust between the cover (5) and the body (7).

9. Install the cover (5) and tighten the nut (4).

Tightening torque: 8 to 10 Nm (5.9 to 7.37 lb ft)

UPSX0104009E01

3. RUBBER CAP 4. NUT 5. COVER

6. ELEMENT 7. BODY

NOTICE: To avoid breaking bolts, do not tighten the nut (4) too much.

10. Install the rubber cap (3).

11. Install the guard (2).

12. Release the stay and close the right side cover in its original position.

6-67

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ADJUST THE ENGINE VALVE WARNING: It is recommended that the following service work be done by a qualified service professional. Specialized product knowledge and training is important to successfully perform this service. Contact your dealer for qualified service.

If the engine power drops noticeably, the color of the engine exhaust changes, the noise level changes, or other engine performance problem is suspected, engine valve adjustment may be necessary.

This ser vice will correct the time lag on the operating timing of the exhaust and intake valves.

CHECK AND ADJUST THE STARTER AND ALTERNATOR Abnormal noise from the starter or alternator could mean a bearing or bushing needs replacement. An alternator not charging could mean worn brushes or other parts need replacement.

6-68

UPSX0104039B01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1500 HOUR MAINTENANCE Perform the following procedures after 1500 hours of operation along with the Daily, 50 Hour, 250 Hour 500 Hour and 1000 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in death or serious injury.

M1087

WARNING It is recommended that the following service work be done by a qualified service professional. Specialized product knowledge and training is important to successfully perform this service. Contact your dealer for qualified service.

CHECK AND ADJUST FUEL INJECTION TIMING Contact your dealer for adjustment of the fuel injection timing to optimize the engine performance.

UPSX0104039B01

6-69

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE Perform the following procedures after 2000 hours of operation along with the Daily, 50 Hour, 250 Hour, 500 Hour, 1000 Hour and 1500 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. Failure to comply could result in death or serious injury.

M1087

6-70

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEAN THE SUCTION STRAINER WARNING: 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. M1295 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

UPW0030004J02

HYDRAULIC LEVEL CHECKING POSITION

1. Park machine on firm level ground in the hydraulic level checking position, stop engine.

1

2. Move safety lock lever to "LOCKED" position.

3. Open the right side cover and support it with stay.

4. Remove the guard.

5. Clean the surface around hydraulic tank to prevent intrusion of foreign matter.

6. Press the rubber cup (1) on the surface of hydraulic tank several (5 to 7) times.

UPW00400128J02

1. RUBBER CUP

7. Loosen four capscrews (2) and remove cover (3).

2

1

NOTICE: Be careful not to drop bolts or tools into the tank while working.

3

5

UPSX0104040B01

1. RUBBER CUP 2. CAPSCREW

3. COVER 5. O-RINGS

6-71

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 8. Take out suction strainer (4).

9. Check strainer for damage. If damaged, replace it with a new one.

1

2

3

10. Clean the strainer with light oil or wash then dry it.

4 5

UPSX0104041B01

1. RUBBER CUP 2. CAPSCREW 3. COVER

4. STRAINER 5. O-RINGS

11. Check the O-rings (5) and (6) on the bottom of the strainer for wear and damage. If worn or damaged, replace with new ones.

12. Insert the strainer (4) into the suction tube.

13. Install cover (3) with capscrew (2).

6 m

m .5 0 44

Tightening torque: 20.7 to 25.3 Nm (15.3 to 18.7 lb ft) 14. Start the engine and operate at low idle for several (five to seven) minutes. Operate each cylinder and swing, then return the machine to the hydraulic level check position. Stop the engine and check the oil level. If the oil level is low, refill with oil.

6-72

UPSX0104010B01

6. O-RINGS

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEAN THE PILOT AND SOLENOID VALVE FILTERS The (P) ports of the right and left pilot valves (for operation and travelling) and the solenoid valve are equipped with connectors and filters. Dust, etc. that adheres on the filters will decrease the oil flow. If the dust, etc., enters the valves it may cause trouble.

Remove and clean these filters periodically.

WARNING: 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. M1295

4

5

P 2

4 1

P

1. Move the machine to firm, level ground, place the attachment in the oil check position and stop the engine.

2. Release the air in the hydraulic line - see Release Hydraulic System and Tank pressure in this chapter.

3. Loosen two bolts (3) on the operating box to remove the cover.

4. Disconnect the hose (1) connected to port “P” on the pilot valve (4) first, then remove the connector with filter (2). After removal, plug the bore to prevent entry of foreign matter.

3 3 UPSX0104051B01

P. PORT 4. PILOT VALVE 1. HOSE 5. O-RING 2. CONNECTOR WITH FILTER 3. TWO BOLTS

5. Wearing face protection, wash the filter with cleaning solvent. Use compressed air to remove any material.

6. Check the O-ring (5) for damage and replace with a new one if damaged.

7. After cleaning, reinstall to original position in reverse order of Steps 3 and 4 above. Refer to Torque Specifications for tightening torque.

Then, remove the in-line filter (7) of the solenoid valve (6) for cleaning.

6-73

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 8. .Remove the right-hand guard (8).

9. After removing the hose, remove the in-line filter assembly (7) from the tee installed on the solenoid valve (6). After removal, the oil holes of the tee and hose should be plugged.

A

8

6 7

VIEW A UPSX0104052B01

8. RIGHT-HAND GUARD 6. SOLENOID VALVE A. VIEW “A” 7. IN-LINE FILTER ASSEMBLY

10. Using a screwdriver, remove the case (7a) and the fitting (7e) then remove the strainer (7b).

11. Spray light oil or air on the strainer (7b) to clean.

Do not forget to clean the inside of the case (7a). Then check the O-ring (7d) for possible damage. If it is damaged, replace with a new one.

12. Using a screwdriver, install the strainer (7b) on the fitting (7e) and fit it in the in-line filter case (7a).

Tightening torque: 60 to 80 Nm (44 to 59 lb ft)

7a

7b

7c

7e

7f

UPW00400004JS1

A. CASE D O-RING B STRAINER E FITTING C LABEL IN-LINE FILTER

6-74

7d

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 13. Remove the plug, install the in-line filter assembly (7) on the solenoid valve (6) and install the hose (1). Then, remove and clean the elbow with filter (9) of the pilot valve (10) for travelling.

12 9 P

11

14. Remove the floor mat and floor plate.

Disconnect the hose (11) connected to port “P” on the pilot valve (10) first, then remove the elbow (9). After the removal, put a plug to the bore (13) to prevent entry of foreign matter.

10

UPSX0104045B01

9. FILTER 11. HOSE 10. PILOT VALVE12. O-RING

15. Dust tends to accumulate on the inside elbow ( 9 ) ( b e n t p o r t i o n ) . C l e a n p a r t s t o avo i d contamination (projected portion).

16. Check the O-ring (12) for damage and replace with a new one if damaged.

17. After the cleaning, install it to the original position in the reverse order of the above removal. Refer to the Torque Specifications for the tightening torque for the hose (11).

12 13

18. Install the floor mat and floor plate.

9 UPW00400108J01

9. INSIDE ELBOW12. O-RING 13. BORE

6-75

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE OIL IN THE TRAVEL REDUCTION UNITS 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 WARNING: Travel reduction gear is under pressure.

Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury. M1721

UPAX1004045B01

NOTICE: For new machines, change the oil after the first 500 hours of operation.

1. Park the machine on a firm, level surface with both attachments resting on the ground. Turn the engine off. Keep all unauthorized persons clear of the area. When parking the machine, make certain the drain port (1) is at the bottom.

2. Place an empty 1 liter (0.26 gal.) container under the drain port.

Container to receive drained oil: 1.0 L (0.26 gal) or more capacity Oil volume to fill: 0.9 L (0.24 gal) LH/RH each UPSX0104032B01

DRAINED OIL

3. Slowly remove the plugs of the FILL port (2) and LEVEL por t (3) with an Allen wrench, then remove the drain port (1) to receive drained oil.

4. Apply a sealing (teflon) tape on the thread of plug of drain port (1) and securely tighten it.

2 3

GL 1 UPSX0104032B01

1. DRAIN PORT 2. FILL PORT 3. LEVEL PORT

6-76

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. Slowly fill in oil through the FILL port (2) up to overflowing of oil from the LEVEL port (3). Refer to Specifications chapter for the Preferred gear oil.

6. Apply a sealing (teflon) tape on the thread of the plug of the LEVEL port (3) and FILL port (2) and securely tighten them. Wipe off any spilled oil.

7. Confirm there are no oil leaks by moving the machine slowly. Fix any leaks found.

NOTICE: Check the waste oil. If there are metal particles in it, contact your dealer.

UPSX0104033B01

FILL TRAVEL MOTOR WITH OIL

6-77

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE GEAR OIL IN THE LOWER ROLLER, IDLER AND UPPER ROLLER WARNING: AVOID INJECTION HAZARD! Grease in the track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Do not loosen grease fitting more than one turn. If grease does not release after one turn of the fitting, call your dealer.

1 2

All idlers have to be removed from the crawler frame to change the gear oil in each of them. The following describes the procedure to remove, reinstall and change the gear oil in each of them. Refer to Specifications section for specified oil and grease.

3 6

4

5

UPWX3404009B01

1. TRAVEL MOTOR 4. CRAWLER BELT 2. SPROCKET 5. UPPER ROLLER 3. LOWER ROLLER 6. IDLER

1. Loosen the rubber crawler show of the side to change the engine oil. Refer to Adjusting the Rubber Crawler tension in the Maintenance chapter.

2. The fixing capscrews (1) of the lower roller are a bit loosened in advance (around one turn).

3. Start up the engine and lift up one side of the machine with boom and arm getting down the back side of bucket to the ground.

2

4. Support the machine with a steady support (5) etc., then stop the engine.

5. Remove the capscrews (1) with washers (2) which are provided to install the lower roller to the crawler frame at two positions of inside and outside. Then remove the lower roller (3).

1

1

2

3

4

UPSX0104046B01

1. CAPSCREWS 2. WASHERS

3. LOWER ROLLER 4. PORT PLUG

6. Remove the feeding port plug (4) with the Allen wrench and discharge the oil engine oil.

7. Fill in the specified volume (110 cc or 6.7 cu in) of engine oil through the feeding port.

8. Apply a sealing (teflon) tape to thread on the plug (4) and securely tighten it. Thoroughly wipe off oil adhered to periphery.

9. Apply Loctite #262 to thread on the capscrews (1) and temporarily install the lower roller (3) to the crawler frame.

10. Remove the safety support which supports the machine to lower the machine to the ground then tighten the capscrew (1).

Tightening torque: 250 to 308 Nm (184 to 227 lb ft) 11. Lift the machine up to adjust the crawler shoe tension. Refer to Adjusting the Tension section in this chapter.

6-78

UPAX1004058B01

LOWER ROLLER

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE OIL IN THE IDLER WARNING: AVOID INJURY OR DEATH! The check and adjustment for the tension of the rubber crawler is done with a track lifted off the ground one side at a time. Unexpected lowering of the machine or movement of the machine can result in serious injury or death. Do not operate the boom, arm or bucket/attachment while adjusting the rubber crawler belt. Follow the instructions provided. This work must be done carefully by two people. The operator must operate the machine as instructed by the signals of the partner.

To service the idlers, the crawler belts must first be removed. Before removing or installing rubber crawler belts, refer to the Removal of the Crawler Belts section in this chapter.

UPAX1004046B01

1. Remove the rubber crawler belt, following the instructions provided earlier in this chapter.

2. Remove the idler (1) and adjuster (2) from the crawler frame.

We i g h t o f i d l e r a n d i d l e r a d j u s t e r = approximately 40 kg (88 lb)

A

1

3. Remove the fill/drain plug (3) with Allen wrench to drain oil gear oil.

4. Fill the idler with 75 cc (4.6 cu in) of the specified oil through the fill/drain port.

5. Apply a sealing (teflon) tape to the threads on the plug (3) and securely tighten it. Wipe off any remaining oil.

6. Apply grease to the sliding face (A) on the piston (4) and cylinder (5) of the idler adjuster (2).

7. Install the idler so that the fill/drain port plug (3) of the idler and the grease fitting (6) of the idler adjuster (2) are facing outside.

5 4 3

2 UPSX010404047B01

A. SLIDING FACE 1. IDLER 4. PISTON 2. ADJUSTER 5. CYLINDER 3. PLUG 6. GREASE FITTING GREASING POINTS

8. Install the rubber crawler belt according to instructions in this chapter.

9. Adjust the tension on the rubber crawler belt referring to instructions in this chapter. After the confirmation for the engagement of the rubber crawler belt with the idler and the conditions for tension, raise the machine off the safety support, remove the safety support and slowly lower the machine to the ground.

6-79

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHANGE THE OIL IN THE UPPER ROLLER To service the idlers, remove the crawler belts. Refer to the Removal and Installation section in this chapter.

6

1. Place the machine in the parked position and stop the engine.

2. Loosen the rubber crawler belt (6) on the side where the gear oil is to be changed. Follow the instructions earlier in this chapter.

1

3. Raise the rubber crawler belt with a hydraulic jack (5).

4

3

2

5

4. Loosen the nuts (2) and bolts (3) used to assemble the upper roller (1) to the machine and remove it.

UPSX0104042B01

1. UPPER ROLLER 4. PLUG 2. NUTS 5. HYDRAULIC JACK 3. BOLTS 6. RUBBER CRAWLER BELT

5. Remove the oil fill/drain port plug (4) with an Allen wrench and drain the old gear oil.

6. Fill the upper roller with 20 cc (1.2 cu in) of the specified oil through the fill/drain port.

7. Apply a sealing (teflon) tape to the threads on the plug (4) and securely tighten it.

8. Thoroughly wipe off any remaining oil.

MACHINE FRONT

3

Install the upper roller in reverse order of the removal. At this time, place the countersink side of shaft (7) facing up and install it. Apply thread lock sealant (Loctite #292 or equivalent) on thread of the bolts (3) and tighten the bolts.

2

7 Tightening torque: 103 to 127 Nm (76 to 94 lb ft)

UPSX0104048E01

2. NUTS 3. BOLTS

6-80

7. SHAFT

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GREASE THE SWING GEAR NOTICE: If the machine is operated in high water with the water level close to the swing gear, water may mix with the grease causing it to deteriorate.

Continued operation of the machine with grease deteriorated by water will cause damage to the swing gears and bearing. Contact your dealer for inspection and advice about changing the grease.

1 A

2

B

UYWX3404012B01

A. SURFACE OF WATER 1. UPPER ROLLER B RIVER BED 2. SWING GEAR/BEARING

NOTICE: It is recommended that the following service work be done by a qualified service professional. Specialized product knowledge and training is important to successfully perform this service. Contact your dealer to obtain qualified service.

2 C

UPWX340413B01

2. SWING GEAR/BEARING C. GREASE

CHECK AND ADJUST THE CONTACT SURFACES OF THE INTAKE AND EXHAUST VALVES Contact your dealer to ensure the integrity of the seals of the exhaust and intake valves to optimize engine performance.

6-81

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE Perform the following procedures after 5000 hours of operation along with the Daily, 50 Hour, 250 Hour, 500 Hour, 1000 Hour and 2000 Hour Maintenance procedures.

WARNING Read, understand and follow all safety precautions contained in this manual before performing any inspection or maintenance procedures on this machine, its system or components. 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

CHANGE HYDRAULIC OIL WARNING: 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. M1295 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

UPAX1004039B01

1. Park the machine on a firm, level surface and swing the upper structure so that the drain plug (1) on the lower section of the hydraulic tank is positioned midway between the crawlers.

2. Remove the right side guard, open the right side cover and support with stay.

3. Clean dirt from the filter to avoid contaminating the hydraulic system.

5

4. Press the valve several (5 to 7) times together with the breather cap and bleed the hydraulic oil tank of remaining pressure.

5. Put an oil pan (5) large enough to hold the discharged oil under the drain plug (1).

Capacity of container should be: 36 liters (9.5 gallons) 1

NOTICE: When loosening the drain plug, avoid contact with oil.

6-82

UPSX0104048B01

1. DRAIN PLUG

5. OIL PAN

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 6. LRemove the drain plug (1) with a 22 mm wrench and drain the remaining oil into the container.

2

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations.

F

1 3

4

7. Tighten the drain plug.

Tightening torque: 68.5 to 75.5 Nm (50.5 to 57.9 lb ft) 8. Loosen four bolts (2) and remove cover (3).

NOTICE: Be careful not to drop tools, nuts, bolts, etc. into the hydraulic tank.

9. Check O-ring (4) for possible damage and replace with a new one when damaged.

10. Fill the hydraulic oil tank with the specified oil at the filling port (F). Refer to Lubricant, Fuel and Coolant Specifications.

UPSX0104049B01

1. DRAIN PLUG 2. FOUR BOLTS 3. COVER 4. O-RING

F. FILLING PORT

11. Install cover (3) with bolts (2).

Tightening torque: 20.7 to 25.3 Nm (15.3 to 18.7 lb ft) 12. Start engine and idle for several (5 to 7) minutes. Operate cylinders and swing, and then return the machine to the hydraulic level checking position. Stop the engine and check the oil level, if the level is low, make up the oil.

Oil volume to be filled in: 34 liters (9.0 gallons)

6-83

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

INSPECTION/MAINTENANCE CHECKLIST MACHINE MODEL : ITEM

SERIAL No. : OK MAINT. PERFORMED

MACHINE HOURS : ITEM

ENGINE OIL LEVEL

SLEWING REDUCTION OIL

ENGINE COOLANT LEVEL

SLEWING RING GEAR

CHECK FOR FLUID LEAKS

GREASE BATH LEVEL

CHECK BELT TENSION

SLEWING RING PINION

CHECK FUEL LEVEL

SLEWING RING SEAL

DRAIN WATER SEPARATOR

SWIVEL JOINT SEALS

CHECK AIR CLEANER

DRAIN WATER FROM BATH

CHECK ENGINE ELECTRICAL

GREASE SLEWING RING

DRAIN WATER FROM FUEL

CHANGE GREASE BATH

CHANGE ENGINE OIL

CHECK BOLTS/HARDWARE

CHANGE OIL FILTER

CHECK LINES FOR DAMAGE

CHANGE FUEL FILTER

CHECK STEPS

CHANGE WATER SEPARATOR

CHECK FRAME STRUCTURE

CHECK AIR INTAKE INDICATOR

CHECK CRAWLERS

CHECK FAN ASSEMBLY

CHECK SPROCKET WEAR

CHECK BELT TENSIONER

CHECK IDLER WEAR

CLEAN RADIATOR

CHECK ROLLER WEAR

CHANGE ENGINE COOLANT

CHECK CRAWLER TENSION

AIR CLEANER ELEMENTS

ADJUST CRAWLER TENSION

ADJUST VALVE CLEARANCE

TRAVEL REDUCTION

HYDRAULIC OIL LEVEL

CHECK BOOM & ARM

CHECK HYD FUNCTIONS

BUCKET TEETH

CHECK FOR OIL LEAKS

SIDE CUTTERS

CHECK HOSES/PIPINGS

GREASE BOOM PINS

CLEAN SUCTION SCREEN

GREASE ARM PINS

CHANGE RETURN FILTER

GREASE BUCKET PINS

PILOT MANIFOLD FILTER

GREASE SWING PIN

CHANGE HYDRAULIC OIL

GREASE DOZER PIN

CLEAN HYDRAULIC TANK

CHECK COOLANT ADDITIVE

INSPECT ALL WIRING

CHECK CRAWLER BELT

OK MAINT. PERFORMED

BATTERY FLUID BATTERY SERVICE HYD. FUNCTION OPERATION CHECK SWITCHES CHECK WARNING LIGHTS CHECK HORN CHECK DISPLAY MONITOR

This list includes parts that the machine may not be equipped with.

MECHANIC: SIGNATURE: DATE: 6-84

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL TROUBLESHOOTING SYS TROUBLE DESCRIPTION

1. All operating speeds are slow or power is lost.

PROBABLE CAUSE

POSSIBLE REMEDY

a. Low hydraulic oil level

Fill oil to specified level

b. Air leaking into the suction pipe

Tighten suction pipe hose clamp or replace hose

c. Hydraulic pump is damaged

Repair or replace

d. Pilot gear pump is damaged

Repair or replace

e. Main relief valve is not adjusted correctly

Adjust or replace

f. Pilot relief valve is not adjusted correctly

Adjust or replace

OPERATING

2. A specific cylinder func- a. Cylinder seal is damaged Repair or replace tions improperly or los- b. Control valve or overload relief valve functions incor- Repair or replace/Rees power. rectly or there are signs of air in the cylinder move air from cylinder c. Pilot valve is damaged

Repair or replace

d. Pilot valve piping is loose

Retighten

3. The cylinder position a. Cylinder seal is scored will not hold with operat- b. Control valve or overload relief valve is damaged ing lever in neutral. c. Pilot valve is damaged

Repair or replace Repair or replace Repair or replace

4. Machine does not slew. a. Hydraulic motor (slewing) is not working or slewing Repair or replace gear is damaged

5. Slewing speed is slow.

b. Slewing bearing is damaged

Repair or replace

c. Pilot valve is not working

Repair or replace

d. Slewing reduction unit is damaged

Repair or replace

e. Solenoid valve is not working

Repair or replace

f. Control valve is not working

Repair or replace

g. Lever lock Solenoid valve is not working

Repair or replace

a. Control valve is not working

Repair or replace

b. Hydraulic motor (slewing) is not working

Repair or replace

c. Hydraulic pump is not working

Repair or replace

d. Pilot valve is not working

Repair or replace

6. Abnormal sound occurs a. Insufficient lubrication of slewing gear and bearings Grease when slewing. b. Pilot valve is not working Repair or replace c. Control valve is not working

TRAVEL

1. Machine does not travel a. Too much crawler tension smoothly. b. Dirty or clogged crawler belts/shoes

Repair or replace Adjust crawler tension Clean crawlers

c. Brake valve is not working

Repair or replace

d. Travel reduction unit is damaged

Repair or replace

e. Control valve is not working

Repair or replace

f. Travel motor damaged

Repair or replace

g. Main relief valve pressure is set incorrectly

Adjust or replace

h. Swivel joint is damaged

Repair or replace

6-85

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SYS TROUBLE DESCRIPTION

TRAVEL

2. Traveling power is insufficient.

PROBABLE CAUSE

POSSIBLE REMEDY

a. Hydraulic pump is damaged

Repair or replace

b. Poor engine performance

Repair or replace

c. Main relief valve pressure is set incorrectly

Adjust or replace

d. Low hydraulic oil level

Fill to proper level

e. Hydraulic motor (travel) is not working

Repair or replace

f. Brake valve is not working

Repair or replace

g. Seal in swivel joint is scored or oil is leaking 3. Machine does not travel a. Unequal tensions on crawlers in a straight line. b. Set pressures of main relief valves unbalanced

Repair or replace Adjust tension.

Adjust.

GAUGE CLUSTER DISPLAY

HYDR AULIC

c. Performances of hydraulic travel motor has deterio- Repair or replace. rated d. Unbalanced flow from control valve

Repair or replace.

e. Unbalanced discharge from hydraulic pump

Repair or replace.

f. Unbalanced flow from brake valve

Repair or replace.

g. Unbalanced flow between RH swivel joints

Repair or replace.

1. Temperature rise in the a. Oil cooler core clogged hydraulic oil temp. b. Engine fan belt slipping

Clean Adjust or replace

c. Low hydraulic oil level

Refill to specified level

d. Wrong type hydraulic oil used

Replace with correct, new oil

e. Hydraulic pump is not working

Repair or replace

1. Engine oil pressure is too low.

a. Engine oil level low

Fill to specified level

b. Oil leaking

Repair & fill to proper level

c. Wrong oil viscosity

Replace with proper oil

2. Abnormal rise in the coolant temperature.

a. Low coolant

Fill to proper level

b. Coolant leaking

Repair & fill to proper level

c. Loose radiator cap

Tighten

d. Radiator core clogged

Clean cooling system

e. V-belt loose or damaged

Tighten to proper tension

f. Rust or scale in coolant

Flush system/fill to level

g. Faulty thermostat

Replace

3. Battery charge.

a. Battery terminals disconnected, loose, or corroded Clean and connect b. Low battery fluid

Replenish

c. Slipping of V-belt or damaged

Adjust or replace

d. Battery service life has run down

Replace

1. Starter does not turn or a. Battery disconnected Connect turns slowly which does b. Battery discharged Charge not start the engine. c. Battery terminals disconnected, loose, or corroded Clean and connect

ENGINE

d. Ground cable disconnected

6-86

e. Engine oil viscosity too thick (Cold Weather) 2. Starter turns but engine a. Insufficient fuel does not start. b. Improper starting procedure

Connect Change to proper oil Refuel Refer to "section 3. MACHINE OPERATION"

c. Air in fuel line

Remove (Refer to 4.10)

d. Clogged fuel filter

Replace element

e. Clogged air cleaner

Replace elements

f. Air heater circuit malfunctioning

Check circuit

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SYS TROUBLE DESCRIPTION

PROBABLE CAUSE

3. Engine tends to stop at a. Low idling RPM low speed b. Fuel filter clogged

4. No power

EN GI NE

5. Engine overheats.

6. Engine exhaust is black.

7. Poor fuel consumption

POSSIBLE REMEDY Serviceman Replace with new element

c. Air cleaner clogged

Replace with new elements

d. Improper engine valve clearance

Serviceman

a. Fuel filter clogged

Replace with new element

b. Air cleaner clogged

Replace with new element

c. Improper engine valve clearance

Serviceman

d. Loose clamps on the air inlet hose

Tighten clamps

e. Cracked air inlet hose

Replace with new hose

a. Insufficient coolant

Refill coolant

b. Clogged radiator

Clean cooling components

c. V-belt to loose or damaged

Adjust or replace belt

d. Faulty thermostat

Replace

a. Air cleaner clogged

Replace with new elements

b. Improper engine valve clearance

Serviceman

a. Fuel leak

Serviceman

b. Air cleaner clogged

Replace with new elements

c. Loose clamps on suction hose

Tighten clamps

d. Cracked suction hose

Replace with new hose

e. Engine oil level is too high

Reduce to specified level

8. Excessive oil consump- a. Improper oil tion. b. Oil leak

Replace with correct oil Serviceman

c. Improper oil replacement intervals

Change at correct interval

d. Improper warming-up operation

Refer to 3.1.4

9. Engine oil pressure does not rise.

a. Low oil volume

Fill to specified level

b. Oil leak

Serviceman

c. Improper oil viscosity

Replace with proper oil

10 Battery dies often.

a. Battery terminals disconnected loose, or corroded

Clean & tighten terminals

b. Low battery fluid

Fill cells with distilled water

c. V-belt loose or damaged

Adjust or replace belt

d. Defective battery

Replace battery

NOTE: Use only genuine parts.

6-87

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL MAINTENANCE PROCEDURES CHANGING THE PATTERN ON THE ROTARY MULTI-CONTROL VALVE The machine is factory-equipped with the BHL control function pattern. To change the control function pattern, follow these steps: 1. Place the attachment on the ground and stop the engine.

2. Pull up the safety lock lever to lock the machine.

BHL UPX00200006E01

3. Open the right side cover of the machine and locate the rotary multi-control lever (1).

1

UPSX0107005B01

1. ROTARY MULTI-CONTROL LEVER

4. Loosen the wing bolt (2) on the rotary multi-control valve and change the lever position to the desired pattern.

2 3

5. Tighten the wing bolt by hand to secure the lever (3). Do not use any tools.

6. Close the cover correctly.

UPSX0107009B01

2. WING BOLT 3. LEVER

6-88

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 7. Slowly operate the control levers to make sure the functions match the pattern shown in the operator’s station. Practice operation in an open area to become familiar with the new control pattern.

UPW00100006E11

MOVING A DISABLED MACHINE WARNING: AVOID INJURY OR DEATH! Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection, maintenance or repair of this machine, attachment or any of its systems.

WARNING: AVOID INJURY OR DEATH! The procedures found in this section should be performed by a well-trained, experienced service technician who is familiar with the machine.

RELEASING LOCK ON TRAVEL MOTOR The travel motors of a disabled machine are locked by the hydraulic control valve and by the mechanical brake system. If the machine is unable to run, it can be moved by releasing the travel motor lock using one of the following methods.

NOTICE: Avoid contamination of reduction units while the covers are removed.

Removing Gears From Travel Reduction Unit (Preferred Method) WARNING: AVOID INJURY! Make sure blocks are secure at front and rear of each track before attempting to release brakes. Do not stand in the path of the tracks when releasing brakes. Provide a support for the attachment if necessary.

1. Place blocks at front and rear of each track to prevent machine from moving when brakes are released.

2. Lower the attachment to the ground.

SUPPORT

BLOCK

UPW00300023E01

6-89

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Place a pan under the travel motor for the oil to drain into.

4. Slowly remove the upper plug, then remove the drain plug (4) to drain the reduction unit oil.

Plug (4): Opposing flat 6 mm

4

PAN XPX00900001E01

2

5. Insert a flat screwdriver into the gap between the body (1) and snap ring (3) and remove the snap ring.

4. DRAIN PLUG

5

1 3

6

XPX00900004E01

1. BODY 2. COVER 3. SNAP RING

6. Remove the cover (2). Be careful when removing cover (2) because the ball (5) falls. If the ball (5) was contaminated, clean it. The crawler belt/track is now free to rotate.

5. BALL 6. SUN GEAR

1

7. Install the cover with the snap ring (3).

8. Install the drain plug (4) and refill the unit with the drained oil from the pan.

9. Tow the machine to a safe place to proceed with the appropriate repairs.

5 6

NOTICE: Avoid oil spills, use pans, rags, and/or paper towels to clean up any oil leakage.

2 4

NOTICE: Dispose of all hazardous waste in accordance with government laws and regulations.

14 3 XPX000900003E01

1. BODY 2. COVER 3. SNAP RING 4. DRAIN PLUG

6-90

5. BALL 6. SUN GEAR 14. O-RING

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Assembling Travel Motor

1

1. After all repairs are complete, assemble the travel motor units.

5 6 2 4 14 3 XPX00900003E01

1. BODY 2. COVER 3. SNAP RING 4. DRAIN PLUG

2. Install the sun gear (6) and ball (5). To prevent the ball from falling from the sun gear, coat the ball with grease.

5. BALL 6. SUN GEAR 14. O-RING 2 5

3. Replace O-ring (14) with new one. Lubricate the O-ring with grease and fit into groove of cover (2).

4. Install cover (2) with snap ring (3). Be careful not to damage the O-ring when installing the cover.

3 6

NOTICE: Clean up all spilled oil.

XPX00900005E01

5. BALL 6. SUN GEAR

2. COVER 3. SNAP RING

LOWERING BUCKET/ATTACHMENT ON DISABLED MACHINE WARNING: AVOID INJURY OR DEATH! The following procedure is to be used only in an emergency of the machine being disabled. Proceed with extreme caution. Keep people away from the bucket/attachment and excavator boom. Block the bucket/attachment to avoid unexpected movement.

Weight may cause unexpected movement of the bucket/attachment, arm or boom during the procedure. Use controls slowly and smoothly to ensure slow and smooth movement of bucket/attachment. Safety lock lever must be released slowly. Do not enter into areas under the bucket/attachment while it is being lowered.

STEP 1

UPSX0109001E01

6-91

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS If the machine is disabled and the engine is stopped, lower the bucket/attachment according to the following procedure within five minutes after the e n g i n e s t o p s. P r e s s u r e i n t h e a c c u mu l a t o r decreases when the engine stops and lowering the bucket/atttachment may not be possible if you wait too long.

STEP 2

STEP 3

1. Put the safety lock lever in the LOCKED position.

2. Turn the ignition key switch to the OFF position.

3. Make sure all the control levers are in NEUTRAL position.

4. Turn the ignition key switch to the ON position.

5. Put the safety lock lever in the UNLOCKED position.

6. Lower the attachment to the ground, slowly manipulating right and left control levers to close the bucket (Step 1), lower the arm (Step 2), and lower the boom (Step 3).

7. Contact your dealer for machine repair.

6-92

UPSX0109002E01

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MACHINE STORAGE

UPW00300079J01

The following procedure applies when the machine is to be stored for a month or more.

WASH THE MACHINE Wash the machine thoroughly.

Check the travel system for any malfunctions and service as required.

Lubricate every required part.

LUBRICATION Check the lubrication oil to make sure it is at the proper level and for contamination.

Replenish if necessary, and change if contaminated.

NOTICE: Lubricating oil deteriorates even when the machine is not used. Make sure to check the oil before operating the machine again.

DUST AND HUMIDITY PREVENTION Keep the machine in a dry place indoors. If the machine must be kept outdoors, lay wood block on flat ground and protect the machine with a cover.

Park the machine with the belts/tracks on top of the wood and with the exposed piston rods of the cylinders retracted as much as possible.

Lower the bucket to the ground on top of the wood.

M ACH INE O PER ATIO N FO R LUB RI CATIO N DURING STORAGE PERIOD If the oil film on the part is insufficient, rust may develop causing abnormal wear to occur when the machine is operated.

Star t the engine and operate the machine and attachment, etc. once a month to lubricate all of the parts.

Before starting the engine, check the engine oil and coolant level, and replenish if insufficient.

Apply sufficient rust inhibitors to portions where rust is likely to occur, especially the exposed rod of the cylinder.

Wipe off the rust inhibitors from the cylinder and piston rod thoroughly.

BATTERY

After starting the engine, warm up the machine completely. Repeat travelling, slewing, and digging several times to lubricate each part of the machine.

Remove the negative terminal from battery and cover the battery, or remove the battery from the machine and store it at room temperature placing it over a wood deck.

Charge the batter y once a month to replenish spontaneous discharging.

Apply rust inhibitors to cylinder rods after the above operation.

Make sure there is proper ventilation during warm-up operation.

OPERATION AFTER LONG TERM STORAGE

COOLANT

Before placing the machine back into operation, proceed as follows before starting up.

If there is a possibility that the coolant may freeze, add antifreeze in the coolant.

Fully wiped off the rust inhibitors from the cylinders and piston rods.

Normally, long life coolant is mixed in, so it is not necessary to change the coolant.

Refill fluids to proper levels and lubricate as required.

6-93

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-94

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuse Box (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fusible Link (For Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL EQUIPMENT WORK LAMP A work lamp is provided on the boom and cap (option) for work at night, etc.

UPSX0102021B01

FUSE BOX (MAIN) WARNING: AVOID INJURY! Make sure the ignition switch is in the OFF position when replacing fuses.

The fuses protect the electrical system from excess current. If an operation is not normal, a fuse may be blown.

Replace blown or faulty fuses with the spare fuses stored in the center of the fuse box.

Replace any fuse generating white powder or in the case that some looseness exists between the fuse and the fuse holder.

NOTICE: When replacing a fuse, replace it with one of the same capacity.

UPSX0102022E01

No.

AMPS

FUNCTION

No.

AMPS

1

FUNCTION

5A

Cluster gauge hour meter

9

10A

Decel motor

2

20A

Wiper washer

10

5A

Relay, fuel pump

3

5A

Air conditioner (option)

11

5A

Horn

4

5A

Air conditioner (option)

12

20A

Work light

5

5A

Air conditioner (option)

13

5A

Room lamp

6

5A

Travel alarm

14

30A

Engine stop solenoid

7

5A

Safety lever lock

15

10A

Hand control solenoid

8

5A

Over load alarm

16

10A

Socket, radio

7-3

CHAPTER 7 - ELECTRICAL FUSIBLE LINK (FOR STARTER) If electrical power does not come on when the ignition key is in the ON position, the fusible link may be the cause. Inspect and replace the fusible link.

1

NOTICE: A fusible link is used in the wiring system to protect the electrical system from current overload. The fusible link functions like a fuse.

UPSX0102023E01

1. FUSIBLE LINK

BATTERIES Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours.

WARNING Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

Wear eye protection and protective clothing when handling or servicing batteries.

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention. Failure to comply could result in injury or death.

M4655

See chapter on Maintenance for details on checking the battery.

7-4

BS07N390

1. CAP 2. TERMINAL 3. TERMINAL COVER A. INDICATOR B. AIR VENT HOLE C. BLUE D. RED E. WHITE F. UPPER LIMIT G. LOWER LIMIT H. GOOD CONDITION I. REFILLING REQUIRED J. CHARGING REQUIRED

CHAPTER 7 - ELECTRICAL ALTERNATOR Ask your Dealer to check the Alternator.

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.

7-5

CHAPTER 7 - ELECTRICAL

7-6

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Canopy Machine Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Cab Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Speed and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Side Digging and Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Crawler Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Bucket Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Canopy Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Cab Type Machine Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Machine and Components Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Boom, Arm, Bucket, and Dozer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Lift Capacities Canopy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Lift Capacities Cab Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Cap Screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Joints and Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Sleeve Type Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Joints for Piping (O-Ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Hydraulic Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

CHAPTER 8 - SPECIFICATIONS

GENERAL SPECIFICATIONS

150 {5.9"} R1180 {3'10.5"}

25 {0.98"}

70 {2.76"}

1960 {6'5.2"}

750{29.5"} 735{28.9"}

CANOPY MACHINE DIMENSION

5420 {17'9.4"}

1940 {6'4.4"}

625 {24.6"}

345 {13.6"}

2550 {8'4.9"}

2340 {7'8.1"} 1770 {5'9.7"} 1180 {3'10.5"}

400 {15.7"}

1690 {5'6.5"} 1990 {6'6.3"} 2480 {8'1.6"} 2910 {9'6.6"}

1560 {5'1.4"} 1960 {6'5.2"}

UPSX0406001E01

150 {5.9"}

R1180 {3'10.5"} 25 {0.98"}

1960 {6'5.2"} 750{29.5"} 735{28.9"} 70 {2.76"}

CAB MACHINE DIMENSIONS

5420 {17'9.4"} 2340 {7'8.1"} 1770 {5'9.7"} 1180 {3'10.5"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

625 {24.6"}

345 {13.6"}

2550 {8'4.4"}

1940 {6'4.4"}

1690 {5'6.5"} 1990 {6'6.3"} 2480 {8'1.6"} 2910 {9'6.6"} UPSX0406002E01

8-3

CHAPTER 8 - SPECIFICATIONS SPEED AND GRADEABILITY Rubber Crawler Belt 8.9 min (8.9 RPM)

Swing Speed

Travel Speed

Iron Crawler Shoe 1

Low (1st)

High (2nd)

Low (1st)

4.6 km/h (2.9 mph)

2.7 km/h (1.7 mph)

4.6 km/h (2.9 mph)

Gradeability

High (2nd)

58% (30°)

ENGINE Model

YANMAR 4TNV88-BXPYBD

Type

Water cooled, 4 cycle type swirl chamber type diesel engine

Number of cylinders - Bore X Stroke Total Displacement

4 - 88 mm X 90 mm (4 - 3.46 in. X 3.54 inch) 2.189 liters (133.6 cubic inch)

Output Rating

29.1 kW (2400 min1) 40 PS (2400 RPM)

Maximum Torque

131.3 Nm (1440 min1) 96.9 lbf ft (1440 RPM)

Starting Motor

12 V (2.3 kW)

Generator

12 V (55 A)

HYDRAULIC COMPONENTS Hydraulic Pump Hydraulic Motor

Variable displacement axial piston + gear pump Axial piston

Hydraulic Motor with Reducer (Travel)

2 - Axial piston, 2-speed motor

Control Valve

11- spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer) Return Filter

Double action cylinder Safety valve containing / Filter Type (30 microns)

SIDE DIGGING AND DOZER Type

Boom swing by hydraulic cylinder

Boom Swing Angle Right

60°

Boom Swing Angle Left

70°

Dozer Blade Travel (Up/Down)

8-4

495/375 (19.5/14.8)

CHAPTER 8 - SPECIFICATIONS CRAWLER TYPE

Type

Width mm {in}

Length between center of idler and center of travel motor mm {ft-in}

Ground Pressure kPa {psi} CANOPY

CAB

29 {4.21}

30 {4.35}

30 {4.35}

31 {4.50}

Rubber belt

400 {15.7"}

1,990 {6'6.3"}

Iron shoe (Optional)

400 {15.7"}

1,920 {6'3.6"}

UPSX0106009E01

BUCKET TYPE

Bucket

Heaped Capacity m3 {cu•yd}

0.16 {0.209}

Outer width mm {in} with side cutter

without side cutter

650 {25.6"}

600 {23.6"}

Number of tooth

Weight kg {lbs}

4

116 {256}

UPSX0106001E01

8-5

CHAPTER 8 - SPECIFICATIONS CANOPY TYPE MACHINE WORKING RANGES

UPSX0106005B01

Item/Attachment A A' B C D E F G H J K L X Y

8-6

Max. digging reach Max. digging reach at ground level Max. digging depth Max. digging height Max. dumping clearance Min. dumping clearance Max. vertical wall digging depth Min. front slew radius Height at min. slew radius 8-feet level digging depth Horizontal digging stroke at ground level Dozer blade

Stroke Minimum Above Below

STD ARM 1.66 m {5'5"} BUCKET 0.16 m3 {0.209 cu•yd} 6,220 {20'4.88"} 6,070 {19'10.98"} 3,910 {12'9.94"} 5,760 {18'10.77"} 4,200 {13'9.35"} 1,510 {4'11.45"} 3,030 {9'11.29"} 2,430 {7'11.67"} 4,380 {14'4.44"} 3,500 {11'5.8"} 3,060 {10'0.47"} 1,790 {5'10.47"} 495 {1'7.49"} 375 {1'2.76"}

CHAPTER 8 - SPECIFICATIONS CAB TYPE MACHINE WORKING RANGES

UPSX0106006B01

Item/Attachment A A' B C D E F G H J K L X Y

Max. digging reach Max. digging reach at ground level Max. digging depth Max. digging height Max. dumping clearance Min. dumping clearance Max. vertical wall digging depth Min. front slew radius Height at min. slew radius 8-feet level digging depth Horizontal digging stroke at ground level Dozer blade

Stroke Minimum Above Below

STD ARM 1.66 m {5'5"} BUCKET 0.16 m3 {0.209 cu•yd} 6,220 {20'4.88"} 6,070 {19'10.98"} 3,910 {12'9.94"} 5,760 {18'10.77"} 4,200 {13'9.35"} 1,510 {4'11.45"} 3,030 {9'11.29"} 2,430 {7'11.67"} 4,380 {14'4.44"} 3,500 {11'5.8"} 3,060 {10'0.47"} 1,790 {5'10.47"} 495 {1'7.49"} 375 {1'2.76"}

8-7

CHAPTER 8 - SPECIFICATIONS MACHINE AND COMPONENTS WEIGHT

UNIT : kg {lbs} ITEM COMPLETE MACHINE

RUBBER SHOE

IRON SHOE

CANOPY

CAB

CANOPY

CAB

5,000 {11,025}

5,130 {11,312}

5,100 {11,246}

5,230 {11,532}

UPPER FRAME ASSEMBLY (Assy of following)

2,475 {5,457}

2,625 {5,788}

2,475 {5,457}

2,625 {5,788}

1.1

UPPER FRAME

577 {1,272}

←

←

←

1.2

CANOPY/CAB

95 {209}

230 {507}

95 {210}

230 {507}

1.3

ENGINE

* 170 {375}

←

←

←

1.4

HYDRAULIC PUMP

* 35 {77}

←

←

←

1.5

RADIATOR

* 4 {9}

←

←

←

1.6

HYDRAULIC TANK

* 40 {88}

←

←

←

1.7

FUEL TANK

1.8

SWING BRACKET

1.

* 6 {13}

←

←

←

105 {232}

←

←

←

1.9

SWING CYLINDER

* 44 {97}

←

←

←

1.10

SLEWING MOTOR

* 36 {79}

←

←

←

1.11

CONTROL VALVE

* 47 {104}

←

←

←

1.12

COUNTERWEIGHT

800 {1,764}

←

←

←

1.13

GUARD•BONNET

84 {185}

←

←

←

1.14

BOOM CYLINDER

* 64 {141}

←

←

←

2.

LOWER FRAME ASSEMBLY (Assy of following)

1,735 {3,826}

←

1,835 {4,046}

←

2.1

LOWER FRAME

571 {1,259}

←

←

←

2.2

SLEWING BEARING

58 {128}

←

←

←

2.3

TRAVEL MOTOR

* 65 {143} × 2

←

←

←

2.4

LOWER ROLLER

11 {24} × 10

←

←

←

2.5

FRONT IDLER

36 {79} × 2

←

←

←

2.6

IDLER ADJUSTER

23 {51} × 2

←

←

←

2.7

SPROCKET

14 {31} × 2

←

←

←

2.8

RUBBER SHOE

222 {490} × 2

←

—

—

2.9

IRON SHOE

—

—

270 {595} × 2

—

2.10

SWIVEL JOINT

* 22 {49}

←

←

←

2.11

DOZER

180 {397}

←

←

←

2.12

DOZER CYLINDER

* 32 {71}

←

←

←

3.

ATTACHMENT ASSEMBLY (Assy of following)

585 {1,290}

←

←

←

3.1

BOOM ASSEMBLY

262 {578}

←

←

←

3.1.1 BOOM

183 {404}

←

←

←

3.1.2 ARM CYLINDER

* 58 {128}

←

←

←

3.2

202 {445}

←

←

←

3.2.1 ARM (STD.)

129 {284}

←

←

←

3.2.2 BUCKET CYLINDER

* 31 {68}

←

←

←

3.2.3 BUCKET LINK

13 {29}

←

←

←

3.2.4 IDLER LINK

4 {9} × 2

←

←

←

ARM ASSEMBLY

3.3

BUCKET ASSEMBLY (STD.)

116 {256}

←

←

←

4.

FLUIDS (Assy of following)

100 {221}

←

←

←

4.1

HYDRAULIC OIL

30 {66}

←

←

←

4.2

FUEL

63 {139}

←

←

←

4.3

COOLING WATER

6 {13}

←

←

←

* MARKS SHOW DRY WEIGHT

8-8

CHAPTER 8 - SPECIFICATIONS BOOM, ARM, BUCKET, AND DOZER SPECIFICATIONS Boom with Arm Cylinder mm (inch)

3,090 x 1,040 x 290 (10’ 7” x 3’ 4.9” x 11.4”)

Weight

kg (lbs)

262 (578)

H

LxHxW

L Arm and Standard Bucket Arm 1.66 m (5’ 5”) + Bucket 0.16 m3 (0.209 cu yd)

Combination mm (inch)

2,870 x 540 x 650 (9’ 5” x 21.3” x 25.6”)

Weight

kg (lbs)

317 (699)

H

LxHxW

L Arm 1.66 m (5’ 5”)

Type mm (inch)

2,120 x 450 x 250 (6’ 11” x 17.7” x 9.84”)

Weight

kg (lbs)

202 (445)

H

LxHxW

L

8-9

CHAPTER 8 - SPECIFICATIONS Standard Bucket m3 (cu yd)

0.16 (0.209)

LxHxW

mm (inch)

780 x 690 x 650 (30.7” x 27.2” x 25.6”)

Weight

kg (lbs)

116 (256)

H

Capacity

L

Dozer mm (inch)

1,180 x 330 x 1,960 (3’10.5” x 13” x 6’ 5.2”)

Weight

kg (lbs)

180 (397)

H

LxHxW

L

8-10

CHAPTER 8 - SPECIFICATIONS LIFT CAPACITIES CANOPY MODEL

A

Machine equipped with 1.66 m (5 ft. 5 in) arm Lift capacities calculated using 15.7 in (400 mm) shoes and SAE heaped 0.2 cu. yd. (0.16 m3 kg) bucket.

B B

LIFT POINT RADIOUS 5' (1.5m)

7.5' (2.3m)

10' (3.0m)

AT MAX. REACH 12.5' (3.8m)

15' (4.6m)

17.5' (5.3m) RADIOUS

A * 1860 * 840

* 1860 12'10" * 840 (3.91m)

1510 680

* 1760 * 790

1500 15'0" 680 (4.59m)

1830 830

1520 680

1520 680

1260 16'5" 570 (5.02m)

1370 620

1130 17'4" 510 (5.28m)

15' (4.6 m)

lb kg

* 1800 * 810

* 1800 * 810

12.5' (3.8 m)

lb kg

* 1640 * 740

* 1640 * 740

1820 820

10' (3.0 m)

lb kg

* 1830 * 830

* 1830 * 830

7.5' (2.3 m)

lb kg

5' (1.5 m) 2.5' (0.8 m)

* 2670 * 1210

* 2670 * 1210

* 2230 * 1010

2040 920

1790 810

1480 670

lb kg

3390 1530

2750 1240

2360 1070

1940 870

1740 780

1440 650

1330 600

1090 490

1300 580

1060 17'8" 480 (5.40m)

lb kg

3220 1460

2590 1170

2270 1020

1850 830

1690 760

1390 630

1310 590

1070 480

1280 580

1050 17'8" 470 (5.39m)

* 3840 * 1740

GROUND lb LEVEL kg

* 3840 * 1740

* 3710 * 1680

* 3710 * 1680

3140 1420

2520 1140

2210 1000

1790 810

1660 750

1350 610

1330 600

1090 17'2" 490 (5.24m)

1650 740

1340 600

1460 660

1190 16'3" 530 (4.95m)

1720 780

1410 14'8" 630 (4.48m)

2340 1060

1910 12'3" 860 (3.74m)

* 2530 * 1140

7'8" * 2530 * 1140 (2.35m)

-2.5’ lb (-0.8 m) kg

* 4130 * 1870

* 4130 * 1870

5230 2370

4040 1830

3130 1410

2500 1130

2180 980

1770 800

-5' lb (-1.5 m) kg

* 6320 * 2860

* 6320 * 2860

5300 2400

4100 1850

3150 1420

2530 1140

2200 990

1790 810

-7.5’ lb (-2.3 m) kg

* 9150 * 4150

* 9150 * 4150

5430 2460

4220 1910

3230 1460

2600 1170

* 2670 * 1210

* 2670 * 1210

-10' lb (-3.0 m) kg

PY11Z00320P1 NOTE: * Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits.

NOTICE: Do not attempt to lift or hold any load greater than these lift capacities at the specified lift point radius and height. Weight of all accessories must be deducted from the above lift capacities.

NOTICE: Lift capacities are based on the machine standing on firm, level and uniform ground. User must make allowance for soft or uneven ground, side loads, sudden sloping of loads, hazardous conditions, inexperienced operators, etc.

NOTICE: Bucket lift hook is defined as lift point.

NOTICE: Above lift capacities are in compliance with SAE J/ISO 10567. They do not exceed 87% of hydraulic lift capacity or 75% of tipping load. Lift capacities marked with an asterisk (*) are limited by hydraulic capacity rather than tipping load.

NOTICE: Operator should be fully acquainted with the machine and adhere to the rules for safe operation of the equipment at all times.

NOTICE: Lift capacities are based on the condition that the machine and its attachments are manufactured by our company.

8-11

CHAPTER 8 - SPECIFICATIONS LIFT CAPACITIES CAB MODEL

A

Machine equipped with 1.66 m (5 ft. 5 in) arm Lift capacities calculated using 15.7 in (400 mm) shoes and SAE heaped 0.2 cu. yd. (0.16 m3 kg) bucket.

B B

LIFT POINT RADIOUS 5' (1.5m)

7.5' (2.3m)

10' (3.0m)

AT MAX. REACH 12.5' (3.8m)

15' (4.6m)

17.5' (5.3m) RADIOUS

A * 1860 * 840

* 1860 12'10" * 840 (3.91m)

1580 710

* 1760 * 790

1570 15'0" 710 (4.59m)

* 1850 * 830

1590 720

1600 720

1320 16'5" 590 (5.02m)

1440 650

1180 17'4" 530 (5.28m)

15' (4.6 m)

lb kg

* 1800 * 810

* 1800 * 810

12.5' (3.8 m)

lb kg

* 1640 * 740

* 1640 * 740

* 1860 * 840

10' (3.0 m)

lb kg

* 1830 * 830

* 1830 * 830

7.5' (2.3 m)

lb kg

5' (1.5 m) 2.5' (0.8 m)

* 2670 * 1210

* 2670 * 1210

* 2230 * 1010

2120 960

1880 850

1550 700

lb kg

3540 1600

2870 1300

2470 1120

2030 920

1830 830

1510 680

1400 630

1150 520

1360 610

1120 17'8" 500 (5.40m)

lb kg

3370 1520

2710 1220

2370 1070

1940 870

1780 800

1460 660

1380 620

1130 510

1350 610

1110 17'8" 500 (5.39m)

* 3840 * 1740

GROUND lb LEVEL kg

* 3840 * 1740

* 3710 * 1680

* 3710 * 1680

3290 1490

2640 1190

2310 1040

1880 850

1740 780

1420 640

1400 630

1140 17'2" 510 (5.24m)

1730 780

1410 630

1530 690

1250 16'3" 560 (4.95m)

1810 820

1480 14'8" 670 (4.48m)

2450 1110

2000 12'3" 900 (3.74m)

* 2530 * 1140

7'8" * 2530 * 1140 (2.35m)

-2.5’ lb (-0.8 m) kg

* 4130 * 1870

* 4130 * 1870

5460 2470

4220 1910

3270 1480

2620 1180

2290 1030

1860 840

-5' lb (-1.5 m) kg

* 6320 * 2860

* 6320 * 2860

5540 2510

4280 1940

3300 1490

2650 1200

2310 1040

1880 850

-7.5’ lb (-2.3 m) kg

* 9150 * 4150

* 9150 * 4150

* 5450 * 2470

4400 1990

3380 1530

2720 1230

* 2670 * 1210

* 2670 * 1210

-10' lb (-3.0 m) kg

PY11Z00321P1 NOTE: * Rated loads marked with an asterisk are hydraulic limits rather than tipping load limits.

NOTICE: Do not attempt to lift or hold any load greater than these lift capacities at the specified lift point radius and height. Weight of all accessories must be deducted from the above lift capacities.

NOTICE: Lift capacities are based on the machine standing on firm, level and uniform ground. Operator must make allowance for job conditions, such as soft or uneven ground, side loads, sudden sloping of loads, hazardous conditions, inexperienced personnel, NOTICE: Bucket lift hook is defined as lift point.

NOTICE: Above lift capacities are in compliance with SAE J/ISO 10567. They do not exceed 87% of hydraulic lift capacity or 75% of tipping load. Lift capacities marked with an asterisk (*) are limited by hydraulic capacity rather than tipping load.

NOTICE: Operator should be fully acquainted with the machine and adhere to the rules for safe operation of the equipment at all times.

NOTICE: Lift capacities apply to the machine as originally manufactured and normally equipped by the manufacturer.

8-12

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS Check the machine for loose bolts and nuts daily b e fo r e s t a r t i n g w o r k a n d a t t h e s c h e d u l e d maintenance interval. Replace missing bolts and nuts with equal specification as the original parts.

Contact the dealer/distributor for assistance if necessary. Tighten loose and replacement nuts and bolts to the specification given in the specific manual section or in the chart below.

NOTICE: Before tightening, check if the tightening torque is specified in this manual. If provided, use the torque in the specific section. When the actual torque value of a fastener is not known, use the value in the following table/s.

A P M UPW00400024J01

A. NUMBER INDICATING BOLT STRENGTH

NOTICE: The torque values in the table do not apply for bolts used with plastic covers. For the tightening torque for such bolts, consult with your dealer.

Over-tightening may cause damage.

NOTICE: Metric hardware with thread size diameter of M5 or greater have a number on the top of the bolt (A) indicating the strength of the bolt.

8-13

CHAPTER 8 - SPECIFICATIONS CAP SCREWS AND NUTS METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES

Torque value Unit : N•m {lbf•ft} Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

4.4±0.5 {3.2±0.4}

3.7±0.4 {2.7±0.3}

9.6±1.0 {7.1±0.7}

8.1±0.8 {6.0±0.6}

17.4±1.8 {12.8±1.3}

14.7±1.5 {10.8±1.1}

M8

P=1.25

10.7±1.1 {7.9±0.8}

9.0±0.9 {6.6±0.7}

23.5±2.0 {17.3±1.5}

19.6±2.0 {14.5±1.5}

42.2±3.9 {31.1±2.9}

35.3±3.9 {26.0±2.9}

M10

P=1.5

21.6±2.0 {15.9±1.4}

17.9±1.8 {13.2±1.3}

46.1±4.9 {34.0±3.6}

39.2±3.9 {28.9±2.9}

83.4±8.8 {61.5±6.5}

70.6±6.9 {52.1±5.1}

M12

P=1.75

36.3±3.9 {26.8±2.9}

31.4±2.9 {23.2±2.1}

79.4±7.8 {58.6±5.8}

66.7±6.9 {49.2±5.1}

143±15 {105±11}

121±12 {89.2±8.9}

M14

P=2

57.9±5.9 {42.7±4.4}

49.0±4.9 {36.1±3.6}

126±13 {92.9±9.6}

106±10 {78.2±7.4}

226±20 {167±15}

191±19 {141±14}

M16

P=2

88.3±8.8 {65.1±6.5}

74.5±6.9 {55.0±5.1}

191±20 {141±15}

161±16 {119±12}

343±39 {253±29}

284±29 {209±21}

M18

P=2.5

122±12 {90.0±8.9}

103±10 {75.8±7.2}

265±29 {195±21}

226±20 {167±15}

481±49 {355±36}

402±39 {297±29}

M20

P=2.5

172±17 {127±13}

144±14 {106±10}

373±39 {275±29}

314±29 {232±21}

667±69 {492±51}

559±59 {412±44}

M22

P=2.5

226±20 {167±15}

192±20 {142±15}

500±49 {369±36}

422±39 {311±29}

902±88 {665±65}

755±78 {557±58}

M24

P=3

294±29 {217±21}

235±29 {173±21}

637±69 {470±51}

520±49 {383±36}

1160±118 {856±87}

941±98 {694±72}

M27

P=3

431±39 {318±29}

353±39 {260±29}

941±98 {694±72}

765±78 {564±58}

1700±167 {1250±123}

1370±137 {1010±101}

M30

P=3.5

588±59 {434±44}

490±49 {361±36}

1285±127 {948±94}

1079±108 {796±80}

2300±235 {1700±173}

1940±196 {1430±145}

M33

P=3.5

794±78 {586±58}

667±69 {492±51}

1726±177 {1270±131}

1451±147 {1070±108}

3110±314 {2290±232}

2610±265 {1930±195}

M36

P=4

1030±98 {760±72}

863±88 {637±65}

2226±226 {1640±167}

1863±186 {1370±137}

4010±402 {2960±297}

3360±333 {2480±246} UYNX0040003E01

8-14

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES

Torque value Unit : N•m {lbf•ft} Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M8

P=1.0

11.3±1.1 {8.3±0.8}

9.5±1.0 {7.0±0.7}

24.5±2.0 {18.1±1.5}

20.6±2.0 {15.2±1.5}

44.1±3.9 {32.5±2.9}

37.3±3.9 {27.5±2.9}

M10

P=1.25

22.6±2.0 {16.7±1.5}

18.7±1.9 {13.8±1.4}

48.1±4.9 {35.5±3.6}

41.2±3.9 {30.3±2.9}

87.3±8.8 {64.4±6.5}

73.5±6.9 {54.2±5.1}

M12

P=1.25

39.2±3.9 {28.9±2.9}

33.3±2.9 {24.6±2.1}

85.3±8.8 {62.9±6.5}

71.6±6.9 {52.8±5.1}

154±16 {114±12}

129±13 {95.2±9.6}

M16

P=1.5

92.2±8.8 {68.0±6.5}

77.5±7.8 {57.2±5.8}

196±20 {145±15}

169±17 {125±13}

363±39 {268±29}

304±29 {224±21}

M20

P=1.5

186±19 {137±14}

155±16 {114±12}

402±39 {297±29}

333±29 {246±21}

726±69 {535±51}

608±59 {448±44}

M24

P=2

314±29 {232±21}

265±29 {195±21}

686±69 {506±51}

569±59 {420±44}

1240±118 {915±87}

1030±98 {760±72}

M30

P=2

637±59 {470±44}

530±49 {391±36}

1390±137 {1030±101}

1157±118 {853±87}

2500±255 {1840±188}

2080±206 {1530±152}

M33

P=2

853±88 {629±65}

706±70 {521±52}

1860±186 {1370±137}

1550±155 {1140±114}

3350±334 {2470±246}

2790±275 {2060±203}

M36

P=3

1070±108 {789±80}

892±88 {658±65}

2330±226 {1720±167}

1940±196 {1430±145}

4200±422 {3100±311}

3500±353 {2580±260} UYNX0040004E01

8-15

CHAPTER 8 - SPECIFICATIONS JOINTS AND HYDRAULIC HOSES NOTICE: All torque values are for clean, dry parts.

SLEEVE TYPE TUBE FITTINGS

TUBE SIZE WRENCH SIZE OD X THICKNESS (mm) (mm)

TIGHTENING TORQUE N•m {lbf•ft}

10 × 1.5

19

44±4.9 {33±4}

15 × 2.0

27

147±20 {110±14}

18 × 2.5

32

177±20 {130±14}

22 × 3.0

36

216±20 {160±14}

28 × 4.0

41

275±29 {200±22}

35 × 5.0

55

441±44 {330±33} UPAX1004012E01

JOINTS FOR PIPING (O-RING SEALING TYPE)

NORMAL SCREW WRENCH SIZE SIZE (mm) (PF)

TIGHTENING TORQUE N•m {lbf•ft}

1/8

14

17±2 {12±1}

1/4

19

36±2 {27±1}

3/8

22

74±5 {54±4}

1/2

27

108±9.8 {80±7}

3/4

36

162±9.8 {119±7}

1

41

255±9.8 {188±7}

O-RING

UPAX1004013E01

HYDRAULIC HOSE

NORMAL SCREW WRENCH SIZE SIZE (mm) (PF)

TIGHTENING TORQUE N•m {lbf•ft}

1/8

17

15±2.0 {11±1}

1/4

19

29±4.9 {22±4}

3/8

22

49±4.9 {36±4}

1/2

27

78±4.9 {58±4}

3/4

36

118±9.8 {87±7}

1

41

137±15 {101±11}

UNION NUT

UPAX10040014E01

8-16

CHAPTER 8 - SPECIFICATIONS UNITS OF PRESSURE

CONVERSION UNITS UNITS OF WEIGHT

Units of Pressure From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

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

yard3

0.00131

quarts

1.0567

ounces (US)

33.81

m3

0.765

in3

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 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

Yard3

UNITS OF TORQUE Units of Torque From

N·m

lbf-ft

Into

Multiply by

lbf-ft

0.738

kgf

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgfm

0.1382552

N·m

1.35582

lbf-in

12

8-17

CHAPTER 8 - SPECIFICATIONS

NOTES

8-18

CHAPTER 9 - INDEX

Chapter 9

INDEX A Alternator ............................................................. 7-5

B Before Operating the Machine ............................. 4-3 Bucket Selection Guide .............................. 4-38, 5-3 Burn Prevention ................................................... 2-8

C Cab Door Latch ................................................... 3-3 Cab Machine Dimensions .................................... 8-3 Canopy Machine Dimensions .............................. 8-3 Components & Controls Nomenclature ... 3-11, 3-12, 3-17

D Decals ................................................................ 2-10 Disposal of Hazardous Waste ............................. 6-6

E Engine Coolant Tank & Engine Air Cleaner Access Doors ............................................................. 3-9

F Fire Extinguisher .................................................. 2-9 Fire Prevention .................................................... 2-9 Fuel Handling Precautions .................................. 2-8

G General Information ............................................. 1-1 Ground Transportation ............5-3, 5-4, 5-5, 5-6, 5-7 Guidelines to Replace Ground Tools ................. 6-25

H Hand Signals ............................................ 2-22, 2-23 Hazardous Chemical Precautions ....................... 2-8 How to Handle Life Hammer ............................... 2-9 Hydraulic Breaker .............................................. 4-39

I Identification Numbers ......................................... 1-4

K Key Switch . 3-10, 3-11, 3-12, 3-13, 3-14, 3-15, 3-16, 3-17, 3-18, 3-19, 3-20, 3-21

L Lifting Machine ...................................... 5-5, 5-6, 5-7

Locking/Unlocking Cab Door ................................3-3

M Machine Access Compartments and Doors .........3-8 Machine Components ..........................................1-3 Machine Dimensions ............................................8-3 Machine Operation in Adverse Weather Conditions .

4-37 Maintenance Precautions .....................................2-7 Metric Coarse Thread Standard Tightening Torque Values ..........................................................8-14 Metric Fine Thread Standard Tightening Torque Values ................................................ 8-15, 8-16 Model, Serial Number, and Year of Manufacture 1-2, 1-4, 1-5, 1-6, 2-22 Mounting and Dismounting Precautions ...............2-5

O Opening and Closing Windshield .. 3-3, 3-4, 3-5, 3-6, 3-7, 3-8, 3-10, 3-11, 3-12, 3-13, 3-14, 3-15, 3-16, 3-17, 3-18, 3-19, 3-20, 3-21 Operating Precautions ..........................................2-6 Operating the machine .........................................4-4 Operation in Extreme Cold .................................4-37 Operation in High Altitudes ....................... 4-37, 4-38 Operation in Sandy and Dusty Areas ....... 4-37, 4-38 Operator Cab Nomenclature ................................3-9 Operator Precautions ...........................................2-5 Operator’s Compartment Controls and Accessories .

3-9 ORS Joint (O-ring Sealing Type .........................8-16

P Personal Safety ....................................................2-3 Practices to Improve Efficiency ..........................4-27

R Right Hand Operator Console and Monitor .......3-11, 3-12, 3-17 Right, Left, Front, and Rear of the Machine .........1-2 Roll-Over Protective Structure (If equipped) ........2-8

S Safety Area ...........................................................2-3 Safety Rules .........................................................2-3 Seat Belt Precautions ...........................................2-9 Selection of the Hydraulic Breaker . 4-39, 4-40, 4-41, 4-42, 4-44, 4-45, 4-46, 4-47, 4-48 Specific Precautions to this Machine ....................2-9 9-1

CHAPTER 9 - INDEX Starter Motor ........................................................ 7-5 Starting and Stopping Precautions ...................... 2-5 Starting Engine ... 4-12, 4-13, 4-14, 4-15, 4-16, 4-17, 4-18, 4-19, 4-20, 4-21, 4-22, 4-23, 4-24, 4-25, 4-26, 4-27, 4-28, 4-29, 4-30, 4-31, 4-32, 4-33, 4-34, 4-35, 4-36, 4-39, 4-40, 4-41, 4-42, 4-44, 4-45, 4-46, 4-47, 4-48

T Torque Specifications ........................................ 8-13 Transportation ..................................................... 5-3 Transporting Precautions .................................... 2-8

U Units of Flow ...................................................... 8-17 Units of Length .................................................. 8-17 Units of Power ................................................... 8-17 Units of Pressure ............................................... 8-17 Units of Torque .................................................. 8-17 Units of Volume ................................................. 8-17 Units of Weight .................................................. 8-17 Use of Optional Attachment ................................. 5-3 Utility Safety ......................................................... 2-4

9-2

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.

Printed in U.S.A. Copyright © 2012 Kobelco Construction Machinery America, LLC. All Rights Reserved.

Kobelco is a registered trademark of Kobelco Construction Machinery America, LLC. 245 East North Avenue Carol Stream Illinois 60188 U.S.A.