Kobelco SK70SR Hydraulic Excavator Operator's Manual PDF

OPERATOR'S MANUAL HYDRAULIC EXCAVATOR

SK70SR

Applicable: SK70SR YT01-00101~ S2YT00002ZE-03

10/03

FOREWORD GENERAL ¯ Thismanualcontains procedures to aidtheoperator gainpeakperformance through effective, economical machine operationand maintenance for the KOBELCOSK70SRHydraulicExcavators. ¯ Beforeoperating the machine, operators mustthoroughly readandunderstand allSafety,Operation andMaintenance instructions foundin thismanual.

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

Skillis gainedas theoperator utilizes thesetechniques and perfects themwithan actualmachine. ¯ Someillustrated pictures maybe different fromyourmachine, as technical improvement is continuous, manuals are periodically updated to reflect thesechanges. ¯ Thismanualmaynotcontain attachments andoptional equipment thatareavailable in yourarea.Pleasecontact an authorized KOBELCODistributor for anyoptional attachments required. ¯ Materials andspecifications aresubject to change without notice.

PERIODIC INSPECTIONS ¯ Afterdelivery of a machine, theAuthorized KOBELCO Distributor willmakeperiodic service inspections.

These inspections willbe freeof charge to theownerof themachine andwillbe at timeintervals setby KOBELCO. Contact an authorized KOBELCO Distributor foranyServicerelated questions notexplained in thismanual.

NOTICE ° Thecontents of thismanualmaynotreflect thespecifications of themachine delivered.

Contact an authorized KOBELCO Distributor to obtainassistance in specifications formachines equipped withoptions notcontained in this manual. ¯ Owing to the policyof continualimprovement,changesmay be made by KOBELCOCONSTRUCTION MACHINERYCO., LTD, to any of its productswithoutany obligationon the partof KOBELCOCONSTRUCTION MACHINERY CO., LTD.

TABLE OF CONTENTS

SectionI-SAFETY PRECAUTIONS ..........................................................................

1-0~ 1-23 SectionII-MACHINE FAMILIARIZATION ......................................................................

2-0~ 2-25 SectionIIIBASIC MACHINE OPERATION .....................................................................

3-0- 3-22 SectionIVMAINTENANCE .............................................................................

4-0- 4-58 SectionV-SPECIFICATIONS ............................................................................

5-0- 5-14 SectionVl-TROUBLESHOOTING ...........................................................................

6-0- 6-3 SectionVIISCHEMATICS ..............................................................................

7-0- 7-3 SectionVIIIOPTIONAL EQUIPMENT ........................................................................

8-0 - 8-14 SectionIX-SPECIAL PROCEDURES .........................................................................

9-0~ 9-8 SectionX-SPECIFICATIONS (EPA ENGINE) ....................................................................

10-0- 10-4 All rightsreserved.

Any use of editorial or pictorial content is strictly prohibited without express written permission fromKOBELCO CONSTRUCTION MACHINERY CO.,LTD.

Section I- SAFETY PRECAUTIONS Tableof Contents

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

1-1 SAFETY PRECAUTIONS ...........................................................................

1-1~ 1-3 PRE-START SAFETY ............................................................................

1-4- 1-6 SAFETY DURING OPERATION ........................................................................

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

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

1-12 WARNING LABELS & DECALS (USA ONLY) .................................................................

1-13- 1-17 1-18- 1-21 WARNING LABELS & DECALS (EUONLY) ..................................................................

PROHIBITED MACHINE OPERATION .....................................................................

1-22~ 1-23 END OFWORK SHIFT SAFETY ........................................................................

1-23

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

1-0

Section I- SAFETY PRECAUTIONS c. CAUTION-Indicates a potentially hazardous situation which,ifnotavoided, mayresult in minor or moderate injury.

It mayalsobe usedto alert againstpossible damageto themachineand its components and is represented as follows:

1.1 GENERAL SAFETY INFORMATION

WARNING Do Notoperate or perform anymaintenance on this machine untilallinstructions foundin thismanual have beenthoroughly readandunderstood.

Improper operation or maintenance of thismachinemay causeaccidents andcouldresult in serious injury ordeath.

Always keepthismanualin theoperators seatpocket.

If itis missing ordamaged, placean orderwithan authorized KOBELCO distributor fora replacement.

If youhaveanyquestions, pleaseconsult an authorized KOBELCOdistributor.

,

,

1.Mostaccidents, whichoccurduringoperation, aredue to neglect of precautionary measures andsafetyrules.

Sufficient careshould betakento avoidtheseaccidents.

Erroneous operation, lubrication or maintenance services are verydangerous andmay causeinjuryor deathof personnel.

Therefore allprecautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONScontainedin thismanualand on the machineshouldbe readand understood by all personnel beforestarting anyworkwithor on the machine

,

Whileoperating the machine, be sureto performwork withgreatcare,so as notto damagethe machine, or allowaccidents to occur.

Continue studying thismanual untilallSafety, Operation and Maintenance procedures are completely understood by all personsworking withthe machine.

1.2 SAFETY PRECAUTIONS

WARNING The properand safe lubricationand maintenance for this machine, recommendedby KOBELCO,is outlinedin the OPERATORSMANUAL for this machine.

2. Operation, inspection, and maintenance shouldbe carefully carried out,andsafety mustbe giventhefirst priority.

Messages of safetyareindicated withmarks.

Thesafetyinformation contained in thismanualis intended onlyto supplement safetycodes,insurance requirements, locallaws,rulesandregulations.

3. Messages of safetyappearin thismanualand on the machine.

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

Itis verydifficult to forecast everydanger thatmay occurduringoperation.

However, safetycan be ensuredby fullyunderstanding properoperating procedures forthismachineaccording to methods recommended by KOBELCO.

Improperperformance of lubrication or maintenanceproceduresare dangerousand could result in injuryor death.Read and understandthe OPERATORS MANUAL before performing any lubrication or maintenance.

The serviceman or mechanic maybe unfamiliar withmany of the systems on thismachine.

Thismakesit important to usecautionwhenperforming servicework.A knowledgeof the systemand or components is important beforetheremovalor disassembly of any component.

b. WARNING-Indicates a potentially hazardous situation which, ifnotavoided, couldresult indeath or serious injury andis represented as follows:

Becauseof thesizeof someof the machinecomponents, the serviceman or mechanicshouldcheckthe weights notedin thismanual.

Useproperlifting procedures when removingany components.

Weightof components table is shownin Page5-3of Section V.

WARNING 1-1

Section I- SAFETY PRECAUTIONS Thefollowing isa listofbasic precautions thatmustalwaysbe observed.

.

1.Readandunderstand allWarning plates anddecals on themachine before Operating, Maintaining or Repairing thismachine.

2.Always wearprotective glasses andprotective shoes whenworking around machines.

In particular, wear protective glasses whenusinghammers, punches or drifts on anypartof themachine orattachments.

Use welders gloves, hood/goggles, apron andtheprotectiveclothing appropriate tothewelding jobbeing performed.

Donotwearloose fitting ortornclothing.

Remove allrings fromfingers, loose jewelry, confine longhairandloose clothing before working onthismachinery.

3. Disconnect thebattery anddischarge capacitors beforestarting to workon themachine.

Hanga "DoNot Operate" tagin theOperators Compartment.

Remove ignition keys.

4.If possible, makeallrepairs withthemachine parked ona level, hardsurface.

Block themachine soitdoes notrollwhile working on orunderthemachine.

There is no notetagwhenrepairing.

Hanga "DoNotOperate"tagin theOperators Compartment.

,

Usestepsandgrabhandles whenmounting or dismounting a machine.

Cleananymudor debris from steps, walkways or workplatforms before using.

Alwaysfacethemachine whenusingsteps, ladders and walkways.

Whenit isnotpossible tousethedesigned access system, provide ladders, scaffolds, or work platforms toperform saferepair operations.

Toavoid backinjury, usea hoist whenlifting componentswhichweigh23 kg (50Ibs)or more.Makesure allchains, hooks, slings, etc., areingoodcondition andarethecorrect capacity.

Besurehooks arepositioned correctly.

Lifting eyesarenottobesideloaded during a lifting operation.

burns, bealert forhotparts on machines 10.Toavoid which havejustbeenstopped andhotfluids in lines, tubesandcompartments.

11.Be careful whenremoving coverplates.

Gradually backoffthelasttwobolts ornutslocated atopposite endsofthecover ordevice andcarefully prycover loose torelieve anyspring orother pressure, before removing thelasttwobolts ornutscompletely.

12.Be careful whenremoving filler caps, breathers and plugson themachine.

Holda ragoverthecapor plugto prevent being sprayed orsplashed by liquids under pressure.

Thedanger isevengreater if the machine hasjustbeenstopped because fluids can behot.

thatis supported onlyby 5.Do notworkon anymachine lift, jacks ora hoist.

Always useblocks orjackstands, capable ofsupporting themachine, before performing anydisassembly.

13.Always usetheproper tools thatareingoodcondition andthataresuited forthejobathand.

Besureyou WARNING understand howto usethembefore performing any service work.

Do notoperate I thismachine unlessyouhaveread andunderstand theinstructions in theOPERA- I TORS MANUAL.Impropermachineoperationis 14.Reinstall allfasteners withthesamepartnumber.

Do I dangerous andcouldresult in injury or death. I notusea lesser quality fastener ifreplacements are necessary. allpressure inair,oilorwater systems before 6.Relieve anylines, fittings orrelated items aredisconnected or 15.Repairs whichrequire welding should be performed removed.

Always makesureallraised components onlywiththebenefit of theappropriate reference information and by personnel adequately trained and areblocked correctly andbealert forpossible pressurewhendisconnecting anydevice froma system knowledgeable in weldingprocedures.

Determine typeofmetal being welded andselect correct welding that utilizes pressure. procedure andelectrodes, rodsor wiretoprovide a weld metal strength equivalent at least to that of the 7. Lower thebucket, blade, ripper or other attachments parent metal. to the groundbeforeperforming anyworkon the machine.

If thiscannot bedone, makesurethebucket, blade, ripper orother attachment isblocked correctly to prevent itfromdropping unexpectedly.

1-2

Section I- SAFETY PRECAUTIONS 16.Do notdamage wiring during removal operations.

Reinstall thewiring soitisnotdamaged norwillbe damaged in operation of themachine by contacting sharpcorners, orby rubbing against someobject or hotsurface.

Donotconnect wiring toa linecontaining fluid.

23.Caution should beusedto avoid breathing dustthat maybe generated whenhandling components con taining asbestos fibers.

Ifthisdustisinhaled, itcan be hazardous to yourhealth.

Components in KOBELCO products thatmaycontain asbestos fibers arebrakepads, brakebandandlining assemblies, clutch plates andsomegaskets.

Theasbestos 17.Besureallprotective devices including guards and usedin thesecomponents isusually boundin a shields areproperly installed andfunctioning correctly resin or sealed insomeway.Normal handling is not before starting a repair.

Ifa guard orshield mustbe hazardous aslongas airborne dustwhichcontains removed to perform therepair work, useextracauasbestos isnotgenerated. tionandreplace theguard orshield after repair is complete.

If dustwhichmaycontain asbestos is present, there areseveral commonsenseguidelines thatshouldbe 18.Themaintenance andrepair workwhileholding the followed. bucket raised isdanger duetothedropofattachment.

Donotfailtolower theattachment andputthebucket a.

Neverusecompressed airforcleaning. totheground before starting thework. b.

Avoidbrushing or grinding of asbestos containing materials.

19.Loose ordamaged fuel, lubricant andhydraulic lines, C° For cleanup, use wetmethodsor a tubesandhosescancausefires.

Do notbendor vacuum equipped witha highefficiency strike highpressure lines orinstall oneswhich have particulate air(HEPA) filter. d. beenbentor damaged.

Inspect lines, tubesand Useexhaust ventilation on permanent hoses carefully.

Donotcheck forleaks withyour machining jobs. hands.

Pinhole(very small) leaks canresult in e.

Wearanapproved respirator if there is high velocity oilstream that willbeinvisible close to noother waytocontrol thedust. thehose.Thisoilcanpenetrate theskinandcause f.

Comply withapplicable rulesandregulations for the work place. personal injury.

Usecardboard orpaper to locate pinholeleaks. g.

Follow environmental rulesandregulations fordisposal ofasbestos.

20.Tighten connections tothecorrect torque.

Makesure h.

Avoidareaswhereasbestos particles thatallheatshields, clamps andguards areinstallmaybeintheair. edcorrectly toavoid excessive heat, vibration or rubbing against other parts during operation.

Shields thatprotect against oilspray ontohotexhaust components inevent ofa line, tubeorsealfailure must beinstalled correctly.

21.Donotoperate a machine if anyrotating partisdamagedor contacts anyother partduring operation.

Anyhighspeedrotating component thathasbeen damaged or altered should be checked forbalance before reusing.

22.Ontrack-type machines, becareful whenservicing or separating thetracks.

Chipscanflywhenremoving orinstalling a track pin.Wearsafety glasses andlong sleeve protective clothing.

Tracks canunroll very quickly whenseparated.

Keepawayfromfrontand rear of machine. The machine can move unexpectedly whenbothtracks aredisengaged from thesprockets.

Blockthemachine to prevent it from moving,

1-3

Section I- SAFETY PRECAUTIONS 1.3 PRE-STARTSAFETY Manyfailures thatoccurduring machine operation or servicing result fromneglecting fundamental safety precautions.

Thefollowing safety precautions aregiven toprevent suchfailures, buttheyareonlya partofwhat youmustfollow.

Read, understand andfollow allsafety precautions foundin thismanual andon themachine thoroughly before operating themachine.

A°

OBSERVE SAFETY PRECAUTIONS Follow allsafety rules, precautions, andoperating procedures.

Ifthere areother personnel and flagmen working in thearea,havethemobserve thespecified signs.

B°

WEAR PROTECTIVE CLOTHING Wearwellfitting safety shoes, hardhat,and working clothes, andputon protective glasses, faceshield, earprotection andgloves.

When necessary, wearreflective vest.

C,

READ and UNDERSTAND THE OPERATORS MANUAL Before operating themachine, readand understand thisoperators manual thoroughly in order tousethemachine effectively andsafely.

D°

KEEP OPERATORS MANUAL IN MACHINE CAB Keepthismanual in thespecified storage area located behind theOperators Seatforquick reference.

Should theOperators Manual become lostor damaged, contact anauthorized KOBELCO distributor to ordertheoperators Manual.

E°

HOW TO HANDLE LIFE HAMMER A lifehammer isprovided ontheleftsideofcab.

Incaseof emergency, takethelifehammer, break thecabglass, andescape fromthecab.

Inaddition, thelifehammer isequipped witha cutter onthelever side tocuttheseatbelt, etc.

OBSERVE ALL SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING STORAGE ,REA

READ MANUAL / KEEP IN MACHINE CAB

HOW TO HANDLE LIFE HAMMER

F. PREPARE FOR EMERGENCIES Havea fireextinguisher andfirst aidkitready foremergencies.

Knowhowto operate theFire Extinguisher andknowwhere theFirst AidKitis located foreasyaccess in caseofemergency.

PREPARE FOR EMERGENCIES

1-4

Section I- SAFETY PRECAUTIONS G. ENSURE SAFETY AT THE WORK SITE Knowtheworkarea!Before operating the machine, carefully survey andrecord the landandworksite features toprevent themachine fromfalling orthesoilfromcaving in.

H. PERFORM PRE-START INSPECTION Before starting themachine, perform a PRESTARTinspection ofthemachine.

If anyproblems arefound, repair or replace defective components immediately.

DO NOT OPERATETHE MACHINE until allproblem areas areproperly repaired.

Always keepthewindshield, working lamps, and mirrors clean forgood visibility.

ENGAGE SAFETY LOCK LEVER BEFORE LEAVING MACHINE Before leaving theoperator’s seat, movethe safety locklever to the"LOCKED" (Up)position.

Thiswillnotallow operation ofanyHydraulic Controls should theybeaccidentally moved.

Ifthe lever isnotsettothe"LOCKED" position and hydraulic controls aretouched accidentally, the machine maymovesuddenly resulting in serious injury.

Alsobefore leaving themachine, lower thebucket totheground, place thesafety locklever inthe "LOCKED" (Up)position, stoptheengine and remove thestarter switch key.

J. SIGNS, SIGNALS& FLAGMEN Install signs on softshoulders andground areas, havea flagman direct theoperation ifnecessary.

Theoperator should notemarks andfollow signals fromtheflagman.

Allpersonnel should knowthe meaning ofthesigns, marks, andsignals.

Only oneflagman should givethesignsandsignals.

K. KEEP FIRE AWAY FROM FUEL AND OIL Oil,antifreeze, andespecially fuelarehighly flammable.

Neverusefirenearthemachine.

Securely tighten allfuelandoilcaps.

Keepfuel andoilin thedesignated storage areas.

Promptly clean up anyallspills anddispose ofwaste properly.

e WORKSITE SAFETY- KNOW THE AREA

PRE-START INSPECTION OF MACHINE LOCKED

1

I O.LOCKED I (DOWN) POSlTION~ SAFETY LOCK LEVER

KEEP FIRE AWAY FROM FUEL & OIL

L. USE CAUTION NEAR NOISE Ifnoise ishighduring operation, hearing lossmay result.

Approved hearing protection should beused ifpersonnel willbeexposed tohighnoise levels fora longperiod oftime.

USE CAUTION NEAR NOISE

1-5

Section I- SAFETY PRECAUTIONS M. MOUNTING & DISMOUNTING MACHINE Whengetting on andoffthemachine, always maintain three point contact by using the handrails andstep.

Inspect andclean handrails, step,andmounting parts.

Remove slippery materials, suchas lubricants, andmud.Always place thecabdoorentrance parallel tothetracks before stopping theengine fordismounting.

AVOID HOT SURFACES & AREAS Immediately after themachine is operated, the temperature andpressure of theengine coolant, engine oil,andhydraulic oilareveryhigh.

Burns mayresult ifcapsareremoved, oroil,water, or filters arechanged under these conditions.

Wait until thetemperature goesdown,before attempting tocheck fluids orchange filters.

N,

°

USE THE PROPER OPTIONAL ATTACHMENT UseonlyOptional Attachments designed forand approved

by KOBELCO. Read,understand and follow allinstructions intheManual accompanying theOptional Attachment.

UseofanyOptional Attachment notapproved

by KOBELCO in writing, cancause serious injury to personnel, damage to themachine anditscomponents andshorten the lifeofthemachine.

Contact anauthorized KOBELCO distributor forOptional Attachments available forthemachine.

R PREVENT FIRES Leaking orspilled fuel, lubricants andhydraulic oilarefirehazards.

Clean andproperly dispose of spills astheyoccur.

Repair orreplace allleaking components to prevent fire.

Also, clean the machine regularly removing alldebris to help prevent fires, payparticular attention toremoval ofleaves, sticks, paper etc.Keepfireextinguisher in an accessible areaandknowhowto usethe fire extinguisher should a fireoccur.

MOUNTING/DISMOUNTING MACHINE

HOT SURFACES

USE PROPER ATTACHMENT

PREVENT FIRES- CLEAN UP SPILLS

1.4SAFETY DURING OPERATION A. STARTINGENGINE Sitintheoperator’s seat.

Sound thehornbefore starting theengine toalert people themachine is beingstarted.

Makesure nooneisnearthemachine.

Donotshort circuit thestarter circuit orbattery to start themachine.

Thismaycause serious injury or cause damage theelectrical system.

SOUND HORN BEFORE STARTING

1-6

Section I- SAFETY PRECAUTIONS B. PASSENGERS Thisequipment isnotintended ordesigned forthe transportation ofpersons.

Never allow persons to rideonthemachine.

Serious injury or death can result fromallowing passengers onorin the machine.

C. TRAVEL Makecertain of thelocation oftheTravel Motors before operating travel controls.

Sound Horn before moving themachine to inform persons that themachine istravelling.

Position theattachment asshown inillustration before beginning travel.

Movethemachine at slowspeeds.

Do notturn suddenly onrough terrain.

Avoid travelling over obstacles.

Should it become necessary to travel overanobstacle, keeptheattachment lowtothe ground andtravel atextremely slowspeed.

D. SWING Makecertain theSwingAreaof machine isclear ofallpersons andobstacles before operating SwingControls.

SoundHornbefore swinging machine.

If necessary, havea Flagman signal operator during operation tohelpprevent injury to persons or damage to obstacles andequipment.

E. BOOM, ARM & ATTACHMENTS Givetheworkyouaredoingyourundivided attention.

Makecertain theattachment being used issuited forthejobathand.

Makecertain of obstacles intheworkareaandoperate the machine within those limits.

If necessary havea Flagman signal theoperator toprevent injury to persons or damage to themachine or obstacles intheworkarea.

ALWAYS PLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB. F. OPERATINGON INCLINESOR SLOPES Operation of thismachine on anincline orslope maycausethemachine to become unstable or unbalanced.

WorkUp andDowninclines or slopes neveracross.

NeverSwingor TurnMachine around onslopes.

Build a level areaforthe machine to operate.

Operate Controls carefully to prevent sudden movements whichmay cause themachine toslide ortipover.

Usea Flagman todirect theoperator.

1-7

NO PASSENGERS

KNOW TRAVEL MOTOR POSITION

SWING SAFETY/USE SWING FLASHERS (Example of EU)

x

©

BUILD BANKING FOR SLOPE OPERATION

Section I- SAFETY PRECAUTIONS G°

WORKING AROUND UTILITIES Ifitissuspected that utility lines such as,gas, water, phone orelectrical power areinthework area, contact thelocal utility authority forline location BEFORE beginning workin thearea.

Use extreme caution around electrical power lines.

Keepa sufficient distance awayfromelectrical lines during operation.

SeeChart below for minimum distances.

LINE VOLTAGE

MINIMUMDISTANCE-M(FEET)

0 - 50,000

3.0M (10) OR MORE

50,000~ 200,000

4.5M (15) OR MORE

200,000~ 350,000

6.0M (20) OR MORE

350,000~ 500,000

7.5M (25) OR MORE

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

10.5M (35) OR MORE 13.5M (45) OR MORE

KEEP A SAFE DISTANCEFROM UTILITIES

H. LIFTING Thismachine isanexcavator.

Useextreme caution whenlifting or moving heavy loads.

Useproper lifting equipment rated ata capacity tohandle the load. NEVERUSE BUCKETTEETHTO LIFT OR MOVE HEAVY LOADS. I. FROZEN & SNOW COVERED WORK SITES Useextreme caution whenoperating themachine on frozen orsnowcovered worksites.

Operate all controls slowly andcautiously toprevent sudden movements thatmaycausethemachine to unexpectedly shift, slide or move.

Evenonthe slightest slope, whensnowispresent orworkarea is frozen canallowa machine to unexpectedly move.

Snowon shoulders or snowdrifts canbe much deeper thanexpected.

Themachine caneasily become buried undersuchconditions.

Use extreme caution whileoperating themachine around or in snow.

J°

X

USE PROPER LIFTING DEVICES

o

oo°

USE EXTREME CAUTION ON FROZEN OR SNOW

FILLED OR UNSTABLE GROUND Becertain thecondition oftheworksiteisstable andcapable of supporting themachine during operation.

Donotoperate attachment tooclose to themachine.

Operation of themachine on shoulders orfilled areas could cause themachine to become unstable presenting a workhazard.

Position theTravel Motors totherearofthe machine, allowing forquick reversal, should the workareabecome unstable.

WORK ON STABLE GROUND

1-8

Section I- SAFETY PRECAUTIONS K°

RESTRICTED WORK AREAS Inworksites withlimited height andswing areas suchas tunnels, bridges, around electrical power lines, other utilities, orinside structures, use extreme caution in keeping themachine andits attachment a safedistance awayto prevent personal injury and/or equipment or structure damage.

Usea Flagman to direct theoperator.

L,

PARKING THE MACHINE Always parkthemachine on a firm, level surface.

Ifnofirm level surface isavailable, block thetracks andlower attachment totheground tohelpprevent machinemovement.

Should themachine be parked on a roadway, move themachine totheshoulder toallow passing of traffic.

Alsopostreflective Warning Signs and Markers ata distance fromthemachine to safely warnmotorists.

Refer tolocal codeandregulations regarding theposting of workareaWarnings and Markers.

M,

STABILIZE ATTACHMENTS Stabilize allattachments removed fromthe machine toprevent theattachment falling over.

BE AWARE OF OBSTACLES

PARKING SAFETY

1.5INSPECTION & MAINTENANCE SAFETY A. "TAG-OUT"MACHINE Before performing anyinspection or maintenance procedures tothemachine, filloutandposttothe operators controls a "DONOTOPERATE" tagto warnpersons nottostart themachine.

Alsoinform theSupervisor andalloperators thatthemachine isunder inspection or maintenance andtheywill beinformed whenthemachine is ready fornormal operation.

STABILIZE ATTACHMENTS WHEN REMOVED

So

TOOLS & EQUIPMENT Usetheproper tools andequipment forthetask athand.

Knowtheproper useof thetools and equipment before starting anyinspection or maintenance procedures.

C°

PERSONAL EQUIPMENT Wearwellfitting WorkClothes, HardHat,Safety Shoes andGloves.

Confine longhair, loose clothing andremove alljewelry before attempting anyinspection or maintenance procedures tothis machine or attachments.

USE PROPER TOOLS

1-9

Section I- SAFETY PRECAUTIONS D. STOP THE ENGINE BE CERTAIN TO TURN ENGINE OFF AND PLACE THE SAFETY LOCK LEVER IN THE "LOCKED" (UP)POSITION beforeattempting any inspection ormaintenance procedures to the machine.

Failure tostopengine could result in serious bodily injury ordeath.

E. SET THE ATTACHMENT Always setthemachine intheHydraulic OilCheck Position before attempting anyinspection or maintenance procedures tothemachine.

Ifit is notpossible toputthemachine inthisposition, secure theboom,armandattachment to help preventsuddenmovement.ALWAYSPLACE ATTACHMENTS ON THE GROUND AND RAISE THE SAFETY LOCK LEVER BEFORE LEAVING THE CAB. F. CLEAN THE MACHINE Keepthemachine clean andfreeof debris, excess orspilled lubricants, fuelandfluids.

Useapproved solvents, detergents andwater toclean the machine anditscomponents on a regular basis.

Becareful nottoallow water toreach electrical components.

Serious damage canoccurto the electrical system byallowing water toreach the electrical components.

Never clean inside ofcab, or electrical components withpressurized water or steam.

G. PRESSURIZED FLUIDS & LUBRICANTS Always release pressure fromHydraulic Reservoir, Engine Coolant, FuelSystem andallsystems containing pressure before removing anycapsor components.

Be cautious ofHotFluids andGasses fromsystems on machines thathavejustbeen stopped.

Allow ampletimeforsystems tocool before performing anyinspection or maintenance procedures.

H. SUPPORT THE MACHINE If itbecomes necessary to raise themachine for inspection or maintenance, always support the machine by positioning themachine as shownin theillustration andusesafety supports orblocks, witha sufficient capacity rating tosupport the machine, underthetracks.NEVERINSPECTOR PERFORM MAINTENANCE PROCEDURES UNDER A RAISED MACHINE THAT IS NOT SUFFICIENTLYSUPPORTED.

LOCKED I POSITION

STOP ENGINE/ENGAGED SAFETY LOCK LEVER

HYDRAULIC OIL CHECK POSITION

KEEP MACHINE CLEAN DEPRESS RUBBER CAP TO RELEASE PRESSURE

RELEASE HYDRAULIC TANK PRESSURE

ii~ii!i!iiiii!i!!!i~!!!i!ii !!!!ii!i i!iiiiiiiii!i SUPPORT THE MACHINE

1-10

Section I- SAFETY PRECAUTIONS I. REFUELING Movethemachine toa wellventilated areafor refueling.

Useonlyspecified fuelasdescribed in theSpecifications section ofthisoperators manual.

Immediately clean upallspilled fuelanddispose ofproperly.

After refueling iscomplete, securely tighten FuelCap. J. HYDRAULIC PRESSURE Under normal conditions, allcircuits ofthe Hydraulic System areunderextreme pressure.

Wheninspecting forleaks, usea small piece of cardboard, woodormetaltolocate leaks.

Small (pinhole) leaks canbe dangerous if contact with skinor eyesis made.Wearapproved safety glasses orfaceshield, gloves, hardhat,safety shoes andworkclothes during allinspection and maintenance procedures.

REFUELING

CHECKING FOR HIGH PRESSURE LEAKS K. TRACK SHOE TENSION Thegrease usedto adjust theTrack ShoeTension isunder extreme pressure in thecylinder.

Use extreme caution whenadjusting trackshoe tension.

Keepface,hands andlegsawayfromthe grease nipple area.

Carefully andslowly loosen thegrease nipple whenlessening track shoe tension.

Never loosen grease nipple morethanone complete turn.

USE CAUTION WHEN ADJUSTING TRACKS L. ELECTRICALSYSTEM Before performing anyinspection or maintenance totheelectrical system, orperforming anywelding procedures, disconnect theNegative(-) cables fromthebattery terminals.

Notdisconnecting the Negative(-) cablecouldcauseextensive damage totheelectrical system.

M. USE APPROVED WORK LIGHTS Useonlyapproved worklights whenperforming inspection andmaintenance procedures to prevent possible fireorexplosion.

Certain types ofwork lights should notbeusedduetothepossibility of ignition of certain flammable gasses andfluids fromthemachine.

DISCONNECT BATTERY NEGATIVE(-) CABLE WHEN INSPECTINGELECTRICAL OR WELDING

ELECTRICAL SYSTEM PRECAUTION

N. DISPOSE OF WASTE PROPERLY Dispose ofoils, fuel, coolant, solvents, filters, batteries etc.according toFederal, State andLocal codesandregulations regarding Hazardous Waste disposal.

Contact Local authorities for proper disposal methods of suchmaterials.

USE PROPER LIGHTING

1-11

Section I- SAFETY PRECAUTIONS 1.7 BATTERY SAFETY A. WEAR PROPER PROTECTIVE CLOTHES Wearlongsleeve shirt,gloves andapproved safety glasses or faceshield whenworking withor around batteries.

Battery electrolyte (acid) willcause severeburnsif allowed to makecontact with clothing, skinor eyes.

Should electrolyte (acid)comein contact with clothes, skinor eyes,immediately remove effected clothing, flushareawithcleanwaterfor15 minutes andgetpromptmedical attention.

B,

KEEP AWAY FROM FIRE OR FLAMES Never allow batteries inthevicinity offireorflames and do not smokewhenworkingwithbatteries.

Explosive hydrogen gas is produced by the electrolyte (acid) inthebatteries.

Always workwith batteries in a wellventilated area.

C,

CHARGING BATTERY Chargebattery offof andawayfrommachine in a wellventilated area.Whencharging battery, removecellcoversto allowgassesto escape.

Avoidbreathing gassesfrombattery.

Wear approvedSafetyequipment when workingwith batteries.

D°

WEAR PROTECTIVE

CLOTHES

KEEP AWAY FROM FIRE OR FLAMES

USING BOOSTER CABLES Wearpropersafetyequipment whenworkingwith batteries.

If usinganother machine or vehicle to boost batteries, makecertain themachine or vehicle DOES NOT touchthe disabledmachine.

Makecertain of thePositive (+)andNegative (-) Terminals on theBooster Battery andtheDisabled Machinebeforeconnecting BoosterCables.

MAKE CERTAIN OF THE POSITIVE (+) AND NEGATIVE (-) TERMINALS

Connect thePositive (+)cablefirst,thenconnect Negative (-).

Whendisconnecting, disconnect theNegative (-) Cablefirst, thendisconnect thePositive (+)Cable.

Referto Maintenance Section of thisManualfor properprocedures foruseof booster cables.

Improper booster cableconnections cancausean explosionresulting in personal injury.

Connect booster cablesusingfollowing procedure.

1.Connect booster cabletopositive (+)battery terminal of discharged battery.

Connect otherendof booster cabletopositive battery terminal ofnormal battery.

2.Connect otherbooster cableto negative (-)battery terminal of normal battery.

Connect otherendof booster cableto upperframeof troubled machine. cablesin reverse 3.Startengineandremovebooster order.

1-12

Section I- SAFETY PRECAUTIONS 1.8WARNING LABELS & DECALS (USA ONLY) Warning LabelsandDecalsareaffixed to themachine to remindoperators andpersonnel specific Safety Precautions in certain areasof themachine.

The following areillustrated examples of allWarning LabelsandDecalsalongwiththeirlocations.

1. SWING- DANGER Located on eachsideof therearcounterweight.

Part Number- YN20T01003P2(2-REQ’D)

4. PREVENT BATTERY EXPLOSIONS- WARNING Located on fueltank.

Part Number-YN20T01001P1

PREVENT BATTERY EXPLOSION ¯ Batteries giveoffhydrogen gasaes thatcan explode andcausepersonal injury. ¯ Keepsparks, openflamesandcigarettes away frombatteries. ¯ Keepmetallic articles awayfrombatteries.

Keepallventilation capstightly secured.

Never checkcharge by placing metalarticles across battery terminals. ¯ Leave battery boxopento improve ventilation whencharging.

YN20T01001 P1

~

5. BOOSTER CABLE-WARNING Located on fueltank.

Part Number- YN20T01015P2

2. HOT COOLANT- WARNING Located on topof engineradiator.

Part Number- YN20T01010P1

Improperboostercableconnections cancausean explosion resulting in )ersonal injury.

Steam of hot coolant can cause injury or blindness.

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

Before opening radiatorcap: ¯ Cool down engine completely. ¯ Cover radiatorwith cloth rag. ¯ Loosen cap slowly to relieve pressure.

Connect booster cablesusingfollowing procedure. booster cabletopositive (+) 1.Connect battery terminal ofdischarged battery.

Connect otherendofbooster cableto positive battery terminal ofnormal battery.

2.Connect otherbooster cableto negative(-) battery terminal ofnormal battery.

Connect otherendof booster cable toupper frame oftroubled machine.

3.Startengine andremovebooster cables inreverse order.

YN20T01010P1

~ ~k,~ N CONNECTING

3. STOP ENGINE- WARNING Located on topof engineradiator.

Part Number- YN20T01009P1

ORMAL

A BOOSTER CABLE (BED) l

BATTERY

~ (~

YN20T01015P2

/ WARNING 6. AVOID ACID BURNS- WARNING Located on fueltank.

Part Number- YN20T01017P1

WARNING AVOID ACID BURNS Rotating partscancausepersonal injury.

Keepawayfromfanandbeltwhenengineis running, Stopenginebeforeservicing, YN20T01009P1

1-13

¯ Electrolyte is an acidandcan causeinjury or blindness if it contacts withskinor eyes. ¯Weareyeprotection andprotective clothing whenhandling or servicing batteries. ¯If electrolyte contacts skinor eyes,flush affected areasimmediately withcleanwater and seekmedicalattention YN20T01017P1

Section I- SAFETY PRECAUTIONS 7. PRESSURIZED HOT OIL- WARNING Located on topof Hydraulic Tank.

Part Number- YN20T01405P1

10. HANDLING BATTERY - DANGER Located on fueltank.

Part Number-PY20T01069P1 "/Vk,A DANGER EXPLOSIVE GASES

WARNING

Cigarettes, flames or sparks couldcausebattery to explode.

Always shield eyesandfacefrombattery.

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

KEEP VENT CAPS TIGHT AND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid.

Avoid contact with skin, eyes orclothing.

In event ofaccident flush with water andcall a physician immediately.

KEEP OUT OF REACH OF CHILDREN

Pressurized hot oil can causeburns.

Depressstem or remove cap slowlywith engineoffto relieve HydraulicTank pressure.

PY20T01069P1 )

YN20T01405P1

11, DO NOT USE COUNTERWEIGHT LIFTING - DANGER Locatedon Counterweight.

Part Number-YN20T01221P1 (2-REQ’D)

RELEASE AIR PRESSURE - CAUTION , Located on Hydraulic Reservoir AirBreather.

Part Number - YN57V00002S007 Applicable MachineNo. YT01-00101-01672

Donotusecounterweight lifting eyes to liftwholemachine.

Lifting eyescanfallunderthisload resulting inpersonal injyry.

Referto operators manualforproper wayof lifting machine.

YN20T01221P1

E INJ

9. DO NOT CLIMB- WARNING Locatedon enginecover.

Part Number - YN20T01049P1

12. ROTATING & HOT PARTS 13. AIR CLEANER - CAUTION - CAUTION Located on aircleaner.

Locatedon Cover.

Part Number YT20T01040P1 Part Number- YN20T01220P1

CAUTION CAREFULLY HOLD -- THE O-RING. --

When servicing or repairing machine, keepsurfaces freeofoil, water, grease, tools, etc.to avoid possible slipping and/or falling from machine, whichcancausepersonal injury.

YN20T01049P1

WATER INSIDE CAUSE ENGINE FAILURE. YT20T01040P1

Enginemay be hotwhich couldcauseburns.

Do nottouchengine until it coolsdown.

YN20T01220P1

1-14

Section I- SAFETY PRECAUTIONS 14. BUCKET TO CAB CONTACT - CAUTION Locatedinsidecab R.H. Part Number - YN20T01013P1

17. SAFETY LOCK LEVER- WARNING Locatedinsidecab R.H. Part Number- PY20T01073P1

CAUTION

~

Bucketcan contactand damage cab when machineequipped with some attachments.

CAUTION FOR (FERE

Check clearance betweenbucketand cab before operation.

Exercise care when operatinga bucketnear cab.

YN20T01013P1

Machine may move suddenly and cause serious personal injuryif a controlleveris accidentally touchedbe sure the safetyleveris disengaged and in the lockedposition beforeexitingthe cab.

PY20T01073P1

18. GENERAL PRECAUTIONS- WARNING Locatedinsidecab R.H. Part Number- YN20T01016P1

WARNING 15. ADJUSTING TRACK TENSION- WARNING LocatedinsidecabR.H. Part Number-2432T6110

WARNING

Extremehighpressurein trackadjustment cylinder can cause personalinjury when adjusting crawlertension.

Loosengreasenipplewithcareto relievepressure gradually.

2432T6110

Read and understand the operators manual before operatingor performingmaintenanceon this machine.

Failureto followor pay attention to instructions in operators manualcan resultin injuryor death.

It is yourresponsibility to be awareof andfollow alllocallawsandregulations.

Before startingmachine,make sure hydraulic control leveris in lockout position andallcontrol leversarein neutral.

Soundhornto alertpeople.

Ensure bystandersand obstaclesare clear of machinebefore moving machineor its attachments.

Do not carryriderson machine.

Beforeleavingoperatorscompartment,park on levelground,lowerattachments to ground,make surehydraulic control leveris in lockout position and stop engine.

YN20T01016P1

16. OPERATION BY FOOT PEDAL - CAUTION LocatedinsidecabR.H. Part No. PY20T01062P1

19. BUCKET TO CAB SKYLIGHT - CAUTION Locatedinsidecab FrontWindow.

Part Number-LE20T01024P1

CAUTION

CAUTION

Attachment operationby foot pedal.

Alwayscheckthe foot pedalcontrolpatternbeforeoperation.

Always read operatorsmanualbefore operating machine.

PY20T01062P1

Becausethe bucketmay interfere withtheskylight do not operateatt at the min.swingposition with the skylightof the cab opened.

LE20T01024P1

1-15

Section I- SAFETY PRECAUTIONS 20. ELECTRICAL POWER LINES- WARNING LocatedinsidecabR.H. Part Number- YN20T01006P1

23. LIFTING FRONT WINDOW - CAUTION Locatedinsidecab FrontWindow.

Part Number-YN20TO1416P1

CAUTION Fallingfrontwindowcan causeinjury.

Alwayslock securelyin placewith lockleveron bothsides,

in severe injury or death.

Keepmachineand attachment a safedistance fromelectrical powerlinesas per following instruction.

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

YN20T01416P1

SAFETY DISTANCE 3.OM(10FT) 4.5M(15FT) 6.0M(20FT) 7.5M(25FT) 10.5M(35FT) 13.5M(45FT)

24. NIBBLER & BREAKER OPERATION POSITION - CAUTION Locatedon RearCover.

Part Number- YT20T01054P1(OPT)

YN20T01006P1

Do not set this switchto nibblercombinedflow operationpositionwhen usingbreaker.

21. SELECTOR VALVE - CAUTION Located insidecabR.H. Part Number - YY20TO1039P1(OPT)

Procedure to change selector valve

YT2OT01054P1

25. KEEP CLEAR WORKING AREA- DANGER Locatedon arm.

Part Number - YN20T01337P1(2-REQ’D)

MAINTENANCE (Whenusingnibbler, breaker or extra)

I Mark INibbler SELECTION

¯ Contamination anddeterioration of hydraulic oil may develop EXTRA malfunctioning of control valves, I= aker Bre I early wearandseizure of hydraulic pumps,and consequential damage ¯Placeadjustsuitable ofentire hydraulic circuit. notch Replace filters andhydraulic oil, to capsrew. refering tothefollowing table. (somemark may not be indicated) (1)Hydraulic oilchange : Every 600HRS. (2)Hydraulic return filter change First : 50 HRS Regular : Every250 HRS

26, LONG ARM PRECAUTIONS - CAUTION LocatedinsidecabR.H. Part Number - YT20T01073P1

YY20T01039P1

22. DOZER BLADE - CAUTION LocatedinsidecabR.H. Part Number- PY20T01077P1

CAUTION Do not excavatewith the machinein transportposition.Such operationcan causeattachmentdamage and cab interference.

Dozerbladecanbe operatied bothwithor without lever-lock in locked position.

PY20T01077P1

TRANSPORTATION

OPERATION J ~~ ~’,. )-: ~ POSITION "/ "~~(~ YT20TO1073P1

1-16

Section I- SAFETY PRECAUTIONS 29. CALIFORNIA PROPOSITION 65 - WARNING LocatedinsidecabR.H. Part Number- 2432T6457

27.HANDRAIL - WARNING LocatedinsidecabR.H. Part Number- 2432T6019

WARNING

WARNING

DO NOT INSTALL ANY OBJECT ON THE HANDRAIL.This can cause the welds that fasten the handrailto the operatorscab to fatigueand crack due to excessivevibrationduringmachine operation.

Injuryto the operatormay resultif he fallsto groundbecauseof the unxpectedbreakageof the welds.

2432T6019

CALIFORNIAProposition65 Dieselengineexhaustand someof its constituents are known to the State of Californialto cause cancer,birthdefects, and otherreproductive harm.

2432T6457

28. AUTOMATIC TWO SPEED TRAVEL - WARNING Locatedinsidecab R.H. Part Number - YN20T01048P1

WARNING Automatictwo speedtravelsystemchangestravel speed automaticallyand can adverselyaffect machine control when descendinga slope and loading or unloading on a trailer.

Personalinjurycan occurfrom suddenchangein machinecontrol.

Puttravelspeedselectswitchin lowspeedposition when descending a slopeand loadingor unloading on a trailer.

YN20TO10-48P1

1-17

Section I- SAFETY PRECAUTIONS 1.9WARNING LABELS & DECALS (EU ONLY) Warning LabelsandDecalsareaffixed to themachine to remindoperators andpersonnel specific Safety Precautions in certain areasof themachine.

The following areillustrated examples of allWarning LabelsandDecalsalongwiththeirlocations.

4. PREVENT BATTERY EXPLOSIONS- WARNING Located on fueltank.

Part Number-YN20T01001P1

WARNING PREVENTBATTERYEXPLOSION ¯ Batteries give offhydrogen gasses that can explode andcause personal injury. ¯ Keep sparks, open flames andcigarettes away from batteries.

Keep metallic articles away from batteries.

Keep all ventilation caps tightly secured.

Never check charge byplacing metal articles across battery terminals. ¯ Leave battery boxopen toimprove ventilation whencharging.

YN20T01001 P1

1. SWING- DANGER Located on eachsideof therearcounterweight.

Part Number-ZL11 M04116(2-REQ’D)

i

5. BOOSTER CABLE- WARNING Located on fueltank.

Part Number- YN20T01015P2

WARNING Improperboostercableconnections cancausean explosion resulting in personal injury,

2. PRESSURIZED HOT OIL- WARNING Located on topof Hydraulic Tank.

Part Number- YN20T01405P1

Connect booster cables usingfollowing; ,~1.," d/jr,., procedure.

1.Connect booster cable topositive (+) battery terminal ofdischarged battery.

Connect otherendof booster cableto positive battery terminal ofnormal battery.

2.Connect otherbooster cableto negative(-) battery terminal ofnormal battery.

Connect otherendofbooster cable toupper frame oftroubled machine.

3.Startengine andremovebooster cables inreverse order.

Pressurized hot oil can cause burns.

Depress stem or remove cap slowlywith engineoffto relieve HydraulicTankpressure.

YN20T01405P1 j

,

~

(RED) (~ CONNECTING A BOOSTER CABLE

D~SCHARGED BATTERY TOTHEUPPER FRAME OFA TROUBLED MACHINE

YN20T01015P2

DO NOT USE COUNTERWEIGHT LIFTING - DANGER Locatedon Counterweight.

Part Number-YN20T01221P1 (2-REQ’D)

6. ROTATING & HOT PARTS - CAUTION Locatedon enginecover.

Part Number- YN20T01012P1

CAUTION

Donotusecounterweight lifting eyes to liftwholemachine.

Lifting eyescanfallunderthisload resulting inpersonal injury.

Rotating engine fan,hotengine parts anddrivebeltcancausesevereinjury.Do not openenginecoveror service enginewithengine running.

Referto operators manualforproper wayoflifting machine.

YN20T01012P1

YN20T01221 P1

1-18

Section I- SAFETY PRECAUTIONS ,

RELEASE AIR PRESSURE - CAUTION Located on Hydraulic Reservoir AirBreather.

Part Number - YN57V00002S007 Applicable MachineNo. YT01-00101-01672

10. HANDLING BATTERY- DANGER Located on fueltank.

Part Number-PY20T01069P1 ’/t~ DANGER EXPLOSIVE GASES Cigarettes, flamesor sparkscouldcausebattery to explode.

Always shield eyesandfacefrombattery.

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

KEEP VENT CAPS TIGHTAND LEVEL POISON CAUSES SEVERE BURNS Contains sulfuric acid.

Avoid contact with skin, eyes orclothing.

In event ofaccident flush with water andcall a physician immediately.

KEEP OUT OF REACH OF CHILDREN PY20T01069P1

8. AIR CLEANER - CAUTION Located on aircleaner.

Part Number YT20T01040P1

CAREFULLY HOLD -- THE O-RING. --

A

WATER INSIDE CAUSE ENGINE FAILURE. YT20T01040P1

°

11.PRESSURIZED HOT OIL & 13. BOOSTER CABLE COOLANT - WARNING - WARNING Located on topof engine radiator.

Located on fueltank.

Part Number- ZLll N00404 Part Number- ZL11 N01104

ROTATING & HOT PARTS - CAUTION Locatedon counterweight.

Part Number- ZL11 N00504

@ 12. DO NOT CLIMB - WARNING Locatedon enginecover.

Part Number- ZL11 N02604

@

14. STOP ENGINE - WARNING Located on radiator.

Part Number- ZL11 N05104

8TOP

1-19

Section I- SAFETY PRECAUTIONS 15. STOP ENGINE - WARNING Located on radiator.

Part Number- ZL11 N05204

16. ADJUSTING TRACK TENSION - WARNING Located insidecab R.H. PartNumber- ZL11 N07704

17. ELECTRICAL POWER LINES - WARNING Located insidecabR.H. Part Number- ZL11 N01304

STOP

18. READ OPERATORS MANUAL - WARNING LocatedinsidecabR.H. Part Number- ZL11 N00104

19. LIFTING FRONT WINDOW - WARNING Locatedinsidecab FrontWindow.

Part Number- ZL11 M06008

20. NIBBLER & BREAKER OPERATION POSITION - CAUTION Locatedon RearCover.

Part Number- YT20T01054P1(OPT)

Do not set this switchto nibblercombinedflow operationpositionwhenusingbreaker.

YT20T01054P1 21. BUCKET TO CAB CONTACT - CAUTION LocatedinsidecabR.H. Part Number - YN20T01013P1

22. SAFETY LOCK LEVER - WARNING LocatedinsidecabR.H. Part Number- PY20T01073P1

CAUTION Bucketcan contactand damage cab when machine equippedwith some attachments.

Check clearance betweenbucketand cab before operation.

Exercise care when operatinga bucketnear cab, YN20T01013P1

1-20

Machine may move suddenly and cause serious personalinjuryif a controlleveris accidentaly touchedbe sure the safetylever is disengaged and in the lockedposition beforeexitingthe cab, PY20T01073P1

Section I- SAFETY PRECAUTIONS 24.OPERATION BY FOOT PEDAL- CAUTION LocatedinsidecabR.H. Part No. PY20T01062P1(OPT)

23. SELECTOR VALVE - CAUTION LocatedinsidecabR.H. Part Number - YY20T01039P1

CAUTI()N Procedure to change selectorvalve

CAUTI()N

MAINTENANCE (Whenusingnibbler, breaker or extra)

SELECTION Nibbler Breaker EXTRA

¯ Contamination anddeterioration of hydraulic oil may develop malfunctioning of control valves, early wearandseizure of hydraulic pumps,and consequential damage ofentire hydraulic circuit. ¯ Placeadjustsuitable notch Replace filters andhydraulic oil, to capsrew. refering to the following table. (somemarkmay not be indicated) (1)Hydraulic oilchange : Every600HRS. return filter change (2)Hydraulic First : 50 HRS Regular : Every250HRS NOTCH~~MARKS

CAPSCREW

YY20T01039P1

25. BUCKET TO CAB SKYLIGHT - CAUTION Locatedinsidecab FrontWindow.

Part Number-LE20T01024P1

CAUTI()N Becausethe bucketmay interfacewith the skylightdo notoperateattat the min.swingposition withthe skylightof the cab opened.

LE20T01024P1

27. SAFETY LOCK LEVER - WARNING Located on controlstand.

Part Number- ZLll N04204

ZL11N04204 ,~

1-21

Attachment operationby footpedal.

Alwayscheckthe foot pedalcontrolpatternbeforeoperation.

Alwaysread operatorsmanual beforeoperating machine, PY20T01062P1

26. ATTACHMENT- CAUTION Locatedon Arm. Part Number - YT20T01038P1(2-REQ’D)

Section I- SAFETY PRECAUTIONS 1.10 PROHIBITEDMACHINE OPERATION Thefollowing examples of machine abuseandmisuseshould neverbe attempted by eventhemostexperienced operator.

Suchabuse andmisuse of this machine anditsattachments canresult in serious bodily injury, death, severe equipment damage and shortened service lifeofthemachine.

Under nocircumstance should anyof theseoperations beattempted.

Usecommon senseandfollow proper operation procedures foundinthisOperators Manual while operating thisequipment.

DO NOT USE TRACTIVE FORCE

A. DO NOT USE TRACTIVE FORCE OF THE MACHINE FOR LOADING THE BUCKET ATTACHMENT. Doingsowillexertexcessive force on themachine structure, front endattachments andcouldcausesevereequipment damage.

Use tracks fornormal travel operations only.

B°

C,

DO NOT USE SWINGING FORCE OF THE MACHINEFOR OPERATIONS. Doingso will exertexcessive force tothemachine structure, front endattachments andshorten lifeoftheswinging system ofthemachine.

Also, serious injury ordeath could result fromsuchoperations.

DO NOT USE SWINGING FORCE

DO NOT PERFORM "HAMMERING" OPERATIONSWITHTHE BUCKET.Performing operations suchas hammering andpiling willcause extensive damage to themachine anditscomponents.

These types of operations canalsoresult inserious injury ordeath.

DO NOT HAMMER WITH ATTACHMENT

D°

DO NOT USE THIS MACHINE FOR ANYTHING OTHER THAN ITS INTENDEDPURPOSE.This machine is designed andmanufactured fordiggingandloading operations only.

Anyother use canexert excessive force tothemachine, itscomponents, itssystems andresult inserious bodily injury ordeath totheoperators andother personnelworking inthevicinity oforwiththemachine.

X

©

USE ONLYFORINTENDEDPURPOSE

1-22

Section I- SAFETY PRECAUTIONS E°

DO NOT OPERATE BUCKET AND ARM CYLINDERS TO STROKE END REPEATEDLY. Extending thebucket andarmcylinders to stroke endtoclean debris fromthebucket, willcause impact tothebucket cylinder causing cylinder damage.

Usehighpressure wateror manually remove stubborn material fromthebucket.

F.

DO NOT OVER EXERT THE MACHINE’S CAPACITIES. Knowthelimitations of themachine anditsattachments andoperate themachine within those specifications.

Never tiporraise the machine to obtain power to movematerial.

This could causeextensive damage to themachine and itscomponents aswellasresult inserious bodily injury ordeath.

1.11 END OF WORK SHIFT SAFETY Perform allofthefollowing procedures after each shift iscomplete toinsure themachine itinoptimaloperating condition forthenextshift orjob site.

A. Movethemachine toa firm, level surface.

B. Lowerattachment to theground.

C. Refill fueltanktofullmarktoreduce airvolume andcondensation (moisture).

Thiswilldecrease thepossibility offreezing inthefuel tank, rusting duetomoisture andotherproblems associated withstart upandoperation.

D. Close andsecure allwindows inplace to prevent water or moisture reaching theelectrical components of themachine.

E.Thoroughly cleanandinspect themachine.

Performlubrication maintenance andrepair orreplace anyproblem areas found before restarting themachine.

F.Ifoperating themachine incoldclimates, itmay be necessary toremove thebatteries fromthemachine andstore in a warmwellventilated area.

Install thebatteries inthemachine before nextstart up.Thiswillhelpprevent premature battery deterioration. keyfromkeyswitch andlockalldoors G. Remove andaccess panels.

1-23

DO NOT OPERATE CYLINDER TO STROKE END

::::::::::::::::::::::::::::::::::::::. ::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::

DO NOT OVER EXERT THE MACHINE

END OF WORK SHIFT SAFETY

Section II-MACHINE FAMILIARIZATION Tableof Contents

2-1 FAMILIARIZATION .....................................................................................

GENERAL MACHINE NOMENCLATURE ............................................................................

2-1 2-2 OPERATOR CABNOMENCLATURE ..............................................................................

2-3- 2-14 COMPONENT & CONTROLS NOMENCLATURE .......................................................................

Right Hand Operator Console ...........................................................................

2-3~ 2-6 2-6~ 2-10 Left Hand Operator Console ...........................................................................

2-6- 2-10 Air Conditioner ..................................................................................

2-10 - 2-12 Rear Panel &Other ................................................................................

Operating Levers & Controls ...........................................................................

2-13~ 2-14 2-15- 2-17 Gauge Cluster ...................................................................................

Operator Cab ...................................................................................

2-18- 2-24 2-24~ 2-25 Machine Access Panels &Doors .........................................................................

/~

WARNING

/~

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

2-0

Section II-MACHINE FAMILIARIZATION 2.1 FAMILIARIZATION 2.2 GENERAL MACHINE NOMENCLATURE TheNomenclature drawing below (Figure 2.1), points Alloperators, service mechanics andpersonnel responsible foroperation, inspection andmaintenance outlocations of majorcomponents of theKOBELCO SK70SRHydraulic Excavator. ofthemachine should become thoroughly familiar with thecontrols andcomponents andtheirfunctions beStudytheseareasandlocate thesecomponents on foreworking withoronthisequipment. themachine.

Specific information regarding these components areexplained on thefollowing pagesof Study theinformation inthissection tobecome familiarwiththecontrols andcomponents ofthismachine. this section.

ARM

ARM CYLINDER

BOOM

SWIVEL JOINT

BUCKET BATTERIES FUEL TANK IDLER LINK

SWING MOTOR

HYDRAULIC OIL TANK

BUCKET LINK

BOOM CYLINDER OPERATOR CAB

MAIN CONTROL VALVE

~

\

PUMP ACCESS DOOR

BUCKET OPERATOR CONTROLS

TRACK SHOE ASSEMBLY (600mm STANDARD)

MUFFLER

HYDRAULIC PUMP TRACK IDLER (1 EACH SIDE)

TRACK SPRING (1 EACH SIDE)

ISUZUA-4JB1 ENGINE COUNTERWEIGHT

UPPER ROLLER (1 EACHSIDE) LOWER ROLLER (5 EACHSIDE)

ENGINE RADIATOR ENGINE AIR CLEANER

FIGURE2.1

2-1

TRAVEL MOTOR

SectionII-MACHINEFAMILIARIZATION 2.3 OPERATOR CAB NOMENCLATURE TheOperator CabNomenclature (Figure 2.2),points outlocations of Operator Controls of theKOBELCO SK70SRHydraulic Excavator Operator Cab. LEFT TRAVEL LEVER

Studytheseareasandlocate thesecomponents on themachine.

Specific information regarding these components areexplained on thefollowing pagesof this section.

RIGHT FOOT REST RIGHT TRAVEL LEVER GAUGE CLUSTER

LEFT FOOT REST

RIGHT TRAVEL

LEFT TRAVEL PEDAL

RIGHT HAND OPERATOR CONTROL

LEFT HAND OPERATOR CONTROL LEVER (HORN SWITCH)

24V CIGARETTE LIGHTER

SAFETY LOCK LEVER (FOR HYDRAULICS)

-ADDITIONAL WORK LIGHT SWITCH (FOR EU SPEC.) TRAVEL ALARM SWITCH .(FOR USA SPEC.)

OPERATORS SEAT (3 WAY ADJUSTABLE)

SWITCH PANEL ARM REST

STORAGE COMPARTMENT

THROTTLE POTENTIOMETER

PANEL

HYDRAULIC OIL INDICATOR LAMP (FOR USA SPEC,) KEY SWITCH

12V POWER SU FUSE BOX

J CAP (FOR OPT. SWITCH)

HEAD REST (ADJUSTABLE)

SWING PARKING BRAKE RELEASE SWITCH

ENGINEEMERGENCY STOP CONTROL

HOUR METER

FIGURE2.2

2-2

SectionII-MACHINEFAMILIARIZATION 2.4COMPONENT & CONTROLS NOMENCLATURE Thefollowing information provides a briefdescription andfur~ction of thecomponents andcontrols of the KOBELCOSK70SR HydraulicExcavator.

All personnel associated withthismachineshould readand understand thisinformation BEFOREbeginning anyworkwithor on thisequipment.

KEY SWITCH POSITIONS ~. ACC Q o~. ° .~

A. RIGHT HAND OPERATOR CONSOLE 1. Key Switch-FIGURE2.3 The Key Switchis locatedon the RightHand Operator Consoleand has 5 operating functions. a. "HEAT"-This position is usedforstarting the engine in coldclimates.

SeeSection II1.

"OFF"-WhenKeyis turnedto thisposition, theenginestopsandelectrical powerto the machine’s electrical systems is stopped after approximately 4 seconds.

"ACC"-Withkey in the"ACC"position only theCigarette Lighter, DC to DC Converter andHornwillhavepower.

"ON"-WhenKeyis in theON position, electrical poweris supplied to allthemachine’s electrical systems.

"START"Whenkeyis turnedto thispositionelectrical powerissupplied tothestarter solenoid causing thestarter to starttheengine.AfterenginestartsKeyshouldbe releasedto go backto the"ON"position.

2. KPSS Mode Switch- FIGURE 2.4 The KPSSModeSwitchis locatedon theRight HandOperatorConsoleand has 3 operating functions. a. "H"Mode-Usethisposition forbestperformancein heavydiggingoperations. b. "S"Mode-Placeswitchin "S"modeforbest performance andcontrol forlightdutyoperations andfuelconsumption. c. "FC"Mode-Usethisposition whenprecisionFineControl is required.

,

ThrottlePotentiometerFIGURE2.5 TheThrottle Potentiometer is located on the RightHandOperatorConsoleand controls EngineRPM.Whenthe ThrottlePotentiometer is rotated to anyposition itincreases or decreases enginerprnand maintains engineat theprogramed RPMforthatparticular position onthedial.

FIGURE 2.3

]

MODE

@ KPSS POSITIONS

FIGURE 2.4

THROTTLE POTENTIOMETER (CONTROL)

FIGURE 2.5

2-3

SELECT

i

Section II-MACHINE FAMILIARIZATION 4. Wiper & Washer Switch-FIGURE2.6 - Pressthisswitch, andthefrontwindowwiperstartsmoving. a. Pressit once: Wipermovesintermittently. b. Pressit again: Wipermovescontinuously c. Pressit oncemore: Wiperstops moving.

Pressthisswitch, andwasherfluid issprayed whileitis pushed.

Also,washer tankis installed inthe front ofradiator ontherearleftside.

FMODE SELECT

WASHER SWITCH

WIPER SWITCH

/

CAUTION Makecertain the Washerreservoir haswasherfluid beforeoperating washer.

FIGURE 2.6

5. WorkingLightsSelectSwitch- FIGURE2-7 - Pressthisswitch, andworking lights installed on boomand frontright sidego on.

Pressit again, andworking lights on boomandfrontrightsidego out.

SELECT PRESS HERE TO STOP BUZZER

6. BuzzerStop Switch- FIGURE2-7 - If various sensors on mechatro con-

[~

troller (selfdiagnosis) fail,warning buzzer sounds intermittently.

To stop sounding, pressbuzzer stopswitch.

NOTE Buzzersounding dueto engineoilpressure dropandenginecooling watertemperature risecannotbe stopped.

2-4

FIGURE 2.7

Section II-MACHINEFAMILIARIZATION .

Hydraulic OilIndicator Lamp- FIGURE2.8 TheColdHydraulic OilIndicator lampislocated totheleft ofthethrottle potentiometer theRight HandOperator Console.

Itspurpose is to informtheoperator, uponstart upofthemachine, that theHydraulic Oiliscoldandhydraulic functions maybeslowandvalve spools willbeslow opening andclosing during operation.

Thelampwillgooutwhenthehydraulic oiltemperature reaches 10°C(50°F).

Normal operatingtemperature ofthehydraulic oilis45°Cto 55°C(113°F to 131°F).

Neverperform normal hydraulic operations withindicator lampon.See Page3-5forproper hydraulic oilwarmupproced u res.

/ HYDRAULIC OIL INDICATOR LAMP

FIGURE2.8 8. TravelAlarmStopSwitch- FIGURE2.9 Thetravel Alarm Switch islocated ontheupper left corner oftheright side panel.

Whentravelis engagedthe alarmsounds automatically.

J

TRAVEL ALARM SWITCH

O (FOR USA SPEC.’

LighterFIGURE2.10 9. 24 VoltCigarette TheCigarette Lighter islocated ontheright wall of cab.To usetheCigarette Lighter theKey Switch mustbe in theON position.

Pushthe lighter in andwaitapproximately 30 seconds foritto"POP" out.Pulllighter from thesocket touse.Replace lighter backintoitssocket afteruse.

Ioo o! use the

FIGURE2.9

I±1

Cigarette Lighter as a power source for 12Voltaccessories.

Itis24Volt outlet.

FIGURE2.10

2-5

Section II- MACHINE FAMILIARIZATION 10.Additional WorkLightSwitch - FIGURE 2.11 Thisswitch is located nextWorking Lights SelectSwitch.

Itsbasic functions aretoturnthe additional cabfront andrearworklights "ON" and"OFF".

PRESS HERE FOR "ON" PRESS HERE FOR "OFF" -

i

- Depress thissidetoturnadditional Cabfront andrearWorklights "ON".

Depress empty sideofswitch toturn additional CabfrontandrearWork lights "OFF".

Q

FIGURE2.11 B. LEFT HAND OPERATOR CONSOLE 1. 12 VoltPowerSupply- FIGURE2.12 The12 VoltPower Supply is located beside the LeftHandOperator Console.

Foruseof common autoaccessories suchas a fanor otheraccessories requiring 12vdc power,pullcoverawayfrom12 VoltPower Supply andinsert 12 VoltMaleSocket into power supply.

Replace cover after use.

1

CAUTION Donotuse12VoltPower Supply asa cigarette lighter.

MAXIMUM CONTINUOUS OUTPUT - 2.5 Amps

FIGURE2.12 .

AirConditioner - FIGURE2.13and2.14 Theair-conditioner provides a comfortable indoorenvironment andfreecontrol ofroomtemperature andalsois usedto remove moisture fromhumid airandtoprotect window glass from frosting.

Theair-conditioner isinstalled under operator’s seatandsends coldairorhotairintocab.

Airoutlet selector Select a preferable airoutlet direction moving grille byhand. (~), (~,,,Airoutlet FIGURE2.13

2-6

Section II-MACHINE FAMILIARIZATION 2-1NAME OF CONTROL SECTIONS AIR OUTLET MODE SELECTOR SWITCH

FRESH AND RECIRCULATE AIR SELECTOR SWITCH

COMPRESSOR SWITCH

LCD DISPLAY

AUTO CONTROL SWITCH

AUTO

O

O

DEFROSTER SWITCH

TEMPERATURE SETTING SWITCH (°C ~ OF SELECTOR SWITCH)

AIR CAPACITY SELECTOR SWITCH

MAIN POWER SWITCH

FIGURE2.14 SUPPLEMENTARY EXPLANATION ThemidLCDdisplay indicates temperature, airoutlet mode,compressor ON - OFF,AUTO,recirculate andflesh airandblower aircapacity.

Eachswitch, fanmarkof blower, andTEMPmarkare lighted upgreen atnight.

FRESH AND REClRCULATE AIR SELECTOR SWITCH

2-2Fundamental use-Figure2.15 Before turning air-conditioner on,close doors ofcab andwindows to achieve thebestperformance.

1. Press control switch AUTOtocontrol aircapacity andoutlet opening automatically, andsetthetemperature in therangefrom18.5°C (63.5°F) 31.5°C (88.7°F).

Andoutlet temperature, outlet opening andaircapacity areadjusted automatically sothatindoor temperature of cabcomescloser to thesettemperature.

2. Select proper modemanually through recirculate andflesh aircapacity selector switch andcompressor switch ON - OFF. 3. Whenaircapacity selected through autocontrol isnotpreferable, select preferable aircapacity manually through air-capacity selector switch.

Then,theindicator lampof "AUTO" in LCDdisplaygoesout.Press"AUTO" switch to return to autocontrol.

2-7

COMPRESSOR SWITCH

AUTO CONTROL SWITCH

AIR CAPACITY SELECTOR SWITCH

FIGURE2.15

SectionII- MACHINEFAMILIARIZATION 2-3 FUNCTION OF SECTIONS ON CONTROL PANEL 1. Main power switchand display-Figure2.16 a. LCDdisplay is litup whenair-conditioner is operating.

Whenair-conditioner is stopped, LCDis unlit.

LCD DISPLAY AUTO I

b,

C°

Pressmainpowerswitch, andallfunctions of airconditioner switches on or off.

Eachtimewhenthisswitchis pressed, thefunctionswitches on and off.And whenswitched on, air-con startsoperating at thepointsetbefore switching off.(Whenit is setto AUTO,in auto mode,if NORMALis selected, in normalmode.)

@,/c

Iii © o

\

MAIN POWER SWITCH FIGURE 2.16

Starter switch isavailable toswitch air-con off,but theoperating condition justbefore switching off may notbe restored whenthe starterswitchis turnedON.

2. Autocontrolswitchand display- Figure2.17 a. LCDdisplay is litup onlyaircapacity andoutlet opening areautomatically controlled. b°

PresscontrolswitchAUTO,andair capacity and outletopening areautomatically controlled, and "AUTO"indicator lampon LCD displaygoeson.

C°

Whenmainpowerswitchis OFF,turnthisswitch ON, and main powerswitchturnsON, and also air-con starts operating.

However, aircapacity andoutlets areoperated in AUTO controlmode.

LCD DISPLAY

AUTO CONTROL SWITCH

o

°

Temperature settingswitchand display - Figure2.18

a.

Thesettemperature is indicated in digitson LCD display.

Temperature setrangeis 18.5°C (65.3°F) to 31.5°C(88.7°F).

b. Pressthetwotemperature setswitches for5 secondsat the smetime,andthe display of Centigradescale(C)and Fahrenheit (F) is switched and"F"is displayed at theendof LCDdisplay.

(Eg.)25°C--~77°F ¢. Press temperatureset switchDOWn or UP to changethe settemperature.

The temperature goesup or downby 0.5°C(1.8°F) in graduation. the settemperature maybe raisedor lowered by continued pressing or theswitch.

2-8

o

\

MAIN POWER SWITCH FIGURE 2.17

LCD DISPLAY

O

O

O

O

TEMPERATURESETTINGSWITCH (°C~ OF SELECTOR SWITCH) FIGURE 2.18

Section II-MACHINEFAMILIARIZATION d. Theset temperature 18°C(64.4°F) is thelowest cooling temperature, and 32°C(89.6°F) thehighest heatingtemperature.

Control beyond either oftheselimits isnotpossible.

4. Air outletmode selectorswitchand display - Figure2.19 a. Airoutlet modeposition is indicated by thearrowon LCD display. b.

Pressblowoutmodeswitchin the condition whereautodisplay is lighting up,andthedisplaymodeis fixed.,"AUTO"indicator lampon LCD displaygoesout,and "AUTO"controlof blowout openingis released.

Pressit again.

Andthelevelischanged in order of VENT --~ BI LEVEL~ FOOT --~ VENT.

AIR OUTLET MODE SELECTOR SWITCH

\ o

-,®

®!,®

l~ o

FIGURE 2.19

/o

/o

Bi-level

Foot

Upperhalfof body,foot

Foot,frontglass

LCD display Airoutletopening Airoutlet direction

Vent Upperhalfof body

5. Defroster switchand display- Figure2.20 a. Pressdefroster switch,andindicator lampof markis indicated on LCDdisplay. b.

C°

FRESH AND RECIRCULATE AIR

Pressairoutletmodeselector switch, and it returns to airoutletmodejustbefore pressing defroster switch.

Pressdefroster switchin thecondition where AUTOdisplayis lighting up,"AUTO"indicator lamp on LCD displaygoes out and the auto control ofairoutlet opening is released.

6. Recirculate and freshair selectorswitchand display - Figure2.20 a. Intakemodeis indicated on LCD display b°

O

o~

Eachtimerecirculate andfleshaircapacity selectorswitchis pressed, themodeis switched toairrecirculate orflesh airintake.

2-9

LCD DISPLAY

o

,,,,’;’¢

o

"#,\ ®i,® /

DEFROSTER SWITCH

\ AIR OUTLET MODE SELECTOR SWITCH

FIGURE 2.20

~,,,° o ]

o

Section II-MACHINE FAMILIARIZATION Compressor switchand display .

- Figure 2.21 Press compressor switch inthecondition where MarkonLCDdisplay isunlit, compressor starts operating andindicator lampof markon LCD display goeson.

Press itagain, andcompressor turns off,and indicator lampof markon LCDdisplay goes out.

LCD DISPLAY

O

AIR CAPACITY COMPRESSOR DISPLAY SWITCH

,/~(~)"

0

o AIR CAPACITY SELECTOR SWITCH

FIGURE2.21 Aircapacity selector switch anddisplay .

- Figure 2.22 Whenit is setto MANUAL mode,aircapacity onLCDdisplay isasfollows.

Display LCD4 lamps arelitup.

LCD3 lamps arelitup.

LCD2 lamps arelitup.

LCD1 lampislitup.

Aircapacity MAX. HIGH MEDIUM LOW

\ LCDdisplay \ l

\ ! i

T 1 / I R

R R R

Aircapacity LOW

MEDIUM

HIGH

MAX.

FIGURE2.22

PressUP or DOWNof aircapacity selector switch, andautocontrol ofaircapacity isreleased, and"AUTO" indicator lampon LCDdisplaygoesout.

C. REAR PANEL AND OTHERS brakerelease switch 1. Swingparking - FIGURE2.23 Swingparking brakeis usually locked.

The swing parking brakeis released in swingand arm-in operation.

Whenitcannot be unlocked duetotrouble, turntoggle switch to"Release lock" (unlock), andtheparking brakeis released.

Then,movemachine to safeareaimmediately andcontact ourrepresentative or service shop.

Andreturn to toggle switch to"NORMAL" positioninnormal condition.

FIGURE2.23

2-10

Section II-MACHINE FAMILIARIZATION 2. TravelSpeedSelectSwitch- FIGURE2.24 Selecthighspeed(2nd speed)or low speed (1stspeed) withthisswitch located ontherighthandtravellever.Whenthestarter switchis turnedfromOFFto ON,thespeedis automaticallysetto LOW.Afterstarting theengine, selectthedesired speed.

PRESSHERE FORlst.2nd SPEEDS

WARNING DO NOT USE ~ SPEED WHEN PERFORMING DELICATE OPERATIONS SUCH AS PIPE LAYING, FINE GRADING OR LOADING MACHINE ONTO A TRAILER. DO NOT CHANGE TRAVEL SPEED WHILE LOADING MACHINE COULD BECOME UNSTABLE AND CAUSE SERIOUS INJURY, EQUIPMENT DAMAGE AND/OR DEATH. .........................

SettoLOWwhenmoving themaLOW (1st)speed

HIGH (2nd) speed

.

chine on a rough or soft road, slope,or in a narrowplace,or whenpowerful tractive forceis required.

FIGURE 2.24

Set to HIGH when moving the machine on flat,hardground.

Fuse Box - FIGURE 2.25 TheFuseBoxis located behindtherightside oftheoperators seat.It contains allnecessary fusesfortheelectrical circuits ofthemachine.

Shouldit becomenecessaryto inspector changea fuse,removethe fusebox coverby gentlypullingeachend awayfromthe box.

Shoulda fuserequirereplacement, usea replacementfuseof the sametype and amperage.Turn key Switchto "OFF"and wait approximately 4 seconds forallelectrical power to stopbeforeremoving or replacing a bad or blownfuse.Thefusecoverincorporates a fuse pullerto removefuses.Referto the MaintenanceSection of thisManual fora detailed diagramanddescription of fusebox.

2-11

I R C2ME

L

FUSE BOX

FIGURE 2.25

Section II-MACHINEFAMILIARIZATION =

Hour Meter - FIGURE 2.26 - Thisindicates thetotaltimetheenginehasrun.Evenif theexcavator is notmoving,themetercontinues tocountaslongastheengine is running.

FIGURE 2.26

2-12

Section II-MACHINE FAMILIARIZATION D. OPERATING LEVERS & CONTROLS 1. SafetyLockLever-FIGURE2.27 TheSafety LockLever is located onthefront outside oftheLeftHandOperator Console and isRedincolor.

TheSafety LockLever isused to lockoutthehydraulic controls disallowing theuseofanyhydraulic function.

TheSafety LockLever has2 operating positions. a.

b.

"UP"-When placedin theup position the Safety LockLever stops allhydraulic controls fromfunctioning andallows theoperatortoenter andexittheoperator seat.

"DOWN"-When placed in thedownposition, theSafety LockLever allows alloperating functions ofthehydraulic controls toresume andalsolockstheLeftHandOperating Console inoperating position.

ALWAYS PLACE THE SAFETY LOCK LEVER IN THE LOCK OUT (UP) POSITIONBEFORE LEAVING THE OPERATOR CAB, NEVER LEAVE THE MACHINE UNATTENDED WITH ENGINE RUNNING OR LEVER IN THE DOWN POSITION.

,

!

EngineEmergency Stop Control - FIGURE2.28 TheEngineEmergency StopControl located atthelower right handsideofoperator seat.

It is usedonlyinan emergency situation to stop theengine quickly.

Ithas2 operating positions.

FIGURE2.27

ENGINE EMERGENCY STOPCONTROL J

a."lN"-Releases thefuelstoplever onthegovernor toallow normal starting oftheengine. b. "OUT"-Activates thefuelstoplever on the enginegovernor to immediately stopthe engine.

FIGURE2.28

CAUTION Do Notsuddenly stoptheengine whenoperating at highRPM.Doingso maydamage turboor engine.

2-13

Section II- MACHINE FAMILIARIZATION

ucotro ,ottoo CAUTION

Operating Patternfor optimummachineperformance andsafety.

Changing theControl Pattern willeffect the performance of the machine.

AR.

OUT ~l

SWINGLEFT

3.FIGURE Left2.29 Hand Operator Control LeverI ~~~ S W~G HT TheLeftHandOperator Control Leveris located atthetopfrontoftheL.H.operator console.

Its purpose is to allowtheoperator to control operations of theSwingandArm.Operating speed of function is variable fromstopto fullstroke ARM IN v~-(~k depending on howfarleveris operated.

The LeftHandOperator ControlLeverhas5 basic operational functions. a. "FORWARD"-VariableSpeed Arm Out. b. "BACKWARD"-VariableSpeedArm In. FIGURE 2.29 c. "LEFT"-Variable SpeedLeftSwing. d. "RIGHT"-VariableSpeedRightSwing.

BOOM DOWN e. "CENTER"NeutralPosition.

Right Hand OperatorControlLever, FIGURE 2.30 TheRightHandOperator Control Leveris locatedatthetopfrontof theR.H.operator console.Itspurpose isto allow theoperator toconBUCKET OUT troloperations of the BoomandBucket.OperBUCKET IN atingspeedof function is variable fromstopto fullstroke depending on howfarleveris operated.TheRightHandOperator Controlhas5 basicoperational functions. a. "FORWARD"-VariableSpeed Boom Down.

BOOM UP b. "BACKWARD"-VariableSpeed Boom Up. ¢. "LEFT"Variable SpeedBucketIn (Digging). d. "RIGHT"Variable SpeedBucketOut(Dump). e. "CENTER"NeutralPosition.

Leftand RightTravelLever& Pedals.

FIGURE 2.31 FIGURE 2.30 TheTravelLever& Pedalsarelocated in front of operator seat.TheyareusecIto movethe ~ LEFT HAND RIGHTHAND Leftor Righttrackof themachine either forward TRAVEL LEVER TRAVELLEVER or backward.

Thesecontrols have3 basicoperational functions.

LEFT HAND _~ ~ / RIGHTHAND a. "FORWARD"-VariableSpeed Forward TRAVEL PEDALS ~J, TRAVELPEDALS ~ Track Movement. b. "BACKWARD"-VariableSpeed Reverse TrackMovement.

FOOT ¢. "CENTER"NeutralPosition.

REST Theseoperations arewithtravelmotorsat the o o rearof themachine.

If travelmotors arepositioned in frontof themachine thefunctions of theTravelLevers willbe opposite.

FIGURE 2.31

t

2-14

Section II-MACHINE FAMILIARIZATION E°

GAUGE CLUSTER The monitordisplaysinformation sent fromsensorspositioned at variousplaceson the excavator, making it possibleto monitorthe excavator’s operating workingconditions.

KPSS WORK MODE LAMP

WATER GAUGE

TEMPERATURE

~ BATTERY

j

FUEL

LEVEL

GAUGE

CHARGE LAMP ~

ENGINE COOLANT TEMPERATURE LAMP

J

~ENGINE ~HIGH

GLOW LAMP (2nd) SPEED

ENGINE OIL PRESSURE LAMP SWING PARKING BRAKE RELEASE LAMP

"~ LOW

FUEL

WARNING

LAMP

--

~ ENGINE AIR CLEANER CLOGGING LAMP

I.T.C.SCONTROLLER CPU LAMP

OVERLOAD

ALARM

LAMP

"~-

~

’’~S

J

FIGURE 2.32

¯

i

1. Fuel Level Gauge ¯ Thisindicates the amountof remain-

F " Fulltankis about85Liter ing fuel. (22gal).

E ¯ Theremaining Fueloilis about ,# 17Liter (4gal).

~I

w,

°

Water TemperatureGauge Thisindicates thetemperature of the enginecoolant water,andoperates whenthestarter switch is turned to the"ON"position.

The temperature is normalin the whiterange.

Iftheneedle enters the redrange, lettheengine idleuntil thewatercoolsdownandtheneedle movesbackintothewhiterange.

2-15

3. KPSS Work Mode Lamp Press any of work mode selector switchesH, S, and FC on switch panel,and the selected workmode indicator lampgoeson green.

Machineis usually in S modeafter starting engine.

SUPPLEMENTARY EXPLANATION Forguideline of workmodeselector switch, seepages 3-8.

Northand SouthAmericanmodelsare designedto be in H modeafterthestart-up, andtheothersareS modestart-up.

Section II-MACHINE FAMILIARIZATION WARNING LAMPS TheBuzzer willsoundtheinstant #4,#5,#10and #11warning lampsaredisplayed.

,

4. ENGINE OIL PRESSURE LAMP Thislights whenthestarter switch should turnoffafter theengine is started.

If a problem arises inthe lubricant oilsystem while theengine isrunning, a warning lamplights.

BATTERY CHARGING LAMP Thislights whenthestarter switch is turned tothe"ON"position, and should turnoffafter theengine is started.

Thelamplights ifa problem arises inthecharging system while theengine isrunning.

Ifthishappens, havetheexcavator inspected at KOBELCO distributor.

I. .l stunedohellO ll oonaa CAUTION

.

r

Theengine mayburnif theexcavator is operated with theengine oilpressure lampon.

1. Stoptheengine andcheckthequantity of engine oil.(Refer topage4-8.)

2. Ifthecause iselsewhere, havetheexcavatorinspected at KOBELCO distributor.

,

5. ENGINE COOLANT TEMPERATURE LAMP

LOW FUEL WARNING LAMP Whenthestarter switch isturned to the"ON"position, a warning lamp lights ifthe fuel islow.

Ifthis lamp lights, please refill fuel tankimmediately.

ENGINE AIR CLEANER CLOGGING LAMP Thislampcomes oniftheaircleaner filter isclogged.

Ifthelampcomes on,cleanor replace theelement immediately.

normally (above 105°C or 221°F) warning lamplights.

1tecooa teeraurersesa I I ,

Thecoolant temperature mayriseabnormally iftheengine isrunwithanexcessive load.

I

CAUTION

Theengine mayburniftheexcavator is operated with thecoolant temperature lampon.

1. Theengine is overheating.

Stopoperation immediately andlettheengine runat low speed toletthecoolant cooldown. hascooleddown,stop 2. Oncethecoolant theengine.

3. Oncetheengine hascooled down,inspect theamount of coolant, andcheckthefan belt forbreaks orslack.

2-16

SWING PARKING BRAKE RELEASE LAMP Whenswing parking brake is notreleased duetotrouble ofelectric system,therelease indicator lampgoes on.Turnswingparking brakerelease switch to"RELEASE" position, movemachine to safeareaimmediately, andcontact ourrepresentativeorservice shopforinspection.

10. I.T.C.SCONTROLLERCPU LAMP Whencontroller equipped withvariouselectrical andhydraulic control mechanisms fail,thislampgoeson andbuzzer sounds.

Whenbeing litup,contact ourrepresentative or service shopimmediately forinspection.

I CPU

Section II-MACHINEFAMILIARIZATION 11 .OVERLOAD ALARM LAMP Thislampwilllights andtheBuzzer willsoundshould theBoomCylinderCircuit Pressure exceed theset, specified pressure.

Should thislamp lights andthebuzzer sound, immediately stopalloperation, stopengineandcontactan authorized KOBELCO Service dealerforserviceassistance.

12. ENGINE GLOW LAMP Whenthestarter switch is moved fromthe"OFF"tothe"HEAT" position,theengineoilandbattery charge lampbothturnon.

Thelamps alsolight whenthestarter switch issetto the"START" posi,tion.

2-17

13. HIGH SPEED TRAVEL LAMP Thislights whenthetravel speed is switched tohigh(2nd.) speed.

Thetravel speed selector switch is located onthegrip oftheright travel lever.

Thespeed automatically returns to low(1st.) speed whenthestarter switch issetto"OFF".

Section II-MACHINEFAMILIARIZATION F. OPERATOR CAB 1. Locking/Unlocking Cab Door UsetheKey SwitchKeyto lockor unlockcab door.InsertKeyintodoorlockandturnclockwiseto unlock or turncounterclockwise to lock cabdoor.See Figure2.33.

FIGURE 2.33

o

Cab Door Latch a. The Cab Door can be latchedin an open position by opening dooruntilit is locked openby thedoorlatchlocated on thecab.

SeeFigure2.34.

FIGURE 2.34 Releasedoorlatchby pushingrelease lever downto releasedoorfromlatch.See Figure2.35. [ PUSHINGLEVER

I OOWNTo

FIGURE 2.35

2-18

Section II-MACHINE FAMILIARIZATION C. Pullreleaselevernearside,and door opens fromtheinsideof cab.- Figure2.36

_ :___

~J~’/~

PULL BACK I RELEASELEVERI

/

3. Opening& ClosingWindshield Frontwindow(upper) canbe storedin ceiling.

±1CAUT, ON

I±

window Securely insertthelevershaftof front (upper) intothelockholeon therearroofandlockit,orthe wiperlockdoesnot function, and consequently the wipermay be damagedbecausethe wipermoves at thetimewhenthewipermotorswitchis turnedon.

a. Pulllevers on therightandleftsidesof front windowuppersectionnearsideandleversare unlocked.

SeeFigure2.37. b. Holdhandleson uppercentraland lowerleft sidesof frontwindow(upper), removethem andmovefrontwindow(upper), andafterlockingthemto locking holeson rearsideof ceiling securely, pullthemdown.

SeeFigure 2.38.

/~l

CAUTION

I/~

~ /

Special attention mustbe paidnotto injurehandsand otherswhenthefrontwindowis closed.

Thelevershafts mustbe inserted securely intotheright andleftlockholesandlockthem.

~~-"

__~___r/~~~~ "

/ /

/

Ilt

~R~

FIGURE 2.38

2-19

i

~I

Section II- MACHINE FAMILIARIZATION 4. Removing& Storing Lower Front Window a. Afterplacing upperfrontwindow in ceiling, holdlowerfrontwindowby handsand removeit fromwindowframe. b. Storethe removedlowerfrontwindowin holder on therearsideof cabsecurely.

C.

Tostoreit,insert theright andleftsides of glassin holder, andsupport it withholder on the lowersectionof windowframe.See Figure 2.39.

\ JHOLDER

IHOLO RI FIGURE 2.39

°

Openingand closingdoor glass a,Opencabdoorglass (upper) sliding ittofront sideafterunlocking it. b. Closethedoorglasssliding it to LOCKposition, thenlockit.SeeFigure 2.40.

FIGURE 2.40

2-20

Section II-MACHINE FAMILIARIZATION .

Openingand closingsunroof Pulllocks onright andleftsides inward, and sunroof opens through theaidof gasspring.

Close sunroof pulling locks inward, andlockit.

Alsotheroofcanbeleftslightly opentoventilateairincabbyplacing lock(~)section on section.

SeeFigure 2.42.

TM ~1=

fJ//

a.PullbackofSunVisor freefromfabric fastener andcarefully pullvisor fromunder Sky Light latches.

Store behind operator seat.

SeeFigure 2.43.

FIGURE2.42

FIGURE2.43 7. Cab Dome Light a. TurnCabDomeLight"ON"by movingthe DomeLight Switch totheright. b.Turn"OFF" bymoving switch totheleft.

See Figure 2.44. c. PlaceDomeLightSwitch in the"CENTER" position andthelight willbeoperated bythe doorswitch.

Whendooris opened thelight willcome"ON"andwhenthedooris closed thelight willturn "OFF".

FIGURE2.44

2-21

i

Section II-MACHINE FAMILIARIZATION .

StorageCompartment TheOperator andPartsManual Storage compartment isa pouch located onthebackofthe Operators Seat.KeeptheOperator andParts Manual forthismachine inthislocation atall timesforquick, easyreference.

SeeFigure 2.45.

FIGURE2.45 9. OPERATOR SEAT ADJUSTMENTS Theoperator seatincorporates several adjustmentmechanisms to insure operator comfort, easeofoperation andoperator safety.

Theadjustment areas areas follows: a. Operator WeightAdjustment - FIGURE2.46 1. Rotate theadjustment knobuntil weight close totheoperators weight is atthe topendofthedial.

FIGURE2.46 b. SeatHeightAdjustment - FIGURE2.47 Adjustment Lever uptoraise 1. PullHeight orlower rearofseat.

2. PushHeight Adjustment Leverdownto raise orlower front ofseat.

FIGURE2.47 c. SeatReclining AdjustmentFIGURE2.48 1. PullReclining Adjustment Leverup to setdesired reclining angle.

2. Release Reclining Adjustment Leverto lock seat inposition.

FIGURE2.48

2-22

Section II-MACHINEFAMILIARIZATION d. Seat Frontto Back Adjustment- FIGURE 2.49 1. Pullup on SeatAdjustment Bailandmove seatforward or backward to desired position.

USE BOTTOMBAILTO ADJUST CONTROL STAND

FIGURE 2.49 e.

Arm Rest Adjustment- FIGURE 2.50 1. LowerArm Restandwithfinger, turnadjustment wheeluntilArmRestis in desiredposition.

FIGURE 2.50 f.

Head Rest Adjustment- FIGURE 2.51 1. MoveHeadRestforwardor backwardto desired reclining angle.

2. Raiseor LowerHeadRest to desired height.

FIGURE 2.51

2-23

Section II-MACHINE FAMILIARIZATION g. SealBelt 1. Sitting in operator seat,bringendsof seatbeltaroundwaistand insertL.H. end intolatch(R.H.end).See Figure 2.52.

2. Adjust seatbeltuntilsnugaroundwaist bypulling looseendof beltonR.H.side See Figure2.52.

3. RemoveSeat Beltby pushingred releasebuttonon latchend.See Figure 2.53.

/

/

r ATTACH BELT ENDS L AROUND WAIST

FIGURE 2.52

WARNING RELEASE BY DEPRESSING , REDRELEASE TAB

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.

2 ~~-ii-’~

~__~~

FIGURE 2.53 G. MACHINE ACCESS PANELS & DOORS 1. Engine CoolantTank & EngineAir Cleaner Access Doors - FIGURE 2.54 Locatedon the L.H.Sideof the machinethe EngineCoolantTankAccessDoorallowsaccessto theEngineCoolant Tank.It alsoholds the EngineAir CleanerAccessDoorclosed.

Use theKeySwitchKeyto lockandunlockthe EngineCoolantAccessDoor.

FIGURE 2.54 2.Main Pump Access Door - FIGURE 2.55 Locateon theR.H.Sideof themachine thisdoor allowsaccessto the MainPump.

FIGURE 2.55

2-24

Section II-MACHINE FAMILIARIZATION .

BatteryBox AccessCover - FIGURE 2.56 Locatedon the R.H.Frontof the upperframe thiscoverallowsaccessto thebatteries and battery relay.

Thisaccesscoveris alsolocked and unlockedby Key SwitchKey. Usestayto leavethecoveropen.

"ccE FIGURE 2.56

°

Fuel cap- FIGURE 2.57 Stopengine,openbatterycover,and remove capon fueltank,thenmakeit up withfuelseeinglevelofgauge.

IIFUEL CAP

FIGURE 2.57 5. Engine Cover- FIGURE 2.58 Openenginecoverwithkeyswitchafterstoppingengine.

Usestayto support it.

FIGURE 2.58

2-25

Section III-BASIC MACHINE OPERATION Tableof Contents

3-1 PRE-START CHECK .....................................................................................

3-1 STARTING & STOPPING MACHINE ENGINE ABOVE 0°C(32°F) ..........................................................

Starting Engine ..................................................................................

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

Emergency Engine Shut Down ...........................................................................

3-1 3-2 STARTING & STOPPING MACHINE ENGINE BELOW 0°C(32°F) ..........................................................

Starting Engine ..................................................................................

3-2 3-2 Stopping Engine ..................................................................................

Emergency Engine Shut Down ...........................................................................

3-2 3-3- 3-4 STARTING MACHINE WITH BOOSTER CABLES ......................................................................

Connecting Booster Cables ............................................................................

3-3 3-4 Starting Disabled Machine ............................................................................

3-4 Disconnecting Booster Cables ..........................................................................

3-5 MACHINE WARM-UP .....................................................................................

3-5 Engine ......................................................................................

3-5 Hydraulic Oil ...................................................................................

3-5 Hydraulic OilinFrigid Temperatures ......................................................................

3-6 CONTROLS DECAL .....................................................................................

3-6 Operating Pattern .................................................................................

3-6 Operating Pattern Decal .............................................................................

3-7- 3-13 BASIC OPERATION OFHYDRAULIC CONTROLS .....................................................................

3-7 Safety Lock Lever .................................................................................

3-8 KPSS(KOBELCO Power Sensing System) ModeSwitch ...........................................................

3-9- 3-11 Machine Travel Controls .............................................................................

3-12~ 3-13 Machine Attachment & Swing Controls .....................................................................

3-13 Using Auto-accel .................................................................................

3-14- 3-15 PRACTICES TOIMPROVE EFFICIENCY ..........................................................................

3-15 OPERATING THE SHOVEL ..................................................................................

3-16 MACHINE OPERATION INADVERSE WEATHER ......................................................................

3-17 ~ 3-22 FLAGMAN HAND SIGNALS .................................................................................

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS,

3-0

Section III- BASIC MACHINE OPERATION 3.1 PRE-STARTCHECK Perform Pre-Start Inspection andMaintenance procedures before starting themachine.

Refer to the Maintenance Section ofthismanual forspecific instructions.

3.2STARTING & STOPPINGMACHINE ENGINE WITH TEMPERATUREABOVE 0°C (32°F) A. STARTINGENGINE Control to "LO"position.

See 1.MoveThrottle Figure 3.1 KeyintoKeySwitch andturntothe"ON" 2. Insert position.

SeeFigure 3.1. thatthemachine 3.Soundhornto warnpersonnel isbeing started.

SeeFigure 3.2.

4.TurnKeyto the"START" position andrelease assoonasengine starts.

Keywillautomatically return tothe"ON"position.

" FIGURE3.1

CAUTION Release keyafter30seconds of cranking ifengine doesnotstart.

Waitatleast 2 minutes before attempting tostart engine again toallow starter motor tocool.

FIGURE3.2 NOTE: Ifengine fails tostart after 3 attempts, inspect fuel systemandcorrect anyproblems found.

Whencranking engine, theabsence of "Blue" or "White" smoke fromtheexhaust indicates no fuelisreaching the engine cylinders.

MACHINE ON FIRM, LEVELSURFACE

B. STOPPING ENGINE- NORMAL CONDITIONS 1.Movemachine toa firm,level areaandplace theattachment intheHydraulic OilCheck Position.

SeeFigure 3.3.

Control to "LO"Position.

See 2.MoveThrottle Figure 3.1.Allow engine toidlefor5 minutes.

3.TurnKeySwitch to "OFF".

C°

EMERGENCY ENGINE SHUT DOWN In onlycasesof emergency should thismethod be used.

1.TurnKeySwitch to the"OFF" position.

2.PullouttheEngine Emergency StopControl located onthelower R.H.sideofcontrol stand until Engine stops.

SeeFigure 3.4.

3.Before restarting engine, pushEmergency EngineStopControl in.

3-1

~

~ FIGURE3.3

FIGURE3.4

ATTACHMENT IN HYDRAULIC OIL ECK POSITION

Section III- BASIC MACHINE OPERATION 3.3STARTING & STOPPINGMACHINE ENGINE WITH TEMPERATUREBELOW 0°C (32°F) A. STARTINGENGINE 1.MoveThrottle Control to"LO"position.

See Figure 3.5.

2.Turnthekeyswitch to "HEAT" andpreheat for 30 seconds tomakestart-up easier.

See Figure 3.6. hornto warnpersonnel thatthemachine 3. Sound isbeing started.

SeeFigure 3.7.

4.TurnKeytothe"START" position andrelease assoonasengine starts.

Keywillautomatically return tothe"ON"position.

FIGURE3.5 1 KEY IN "HEAT" POSITION I FOR 30 SECONDS

I

CAUTION

I/’

/--

/"

Release keyafter 30seconds of cranking if engine doesnotstart.

Waitatleast 2 minutes before attempting tostart engine again toallow starter motor tocool.

GLOW

LAMP

FIGURE3.6 NOTE Ifengine fails tostart after 3 attempts, inspect fuel systemandcorrect anyproblems found.

Whencranking engine, theabsence of "Blue" or "White" smoke fromtheexhaust indicates nofuelisreaching the engine cylinders.

B. STOPPING ENGINE- NORMAL CONDITIONS 1.Movemachine to a firm, level areaandplace theattachment intheHydraulic OilCheck Position.

SeeFigure 3.8.

2.MoveThrottle Control to "LO"Position.

See Figure 3.5.Allow engine toidlefor5 minutes.

3.TurnKeySwitch to "OFF".

i MACHINE ON FIRM, LEVEL SURFACE

C. EMERGENCY ENGINE SHUT DOWN In onlycasesof emergency should thismethod be used.

1.TurnKeySwitch tothe"OFF" position.

2.PullouttheEngine Emergency StopControl located onthelower R.H.sideof control stand until engine stops.

SeeFigure 3.9.

3.Before attempting torestart theengine, push Emergency Engine StopControl in.

FIGURE3.7 ~

~ FIGURE3.8

ENGINE STOPI !

CONTROL I.,,

FIGURE3.9

3-2

ATTACHMENT IN HYDRAULIC OIL HECK POSITION

Section III-BASIC MACHINE OPERATION KEYSWITCH POSITIONS

3.4STARTING MACHINE ENGINE WITH BOOSTER CABLES A. CONNECTING BOOSTER CABLES 1.Movevehicle or machine to be usedforboostingasclose tothebattery boxofthedisabled machine as possible.

WARNING DO NOT ALLOW THE VEHICLE OR MACHINE USED FOR BOOSTING TO TOUCH METAL TO METAL WITH THE DISABLEDMACHINE.THIS COULD SHORT CIRCUIT ELECTRICAL SYSTEMS AND CAUSE EXTENSIVE DAMAGE TO THE CPU AND OTHER COMPONENTS.

Q

CAUTION

FIGURE3.10

Useonlyvehicles or machines with24VDC electrical system forboost starting thismachine.

KeySwitch of disabled machine 2. Makecertain isinthe"OFF" position before proceeding with booster cableconnection.

SeeFigure 3.10.

WEAR HARD HAT, APPROVED SAFETY GLASSES OR FACE SHIELD, GLOVES AND OTHER SAFETY EQUIPMENT WHEN WORKING WITH BATTERIES. andconnect oneendof thebooster cable 3,Locate tothePositive (+)terminal onthebattery ofthe disabled machine.

SeeFigure 3.11.

4.Connect other endof positive booster cable to positive (+)terminal ofbattery being usedfor boosting. andconnect second cableto theNega5. Locate tive(-)terminal ofthebattery being usedfor boosting. other endofNegative (-)cable tothe 6. Connect upperframeof disabled machine as faraway frombattery aspossible.

SeeFigure 3.12.

FIGURE3.11

WARNING THE NEGATIVE CABLE, WHEN CONNECTED TO THE UPPER FRAME OF DISABLED MACHINE, MAY ARC CAUSING SPARKS. SPARKS COMING IN CONTACT WITH BATTERIES, COULD TRIGGER AN EXPLOSION. NEVER CONNECT NEGATIVE CABLE TO NEGATIVE(-)TERMINALOF DISABLEDBATTERY.

FIGURE3.12

3-3

Section III-BASIC MACHINE OPERATION B. STARTING BOOSTING MACHINE ENGINE 1.Start engine of boosting machine in normal manner according toclimate conditions.

Refer topages 3-1& 3-2forspecific starting instructions.

2. Allow fiveminutes or moretoprovide partial charge tothedischarged batteries.

C. STARTING DISABLED MACHINE ENGINE 1.Start engine of disabled machine innormal manner according toclimate conditions.

Refer topages 3-1& 3-2forspecific starting instructions.

D. DISCONNECTING BOOSTER CABLES 1.After disabled machine engine is running, disconnect theNegative(-) Cable fromdisabled machine upperframe.

SeeFigure 3.13.

2.Disconnect Negative(-) Cable fromBattery used forboosting.

Positive(+) Cable frombattery used 3. Disconnect forboosting.

4.Disconnect Positive(+) Cable fromterminal disabled machine.

SeeFigure 3.14.

FIGURE3.13

CAUTION WhenusingBooster Cablesremember; 1.Connect Positive (+)Cable First.

2.Disconnect Negative (-)Cable First fromframe disabled machine.

FIGURE3.14

3-4

Section III- BASIC MACHINE OPERATION 3.5MACHINE WARM UP A. ENGINE 1.Allow theengine to runfor5 minutes under no loadconditions withThrottle Control at"LO" idleposition.

SeeFigure 3.15.

2.During warmup,visually andaudibly inspect engine forabnormal conditions suchasunusual exhaust color, excessive vibrations andexcessiveorunusual noises. problem areasbenoticed, stopengine, 3.Should locate andrepair problem areas before restart -ingoroperating themachine.

B. HYDRAULICOIL machine untiltheColdHydrau1.Do notoperate licOilIndicator Lampisout.SeeFigure 3.15.

2.MoveThrottle Control to"HI"idleposition.

Bucket inandholdoverrelief for10to 3.Operate 15 seconds, thenoperate bucket outandhold overrelief for10to15seconds.

Repeat thisoperation for5 to10minutes tohelpoiltoreach operating temperature.

SeeFigure 3.17.

Control toMidposition andoper4.MoveThrottle atetheBoom, ArmandSwingcontrols for5 to 10 minutes each.SeeFigure 3.18.

5.WhentheColdHydraulic OilIndicator Lampis out,normal machine operations maybegin.

I

RUN ENGINE 5 MINUTES WITH I THROTTLEIN "LO" IDLE POSITION

I

HYDRAULIC OIL INDICATOR LAMP

FIGURE3.15

BUCKET IN

C. HYDRAULIC OIL IN FRIGID TEMPERATURES 1.Perform normal Hydraulic OilWarm-Up procedures.

Perform these until Indicator Lampisout.

Warm-Up timewilltakelonger infrigid temperatures.

NOTE Ifmachine isoperated infrigid temperatures daily, itmay be necessary to change theHydraulic Oilto an oildesigned foroperation infrigid climates.

Refer tomaintenance section forhydraulic oilspecifications.

I

R.H. CONTROL LEVER

FIGURE3.17 Loll.CONTROLLEVER

ARM OUT

SWING LEFT

CAUTION

RIGHT

Inoperating themachine withcoldhydraulic oil,the operator mayexperience slowor unexpected movement of functions.

Damage to Hydraulic components mayresult dueto thecoldoilnotproviding adequate lubrication.

FIGURE3.18

3-5

SectionIII- BASICMACHINEOPERATION 3.6CONTROLS DECAL A. OPERATING PATTERN TheOperating andTravel Controls ofthismachine arefactory settoISOstandard operating patterns foroptimum performance of themachine andits systems.

window inside theOperator Cab.Study thisdecal andunderstand thedirections eachcontrol can be operated andthefunctions associated with eachmovement of particular control.

Detailed instructions foreachcontrol anditsfunctions are explained onthefollowing pages ofthissection.

Should thisdecalbecome damaged or missing, install newdecalKOBELCO PartNumber YN20T01089P1

B. OPERATING PATTERN DECAL Figure 3.19isa representation ofthe "CONTROLS" Decallocated on theR.H.Side

CONTROLS

LEFT CONTROL LEVER

O

LEFT TRAVEL LEVER AND PEDAL

RIGHT TRAVEL LEVER AND PEDAL

RIGHT CONTROL LEVER

O

O

0 0

@ FIGURE3.19

3-6

Section III-BASIC MACHINE OPERATION 3.7BASIC OPERATION OF HYDRAULIC CONTROLS Thefollowing instructions areaimed at providing an operator withthebasic function ofeachhydraulic control.

Useofthese instructions, andpractice witha machine, willallowa given operator to become more efficient intheoperation ofthisequipment.

Eachoperator mustread, understand andfollow these basic instructions along withallsafety precautions foundin thismanual andon themachine before operating thisequipment.

WARNING NORMAL POSITIONING OF THE MACHINE FOR THE SAKE OF DETERMININGFRONT, REAR, FORWARD AND REVERSE ARE WITH THE TRAVEL MOTORS LOCATED AT THE BACK OF THE MACHINE.SEE FIGURE3.20.

ALWAYS KNOW THE LOCATION OF TRAVEL MOTORS BEFORE OPERATING ANY HYDRAULIC CONTROLS.

FIGURE3.20

A. SAFETY LOCK LEVER- FIGURE 3.21 1. Unlocked Position Before anyHydraulic Operation is possible the Safety LockLevermustbeplaced in the "UNLOCKED" (DOWN)position.

Placing the SafetyLockLeverin the UNLOCKED (DOWN) position alsopositions theL.H.Operators Consoleinitsoperating position.

2. Locked Position Before leaving theoperator cab,place the Safety LockLever in the"LOCKED" position by pulling lever up.WithSafety LockLever inthe "LOCKED" (UP)Position, no hydraulic operationis possible andallows easyaccess inand outoftheoperator seat.

(DOWN) POSITION

WARNING ALWAYS PLACE THE SAFETY LOCK LEVER IN THE "LOCKED"(UP) POSITIONBEFORE LEAVING CAB TO PREVENT ANY OPERATION OF HYDRAULIC CONTROLS. FAILURE TO PLACE SAFETY LOCK LEVER IN THE LOCKED (UP) POSITIONCOULD RESULT SERIOUS INJURY OR DEATH AS WELL AS SERIOUS DAMAGE TO THE MACHINE AND ITS COMPONENTS.

FIGURE3.21

3-7

Section III- BASIC MACHINE OPERATION B. KPSS

(KOBELCO SWITCH

MODE

POWER

SENSING

SYSTEM) ~,~

Beforeselectinga machinework mode, the operatorshouldalwaysstudyeach job site to answer some basic questions.

1. Is the machinecapableof performingthe particular job?

2. What attachment (bucket)is best suitedfor the

KPSS SWITCH J

SE,Ecr

job?

3. What type of materialwill the machinebe excavating?

4. What operating mode is bestsuitedfor the job?

@

1. KPSS WORK MODE FUNCTIONS- FIGURE 3.22 a. The KPSS Work mode switch allows the opera-

KPSS POSITIONS

tion selectand controlthe operation of the machineand the attachment effectively for a particular job by selecting one of threepositions.

FIGURE 3.22 1. "H" Mode-

Provides Maximum Speed and PowerFor DiggingOperations.

2. "S" Mode-

Provides Standard Power and Best Fuel Consumption.

3. "FC" Mode- AllowsFine Controlof Hydraulic Functions for Attachment.

Selectthe KPSS Work Mode best Suitedfor the particular jobat hand.

KPSS

WORK

MODE

SELECTION

TABLE

.

The KPSS Work Mode Selection Table gives examples of Work Types, Work Requirements and MaterialsBeingExcavated.Use this table when decidingthe KPSS Work Mode best suited for thespecific jobat hand.

KPSS

I

WORK

DIGGING

WORK TYPE

MODE

SELECTION

TABLE

LOADING CORRECTIONREFILLING& CRUSHING CORRECTION i

3,2;., 23

REQUIREMENTS JWORK MATERIAL SOFT VISCOUSSOIL

mmm mmmm

m

FC

H

S

FC FC FC FC

FC

LOOSE SANDY SOIL

H

S

FC

H

S

FC FC FC FC

TIGHT SANDY SOIL

H

S

FC

H

S

FC S

FC FC

GRAVEL & STONE

H

H

S

H

H

S

S

S

FC

TIGHTGRAVEL/ MIXEDSOIL H

H

S

H

H

S

H

H

S

H

H

H

H

H

H

H

H

H

S

FlatLand"S"

FC H

SOFT STONE

H

TRANSFER

Slope& Long Distance Travel "H" Loading& Unloading etc."FC"

WORKREQUIREMENTS.l= LargeVolumes at FastSpeed¯ 2= NormalWork,LessFuel° 3= FineControl of Attachment

3-8

Section III- BASIC MACHINE OPERATION C. MACHINE TRAVEL CONTROLS Thismachine incorporates several Travel Controls fortheconvenience oftheoperator.

Eachtrack canbe operated independently to turnthemachine orsimultaneously tospinturn themachine orto travel straight.

1. Operating BothTravel LeversTogether a.PushbothTravel Levers toward front ofmachineandmachine willtravel "FORWARD".

SeeFigure 3.23. b.PullBothTravel Levers toward operator seat andmachine willtravel in "REVERSE".

See Figure 3.24. c. Return bothTravel Levers to "NEUTRAL" (center) position andmachine willstop.

ParkingBrakes areautomatically applied when Travel Levers areinNeutral position.

FIGURE3.23

NOTE Thedistance Travel Levers arePushed or Pulled determinesTravel Speedof theMachine.

EXAMPLE: Travel Levers arepulled or pushed to full strokeMachine willTravel at topspeed.

Travel Levers arepulled orpushed to mid PositionMachine willTravel at1/2speed.

2. Useof Travel SpeedSelect Switch a. Forfasttravel speed, depress andrelease theTravel SpeedSelect Switch oncebefore operating thetravel controls.

SeeFigure 3.25.

Thisputsthetravel motors in "FAST"(~Ib) travel speed andthelampfor"FAST"(~I~,), theGauge Cluster Display, willcomeon. b.Toreturn to"SLOW" travel speed, stoptravel anddepress andrelease Travel SpeedSelectSwitch once.

SeeFigure 3.25.

FIGURE3.24

,~

.ow

SELECT SWITCH

CAUTION Use"FAST"(J~) Travel Speedon Firm,Level Surfaces Only.

FIGURE3.25

3-9

PRESS HERE FOR "FAST" &

Section III-BASIC MACHINE OPERATION 3. Turning Machine a.PushtheL.H.Travel Lever toward front of machine to turnmachine RIGHTin Forward Motion.

SeeFigure 3.26. b.PulltheL.H.Travel Lever backtoward operator seattoturnmachine totheLEFTin reverse motion. c.PushtheR.H.Travel Lever toward front of machine to turnmachine totheLEFTinforwardmotion.

SeeFigure 3.27. d.PullR.H.Travel Lever toward operator seat toturnmachine to theRIGHT inreverse motion.

FIGURE3.26

4. Spinning Machine a. PullL.H,Travel LeverBACKandPushR.H. TravelLeverFORWARD to spinmachine to theLEFT.SeeFigure 3.26. b. PullR.H.Travel LeverBACKandPushL.H. TravelLeverFORWARD to spinmachine to theRIGHT. SeeFigure 3.29.

NOTE Allthefunctions explained withuseofTravel Levers can alsobe performed usingtheTravel Pedals.

FIGURE3.27

CAUTION 1.Depending on Shoetypeandground conditions this machine ° hasa maximumclimbing ability of 35 (70%)Maximum.

2.Whenapproaching or descending a slope, operate theTravel Slowly.

3.ForBraking, slowly return Travel Levers orpedals to theNeutral (center) position.

Brakes areengaged automatically.

4.Thetravel operation for2 hours or moremaycause thefailure oftravel motor detotheriseofoperating temperature.

Donottavel itfor2 hours ormore.

5.Inextremely coldconditions, below -20°C (-4°F), the Travel Lever or Pedal action maybe"heavier" than normal.

Thisis normal dueto theviscosity of the Hydraulic OilinFrigid Climates.

FIGURE3.28

FIGURE3.29

3-10

SectionIII- BASIC MACHINEOPERATION 5. Travel Safety a.Makecertain Travel Motor Location is known before performing anytravel operation. b.Travel onfirm, level surfaces as muchas possible. ¢. WhenTraveling onrough terrain, travel in SLOWspeedwithengine at a lowidle. d. Whentraveling or operating machine on snoworicysurfaces, clean track shoes frequently toprevent clogging.

Thiswill helpkeepthemachine fromsliding unexpectedly. e.Keepa safedistance fromstationary objects andelectrical power lines. f. Be awareof LoadCapacities of bridges androadshoulders.

Reinforce ifnecessary. g.Usedecking or plating toprotect road surfaces asmuchas possible.

Becareful whenturning or spinning machine on asphalt pavement. h.Do notallow large orheavy objects to strike travel motors. i. DonotTravel overlargeobjects suchas boulders rocks etc. j. Ifnecessary to travel or operate machine ina river orother water, thebedmustbe firmandwatercurrent slow.WaterMUST NOT BE DEEPERTHAN540 mm (1 ’-9").

SeeFigure 3.30.

NOTE If themachine is operated whiletheswingbearing is submerged inwater, thentheswing bearing, swing pinion, andtheswivil jointma wearoutprematurely.

Immedite replacement of grease in grease bathandoverhaul of theswingbearing is required.

SeeMaintenance Section.

k°

On softground or mudthemachine can slowly sink.

Stayconstantly aware of undercarriage position.

3-11

BED MUST BE FIRM & STABLE

FIGURE3.30

Section III- BASIC MACHINE OPERATION D. MACHINE ATTACHMENT & SWING CONTROLS Thefollowing instructions forOperation of AttachmentControls areforusewithHoeBucketattachment.If otherattachments arebeingused,consulttheOperators Manual fortheparticular attachment.

PULL BACKBOOM UP

PUSH FORWARDBOOM DOWN

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS DURING ALL OPERATIONS OF THIS MACHINE AND ITS ATTACHMENT. 1. Boom Operation-FIGURE 3.31 a. Operation of theBoomis performed by pushingandpulling theR.H.Control LeverForwardand Backward.BoomSpeedis determinedby howfartheLeveris activated.

1.PullingR.H.ControlLeverBACKraises Boom.

2.PushingR.H. ControlLever FORWARD lowersBoom.

3. Returning R.H.Control Leverto theNeutral(center) position stopsoperation the Boom.

2. Arm Operation-FIGURE3.32 a. Operation of theArmis performed by pushingor pulling theL.H.Control LeverForward and Backward.Arm Speedis determined by howfartheLeverisactivated. the L.H.Control Lever 1. Pushing FORWARD moves the Arm out.

2.Pullingthe L.H.ControlLeverBACK movesthe Arm in.

3.Returning theL.H.Control Leverto the Neutral (center) position, stopsoperation of theArm. 3. BucketOperation-FIGURE3.33 a. Operation of theBucket is performed by movingtheR.H.Control Leverto theRightor Left.

1.MovingtheR.H.Control Leverto theLEFT operates theBucketIN (digging).

2. MovingtheR.H.Control Leverto the RIGHToperatesthe BucketOUT (dumping).

FIGURE 3.31

PULL BACKARM IN

PUSH FORWARDARM OUT

FIGURE 3.32

PULL LEFTBUCKETIN I

PUSH RIGHTBUCKET OUT

FIGURE 3.33

WARNING BE CAREFUL WHEN OPERATING CERTAIN ATTACHMENTS CLOSE TO TEH CAB. CERTAIN ATTACHMENTS CAN HIT AND DAMAGE CAB. STOP ATTACHMENT A SAFE DISTANCE AWAY FROM CAB TO AVOID DAMAGE OR INJURY.

3-12

SectionIII- BASIC MACHINEOPERATION 4. SwingOperationFIGURE3.34 a. Swingoperation is performed by moving the L.H.Control lever totheright andleft.

Swing speedisdetermined by theamount thelever is moved.

1.Moving theL.H.Control Lever to theLEFT swings themachine totheleft.

2.Moving theL.H.Control Lever totheRIGHT swings themachine to theright. control totheNeutral (center) 3. Returning position stops swing.

PUSH LEFT SWING LEFT

WARNING

FIGURE3.34

MAKE CERTAIN AREA IS CLEAR OF OBSTACLES AND PERSONS BEFORE BEGINNING SWING OPERATION OF THE MACHINE .SOUND HORN BEFORE BEGINNING SWING OPERATIONS.

LEFT CONTROL LEVER ] I RIGHT CONTROL LEVER

E. USING AUTO-ACCEL Theengine isturned automatically totheidling condition whenthelever isplaced ontheneutralposition.

And,theengine speed israised in proportion to thelever anglewhenreturning, consequently thefineoperaration ismadeeasy resulting in thelowfuelconsumption andlow noise.

Autoacceloperation andcontrol 1. Whenthepilot secondary pressure foroperatingpedalisnotgenerated for4 seconds during working, iftheaccel dialposition is setto1050rpm orhigher, theautoaccel functionactsautomatically andtheengine speed returns to 1050rpm.

2.Whentheaccel dial setposition issettoauto accelspeedor lower, thespeedis maintained totheaccel dialsetspeed.

Autoacceloperation andcontrol Operate attachment, slowing andtravel control levers, andthespeed gradually returns to the accel dialsetposition withtheoperation.

BLADE CONTROL LEVER IS UNAVAILABLE FOR AUTO ACCEL RELEASING.

PULL RIGHT SWING RIGHT

I

THROTTLE POTENTIOMETER

FIGURE3.35

NOTE Operation andcontrol of autoaccel during working, when thepressure oftheremote control forcontrol lever and pedal doesnotactfor4 seconds, iftheaccel dial position is setover1050rpm or more,theautoaccelactuates automatically to maintain theengine speed in 1050rpm.

3-13

Section III-BASIC MACHINE OPERATION 3.8 PRACTICESTO IMPROVE EFFICIENCY USE ARM IN ACTION AS MUCH AS POSSIBLE

A. Use ArmIn Action-FIGURE3.36 Operate thebucket at shallow depths andusethe ArminAction tofillthebucket.

Setting the bucket toodeepwilldecrease themachine’s efficiency.

FIGURE3.36 B. OperateBoom Smoothly-FIGURE3.37 Always beginandendBoomOperation slowly with smooth, careful movement of thecontrol lever.

Do notperform sudden starts andstopsof theboom as thiscreates unnecessary stress onthemachine anditscomponents.

OPERATE BOOM SMOOTHLY DURING ALL BOOM OPERATIONS

FIGURE3.37 C. BucketTeethDirectionFIGURE3.38 Always point bucket teeth inthedirection themachine willbedigging toreduce digging resistance andthepossibility ofbucket teeth damage.

ALWAYS POINT BUCKET TEETH IN DIRECTION OF DIGGING

o 1"--~

FIGURE3.38 3.39 D. MaximumDiggingForcePosition-FIGURE Theattachment willprovide maximum digging force whentheArmandBoomareat90° - 110 ° of eachother.

MAXIMUM DIGGING FORCE IS OBTAINED WITH BOOM AND ARM AT 90° ~ 110° OF EACH OTHER

FIGURE3.39

3-14

Section III- BASIC MACHINE OPERATION E.Cleaning Sand& SoilfromBucketFIGURE3.40 Operate Armto a nearlevel position andbring thebucket to a dumping position.

Ifsandandsoil donotfallout,movethebucket lever backand forth a fewtimes.

OPERATE BUCKET IN & OUT WITH ARM OUT TO DISLODGE MATERIAL FROM BUCKET

CAUTION Avoid shaking outsoilusing shocks at theendof the bucket cylinder stroke.

F.StopSwingMotionEarly-FIGURE3.41 Tostopswing action, release theswing lever beforeyougettoyourfinal point ofdigging ordumping.

FIGURE3.40 RELEASE SWING BEFORE REACHING DESIRED DIGGINGPOSITION

G. BackFilling & LevelingFIGURE3.42 Forbackfilling andleveling workafter digging, movethebucket backandforth horizontally.

NOTE Do notpushorpullmaterial withthebucket likea bulldozer whenusing themachine to level material.

FIGURE3.41 1.Inleveling ground toward machine, pullthearm gently, liftthebooma little andwhenthearm haspassed thevertical point, lower theboom gently andmanipulate themachine so the bucket moveshorizontally. ground awayfrommachine, reverse 2.Forleveling operation instep1 above.

3.In theaboveoperation, bucket motion maybe usedtogether withtheboom.

Bycontrolling the action oftheboomworklever, youcandiga slopelike, slope facing operation.

4.Never travel withattachment touching the ground.

Severe structural damage could occur.

USE ARM TO MOVE BUCKET HORIZONTALLY FOR LEVELING

FIGURE3.42 Operating the Shovel-FIGURE3.43 Digging withtheshovel differs slightly fromdiggingwithbackhoe.

1. Using thearmcylinder, scrape theground. theground at2o-3 ° toimprove draining 2. Scrape in areas nearthegroundwater level. notto bumpthereversed bucket 3.Be careful intothecab.

4.Theexcavating power during shovel operations is lessthanthatduring backhoe operations.

5.Ifmachine bucket isequipped witha lifting eye,check tomakesurethattheeyewillclear armwithbucket cylinder infullextended (full dump) position.

3-15

GRADE AT 2 ~ 3° SLOPE FOR DRAINAGE

t FIGURE3.43

Section III- BASIC MACHINE OPERATION I. MACHINE OPERATIONIN ADVERSE WEATHER CONDITIONS 1. Operation in Extreme Cold a. Follow procedures on page3-2as Starting engine maybedifficult duetoextremely cold temperatures. b. UseanEngine Oil,Hydraulic OilandFuel Oildesigned foruseincoldclimates.

Also, keepbattery fully charged. c. Makecertain to perform Machine Warm-Up procedures as described on page3-5topreventpremature wearor damage to pumps, motors andothercomponents.

NOTE In extremely frigid climates, covering theradiator is a method to aidthemachine warm-up.

Ifnecessary to maintainoperation temperatures, cover partof theradiator.

However, keepa closewatchon theTemperature Gauge andOilPressure Gauges during operation. d. Makecertain thattheEngineCoolant mixture issufficient tokeepthemachine safe.

Take intoconsideration windchill factors when mixing Coolant ratios.

NOTE MixCoolant toa protection temperature of5°0(9°F) lower thanthemachine willexperience during operation, storageortransport. e. KeepBattery Terminals freeoficeandsnow.

Iceandsnowcould causetheterminals to short circuit andcause extensive damage to themachine systems.

ChecktheBattery Electrolyte (acid) level frequently andfill necessary withdistilled water.

Ifthemachine will beleftoutside overnight, itisrecommended to remove thebatteries andstorein a warmarea.

2. Operation in Extreme Heat a.UseanEngine Oil,Hydraulic OilandFuelOil designed forusein hotclimates.

Also, keep Battery fully charged. b.Clean Radiator, OilCooler andDebris Screen oftentoprevent damage or overheating of themachine.

±l

I±l

Do notallowDirtandDebris to accumulate intheI Radiator Fins,OilCooler Finsor Debris Screen.

I I

3-16

c.KeepallBelts properly tensioned. d. Makecertain thattheEngine Coolant mixtureissufficient tokeepthemachine safe. e.If themachine becomes overheated, idlethe machine to helpcooltheengine, turnengine "OFF" andcheck Coolant level.

After filling toproper level themachine continues toover heat, stopengine, allow tocool, drain and flush entire cooling system andrefill withthe proper mixture offresh, clean coolant. f.Check theBattery electrolyte (acid) level frequently andfillasnecessary withdistilled water. g.Keepwatch on theTemperature andOilPressureGauges during operation.

Avoidunnecessary lowspeedrunning of theengine duringoperation.

During slow, ornoworkperiods,place throttle control in"LO" Idleposition.

2. Operation in HighAltitudes a.Duetolowatmospheric pressure athighaltitudes, a decrease inengine power willbeexperienced.

Be aware of thisfactwhenplacingmachine under heavy loadinhighaltitudeclimates. b. Keepclosewatchon theEngine TemperatureGauge toavoid overheating of theengine.

3. Operation in SandyandDustyareas. a.ChecktheEngine AirCleaner Elements Frequently inSandy orDusty conditions. b.WhenAirCleaner Restriction lampislit, Change Filters immediately regardless of time intervals. c.Sevice FuelFilter, Water Separator, andall Hydraulic Filters frequently.

4. Operation at Seashore or SaltyClimate a.Thoroughly washmachine daily tohelpavoid corrosion of machined areas electrical components andcylinder rods. b. Frequently check allmounting hardware for proper tightness.

Torque toproper value to aidinpreventing saltfromentering themachinesystems.

5. Operation in HumidClimate a.InClimates withhighhumidity, thoroughly washthemachine daily andcoatallbare surfaces withanoilbased lubricant tohelp prevent corrosion.

Section III-BASICMACHINE OPERATION 3.9 FLAGMAN HAND SIGNALS Thefollowing is a compilation of theHandSignals to be usedwhena flagmanis required for Excavator Operation.

Allpersonnel associated withtheoperationof theexcavator shouldknowthesesignals and theirmeaning beforeattempting to operate thismachine.

t

A. RAISE LOAD VERTICALLY FaceMachine Operator, raiserightforearm vertical, withindexfingerpointing up andmovehand in a smallcircular motion.

SeeFigure 3.44.

FIGURE 3.44 B. LOWER LOAD VERTICALLY FaceMachineOperator, extendrightarm down, pointindexfingerdownandmovehandin a small circular motion.

SeeFigure3.45.

FIGURE 3.45 C. MOVE LOAD IN HORIZONTALLY FaceMachineOperator, extendrightarm toward operator withhandfacingoperator andmovehand in direction of movement required.

SeeFigure 3.46.

FIGURE 3.46 D. MOVE LOAD OUT HORIZONTALLY FaceMachineOperator, extendrightarm toward operator withbackof handfacingoperator and movehandin direction of movement required.

See Figure 3.47.

FIGURE 3.47

3-17

Section III-BASICMACHINE OPERATION E. RAISE BOOM FaceMachineOperator, extendrightarmout horizontally fromshoulder, makea fistwiththumb up.SeeFigure3.48.

t

FIGURE 3.48 F. LOWER BOOM FaceMachineOperator, extendrightarm out horizontally fromshoulder, makea fistwiththumb down.See Figure3.49.

FIGURE 3.49 G. SWING LEFT FaceMachine Operator, extendrightarmouthorizontally fromshoulder, makea fistwithindexfingerpointing in swingdirection.

SeeFigure 3.50.

FIGURE 3.50 H. SWING RIGHT FaceMachine Operator, extendleftarmouthorizontally fromshoulder, makea fistwithindexfingerpointing in swingdirection.

SeeFigure 3.51.

FIGURE 3.51

3-18

SectionIII- BASIC MACHINEOPERATION I. ARM IN FaceMachineOperator, bendat elbowswitharms facingoperator, makefistsandpointthumbsin towardeachother.SeeFigure3.52.

FIGURE 3.52 J. ARM OUT FaceMachineOperator, bendat elbowswitharms facingoperator, makefistsandpointthumbsout awayfromeachother.SeeFigure3.53.

FIGURE 3.53 K. COUNTER ROTATE LEFT FaceMachineOperator, placerighthandon top ofhardhat,bendleftarmat elbowto theright, makea fistwithlefthandwithindexfinger pointing outandrotate handin a reverse circular motion.

See Figure3.54.

FIGURE 3.54 L. COUNTER ROTATE RIGHT FaceMachineOperator, placelefthandon top ofhardhat,bendrightarmat elbowto theleft, makea fistwithrighthandwithindexfinger pointing outandrotate handin a forward circular motion.

See Figure3.55.

FIGURE 3.55

3-19

Section III-BASIC MACHINE OPERATION M. TRAVEL FORWARD FaceMachine Operator, bendbothelbows in, makefists androtate fists oneovertheother ina reverse circular motion.

SeeFigure 3.56.

N. TRAVEL REVERSE FaceMachine Operator, bendbothelbows in, makefists androtate fists oneovertheother ina forward circular motion.

SeeFigure 3.57.

i

FIGURE3.57 O. CLOSE BUCKET (BUCKET IN OR DIG) FaceMachine Operator, holdlefthandin,closed andstationary, holdright handin,makea fistwith index finger pointing toward lefthandandmove right handina small reverse circular motion.

See Figure 3.58.

J FIGURE3.58 P.OPEN BUCKET (BUCKET OUT OR DUMP) FaceMachine Operator, holdlefthandin,open andstationary, holdright handin,make a fistwith index finger pointing toward lefthandandmove right handina small forward circular motion.

See Figure 3.59.

FIGURE3.59

3-20

Section III-BASIC MACHINE OPERATION Q. TURN LEFT FaceMachineOperator, raiserightforearm up, makefistwithrighthandandholdstationary, bend leftarmin,makefistwithlefthandandrotate left fistin a smallreverse circular motion.

SeeFigure 3.60.

FIGURE 3.60 R. TURN RIGHT FaceMachine Operator, raiseleftforearm up, makefistwithlefthandandholdstationary, bend rightarmin,makefistwithrighthandandrotate rightfistin a smallforward circular motion.

See Figure3.61.

FIGURE 3.61 S. MOVE THIS MUCH FaceMachineOperator, raisebothforearms up, handsopenand facingeach other,move hands in laterally indicating howfarto go.SeeFigure 3.62.

FIGURE 3.62 1". MOVE SLOWLY FaceMachine Operator, raiseleftarmouthorizontally towardrightshoulder withhandopenand facingdown,pointrightindexfingerup toward openlefthandandrotaterighthandin a reverse circular motion.

(Raise LoadSlowly isIllustrated.)

SeeFigure3.63.

FIGURE 3.63

3-21

SectionIII- BASIC MACHINEOPERATION U. STOP FaceMachine Operator, raise leftarmouthorizontally fromshoulder withhandopenandfacing down,movearmin a horizontal motion backand forth.

SeeFigure 3.64.

FIGURE3.64

V. EMERGENCY STOP FaceMachine Operator, raise botharmsouthorizontally fromshoulders withhands openandfacingdown,movearmsin a horizontal motion back andforth.

SeeFigure 3.65.

FIGURE3.65

W. STOP ENGINE FaceMachine Operator, rightarmat side, draw leftthumb orindex finger across throat.

See Figure 3.66.

FIGURE3.66

3-22

NOTES

Section IV- MAINTENANCE Tableof Contents

4-1 GENERAL INFORMATION ............................................................................................

4-1- 4-3 GENERAL-SAFETY ...............................................................................................

4-4~ 4-5 INSPECTION & MAINTENANCE CHART .....................................................................................

4-6- 4-7 FLUIDS & FILTERS ..............................................................................................

4-6 Required Fluids & Quantities ....................................................................................

4-6 Required Filters ...........................................................................................

4-6 KOBELCO Fluids & Lubricants ....................................................................................

4-7 Lubricant Specifications .......................................................................................

4-8- 4-20 PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE .....................................................................

4-8 Engine Oil Level ...........................................................................................

4-8 Engine Coolant Level .........................................................................................

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

4-9 Fan Belt Wear &Tension .......................................................................................

4-9 - 4-10 Fuel Level ..............................................................................................

4-11 Air Cleaner ..............................................................................................

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

4-12- 4-13 Hydraulic Oil Level .........................................................................................

4-14 Hydraulic Functions .........................................................................................

4-14 Hydraulic Oil Leaks .........................................................................................

4-14 Machine Electrical ..........................................................................................

4-15 Swing Stopping Test .........................................................................................

4-16 Swing Drift Test ...........................................................................................

4-17 Step & Handrails ...........................................................................................

4-17 Frame Structure ...........................................................................................

4-17- 4-18 Tracks & Components .........................................................................................

4-19 Track Tension .............................................................................................

4-20 Boom & Arm ..............................................................................................

4-20 Bucket Teeth &Side Cutters .....................................................................................

4-21- 4-27 50 HOUR(WEEKLY) & NEWMACHINE BREAK-IN INSPECTION & MAINTENANCE .......................................................

4-21 Engine Oil Filter Element ......................................................................................

4-22 Engine Oil ..............................................................................................

4-23 Fuel Tank Drain ...........................................................................................

4-23 Water Separator ............................................................................................

4-23 Air Intake System ...........................................................................................

4-24 Radiator, Oil Cooler, Debris Screen ................................................................................

4-25 Hydraulic Return Filters .......................................................................................

4-26 4-27 Batteries ...............................................................................................

4-28 100HOUR (MONTHLY) INSPECTION & MAINTENANCE ............................................................................

4-28 Attachment Lubrication ........................................................................................

4-29~ 4-30 120HOUR INSPECTION & MAINTENANCE ...................................................................................

4-29 Swing Motor Reduction Oil......................................................................................

4-30 Travel Motors Reduction Oil.....................................................................................

4-31~ 4-33 250HOUR (3-MONTH) INSPECTION & MAINTENANCE ............................................................................

4-31 Attachment Lubrication ........................................................................................

4-33 Belt Tensioner (Fan & AirConditioner) ..............................................................................

4-34 ~ 4-39 500, 1,000 HOUR INSPECTION & MAINTENANCE ..............................................................................

4-34- 4-35 Engine Oil &Filter .........................................................................................

4-35 Fuel Filter ..............................................................................................

4-35 Bleeding Airfrom the Fuel System .................................................................................

4-36 Greasing the Slewing Ring ......................................................................................

4-37 Checking Slewing Ring Fitting Bolts forloosening .......................................................................

4-0-1

Section IV- MAINTENANCE

2000 HOUR INSPECTION & MAINTENANCE ....................................................................................

4-38~ 4-47 Change Engine Coolant ..........................................................................................

4-38~ 4-39 Change Hydraulic Oil ...........................................................................................

4-40~ 4-42 Change OilinTravel Motor Reduction Units .............................................................................

4-42 Change inSwing Reduction Units ....................................................................................

4-43 Change Grease inSwing Ring Grease Bath ...............................................................................

4-43 Hydraulic Tank Breather .........................................................................................

4-44 Attachment & Dust Seals .........................................................................................

4-45- 4-47 Windshild Washer .............................................................................................

4-47 MISCELLANEOUS .................................................................................................

4-48~ 4-56 Fuses ..................................................................................................

4-48 Towing the Machine ............................................................................................

4-49 Periodical Inspection Items .......................................................................................

4-49~ 4-51 Machine Storage .............................................................................................

4-52 Transporting Machine ...........................................................................................

4-53~ 4-54 Lifting Machine .............................................................................................

4-55~ 4-56

4-0-2

Section IV- MAINTENANCE 4.1 GENERAL INFORMATION

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY 1 PRECAUTIONS CONTAINED IN THIS MANUAL I BEFORE PERFORMING ANY INSPECTION OR I MAINTENANCE PROCEDURES TO THIS MACHINE, I ITS SYSTEMS OR COMPONENTS. I A. It is recommended

by KOBELCOCONSTRUCTION MACHINERY CO.,LTD.thatan Inspection and Maintenance Schedule be developed andmaintained ona regular basis forthismachine.

Developingandmaintaining sucha schedule, helpsto keepthemachine in optimum operating condition.

SeeFigure 4.1.

B.Theinformation contained inthisSection gives theproper procedures forperforming Inspection andMaintenance functions forthismachine.

Use theseprocedures whenperforming Inspection and Maintenance as theywillguide theTechnician step bystepforeachprocedure.

Also, refer totheInspection andMaintenance Charts forgeneral service interval recommendations.

NOTE TheInspection andMaintenance Charts provided give onlygeneral timeintervals.

Itmaybenecessary todevelopea Custom Schedule to perform machine maintenance atmorefrequent intervals based on theworkconditions.

C. UseonlyKOBELCO oils, fluids, lubricants, filters andreplacement partstokeepmachine in optimumoperating condition.

SeeFigure 4.2.

4.2 GENERAL SAFETY A. Disposal of Hazardous Waste-FIGURE4.3 Dispose ofwaste oils, fluids, lubricants, filters and otherhazardous waste properly.

FIGURE4.1

KOBELCO

FIGURE4.2

Dispose of Waste Properly FIGURE4.3

CAUTION

O

Dispose of allHazardous Wastein accordance with Government Environmental Regulations, Lawsand Codes.

B. Keep MachineClean-FIGURE4.4 Thoroughly cleanmachine before performing Inspection andMaintenance procedures.

It iseasier andsaferlocate problems, perform maintenance andalsoreduces theriskofHydraulic System contamination whenmachine is clean.

4-1

FIGURE4.4

Section IV- MAINTENANCE C. HotSurfaces & FluidsFIGURE4.5 Usecaution andweartheproper safety equipment whenworking around hotareas.

Neverchange oils, engine coolant orfilters immediately after a machine hasbeenstopped.

Allowmachine to cool before performing maintenance procedures.

D. WarmEngineOil Engine oilshould havea temperature of 20°C~ 40°C(68°F - 104°F) before oilischanged.

Ifnecessary runengine until oiliswarm.

E. "Tag-Out" MachineFIGURE4.6 Before beginning anyInspection or Maintenance procedures, securea "DO NOTOPERATE" Tag totheoperators console toinform theoperator that themachine willbe inoperable forinspection and maintenance.

Thistagwillhelpprevent accidentalstarting ofthemachine.

FIGURE4.5

0

DO NOT OPERATE o

F.Inspect WasteOilsandFiltersFIGURE 4.7 Before disposal, inspect allwaste oils, fluids and filters fordebris andforeign material.

Thiscanhelp in determining problem areas.

FIGURE4.6

G. PreventContaminationFIGURE4.8 Always capor pluglineswhenhydraulic components areremoved tohelpprevent hydraulic systemcontamination thatcanbecaused bydirt, dust anddebris entering a lineorport.

CHECK FOR DEBRIS

CAUTION Never allow a hydraulic lineorcomponent to become contaminated.

Thiscouldcausesevere systemdamage.Contactan authorized KOBELCO dealer toobtain theproper capsandplugs tobe used on thismachine.

FIGURE4.7

H. Seals& "O"-Rings Always replace sealsand"O"-Rings withnew parts.

Never reuse a sealor"O"-Ring during reassembly of components.

Before installing a new seal or"O"-Ring, coat witha thin layer ofoilto help sealing ability.

FIGURE4.8

4-2

Section IV- MAINTENANCE StopEngine Nev_erattempt anyMAINTENANCE withengine running.

Always StoptheEngine andallow machine to cool.

J.

WearSafetyEquipmentFIGURE4.9 WearHardHat,Safety Goggles or FaceShield, WorkGloves, Safety Shoes andwellfitting work clothes whenperforming inspection andmaintenanceprocedures on thismachine.

FIGURE4.9 TO RELEASE PRESSURE

K. Cleaning Parts Useonlyapproved cleaning solvents andproper equipment toclean parts.

WARNING

/~

NEVER USE GASOLINE, DIESEL FUEL OR OTHER FLAMMABLE SOLVENTS TO CLEAN PARTS. ALWAYS CLEAN PARTS IN A WELL VENTILATED AREA. L. Hydraulic TankPressure Always release theinternal pressure ofthehydraulictankbefore performing inspection ormaintenanceprocedures.

FIGURE4.10

_sw ,o,W ii i i/

cap"DOWN" to release air 1.Pushrubber pressure inthereservoir.

SeeFigure 4.10.

/~lGassesfrom CAUTION I/~ Hydraulic Tankmaybe Hot. Wearsafety equipment.

FIGURE4.11 M. Welding Safety Turn Key Switch to "OFF".

Wait4 seconds for 1. electrical power todisconnect.

SeeFigure 4.11.

Negative (-)CablefromBattery Termi2.Remove nal.SeeFigure 4.12. welder ground cable 1 m (3’-3") awayfrom 3.Attach component beingwelded.

4.Makecertain welder ground is notlocated ata sealorbearing.

FIGURE4.12

4-3

Section IV- MAINTENANCE 4.3 INSPECTION & MAINTENANCE CHART Follow thechartbelowforrecommended intervals of regular inspection andmaintenance procedures.

SYSTEM

MAINTENANCE PERFORM

TO

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS FOUND IN THIS MANUAL BEFORE PERFORMING INSPECTION & MAINTENANCE.

CHECK OIL LEVEL

COMPONENT LOCATION REAR SIDE OF ENGINE

8 0

CHECK COOLANT LEVEL

RESERVOIR

0

4-8

CHECK FOR FLUID LEAKS

COMPLETE ENGINE

0

4-9

CHECK BELT TENSION

FRONT OF ENGINE

0

4-9

CHECK FUEL LEVEL

GAUGE CLUSTER

0

CHECK AIR CLEANER

AIR CLEANER

:;,,,

INTERVAL ( HOURS ON HOURMETER) 50 120 250 500 1,000 2,000 REF. PAGE # 4,,8

4,11

CHECK ENGINE ELECTRICAL COMPLETE ENGINE

4-12

DRAIN WATER FROM FUEL

FUEL TANK BOTTOM

0

CHANGE ENGINE OIL

OIL PAN

¯

0

CHANGE OIL FILTER

R.H. SIDE OF ENGINE

¯

0

,,

ENGINE

CHANGE FUEL FILTER

LH. SIDE OF ENGINE

DRAIN WATER SEPARATOR

FRONT OF FUEL TANK

CHECK AIR INTAKE SYSTEM

HOSES & CLAMPS

CHECK FAN ASSEMBLY

FRONT OF ENGINE

i ~ECK BELT TENSIONER

FRONT OF ENGINE

CLEAN RADIATOR

RADIATOR

0

CLEAN DEBRIS SCREEN

BETWEEN RADIATOR AND OIL COOLER

0

HYDRAULIC

0 0

0

RADIATOR

A~UST VALVE CLEARANCE

ENGINETOP

HYDRAULIC OIL LEVEL

SIDE OF HYD TANK

0

CHECK HYD FUNCTIONS

CAB

0

RYDRAULIC SYSTEM HYDRAULIC TANK

CHANGE RETURN FILTERS

HYDRAULIC TANK

~NGE

HYDRAIUUC TANK BREATHER ....

0

4-11 !iiill

0

4-14

0 0

4-14

o O

4-25,

HYDRAULIC TANK

CHANGE HYDRAULIC OIL

HYDRAULIC TANK

;~EAN HYDRAULIC TANK

HYDRAULIC TANK

INSPECT ALL WIRING

COMPLETE MACHINE

ELECTRICAL

14-24 4-24

AIR CLEANER

CLEAN SUCTION SCREEN

....4-23

0

CHANGE AIR CLEANER ELEMENTS

CHECK HOSES/LINES

4-23 0

CHANGE ENGINE COOLANT

: CHECK FOR OIL LEAKS HYDRAULIC SYSTEM

,,,,

4-22,4-34

I

0

4-40~ 4-42

o HHHHI HI

I

0

III I ,

4-14

BATTERIES BATTERY SERVICE

¯

BATTERIES

O - RegularInspection& MaintenanceRequired. ¯ - Break-In(Afterfirst50 Hours)Inspection & Maintenance Required.

4-4

O

4-26- 4-27

Section IV- MAINTENANCE COMPONENT LOCATION CAB HYD, FUNCTION OPERATION

SYSTEM

MAINTENANCE PERFORM

CHECK SWITCHES

8 O

CAB

O

4-14 ¯

O

:i

CHECK TRAVEL ALARM

CAB

CHECK SWING BRAKE

CAB

O

4-15- 4-16

CHECK WARNING LIGHTS

CAB/FRAME/BOOM

O

4-14

CHECK BUZZER

CAB

O

4-14

CHECK GAUGES

CAB

O

4-14

I

CHECK HORN

CAB

O

4-14

O

4-14

CHECK GAUGE CLUSTER

CAB

CHECK SWING REDUCTION OIL LEVEL & FILL

UPPER FRAME

CHECK BOLTS/TORQUE

SLEWING RING

O

CHECK SLEWING RING & PINION WEAR

SIGHT WINDOW IN BATTERY BOX

0

CHECK SLEWING RING SEAL

SLEWVING RING

0

CHECK SWIVEL JOINT SEALS

0

DRAIN WATER FROM SLEWING RING GREASE BATH

SWIVEL JOINT LOWER FRAME CAVITY DRAIN PORT

GREASE SLEWING RING

SLEWING RING

0

CHANGE GR~E IN SLEWING RING GREASE BATH

REMOVE UPPER

CHANGE SWING REDUCTION UNIT OIL

SWING MOTOR

CHECK BOLTS/TORQUE

COUNTERWEIGHT

CHECK FOR OIL LEAKS

COMPLETE SYSTEM

O

CHECK LINES FOR DAMAGE

FRAME CAVITY

O

UPPER FRAME

LOWER FRAME

INTERVAL ( HOURS ON HOURMETER 50 120 250 500 1,000 2,000 REF. PAGE #

TO

I;

O I

O

CHECK FRAME STRUCTURE

O

CHECK TRACKS & LINKS

TRACKS

O

CHECK SPROCKET WEAR

FRONT OF TRACKS

O

CHECK IDLER WEAR

REAR OF TRACKS

O

CHECK ROLLER WEAR

TRACKS

O

CHECK TRACK TENSION

RAISE TRACKS

O

" ADJUST TRACK TENSION

FRAME RAILS

CHECK TRAVEL REDUCTION UNIT OIL LEVEL& FILL

TRAVEL MOTORS

BUCK~ PINS

4-17~ 4-18

4-18

4-19

4-30

O

[ MOTORS[

" ¯

i

BUCKET

O

,

.... | .......

....

& BUC~

,iiiiii i0 iiiiiii i

|

4-20

O

ARM ARM

¯

O

O

GREASE ARM PINS GREASE

4-17

ENTIRE MACHINE

CHECK BUCKET TEETH & SIDE CUTTERS ATTACHMENT ..... .... .....

GREASE BOOM PINS

¯

4-14

¯

BOOM

4-43

O

FRAME RAILS

CHECK BOOM & ARM STRUCTURE

4-36 4-43

FRAME

TRAVEL

.~.~ ~P’J/

!~i~L ¸!

ENTIRE FRAME

CHECK BOLTS/HARDWARE

4-29

0

CHECK STEPS

CHANGE TRAVEL REDUC~ON UNIT OIL

O

¯

¯ 4-31

O MNK

I .... |

O - RegularInspection& MaintenanceRequired¯ ¯ - Break-In(Afterfirst50 Hours)Inspection & Maintenance Required¯

4-5

~too HOURS)

|ii̧ZZ!!iiiiiii i

Section IV- MAINTENANCE 4.4 FLUIDS & FILTERS chartisprovided giving specific information fortheproper Thefollowing charts listallthenecessary lubricants, lubricants, oils,greases, fuelsandcoolants tobe usedin oils, greases, fuels, coolants andfilters required for certainclimates.

Contactan authorized KOBELCOdealer the KOBELCOSK70SRHydraulicExcavator.Also a to ordertherequired Filters, Fluids andLubricants.

A. REQUIRED FLUIDS & QUANTITIES TYPE FLUID

LOCATION OF USE HYDRAULIC TANK

HYDRAULIC HYDRAULIC SYSTEM

B. REQUIRED FILTERS

QUANTITIES REQUIRED 55 Liters (14.5GAL)

LOCATION OF FILTER USE RETURN FILTER

92 Liters

ELEMENT

SYSTEM

(24.3GAL)

TANK SUCTION YT50V00001F1

8 Liters

STRAINER

(H LEVEL)

(2.1 GAL)

TANK BREATHER

ENGINE OIL PAN

6 Liters

FILTER ELEMENT

(L LEVEL)

(1.6GAL)

ENGINEOIL FILTER

LOWER ROLLER

YNSTV00002~

"897049-7081

20cc X2

ENGINE

CARTRIDGE

(1.2cu.in.X2)

AIR CLEANER

90cc Xl0

ELEMENT

(5.5cu.in.Xl0)

ENGINE FUEL FILTER

160ccX2

IDLER

FUEL

LE11P00002S002

*894414-7963

CARTRIDGE

(9.8 cu.in.X2)

ENGINE FEED PUMP

SWING MOTOR

1.5Liter

GAUZE FILTER

REDUCTION UNIT

(0.4GAL)

TRAVEL MOTOR

1.7Liter X2

REDUCTION UNIT

(0.45GALX2)

OPERATING

"U" JOINT

LEVER JOINT

EACH SIDE

ATTACHMENT

PINS

AIR-CON FILTER YT50V01002P1

OPERATOR

(OUTER)

CAB

AIR-CON FILTER (INNER)

* AVAILABLE FROM AN AUTHORIZED ISUZU DEALER ONLY.

13 PLACES

EP GREASE

YRSOV00006F2

ENGINE OIL PAN

UPPER ROLLER

MOTOR OIL

HYDRAULIC

SK70SR

SLEWING RING GEAR

1 PLACE....

90° X 4

WITH UTHIUM BASE MoS= GREASE

TRACK TENSION

2 PLACES

ADJUSTMENT

AS REQ’D

SWING GEAR

5 kg

SUMP (BATH)

(11.0 Ibs) 3.9Liars

ENGINE

COOLING SYSTEM

12 Liters

COOLANT

TOTAL VOLUME

(3.2GAL)

FUEL

FUEL TANK

C. KOBELCO (Brand) FLUIDS & LUBRICANTS PART NUMBER

DESCRIPTION

KSP1000-1001

ENGINE OIL- SAE 15W/40 (1 GALLON)

85 LITERS

KSP1000-1005

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

(22.5GAL)

KSP1000-1055

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

KSP1000-2005

HYDRAULIC OIL- AW 46 (5GALLON)

4-6

KSP1000-2055

HYDRAULIC OIL- AW 46 (55 GALLON)

KSP1000-4014

GREASE EP/2- 14 OUNCE

KSP1000-4035

GREASE EP/2-35 POUNDS

KSP1000-120

GREASE EP/2- 120 POUNDS

KSP1000-3035

GEAR OIL 80W90- 5 GALLONS

Section IV- MAINTENANCE D. LUBRICANT SPECIFICATIONS Thefollowing information is designed to allowusageof theproperoils,greases, fuelsandcoolants in various climates andcertain working conditions.

CLIMATE ZONE

LUBRICANT HYDRAULIC OIL (ANTI-WEAR, ANTIOXIDANT AND NON-FOAMING) * MobileDTE13MoilwithHighViscosity

FRIGID -30°C~ 15°C (-22°F- 59°F)

FRIGID -20°C- 30°C (-4°F- 86°F)

FRIGID-WARM .25°C_ 40°C (-13°F-104°F)

WARM .5°C_ 40°C (23°F- 104°F)

VERY HOT 5°C ~ 55°C (41°F - 131°F)

ISOVG22

ISOVG32

ISOVG32S*

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT ENGINE OIL* A.P.I.CLASSIRCATION FOR "SERVICECD" * ALL ENGINESSHIPPEDFROM FACTORYWITH SAE30 OR SAE15W40OIL ACCORDINGTO AMBIENTTEMPERATUREIN ENGINEOIL PAN.

FRIGID .30°C_ 30°C (-22°F- 86°F)

WARM .5°C_ 40°C (23°F- 104°F)

VERY HOT 30°C and Above (86°Fand Above)

SAE10W30

SAE15W40

SAE15W50

CLIMATE ZONE

LUBRICANT

FUEL

FRIGID -15°C~ -25°C (5°F- -13°F) WINTERIZED ASTM D975 No.1

LUBRICANT

WARM -5°C- -15°C (23°F- 5°F)

VERY HOT -5°C and Above (23°Fand Above)

ASTM D975 No.2

ASTM D975 No.2

FOR ROLLERS AND IDLERS ON ALL MODELS. FOR SWING MOTOR REDUCTION UNIT AND TRAVEL MOTOR REDUCTION UNITS ON THE

ENGINE OIL (FOR GENERAL PURPOSE LUBRICATION)

FOLLOWING MODELS : SK70SR A.P.I.Classification for "Service CD" - SAE30

LUBRICANT

GENERAL LUBRICATION EXTREME

GREASE

SWING GEAR SUMP (BATH)

PRESSURE MULTIPURPOSE

N.L.G.I.No.2 LITHIUM BASE WITH

GREASE No.2

MoS2 GREASE

EP TYPE GREASE LUBRICANT

ANTIFREEZE (LLC) -34°C(-29.2°F)

ENGINE COOLANT

Mixtureratioshouldprotectto 5°C (9°F)lowerthanthe coldesttemperature the machinewill

(50% MIXTURE)

experience, Take intoconsideration WindChillFactors.

NOTE: Use of Bio-degradable Oils Whenyou use Bio-degradable Oil (BIOOIL),referto the following information.

1.Thereare two typesof BIO OIL available;vegetable-based and synthetic-based.

You are recommended to use the synthetic-based type,becausethe vegetable-based oil has a maximumusagetemperature of 80°C (176°F).Becauseof this,the degradation of vegetable-based oil occursmorerapidly,and causedreduced service life.

2. Do not mixeithertypeof BIOOIL withtheoriginal factory-filled mineraloil.In the casethatyou do use BIO OIL.It is required to flushthe hydraulic systemthat wasfilledwithmineraloiltwo times. willbe reduced,becauseof the lower 3. If you use BIO OIL, swingand propelparkingbrakeperformance friction factorof BIO OILcompared to thatof mineral oil. aboutrecommended Bio-degradable oil, pleasecontactlocaldealer.

4. For furtherinformation

4-7

Section IV- MAINTENANCE 4.5 PRE-START(EVERY 8 HOURS) INSPECTION MAINTENANCE The following procedures are to be performed every8 hoursor daily, before themachine is started.

I I IENGJNEO,LOIPST REAR ,OE OFENG,N

WARNING H

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

J

FIGURE 4.13 A. ENGINE OIL LEVEL 1. Raiseenginecover.

2.Locateandpullenginedipstick.

Wipedipstick clean usinga clean, dry,lintfreecloth andreinsertintoengine.

Pullagainandvisually inspect theengine oillevelon dipstick.

SeeFigure 4.13.

3. If necessary to addoil,remove OilFiller Cap andfillengine oilto proper level.

SeeFigure 4.14andrefer to page4-7foroilspecifications.

NOTE After adding oil,check oillevel, replace oilfiller cap,replacedipstick andcloseenginecover.

B. ENGINE COOLANT LEVEL 1.Open EngineAccessCoverand inspect coolant levelin enginecoolant reservoir.

See Figure 4.15.

2. Propercoolantlevelis between"FULL"and "LOW"marks.See Figure4.15.

3. If necessary to addcoolant, removereservoir capandfillto proper levelwithfreshcoolant.

SeeFigure 4.15andreferto page4-7forproper coolant specifications.

4. Ifnocoolant is inreservoir, checkcoolant level inradiator.

Fillradiator toproper level andreplacecap.SeeFigure4.16.Thenfillreservoir toproper level.

~_~

ENGINE OILI FILLERCAPJ

FIGURE 4.14

PROPER ~-----~,I~__~~ ~, | ENGINE COOLANT

\ _FULL

FIGURE 4.15

~

ENGINEIS HOT

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

FIGURE 4.16

4-8

Section IV- MAINTENANCE C. ENGINE FLUID LEAKS 1.10spect complete engine forsigns offluid leaks. around pressure linesand 2.Wheninspecting hoses usea stiff piece ofcardboard.

See Figure 4.17.

I CAUTION I Never usehands tocheck forleaks.

Highpressure fluid leaks willpenetrate theskinandcause severe injury.

I

~ .....

FIGURE4.17 D. FAN BELT WEAR & TENSION 1.Inspect fanbeltforexcessive wearor damage.

SeeFigure 4.18.

2.Measure belttension on longest spanofbelt.

Beltdeflection should be 8 mm - 10 mm (0.3" ~ 0.4").

SeeFigure 4.19 mounting nutandadjusting nut,and 3.Loosen adjust tension ofbelt.

Figure 4.19 adjusting bolt, adjust fanbelttothe 4.Loosen specified tension, andtighten mounting nutand adjusting nut.

5.After adjustment, rotate engine atlowidling for 5 minutes, thencheck thetension ofbelt.

~.r

I

I I

i

, _ ~MPRESSOR ICRANK PULLEY I ~ FIGURE4.18 MOUNTINGNUT ,

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NOTE Whenmoving thealternator, trynottodamage thestater coilsection between thefront andrearbrackets orthe bolts.

E. FUEL LEVEL 1.TurnKeySwitch to"ON"position.

Visually watch FuelLevelGaugeon Gauge 2.

Cluster Panel.

SeeFigure 4.20.

/~RE’4.19

FIGURE4.20

4-9

I

/

Section IV- MAINTENANCE Tank canbefilled through theFuelFiller 3.TheFuel Caplocated ontopoftheFuelTankorby using theauxilliary fuelpumplocated inside the Battery Access Door. a. Filling Tankthrough FuelFiller Cap 1.OpenBattery Access CoverwithKey Switch Keyandfill tanktoproper level with Diesel Fuel.

SeeFigure 4.21andrefer to page4-7forFuelSpecifications. b. Filling TankusingAuxilliary FuelPump AccessCover, remove 1.OpenBattery thefilter endoftheFuelPumpSuction Hosefromitsstorage housing andinsert thefuelsuction hoseintofuelsupply reservoir.

SeeFigure 4.22.

2.Locate theAuxilliary FuelPumpSwitch inside theStorage BoxAccess Door.

Place theSwitch inthe"ON"position.

See Figure 4.22.Place PumpSwitch in the "OFF" position whenFuelTankisfull.

FIGURE4.21

NOTE Delivery rateoftheAuxilliary FuelPumpis30liters per minute (7.9U.S.Galperminute).

4.Afterremoving FuelDelivery Hosefrom fuelsupply reservoir, coilhoseandplace filter intoitsstorage housing.

Replace FuelStrainer andFuelFiller Cap.

FIGURE4.22

4-10

Section IV- MAINTENANCE F. AIR CLEANER 1. OpenEngineAir CleanerAccessDoorwith starter Switchkey.SeeFigure 4.23.

FIGURE 4.23 2. ReleaseClampfromtheAir Cleanercover.

See Figure4.24.

FIGURE 4.24 3. Removethe Air CleanerElementfromthe housing.

SeeFigure4.25.

4.Cleantheinside of thehousing usinga clean, lintfreeclothdampened withwater.

5.Thoroughly drytheinsideof thehousing witha clean, dry,lintfreecloth.

6. Reinstall AirCleaner Element in reverse order.

SeeFigure4.25.

J

CAUTION FIGURE 4.25

Carefully HoldThe O-ringWaterInsideCause EngineFailure.

NOTE FilterElements shouldnotbe changeduntilthe Engine AirCleanerlamplightson theGaugeClusterPanel.See Figure4.26.

FIGURE 4.26

4-11

Section IV- MAINTENANCE G. ENGINE ELECTRICAL 1.Visually andmanually inspect allengine electricalwiring, connectors andcomponents forsigns of damageand malfunction.

See Figure4.27.

2. Repairor replace alldamaged or malfunctioning wiring,connectors and components before resuming operation of themachine.

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WARNING

REPAIR OR REPLACE I t ALL DAMAGED OR FAULTY ,~ ~.~ ~ ~ t ELECTRICAL COMPONENTS ~,,,,’7~’~ ~ ~ t

/~

OPERATING THE MACHINE WITH DAMAGED OR MALFUNCTIONING ELECTRICAL COMPONENTS CAN CAUSE SERIOUS DAMAGE TO THE MACHINE AND SERIOUS INJURY TO PERSONNEL. REPAIR OR REPLACE FAULTY COMPONENTS IMMEDIATELY.

FIGURE 4.27

IHYDRAULIC OIL CHECK POSITION I

H. HYDRAULIC OIL LEVEL 1. Placethemachine in theOilCheckPosition on a firmsurface as shownin Figure4.28.

FIGURE 4.28 2.OpenBatteryAccessCoverand viewthe hydraulic oillevel in thesightglass on sideof hydraulic oiltank.SeeFigure 4.29.

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WARNING

I HYDRAULIC

OIL

r ~/’]

I LEVEL SIGHT GLASSl.

I~

~

~

/~

FOR SAFE OPERATION ON INCLINES, THE HYDRAULIC OIL LEVEL MUST BE MAINTAINED BETWEEN "PROPER LEVEL" AND "UPPER LIMIT" MARK. /

FIGURE 4.29 rr

3.Usethefollowing instructions to addhydraulic oil: a. Release hydraulic tankpressure.

SeeFigure 4.30.

±1

DEPRESS RUBBER CAP I TO RELEASE PRESSURE

CAUTION Tankmay be Hot. Gasses fromHydraulic Wearsafetyequipment.

FIGURE 4.30

4-12

Section IV- MAINTENANCE I SLOWLY REMOVE I BOLTS & COVER

b. Removethesix(6)mounting boltsfromthe Hydraulic SuctionScreenCoverPlate.See Figure 4.31.

I

FIGURE 4.31 c. AddHydraulic oilthrough thesuction screen, filling hydraulic tankto theproper level.

See Figure4.32. d. Before replacing FilterCover, replace "O"Ring. Order KOBELCOPart Number ZD11G15500.

See Figure4.32. e. Placenew"O"-Ring in seat.Placecoverover opening andinstall mounting boltswith Iockwashers. f. Torquemounting boltsto propervalue.Refer to TorqueSpecifications Table.

I

CLEAN UP ALL SPILLED OIL TO PREVENT FIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS,

REPLACE "O"-RING PART No. ZD11G15500

I I_t"~ "h~’~

i COVER&

FIGURE 4.32

4-13

Section IV- MAINTENANCE I. HYDRAULICFUNCTIONS 1.Check allHydraulic Controls forproper functionality before operating themachine.

See Figure 4.33.

I

CHECKALLCONTROLS I FOR PROPER FUNCTION I

NEVER OPERATE THE MACHINE WITH A FAULTY CONTROL OR FUNCTION. MAKE ALL NECESSARY REPAIRS BEFORE ALLOWING ANY OPERATION.

o o

FIGURE4,33 J. HYDRAULICOIL LEAKS 1.Check complete hydraulic system forleaks.

Use a smallpieceof cardboard whenchecking areas withhighpressure.

SeeFigure 4.34.

CAUTION

I/

1

I Never usehands tocheck forleaks.

Highpressure fluid leaks willpenetrate theskinandcause severe injury.

J 2.Check allhoses andlines forsigns of damage.

3.Repair or replace damaged hosesandlines before allowing anyoperation.

FIGURE4.34

CLEAN UP ALL SPILLEDOIL TO PREVENTFIRES. DISPOSE OF HAZARDOUS WASTE ACCORDING TO ENVIRONMENTAL LAWS AND REGULATIONS,

IKPSS WORK MODE LAMP I

K. MACHINE ELECTRICAL 1.Check allswitches forproper operation.

2.Visually check allwiring andconnectors for signs of damage, corrosion etc..

3.Repair orreplace alldamaged orfaulty electricalcomponents before allowing anyoperation of themachine.

4.CheckallGaugesandWarning Lampson the Gauge Cluster Panel forproper operation.

SeeFigure 4.35.

WARNING LAMP

WARNING LAMP

WARNING DAMAGED OR FAULTY ELECTRICAL COMPONENTS CAN CAUSE SEVERE DAMAGE TO THE MACHINE AND CAUSE SERIOUS PERSONAL INJURY OR DEATH.

WARNING LAMP

CHECK ALL GAUGES AND WARNING LAMPS

FIGURE4.35

4-14

Section IV- MAINTENANCE L. SWING STOPPING TEST Usethefollowing testto checkforproper operationof theSwingBrake.

1. Tools& Equipment. a. DeviceforMarking Starting Point 2. MachineSettings& SiteCondition a. Machine throttle in"High" Idleposition. b. Hydraulic ° oiltemperature at 45°Cto 55 (113°Fto 131°F). c.Firm, level testing site.

3. Swing StoppingTest Procedure a. Movethemachine to a firm,leveltesting area.

BUCKET IN CYLINDER EXTENDED

ARM OUT CYLINDER RETRACTED

FIGURE 4.36

WARNING MAKE CERTAIN THE TEST AREA WILL ALLOW 360° SWING OF THE MACHINE. MAKE CERTAIN NO PERSONS OR OTHER EQUIPMENT ARE WITHIN 3 METER (10 FEET) THE SWING AREA,

1.5M (4’-11 ")

FIGURE 4.37 b. Movethrottle to HighIdleandplaceKPSS switchin "H"mode. ¢. Operate theArmOutControl untilarmis completely out(retracting cylinder).

See Figure4.36. d. Operate theBucketIn Control untilbucket is completely in (extending cylinder).

See Figure 4.36. e. Adjustboomup or downuntilbucketteeth are1.5m(4’-11 ") fromgroundlevel.

See Figure4.37.

±1

I L.H.CONSOLE

CAUTION FIGURE 4.38

Soundhorn BEFOREstartingswingmotion.

SeeFigure4.38.

I

f. Aftersounding horn,operate swingcontrol at fullstroke foronecomplete rotation clockwise.

Whenbucketreachesstarting point,release theswingcontrol andallowrotation to completely stop. g. Measure thedegreeof anglefromthestartingpointtothestopping pointof the bucket.Recordthe angledegree.Repeat stepf two moretimesand averagethe readings.

Compareto SwingStopSpecificationChart.SeeFigure 4.39. h. Repeatstepsb throughg swinging counterclockwise.

.

STOPPING POINT _~TAI~TE~..~.:.:ING ~u~N~

CLOCKWISE

I

STOPPING POINT COUNTERCLOCKWISE

FIGURE 4.39

SWING STOPPING SPECIFICATIONS

t 4-15

CLOCKWISE/COUNTERCLOCKWISE

MODEL SK70SR

t

° 70°-100 Unit of measure:Degreeof Angle

Section IV- MAINTENANCE M. SWING DRIFT TEST 1. Tools& Equipment. a. Device forMarking Starting Point b. Stopwatch 2. MachineSettings& SiteCondition a. Hydraulic ° oiltemperature at 45°Cto 55 (113°Fto 131°F). b. Firmtesting areawith10° slope.

3. SwingDriftTestProcedure a. Movethemachine to a firmtesting areawith 10° slopeas shownin Figure4.40. b. Operate theBucket InControl untilbucket is completely in (extending cylinder).

See Figure 4.41. theArmOutControl untilthearmis ¢. Operate completely out( retracting cylinder).

See Figure4.41. d. Adjust theboomup or downuntilbucket teeth are1.5m(4’-11 ") fromground level.See Figure 4.42. e. Stopengineandallowthemachine to sitfor 5 minutes. f. Measure thedistance theswingdrifted, down grade, whilesitting.

Record thedistance.

See Figure4.43. g. Repeatstepsb through f two moretimes.

Averagethe distances and compareaverageto theSwingDriftSpecification Chart. h. Startengineand swingmachine180 °.

Repeatstepsb throughg.

FIGURE 4.40

ARM OUT CYLINDER RETRACTED

BUCKET IN CYLINDER EXTENDED

FIGURE 4.41

1.5M (4’-11"

FIGURE 4.42

ST..T,.O I IIPlIIIIII POINT

---STOPPING POINT (20 SEC,) ~

J

/

IH

IIIIIIII

J

FIGURE 4.43 SWING DRIFT SPECIFICATIONS MODEL SK70SR

4-16

SPECIFICATION 0mm (0") / minutes

Section IV- MAINTENANCE O. STEPS AND HANDRAILS inspect allmounting steps andhand1.Carefully rails onthemachine tomakesuretheyareclean andinsafeworking condition.

SeeFigure 4.44. orreplace allareas before allowing any 2. Repair operation ofthemachine.

/

I

1

CAUTION

Usesteps, andhandrails whenmounting and dismounting themachine.

Keepsteps, handrails and catwalks clean andinsafeworking condition.

FIGURE4.44

P. FRAME STRUCTURE 1.Carefully inspect theentire frame structure for signs of damage, broken welds etc..

2.Repair or replace allframecomponents found to be damaged before allowing anyoperation ofthemachine.

3.Incases where welding repair is required, consult an authorized KOBELCO Service Dealer forproper procedures concerning weldrepairs.

Useonlycertified welding personnel familiar withstructural welding methodsto perform repairs requiring welding.

E) DISCONNECT BATTERY NEGATIVE(-) CABLE WHEN INSPECTINGELECTRICAL OR WELDING

FIGURE4.45

WARNING DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE.SEE FIGURE4.45.

CONNECT WELDER GROUND CABLE 1M (3’-3") AWAY FROM AREA TO BE WELDED Q. TRACKS & COMPONENTS 1. TrackShoes a.Visually inspect track shoes forsigns ofexcessive wearor damage.

SeeFigure 4.46. b. Haveallrepair or replacement workdoneby an authorized KOBELCO Service Dealer. c. Checktightness of shoemounting boltsand nuts.

Ifloose, torque to30+ 3 kgf-m (217+ 22ftIbs).

SeeFigure 4.47.

FIGURE4.46

FIGURE4.47

4-17

Section IV- MAINTENANCE 2. TrackLinks a.Inspect links forsigns ofexcessive wearor damage.

SeeFigure 4.48. b.Haveallrepair orreplacement workdoneby an authorized KOBELCO Service Dealer.

FIGURE4.48 3. Sprockets a. Inspect Sprockets forexcessive wearand damage.

SeeFigure 4.49. b.Should thesprockets require service, contactan authorized KOBELCO Service Dealer forassistance.

FIGURE4.49 4.Idlers a.Inspect Idlers forexcessive wearand damage.

SeeFigure 4.50. b.Should theIdlers require service, contact an authorized KOBELCO Service Dealer for assistance.

FIGURE4.50 5. Rollers a. Inspect Rollers forexcessive wearand damage.

SeeFigure 4.51. b.Should theRollers require service, contact an authorized KOBELCO Service Dealer for assistance.

LOWER ROLLER

UPPER ROLLER INSPECT THESE SURFACES

FIGURE4.51

4-18

Section IV- MAINTENANCE R. TRACK TENSION Swing,Arm,BucketandBoomCon1.Operate trois until machine issetupasshown inFigure 4.52.

SUPPORT LOWER FRAME WITH SUITABLE BLOCKS.

FIGURE4.52 Incenter oftrack, measure thedistance between thebottom offrame rails andsurface of shoe.

SeeFigure 4.53.

Perform steps 1 and2 onright track. , 4.To increase track tension, setmachine as shown inFigure 4.52andwithgrease guninject Extreme Pressure No.2 Grease intoidler adjustmentgrease fitting until proper tension is reached.

SeeFigure 4.54.Perform thisprocedureonbothtracks. ,

NOTE After injecting grease, operate thetravel control forward andreverse forthetrack being adjusted.

Thiswillbalancethetension between theIdler andtheSprocket.

Then re-measure as shownin Figure 4.53.

FIGURE4.53 TRACK ADJUSTING GREASE FITTING

5.To decrease track tension, setmachine up as showninFigure 4.52. loosen theadjusting grease fitting 6. Carefully toallowgrease to escape.

SeeFigure 4.54.

WARNING GREASE IN TRACK TENSIONING MECHANISM IS UNDER EXTREME PRESSURE AND CAN PENETRATESKIN CAUSING SEVERE INJURY. KEEP FACE AND BODY AWAY FROM GREASE FITTINGAREA. NEVER LOOSEN GREASE FITTING MORE THAN ONE (1) COMPLETETURN. IF GREASE DOES NOT RELEASE AFTER ONE TURN OF THE FITTING,CALL AN AUTHORIZED KOBELCO SERVICE DEALER FOR ASSISTANCE.

FIGURE4.54

7.Tighten grease fitting, measure track tension as shownin Figure 4.54. perform steps 5 through 7 onother 8.Ifnecessary, track.

4-19

Section IV- MAINTENANCE S. BOOM & ARM 1.Inspect BoomandArmstructures forsignsof excessive wearanddamage.

SeeFigure 4.55.

2.Should repair or replacement be necessary, contact an authorized KOBELCO Service Dealer forassistance.

FIGURE4.55

WARNING

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DISCONNECT BATTERIES BEFORE WELDING ON THIS MACHINE.SEE FIGURE4.56.

CONNECT WELDER GROUND CABLE 1M (3’-3")AWAY FROM AREA TO BE WELDED.

E~ DISCONNECT BATTERY NEGATIVE (-) CABLE WHEN INSPECTING ELECTRICAL OR WELDING

FIGURE4.56 T. BUCKET TEETH & SIDE CUTTERS 1.Inspect bucket teeth andsidecutters forsigns of excessive wearanddamage.

SeeFigure 4.57.

2.Should repair or replacement be required, followKOBELCOrecommendations.

CAUT, ON WearSafety Equipment andusetheproper toolswhenI performing repair or replacement procedures.I

FIGURE4.57

4-20

Section IV- MAINTENANCE 4.6 50 HOUR (WEEKLY)& NEW MACHINEBREAK-IN INSPECTION & MAINTENANCE PROCEDURES. Change theengine oilandfilter ona newmachine after thefirst 50hours ofoperation.

Thenchange theengine oilatevery 500hours ofoperation.

EXTENTION BAR ~-~~

RATCHET

HANDLE

NOTE Onenewoilfilter isshipped withthemachine inthesupport kit.

This istobeused atthe50hour oil& filter change.

A. ENGINEOIL FILTERELEMENT 1. Movethemachine toa firm, level surface and runengine for5 minutes towarmtheoil.

DRAIN PLUG ENGINE OILPAN

WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING.THE OIL WILL BE EXTREMELY HOT, ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING.

FIGURE4.58

I

APPLY CLEAN ENGINE OIL J

NOTE ¯ Check thewaste oil.Ifthere aremetal chips or powder mixed in theoil,contact yourKOBELCO distributor. ¯ TheOilFilter cannotbereused because itiscartridge type. .

.

.

.

.

.

.

Remove thefour(4)mounting boltsfromthe Engine lower cover plates.

Apply flared rubber forremoval andinstallation andfilter wrench onengine oilfilter.

See Figure 4.58.

Apply ratchet handle on extension barto rotate itcounterclockwise.

SeeFigure 4.58.

Clean filter base, apply clean engine oilon gasket section ofnewoilfilter, andtighten it clockwise softly until gasket comes incontact withsealsurface.

SeeFigure 4.59.

Partially fill filter with oilbefore installing.

Tighten it1 1/4turns withfilter wrench from this position.

Start engine, operate itatidling operation for several minutes.

Thencheck filter fitting section foroilleakage.

Install cover justbelow theengine tothe regular position.

4-21

FIGURE4.59

Section IV- MAINTENANCE B. ENGINEOIL Change theengine oilon a newmachine afterthe first 50hours ofoperation.

Thenchange the engine oilatevery 500hours ofoperation.

REMOVE BOLTS AND LOWER COVER

NOTE Onenewoilfilter isshipped withthemachine inthesupport kit.

This istobeused atthe50hour oil& filter change.

1.Movethemachine to a firm, level surface and runengine for5 minutes towarmtheoil.

DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING.THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. .

FIGURE4.60

Remove thefourretaining bolts fromtheoil panaccess cover on thebottom, rearcenter of machine.

SeeFigure 4.60.

engine bonnet andremove oilfiller cap.

3. Raise SeeFigure 4.61. ,

°

°

Remove CapfromEngine OilDrainby hand.

SeeFigure 4.62.

Place a 10liter (2.6Gal) capacity container under oilpan.

Install Drain Hoseontooildrain withother end ofhoseintocontainer.

SeeFigure 4.62.

After alloilhasdrained, remove Drain Hoseandreplace OilDrain Cap.

FIGURE4.61

Refer topage4-7fortheproper oiltouseand fill engine oiltoproper level. ¯ Total oilvolume tobereplaced SK70SR : 8 liters (2.1Gal)

7.Install oilfiller cap.

Clean upallspilled oil.

8.Start engine, runfor5 minutes.

While running, check foroilleaks.

9.Should anyoilleaks be found, repair immediately andrefill with proper oil.

10.Check OilLevel andclose cover.

4-22

FIGURE4.62

Section IV- MAINTENANCE C. FUEL TANK DRAIN 1. Locateand openFuelTankDrainValveon bottomof fueltank.SeeFigure4.63.

2.Allowallwaterandsediment to drainfromfuel tankintoa wastecontainer, thenclosethe drainvalve.

FIGURE 4.63 D°

WATER SEPARATOR Thewaterseparator isolates waterthatmixes inwiththefuel.Thecaseis equipped witha float.

Whenwateraccumulates, thefloatrises.When thefloat rises tothelevel line,drain thewater.

SeeFigure4.64.

!vE, L.E Eo, j

1.Loosenthedrainplugto drainthewater.

2.Whenthe floatcomesdownto the bottom, closethedrainplug.

.

I DRAINPLUG

Checkthatfuelis notleaking.

Drainwaterwhenever thefloatrisesto the levelline,regardless of inspection time.

FIGURE 4.64

CAUTION Clean upallspilled fueltoavoida fire.

Disposeof allhazardous wastein accordance with government environmental regulation.

HOSE & CLAMPSFROM AIR CLEANERHOUSING

HOSE & CLAMPSFROM AIR CLEANER

E. AIR INTAKE SYSTEM Inspect allhosesandclamps of theAirIntake Systemon a newmachine afterthefirst50 hoursof operation.

Thenat every500hoursof engineoperation. allhosesfordamageandtighten all 1. Inspect hoseclamps.See Figure4.64-A. FIGURE 4.64-A 2. Replaceany hosefoundto be damaged beforeallowing any operation of themachine.

4-23

Section IV- MAINTENANCE F. RADIATOR, OIL COOLER & DEBRIS SCREEN 1. Cleanradiator afterevery50 hoursof operationusingpressurized water.

/~l

CAUTION

~

ENGINE

IENGINEAIR I IHI/’~.II )l II );~

I/~]

Aj

Do notusepressure washeras it willbendthe radiator fins.Usestandard waterpressure.

2.Openengineair cleaneraccessdoorand engine coverforcleaning theradiator andoil cooler.

SeeFigure4.65.

FIGURE 4.65

I SCREE N

3.Openenginecoverand removethe wingbolts retaining thedebrisscreen.

SeeFigure4.66.

Carefully removedebrisscreenandcleanwith pressurized water.

-

~

\

’1 l° sOREE. I

FIGURE 4.66 4. Removewash out accesscoverfrombottom of machine.

SeeFigure4.67.

5. Rinsealldirtanddebrisfromenginecompartment.Reinstall debrisscreenandwashout accesscover.

/’~]

CAUTION

COVER

I/~

Be careful notto bendor damagecooling finsof the radiator or oilcooler.

Replace debrisscreenif damage is found.Repairdamaged cooling finsof radiator andoilcooler.

FIGURE 4.67

4-24

Section IV- MAINTENANCE G. HYDRAULIC RETURN FILTERS Change theHydraulic TankReturn Filters on a new machine after thefirst 50hours ofengine operationthenchange every 500hours.

fr

DEPRESS RUBBER CAP I TO RELEASE PRESSURE

NOTE OnenewHydraulic Return Filter is shipped withthemachine inthesupport kit.Thisistobeused atthe50hours filter change.

Movemachine to firmleveled ground andplaceattachmentinoillevel check position.

Hydraulic TankPressure.

SeeFigure 1.Release 4.68.

FIGURE4.68

Y

SLOWLY REMOVE I BOLTS & COVER

f

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT, RELEASE HYDRAULIC TANK PRESSURE BEFORE WORKING WITH ANY HYDRAULIC COMPONENT. thesix(6)mounting boltsfromthe 2. Remove Hydraulic Return Cover Plate.

SeeFigure 4.69.

FIGURE4.69

BOLT

lyremove themounting bolts.

Thefilter cover plate isunder spring tension.

~

- COVER

SPRING WASHER S~’~:~/O-RING

3.Remove "O"-Rings, filter springs andbypass valves.

SeeFigure 4.70.

SPRING

~ ~

BYPASS

thefilter fromthehousing.

See 4. Remove Figure 4.70.

5.Install newfilter, bypass valve andspring into housing. ,

,

~/1.’,

~ FILTER

Install New"O"-Ring, KOBELCO partnumber ZD11G15500.

Lubricate "O"-Ring before installing.

Install Cover Plates andtorque mounting bolts toproper value.

Refer toSpecifications Section fortorque value.

FIGURE4.70

4-25

VALVE

Section IV- MAINTENANCE H. BATTERIES Perform complete battery service on a newmachine after thefirst 50hours ofengine operation.

Then, check electrolyte (acid) every 50 hours.

1. WEAR SAFETY CLOTHES, GOGGLES OR FACE SHIELD, GLOVES AND SAFETY SHOES WHEN WORKING WITH BATTERIES. 2. WORK IN A WELL VENTILATEDAREA. 3. BATTERYELECTROLYTE(ACID)IS CORROSIVE. IF IT COMESIN CONTACTWITH SKIN,EYES OR CLOTHING, FLUSH WITH LARGE AMOUNTS OF WATER AND SEEK IMMEDIATE MEDICAL ATTENTION. SEE FIGURE4.71.

4.BATTERY ELECTROLYTE (ACID) PRODUCES HYDROGEN GAS THAT IS HIGHLY EXPLOSIVE. DO NOT ALLOW NEAR SPARKS, FIRE OR FLAMES AND DO NOT SMOKE WHEN WORKING WITH BATTERIES.SEE FIGURE4.71.

FIGURE4.71

1. OpenBattery Access Door.SeeFigure 4.72.

2.Remove battery cellcapsandvisually inspect electrolyte (acid)level.

Proper level is10-15 (0.4" ~ 0.6") above cellplates.

SeeFigure 4.73.

3.Ifnecessary, fill eachcell toproper level with distilled water only.

4.Remove cables fromterminals andcleanwith hotwater.

Coateachterminal witha thinlayer ofpetroleum jelly.

Clean cables inthesame manner andreinstall ontobattery.

5.Ifcables arefound tobeinpoorcondition, replace withnewparts immediately.

/~ WARNING

FIGURE4.72 TE LEVEL

PREVENT BATTERY EXPLOSION ¯Batteries giveoffhydrogen gassesthatcanexplodeandcausepersonal injury. ¯Keepsparks, openflamesandcigaretes awayfrom batteries. ¯ Keepmetallic articles awayfrombatteries. ¯ Keepallventilation capstightly secured. ¯Nevercheckchargeby placingmetalarticles across battey terminals. ¯Leavebatterybox opento improveventilation whencharging.

~

10-15MM (0.4"~0.6")

~-~-_-::1 IIPLATES

FIGURE4.73

4-26

Section IV- MAINTENANCE tocheck thespecific gravity 6.Usea Hydrometer ofeachcell.

Compare readings tothechart below.

NOTE Usehydrometer according to itsmanufacturer’s instructions.

CHARGE %

ATMOSPHERIC TEMPERATURE 20°C 0°C -10°C (68°F) (32°F) (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1,24

75%

1.21

1.22

1.23

.

o,sco..ECT

FIGURE4.74

Whendisconnecting batteries, remove the Negative(-) cable first.

Whenconnecting batteries, connect theNegative(-) cable last.

See Figure 4.74.

8. Whenthebattery requires charging; a. Disconnect battery cables fromterminals. b.Remove allcellcaps. ¢.Check forproper electrolyte (acid) level. d.Connect charger leads to theproper battery terminals.

c,,o.,o.

a e certain nottocross Positive andNegative terminals whenconnecting charger. e.Stopcharge ifbattery overheats. f.Periodically check thespecific gravity ofthe batteries witha hydrometer.

Stopcharging batteries when100%charged.

NOTE Battery lifecanbe shortened by overcharging andover discharging of thebattery.

Replace anybattery thatwill nothold charge orisdifficult tocharge.

4-27

Section IV- MAINTENANCE 4-7 100 HOUR (MONTHLY)INSPECTION MAINTENANCE PROCEDURES.

ATTACHMENT LUBRICATION POSITION

NOTE Perform allPre-Start (Every 8 Hours and50 Hour) Inspection & maintenance Procedures alongwiththe following 100HourInspection andMaintenance Procedures.

A. ATTACHMENT LUBRICATION UseExtreme Pressure Multi-Purpose Grease No.2 EPTypeGrease.

Lubricate allpoints until grease purges.

NOTE If attachment issankinwater, it isrecommened to lubricate itevery 8 hours.

FIGURE4.75

TO BUCKET~ R RO0 LINKPIN

1.Idler linkandBucket Pin.SeeFigure 4.76.

2.Bucket Cylinder RodEnd.SeeFigure 4.76.

4.76.

3.ArmTopPin.SeeFigure LinkPins.

SeeFigure 4.76.

4. Bucket

ENO

I

\\ ~’_Vo\ "I’°LE" L,NK I ARM TOP I PIN IBOTTOM BUCKET \

LNKPN I

I

FIGURE4.76

4-28

Section IV- MAINTENANCE 4.8 120 HOUR INSPECTION & MAINTENANCE PROCEDURE. A. SWING MOTOR REDUCTION OIL Check theoillevel of theSwing Motor Reduction Unitona newmachine after thefirst 50 hours of engine operation.

Thencheckevery120hours. .

Locate theDipstick onthesideoftheswing motor.

SeeFigure 4.77.

Pulldipstick, wipeclean andreinsert allthewayin.

2.Pull Dipstick andread oillevel.

FIGURE4.77 .

Ifnecessary toaddoil, remove plugfromoilfill port andfill tofull level with proper oil.

See Figure 4.77andRefer topage 4-7foroilspecifications.

±1

CAUTION

Reduction unitmaybe underpressure.

Remove plugslowly.

4. Todrain oilfromSwing Motor Reduction Unit; drain portunder rearofmachine.

See a.Locate Figure 4.78. b.

Place a 2 liter (0.5gallon) container under drain portandremove plugallowing oilto drain into container.

¢.Replace plug andtighten securely after alloil isdrained. d°

Fillthrough fill port using proper oil.See Figure 4.77andRefer topage4-7foroil specifications.

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT.

4-29

FIGURE4.78

Section IV- MAINTENANCE B. TRAVEL MOTORS REDUCTION OIL Inspect OilLevel of Travel Motor Reduction Unit ona newmachine after thefirst 50hours ofengineoperation.

Thencheck every120hours.

1.Movemachine to a firm, level surface.

Operate travel until "FILL" Plugs ontravel motors areat top.SeeFigure 4.79.

2.Stopengine andremove theTravel MotorReduction UnitOilLevel Plug.

SeeFigure 4.79.

Ifoiljust seeps from theport, oillevel iscorrect.

Travel Reduction unitcouldbe underpressure.

Carefully Iossen plugandremove slowly fillair pressure is released,

FIGURE4.79

3.Toaddoil,remove theoilfillplugandadd Engine oiluntil oiljust begins toflowfrom check plug.

4. Todrain oil,remove FillPlugandDrain Lug. Allow oiltodrain intoa 2 liter (0.5Gal) capacitycontainer.

Replace drain plug, remove Level Plugandfillthrough Fillport using Engine oil.

NOTE Capacity of eachTravel Motor Reduction Unitis 1.7 liters (0.45 Gallons).

5.Replace allplugs andtighten securely.

4-30

Section IV- MAINTENANCE ATTACHMENT LUBRICATION POSITION 4.9250 HOUR (3-MONTH) INSPECTION MAINTENANCE PROCEDURE. NOTE PerformallPre-Start (Every8 Hourand50 Hour) Inspection & Maintenance Procedures alongwiththe following 250 HourInspection and Maintenance Procedures.

A. ATTACHMENT LUBRICATION Lubricate Attachment Pinsevery250 hoursof engineoperation.

Use Extremepressure MultiPurposeGreaseNo.2EP Type Grease.Lubricate allpoints untilgreasepurges.

SeeFigure4.80.

FIGURE 4.80

~ BOOM CYLINDE f R

NOTE If attachment is sankin water, it is recommended to lubricate it every8 hours.

~1 BOO.I ,

’HEADPIN I/~1, _

1.Boom CylinderHead and Rod Pins.See Figure4.81.

I ~

I/

2. BoomFootPin.SeeFigure4.82.

FIGURE 4.81 3. Arm Cylinder HeadPin.See Figure4.82.

BOOMFOOTPINI (CENTER) FIGURE 4.82 4.Arm CylinderRod End.See Figure4.83.

I,..~°.°°. L ~ /

5.Arm to BoomPin.See Figure4.83.

6. BucketCylinder headEnd.SeeFigure4.83.

ARM CYLINDERI ~ /, ~3"RODEND I ~"~~

iBOCKET CYL,NDER HEAD END I FIGURE 4.83

4-31

Section IV- MAINTENANCE B. Inspection of recirculate andfreshairfilters on air conditioner Cleaning recirculate andfreshairfilters.

Recirculate airfilter ......

Every500 hours Fresh airfilter. ..............

Every250 hours 1.Cleaning fresh airfilter a. Loosen3 boltsunderoperator’s seat,and removecover. b.Remove cover, andtakefleshairfilter out. c.Blowcompressed airto cleanfreshairfilter.

NOTE Waterwashing is notallowed to cleanairfilterbecause itispaper filter. d. Cleaning about10 timesis allowed, or replace it withnewoneeverytwo(2)years.

FIGURE 4.84 RECIRCULATE AIR F LTER I

IFRESH- AIRFILTERI

2.Cleaning recirculate airfilter a.Raise recirculate airfilter slightly, andpullit out. b. Cleanit withwateror compressed airblow.

NOTE Washing withorganic solvent (gasoline, trichlene, thinner, etc.) isstrictly prohibited.

MACHINE FRONT

c. Whenfrequently clogged, or damageis serious, replace it withnewone. d.Afterdrying, setoutside andrecirculate air filters andinstall cover.

FIGURE 4.85

C.lnspecting counterweight attaching boltsfor loosening - Figure4.85A Checkboltsandnutsforloosening.

Correct torueis 57+6kgf*m(412+43)

CAUTION Striking counterweight againstobstruction maycause loosening of bolts.Checkboltsforloosening after50 hoursthefirsttime,andevery250hoursafterthat.

Unit: Kgf*m(ft,lbs MODEL

TORQUESPECIFICATION ApplyLocktite#242

SK70SR

57+6(412+43) FIGURE 4.85A

4-32

Section IV- MAINTENANCE C.BELT TENSIONER(FAN & AIR CONDITIONER) Inspect BeltTensioner assembly on a new machine after thefirst 50hours ofoperation.

Thenatevery250hoursof engine operation. belttension on longest spanofbelt.

1.Measure Beltdeflection should be8mm- 10ram.

BELT DEFLECTION FAN BELT 8 mm ~ 10 mm (0.3"0.4") AIR CONDITIONER 10 mm - 12 mm (0.4"-0.5")

/ FIGURE4.86

2.Loosen mounting nutandadjusting nut,and adjust tension ofbelt.

Figure 4.86. adjusting bolt, adjust fanbelttothe 3. Loosen specified tension, andtighten mounting nut andadjusting nut.

/

IIO’ERPUL’Evl I ’..--~

adjustment, rotate engine atlowidling for 4.After about 5 minutes, thencheck thetension of belt. thetension ofbeltofairconditioner 5.Adjust turning adjusting boltofidlepulley.

Figure 4.87.

coMP.Esso.

I FIGURE4.87

4-33

Section IV- MAINTENANCE 4.10 500, 1000 HOUR INSPECTION& MAINTENANCE PROCEDURES PerformallotherInspection & Maintenance Proceduresas previously described in thissection.

REMOVEBOLTS AND LOWER COVER

A. ENGINE OIL & FILTER Changetheengineoilandfilteron a newmachineafterthefirst50hoursof operation.

Then changetheengineoilat every500hoursof operation.

1.Movethemachine to a firm,levelsurface and runenginefor5 minutes to warmtheoil.

FIGURE 4.88

WARNING DO NOT CHANGE OIL ON A MACHINE THAT HAS JUST STOPPED WORKING. THE OIL WILL BE EXTREMELY HOT. ALLOW THE ENGINE TO COOL UNTIL OIL IS JUST WARM BEFORE CHANGING. 2. Remove thefourretaining boltsfromtheoil panaccesscoveron thebottom, rearcenterof machine.

See Figure4.88.

3. Raiseenginebonnetandremoveoilfillercap.

See Figure4.89.

4. Placea 10 liter(2.6gal)capacity container underoilpanandremoveoildrainplug.See Figure4.90.

5.Allow alloiltodrain intocontainer, clean oil drainplugandinstall backintopan.Tighten plugsecurely. rubberforremoval andinstallation 6. Applyflared andfilter wrench on engine oilfilter.

See Figure 4.90.

7.Applyratchet handleon extension barto rotate it counterclockwise.

SeeFigure4.90.

FIGURE 4.89 EXTENTION BAR~ / ,,.~

w

RATCHET HANDLE ENGINE OIL FILTER

DRAINPLUG ENGINEOILPAN

~ 8.Cleanfilter base,applycleanengine oilon gasket section ofnewoilfilter, andturnit clockwise softlyuntilgasketcomesin contact withsealsurface.

SeeFigure4.91.

Tighten it 1 1/4turnswithfilter wrench from . thisposition.

10.Referto thecharton page4-7fortheproper oiltouseintheengine andfillengine to proper levelwithnewoil.

FIGURE 4.90

IAPPLYCLEANENGINEOILI

FIGURE 4.91

4-34

Section IV- MAINTENANCE 11.Install oilfiller cap.Clean upallspilled oil. runfor5 minutes.

Whilerun12.Startengine, ning,checkforoilleaks.

13.Shouldanyoilleaksbe found,repairimmediately andrefill engine tolevelwithproper oil.

14.CheckOil Leveland closebonnet.

NOTE Foradditional OilFilters, contact an authorized dealer and orderISUZUpartNumber: 897049-7081.

B. FUEL FILTER

CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES.

L

FUEL F LTER I ~

1.Usethefilter wrench to remove thefuelfilter andreplaceit witha newone.SeeFigure 4.92.

NOTE Thefuelfilter iscartridge type,andso cannot be reused.

REMOVAL

/ /\

INSTALLATION

FIGURE 4.92

base.Before 2. Cleanthesealfaceof thefilter installing thefuelfilter, apply clean fueloilto thesealing face. thefuelfilter andscrew itbyhanduntil it 3. Install contacts thefilter base.Thenusethefilter wrenct~ totighten thefilter 2/3turn.

C. BLEEDING AIR FROM THE FUEL SYSTEM

--

CLEAN UP ALL SPILLED FUEL. FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL CAN CAUSE FIRES. FIGURE 4.93 If aircontaminates thefuelsystem, theengine maybecomehardto startor it malfunction.

Bleed theairwhenever thefueltankis empty,thewater separator is drained, orthefuelfilter element is replaced.

1.Airbleeding procedure a.Fillfueltankwithfuel. b. Checkthatairbleedplugon upperpartof waterseparator anddrainplugaretightened.SeeFigure4.93. ¢. Loosenairbleedscrew,turnuppersection of pumpcounterclockwise, and movefeed pumpup and downuntilfuelmixedwithout foamsflowsout.SeeFigure4.94.

4-35

FIGURE 4.94

Section IV- MAINTENANCE NOTE Neverloosenplugon uppersectionof waterseparator whenbleeding air.

Loosening of theplugdoesnotallowbleeding of air. d. Tighten airbleedscrew.

Tighten airbleedscrewaftermovingfeed pumpup and down untilthe movement becomesheavier.

See Figure4.95. e.Afterstarting engine, checkfuelsystem for leakage.

FIGURE 4.95 D. Bleeding air in fuelsystem (Autoair bleedingdevice/option) Thismachineis equipped withfuelpumpunder theengine.

SeeFigure4.96.

1.Airbleeding procedure a.Fillfueltankwithfuel. b. Turnstarter keyON,andfueling pumpstarts operating forapprox, two(2)minutes and bleedairautomatically.

FIGURE 4.96 E. GREASING THE SLEWING RING 1.Locate thegrease fitting at thefrontofthe slewing ring.SeeFigure4.97.

,

Usinggreasegun filledwithGeneral Purpose EP Grease(Referto page4-7),lubricate slewing ringwithseveral shotsfromgrease gun.

.I I

3.Swingmachine 90° right,andrepeatstep2.

See Decalon frame.

,

Continue to swingmachineat 90° increments andlubricating slewing ringuntilringhasbeen completely greased.

4-36

FIGURE 4.97

Section IV- MAINTENANCE slewingringfittingboltsfor loosenF. Checking ing_ Checkthatboltssecuring slewing ringarenot loosened.

If loosened, removeboltsonce,applyLocktite #262or equivalent, andtighten themagain.

Torque specification 13to 19kgfom(94to137ft.Ibs.) Alternately tighten boltsfacing eachotherin order.SeeFigure4.98.

11 FIGURE 4.98

NOTE Sincethetightening of slewing ringrequires special tools,contact ourrepresentative or service shop.

4-37

Section IV- MAINTENANCE 4.112000 HOUR INSPECTION& MAINTENANCE PROCEDURES Perform allother Inspection & Maintenance Procedures aspreviously described inthissection.

A. CHANGING ENGINE COOLANT- 2000 HOURS

WARNING B-IE ~ OF I-lOT F"EUIDS AND SURFACES. WEAR GOGGLES, SAFETY SHOES, HARD HAT, WORK CLOTHS AND WORK GLOVES TO PERFORM INSPECTION AND MAINTENANCE ON THIS MACHINE. ALLOW ENGINE TO COOL BEFORE CHANGING FLUIDS.

FIGURE4.99

1.Raiseengine bonnet andslowly remove radiator cap.SeeFigure 4.99.

2.Locate coolant drain access coverunder L.H. rearof machine.

SeeFigure 4.100.

Remove thefour (4)retaining bolts. radiator Drain Valve, place a 12liter (3 3.Locate Gal)capacity container under drain tubeand turndrain valvecounterclockwise toopen.

See FIGURE4.100 Figure 4.101.

4.After drainage, close drain valve anddrain ENGINE DRAIN PLUG RADIATORDRAINVALVE I plug, andfeedwater init.

5.Opendrain valve anddrain plug.

Andclean it withflowing water for10minutes inlowidling state.

Becareful thatwater hoseisnotdisconnected fromwater feeding portofradiator while cleaning andflowing water.

6.After cleaning, stopengine, andalsostop water feeding.

Thenafter draining water, close drain valve anddrain plug.

FIGURE4.101 draining, clean itwith radiator flush.

7.After Clean itfollowing Instruction Manual forflush inuse.

8.After cleaning, opendrain valve anddrain NOTE plug, thenclose themafter completely draining Expected minimum temperature Longlifecoolant water, andfillitwithwater andclean out -14.5°C (5.9°F) 30% mixed radiator flush material completely.

- 34oc(-29.2°F) 50% mixed

I

NOTE Never spill thecoolant on theground thatcancause the environmental pollution.

Change contaminated andfoamycoolant withnewone assoonaspossible.

Cooling water other thanlonglifecoolant should be changed two(2)times a year, in autumn andspring.

4-38

Section IV- MAINTENANCE withwater, opendrain valve and 9.Fillradiator drain plug, andclean itflowing water with engine ina lowidling state until clean water is flowing out.

Adjust water feeding anddraining soasto keep radiator infullcondition.

10.After clean water hasdrained out,stop engine andclose drain valve anddrain plug.

SeeFigure 4.102.

Fill with "long life coolant" inappropriate concentration.

Refer topages 4-7.

11.Runengine atlowidling for5 minutes and highidling for5 minutes tobleed aircontaminated incoolant (with capofradiator removed).

12.drain coolant inreservoir, clean inside of reservoir andfill itupwith long life coolant in appropriate concentration tomidpoint of FULL andLOW.SeeFigure 4.103.

13.Stop engine, fillitwith water tothetopof radiator about 3 minutes later, andtighten cap.

14.Return engine bonnet andaccess doorto the closed position respectively.

NOTE Total cooling system volume is approximately 12 liters (3.2 Gal).

4-39

FIGURE4.102

FIGURE4.103

Section IV- MAINTENANCE B. CHANGE HYDRAULICOIL- 2000 HOURS

IHYDRAULIC OIL CHECK POSITION I NOTE Thefollowing procedures aretobe usedfornormal changingoftheHydraulic Oilonly.

Ifnecessary tochange theHydraulic OilViscosity, change Hydraulic Oilduetohydraulic component failure orchangingmainpump,contactan authorized KOBELCOServiceDealer forassistance.

FIGURE4.103 ~. ..~

TO RELEASERUBBER PRESSURE DEPRESS CAP

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

/

1.Movethemachine to a firm, level surface and place theattachment intheHydraulic OilCheck Position.

SeeFigure 4.103.

FIGURE4.104

NOTE If machine is cold, warmthehydraulic oilbyoperating attachment controls before placing machine in theHydraulic OilCheck Position.

BOLT--~ .,~,~..~.~..~ WASHER " ~

SPRING

2. Release Hydraulic TankPressure.

SeeFigure 4.104.

Cleanareaaroundcoverof dirtand debris.

~

3.Slowly remove thesix(6)retaining bolts from theSuction Strainer CoverPlate.

SeeFigure 4.105.

~

,~~~

4. Remove "O"-Ring, andSuction Strainer from Hydraulic Tank.SeeFigure 4.105.

SUCTION

STRAINER

FIGURE4.105

5. Install Special Suction Stopper, PartNumber 24100P978F4, oversuction tubeinside hydraulictank.SeeFigure 4.106.

Putenvironmental warning about spilling andsafedisposal.

NOTE Never spill thehydraulic oilontheground, thatcancase theenvironmental pollution.

/

COVE O-RING

TANK

~

SUCTION STOPPER ASSEMBLY ~ART No. 2410

SUCTION TUBE

FIGURE4.106

4-40

R

[

Section IV- MAINTENANCE remove thesix(6)retaining bolts from 6. Slowly theHydraulic Return Filter Cover Plates.

See Figure 4.107.

SLOWLY REMOVE I BOLTS & COVER

y-

7.Remove "O"-Ring, Bypass Valve andFilter from Hydraulic Tank.SeeFigure 4.108.

8.Remove coverplateunderHydraulic Tankand locate theHydraulic Drain Plugon bottom of Hydraulic Tank.SeeFigure 4.109.

9.Place a 60liter (16Gal)capacity container under Drain Plug.

Remove plugandallow alloil fromhydraulic tanktodrain ontocontainer.

FIGURE4.107

10.After alloilhasdrained, carefully andthoroughly clean inside ofHydraulic Tank.

11.Replace Drain Plugandtighten securely.

12.Clean Bypass Valve, Suction Strainer andCoversusing approved solvent anddrythoroughly.

13.Inspect filters andoldoilforsigns ofcontaminationfortroubleshooting purposes.

14.Install NewReturn Filters, PartNumber YR50V00004P1, alongwiththecleaned Bypass Valves andSprings.

FIGURE4.108

NOTE OrderPartNumber YR50V00006F2 Element Kit.Thiskit includes 1 Filter(PartNumberYR50V00004P1) and "O"-Ring (PartNumberZD11G11500).

Suction Stopper andcleanoutside of 15.Remove suction tubewitha clean, drycloth. inspect Suction Strainer fordamage.

18.Carefully Ifanydamage isfound, replace Strainer with newpart.Orderpartnumber YT50V00001 S001.

FIGURE4.109

4-41

Section IV- MAINTENANCE 17.Install Strainer Assembly ontoSuction Tube.

18.Install new"O"-Ring, partnumber ZD11G15500, incover plate mounting surface groove andinstall Suction Strainer Cover Plate ontoHydraulicTank.

Makecertain Plate Bossisinside SuctionStrainer Holder.

SeeFigure 4.110.

19.Torque retaining bolts toproper value.

Refer to Specifications Section.

20.FillHydraulic Tanktoproper level withfresh, clean Hydraulic Oilthrough Hydraulic Return Filter.

SeeFigure 4.111.

CAUTION

I/

BOLT SPRING

~

WASHER

COVER "~P~*’~~~

~"

SUCTION STRAINER /

1

Usesameviscosity oilin Hydraulic Tankas wasI drained.

Refer to Page4-7foroilSpecifications.

I

FIGURE4.110

NOTE Thismachine wasshipped fromthefactory withISOVG46 viscosity Hydraulic Oilinhydraulic system.

C.CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS- 2000hours Change theTravel reduction units oilon a new machine after thefirst 500hours ofengine operation thenchange every2000hours.

WARNING NEVER CHANGE OILS OR FILTERS ON A MACHINE THAT HAS JUST FINISHED WORKING. ALLOW MACHINETO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. Move machine toa firm,level surface.

Operate 1. travel until "FILL" Plugs ontravel motors areat top.SeeFigure 4.112.

2.Stopengine andremove theTravel Motor Reduction UnitOilLevel Plug.

SeeFigure 4.112.

Ifoiljust seeps from Level port, oillevel iscorrect. remove theoilfillplug andadduntil 3.Toaddoil, oiljustbegins toflow fromlevel plug. oil,remove FillPlugandDrain Plug.

4.Todrain Allow oiltodrain into a 2 liter (0.5 Gal)capacitycontainer.

Replace drain plugusing teflon tape, remove Lever Plugandfillthrough Fill portusing A.P.I Classification for"Service CD"SAE30 Engine oil.

NOTE Capacity ofeachTravel Motor Reduction Unitis1.7 liters (0.45 Gallons).

5.Useteflon tapeon FILL/LEVEL plugsand replace them.

4-42

/ O-RING

FIGURE4.111

FIGURE4.112

Section IV- MAINTENANCE D. CHANGE OIL IN SWING REDUCTIONUNIT-2000

r

I SWING 1

,

~.1. MOTORI j ~.

I DIPSTICK J Change theSwingreduction unitoilon a new machine after thefirst 500hours ofengine operationthenchange every2000hours. ~..~

.~~~

J~////

o

THAT HAS JUST FINISHED WORKING. ALLOW MACHINE TO COOL FIRST UNTIL OILS AND FLUIDS ARE WARM NOT HOT. FIGURE4.113 1. Remove thedrain Plugontherearlower sideof theswing reduction unittodrain oiltothe container.

SeeFigure 4.114.

f,,,

2.Clean thedrain plugsealitwithteflon tape, and install.

~~~~

3.Remove theoilfiller plugandfill withengine oil.

~

4.Using thedipstick, confirm thattheengine oil levels iswithin thedesignated range.

SeeFigure 4.113.

’-~

~// \ ]l

’’

""

~-" "-" FIGURE4.114

5.Clean thefill plug andinstall.

NOTE Capacity ofeachSwing Reduction Unitis1.5liters (0.4 Gallons).

E. CHANGE GREASE IN SLEWING RING GREASE BATH 1.Drain water byremoving drain plate located in lower frame cavity.

SeeFigure 4,114-A.

CAUT, ON

FIGURE4.114-A

If theSlewing Ringeverbecomes submerged in water, J it ismandatory I thatthesumpbathgrease bechanged.

2.Toreplace theslewing bathgrease itisnecessaryto remove theupperframe.

Contact your KOBELCO Service Dealer to do it.SeeFigure 4.114-B. SUMP BATH GREASE QUANTITIES CHART SK70SR GREASE TYPE 5 kg N.L.G.I.LITHIUM (11.0 Ibs) BASE W/MoS2 FIGURE4.114-B

4-43

Section IV- MAINTENANCE F.HYDRAULIC TANK BREATHER-2000 HOURS 1.Release Hydraulic TankPressure.

SeeFigure 4.115,

/

) ~BBER CAP ~’~L...J"/J TO RELEASE PRESSURE

THE TEMPERATUREOF HYDRAULICOIL IS HIGH IMMEDIATELYAFTER STOPPINGTHE OPERATION. SPECIAL ATTENTION MUST BE PAID WHEN RELEASING THE PRESSURE BECAUSE HOT GASES MAY ERUPT.

FIGURE4.115 2.RemoveRubberCapandNut.SeeFigure 4.116.

Breather Housing.

SeeFigure 4.116.

3.Remove

FIGURE4.116 oldFilter, cleanmounting surfaces and 4. Remove install newfilter.

SeeFigure 4.117.

Order Part NumberYN57V00002S002.

5.Install Breather Housing.

Retaining Nutandtighten securely.

6. Install Torque; 1.0- 1.4kgf°m (7.2- 10ft°lbs) 7.Install Rubber CapPartNumber YN57VO0002S005.

REMOVE FILTER

FIGURE4.117

4-44

Section IV- MAINTENANCE G.ATTACHMENT & DUST SEALS 1. BucketClearance a. Inspect bucketclearance frequently forwear.

If clearance betweenbucketandbucketlink and/orbetweenarm and bucketis greater than1.2 mm (0.05") adjustclearance accordingto bucketmanufacturers instructions.

CAUTION Setthe safetyleverto thelockposition and stop the enginewhenadjustingthe clearance of the bucket.

FIGURE 4.118

Standard clearance of thebucket 1.2mm (0.05") or less

® I

a.Lowerthebucketontothegroundto stabilize, as shownin therightfigure.

SeeFigure4.118. b. MovetheO-ringfromitsnormalposition to the bucketboss.SeeFigure4.119.

C.

Slightly rotate intheleftdirection toslightly pushthearmendto thebucketleftside (whereno clearance adjusting mechanism is equipped).

leverto thelockposition; then d. Setthesafety stoptheengine. e.

f.

Measurethe clearance(~ betweenthe arm andbucketboss.If the measurement valueis 1.0mm (0.04") or more,adjusttheclearance.

Sevenshims1.0 mm (0.04")on the average areinserted in thethreecapscrews at the clearance adjusting part.Loosenevery capscrewsand removeshimscorresponding theclearance.

See Figure4.120.

BUCKET BOSS I FIGURE 4.119 I SOCKETHEAD CAPSCREWSI I I’~"1 (~ , J O-RING I

g. Tighten thecapscrews equally to thespecifiedtightening torque.

Tightening torque : 6 kgf.m(43ft°lbs.) h. ReturntheO-ring to thenormal position.

FIGURE 4.120

4-45

:!

Section IV- MAINTENANCE 2. ReversingBackhoeBucket a. Movethemachine to a firm,levelsurface andrestthe bucketon theground,making certain thebucketis stable.

SeeFigure 4.121.

FIGURE 4.121

b=

Removeflexible ring(1 ) andpin,andalso removebucketpinand linkpin.SeeFigure 4.122.

C°

Cleanpinsand pinhole,andapplygrease onit.

d°

Carefully removeMainPinsmountingarm andbucketlinkto bucket.

e°

Rotatebucket180° or movemachine, install ArmandBucketLinkin theirrespective positions.

SeeFigure4.123.

NOTE Makecertain "O"-Rings areon bucketbossforreinstallation.

FIGURE 4.122

f. Roll"O"-Rings intogrooves betweenbucket/ armandbucket/bucket link. g.Aligneachpinholes, insertbucket pin,and fitflexible ringandpin.

NOTE Inspect "O"-Rings fordamageor excessive wear.If wornor damagedreplacewithnew partsto protect seals,pinsandsurfaces fromdirtanddebriswhichcan causepremature failure.

"O"-RingPart Number(4 Required) 2445Z912.

FIGURE 4.123

4-46

Section IV- MAINTENANCE 3. DustSeals a. The attachment incorporates severaldust sealsthatshouldbe periodically checked for damageand excessive wear.See Figure 4.124. b. If excessive wearor damageis foundremove sealandreplace withnewparts.

NOTE Orderthefollowing partnumbers forreplacement seals: ¯ BOOM FOOT-2445R138D3(2 Req’d) ¯ ARM to BOOM-2445R138D3(2 Req’d) ¯ ARM to IDLER LINK-2445R138D19 (2 Req’d) ¯ BKT CYLINDER to BKT LINK-2445R138D19 (4 Req’d) ¯ ARM to BUCKET-2445R220D5(2 Req’d) ¯ BOOM CYLINDER HEAD-2438U1946S25 (2 Req’d) ¯ BOOM CYLINDER ROD-LP01V00007S026 (2 Req’d) ¯ ARM CYLINDER HEAD AND ROD-2438U721S26 (4 Req’d) ¯ BKT CYLINDER HEAD AND ROD-2438U717S21 (4 Req’d)

LOCATION OF ATTACHMENT SEALS

FIGURE 4.124

replacement sealsas shownin Figure ¢. Install 4.125. d. Makecertainpinsurfaceand taperedend aresmoothandfreefromallburrsor imperfections.

Roughpinsurfaces cancausedamage to thenewseals.

BUSHING --SEAL

FIGURE 4.125

D. WINDSHIELD WASHER RESERVOIR FilltheWindshield WasherFluidReservoir as requiredusingapproved windshield washing fluid.

1. Openengineaircleaneraccessdoorto locate washerfluidreservoir.

SeeFigure4.126.

Pull Cap off and fill with proper windshield wash2. ingfluid. engineaircleaner 3. Replacecapand reposition accessdoor.

OPEN ENGINE AIR CLEANER ACCESS DOOR

/ ’ //

FIGURE 4.126

4-47

Section IV- MAINTENANCE 4.12 MISCELLANEOUS A. FUSES Followtheprocedures belowto replace "blown" orfaulty fuses.

1. Moveseatandseatbasecompletely forward.

2. RemoveFuseBox Coverfrom fuse box. See Figure4.127.

3.Locateandremovefaultyfuse.Replacefuse with same amperagefuse as removed.

FUSEBOX I

WARNING FIGURE 4.127

NEVER REPLACE A FAULTY FUSE WITH A HIGHER AMP FUSE. NEVER USE A "JUMPER" IN PLACE OF A FUSE. NEVER SPLICE ACCESSORIES DIRECTLY INTO FUSE TERMINALS.

11

4. Referto FuseBoxCoveror Figure4.128for Fuseamperage and theirfunctions.

1918 >~2-P"

NOTE Whenordering replacement fuses, orderthefollowing part numbers: 5 AMP- Part Number 2479R655S10 10 AMP- Part Number 2479R655S8 15 AMP- Part Number 2479R717S7 20 AMP- Part Number 2479R655S9

g lO No. AMPS

FUNCTION

2

5A

Wiper, Washer Relay

3 4

5A

DCto DCConverter

5A

5 6

NONE None

8

20A Fuel Pump

10

20AStarter Switch

12

iiiii!iiiiiii| !!iiiiiii! i NONE None

14

20A Wiper,Washer

16

15A WorkingLight

18

20AHeater, AirConditioner

20

20A Spare24V

cJ.ste,

FIGURE 4.128

4-48

Section IV- MAINTENANCE B. TOWING THE MACHINE 1.Ifthemachine should become stuck insoftsoil areas it maybenecessary to towthemachine.

Attach a wireropeorchain, withthecapacity to pullthemachine out,tothelower frame towing eyes.SeeFigure 4.129. other endtothevehicle usedtopullthe 2.Attach machine.

Operate theMachine’s Travel Controls intheproper direction while pulling with theother vehicle.

C. PERIODICALINSPECTIONITEMS Since there isnodefinite time table forthereplacementofhydraulic lines, tubes andhoses, inspect thefollowing periodically fortightness andsigns of damage.

Replace alldamaged lines, tubesand hoses withnewparts.

RefertotheParts Manual forcorrect partnumbers whenordering.

FIGURE4.129

WARNING DO NOT BEND, STRIKE OR DAMAGE HIGH PRESSURE LINES. DO NOT INSTALL BENT OR DAMAGEDLINES, TUBES OR HOSES. REPLACE ALL DAMAGEDLINES, TUBES AND HOSES IMMEDIATELY. TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONSTO THE PROPER TORQUE VALUE. CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELYTO HELP PREVENTFIRES. NEVER USE HANDS TO CHECK FOR LEAKS

FIGURE4.130

CAREFULLYINSPECTALL LINES, TUBES AND HOSES FOR: 1. FITTINGS& CONNECTIONSDAMAGEDOR LEAKING. 2.OUTER COVERING OF HOSES WORN, CUT OR DAMAGED EXPOSING WIRE REINFORCEMENT. 3.HOSE SWELLING OR "BALLOONING".

4.EVIDENCEOF HOSE BEING KINKED OR COLLAPSED. 5.STEEL PROTECTIVE COVERING WORN OR DAMAGED. 6.LOOSE FITTINGS AND CONNECTIONS. MAKE CERTAIN ALL CLAMPS, GUARDS AND HEAT SHIELDS ARE IN PLACEAND SECURE.THIS WILL HELP PREVENTVIBRATION, EXCESSIVE WEAR OF COMPONENTS AND EXCESSIVE HEAT DURING OPERATION.

FIGURE4.131

HeaterHoses , Inspect theHeater Hosesbetween Heater and Engine forsignsof damage andwear.See Figure 4.130. ,

,

ARM HOSES AND TUBES

Boom Hoses & Tubes InspectBoomHeadand RodHosesand Tubesfordamage, wearandlooseconnections.

SeeFigure 4.131.

Arm Hoses & Tubes Inspect Arm HeadandRodHosesandTubes fordamage, wearandlooseconnections.

See Figure 4.132.

FIGURE4.132

4-49

Section IV- MAINTENANCE 4. Bucket Hoses & Tubes InspectBucketHeadand Rod Hosesand Tubes for damage,wearand looseconnections.

See Figure4.133.

5. Fuel Linesand Hoses InspectFuelLinesandHosesfor damage, wear andlooseconnections.

Repairor replaceFuel LinesandHosesbeforeoperating themachine.

FIGURE 4.133 6. HydraulicSuctionTubes& Hoses Inspect allHydraulic TubesandHosesfordamage,wearand looseconnections.

See Figure 4.134.

FIGURE 4.134 7. RadiatorHoses& Cap Inspect theRadiator Hosesforsignsof damageor deterioration.

Replace hosesif found to be inbadcondition.

Inspect theRadiator Cap Sealforsignsof damageanddeterioration and replace withnewpartif foundto be in badcondition.

SeeFigure4.135.

FIGURE 4.135 8. Foam Seals Inspectthe FoamRubberSealsaroundthe Radiator, OilCoolerandon theEngineCover.

MakeCertaintheyare in placeandsecureto preventoverheating of theengine.

See Figure 4.136.

FIGURE 4.136

4-50

Section IV- MAINTENANCE 9. FuelFillerStrainer Inspect theFuelFiller Strainer beneath Fuel Filler Capfordamage, dirtanddebris.

MakecertaintheStrainer is cleanandin placebefore fueling themachine.

SeeFigure4.137.If the Strainer is damaged, replace witha newpart.

Order Part Number2446R326.

NOTE Do notremovethisfilterto refuelmachine.

To do so mayallowdirtanddebris to enterfueltank.

FIGURE 4.137

4-51

Section IV- MAINTENANCE D. MACHINE STORAGE Perform thefollowing procedure toprepare the machine forlongtermstorage.

1.Perform allInspection andMaintenance procedures aspreviously described inthissection.

2.Thoroughly clean themachine, inspect fordamagedor wornpartsandcomponents andreplace or repair alldamaged or wornparts.

I

3.Completely fill fuel tankwith fresh, clean fuel to aidinpreventing condensation of moisture inside thefueltank.

4.Movemachine to anindoor location forstorage.

5.Operate bucket andarmcompletely "IN"extendingcylinders¯ Thenlower boomuntil attachment isresting onthefloor¯ SeeFigure 4.138¯ 6.Coatcylinder rodswitha heavy coatofgrease toprevent corrosion during storage.

7.Remove Batteries andstore ina wellventilated, warmarea.

CAUTION

Protect CPUandallelectrical components fromwater I andsteamwhencleaning themachine. I

POSITION MACHINE AS SHOWN INSIDE A STORAGE BUILDING

t’~ ~

_ HEAVILY GREASE ALLCYLINDER RODSTO PREVENTCORROSION FIGURE4.138

E. CARE DURING STORAGE 1.Every 30daysduring storage, itwillbenecessarytostart andrunthemachine tocirculate thefluids through thesystems.

Before starting clean cylinder rodsandafter running re-grease cylinder rods.

NOTE Runandoperate machine forapproximately 1 hourto allow allfluids tocirculate wellandreach normal operatingtemperatures.

4-52

F. REMOVING MACHINE FROM STORAGE allInspection andMaintenance proce1.Perform dures asdescribed inthissection before bringingmachine outofstorage fornormal operation.

2.Remove drainplugsfromTravel Motorand Swing GearReduction Units to drain offany moisture whichmayhaveaccumulated during storage.

3.Carefully andclosely inspect allHydraulic Hoses after longperiods ofstorage forsigns of deterioration.

Replace allhoses showing these signs.

Section IV- MAINTENANCE E. TRANSPORTING MACHINE 1. MachinePreparation a. Knowthetotalweight, length, widthand heightof themachinebeingtransported.

See Figure4.139. b. Knowrouteto be traveled.

Investigate bridges, overpasses, trusses andtraffic flow on route. c. Obtainanypermitsrequired fromproper government agencies fortransport of machine. d. Useonlya trailer witha ratedcapacity sufficient to transport themachine. e. Makecertain trailer hasrampsor a rampis available forloading andunloading the machine.

5,790(19’)

N o

Dimensions and weights are with2.07m (6’-9")Arm, 0.22m3 (0.29cu. yd.)Bucketand 3.72m (12’-2") MACHINE MODEL SK70SR

WEIGHT 450 mm SHOE 6,740kg

600 mm SHOE 6,850kg

(14,860 Ibs)

(15,100 Ibs)

FIGURE 4.139

2. Loadingthe Machine

ITHRO CONTROL

NEVER ATTEMPT TO LOAD OR UNLOAD MACHINE WITHOUT RAMPS. NEVER USE ATTACHMENT AS AN AID IN LOADING OR UNLOADING THE MACHINE. a. Applyparking brakes on tractor andtrailer andchocktrailer wheelsbeforeattempting to loador unloadmachine. b. Lowerrampsof trailer. ¢. PlaceTravelSpeedSelectSwitchon travel leverin lst(,d~) Speedposition andmove Throttle Control to the"LO"idleposition.

See Figure4.140. d. Slowlytravelmachine up trailer rampsand overrearaxles oftrailer.

I I

ITRAVEL SPEED ISELECT SWITCH

(~

FIGURE 4.140 STOP MACHINE OVER TRAILER AXLES

WARNING ro PREVENT THE ARM AND BUCKET CYLINDER (S) FROM ANY DAMAGE, YOU ARE ADVISED TO FOLLOW THE FOLLOWING

’RAILER RAMPS

INSTRUCTIONS.

FIGURE 4.141

DO NOT HAVE THE ARM AND/OR BUCKET CYLINDER FULLY EXTENDED TO A "RAMP OVER CENTER" SITUATION. THIS

SLOWLY SWING MACHINE UNTIL ATTACHMENT IS TOWARD REAR OF TRAILER

ALLOWS SUDDEN AND ABRUPT CONTACT OF THE ARM OR BUCKET TO A TRAILER DECK, RAMP OR THE GROUND. THIS CAN RESULT IN INTERNAL MECHANICAL CONTACT, WHICH CAN STRETCH THE CYLINDER ROD(S).

SEE FIGURE 4.141.

e. Slowly travelmachine completely ontotrailer untilinproper transport position. f. SlowlySwingmachine 180° untilattachment is toward rearof trailer.

SeeFigure 4.142. g, SlowlylowerBoomuntilattachment restson trailer bed.

4-53

FIGURE 4.142

Section IV- MAINTENANCE h. PlaceSafety LockLeverin theup "LOCKED" position.

SeeFigure 4.143. i. Turnmachine "OFF", remove Keyandlockall doors, filler capsandaccess panels.

/~1 I CAUTION pipeofI/~ Placea coverovertheexhaust themachine I andsecure to avoid water entering theengine.

I i

FIGURE4.143 3. Securing Machine to Trailer a.Using cable orwireropeofsufficient capacity, secure front andrear ofeach track totrailer.

SeeFigure 4.144. b.Secure attachment totrailer asshown in Figure 4.144. c.Secure allloose components totrailer.

SECURE IL 1)-----

I FRONT & REAR ~-~ | OF EACH TRACK~J_~

- ~,.~.~,,,~,.,~ .... ~_J

SECURE I

/

IATTACHMENT I

FIGURE4.144

4-54

I

Section IV- MAINTENANCE F. LIFTING MACHINE Thefollowing procedures areforlifting themachine, as built by KOBELCOCONSTRUCTION MACHINERY CO., LTD. These proceduredo nottakeintoaccount modifications madeto the machinethataffectmachineweightor center ofgravity.

WEIGHT:6,625kg(14,6051bs) ARM:1.65m(5’-5") SHOE:450mm(17.7")

lifting locations at thefrontandrearof 1. Locate eachcrawlerframe.See Figure4.145. cables or wireropewitha capacity rating 2.Attach sufficient toliftthemachine, atlifting locations.

CAUTION Placea hardwoodor Steelblockbetweencablesand crawlerframeto preventdamageto thetracksfrom cables during lifting.

SeeFigure 4.145.

CENTER OFGRAVITY

at machine 3. Bringlooseendsof cablestogether center ofgravity andattach toan overhead liftingdevice witha ratedlifting capacity sufficient to liftthemachine.

SeeFigure4.145.

NOTE It maybe necessary to placereinforced spreader bars betweenlifting cablesto preventdamageto the machine during lifting.

SeeFigure 4.145to 146.

(25.6") (21.6") PLACE BLOCK BETWEEN EACH CABLE AND FRAME

~ ,../ 3600 (11’-10") /~

to desired loca4. Slowlyliftandmovemachine tion.

ALWAYS USE PROPER LIFTING EQUIPMENT AND DEVICES. USE OF IMPROPER LIFTING EQUIPMENT COULD ALLOW THE LOAD TO SHIFT OR FALL CAUSING SEVERE DAMAGE, SERIOUS INJURY OR DEATH.

FIGURE 4.145

DANGER Do not use counterweight liftingeyesto liftwhole machine.

Lifting eyescanfallunderthisloadresulting in personal injury.

Referto operatorsmanualfor properway of liftingmachine.

4-55

ARS

Section IV- MAINTENANCE G.LIFTING MACHINE (WITH DOZER BLADE) Thefollowing procedures areforlifting themachine,as builtby KOBESTEEL,LTD.Theseproceduredo nottakeintoaccount modifications madeto the machinethataffectmachineweight orcenter ofgravity.

WEIGHT:6,960kg(15,3401bs) ARM:1.65m(5’-5") SHOE:450mm(17.7")

PLACE BLOCK lifting locations atthefront andrearof 1. Locate eachcrawlerframe.See Figure4.145. cables or wireropewitha capacity rating 2. Attach sufficient toliftthemachine, atlifting locations.

CAUTION Placea hardwood or SteelblockbetweencablesandI crawlerframeto prevent damageto thetracksfromI cablesduringlifting.

SeeFigure4.145.

I

CENTEROF GRAVITY

3.Bringlooseendsof cablestogether at machine center ofgravity andattach to anoverhead liftingdevice witha rated lifting capacity sufficient to liftthemachine.

SeeFigure 4.145.

SHACKLE

NOTE It may be necessary to placereinforced spreader bars between lifting cablesto preventdamageto themachine during lifting.

SeeFigure 4.145.

FIGURE 4.145 4.Slowlyliftandmovemachine to desired location.

WARNING ALWAYS USE PROPER LIFTING EQUIPMENT AND DEVICES. USE OF IMPROPER LIFTING EQUIPMENT COULD ALLOW THE LOAD TO SHIFT OR FALL CAUSING SEVERE DAMAGE, SERIOUS INJURY OR DEATH.

WEIGHT:5,780kg(12,7401bs)

H. LIFTING MACHINE (WITHOUT ATTACHMENT) Liftup machine without attachment is theproceduredescribed above.See Figure4.146.

SHACKLI

PINHOLE

,

)

FIGURE 4.146

4-56

CENTEROF GRAVITY

Section IV- MAINTENANCE G. CHECKINGTHE AIR CONDITIONER REFRIGERANT 1.Start theengine.

Settheengine speed tothe middle speed position.

COMPRESSOR SWITCH

2.Setthemachine to theconditions shownbelow whenchecking therefrigerant.

SeeFigure 4.167. ¯ Airconditioner :ON switch ¯ Fanswitch :HIposition (MaximurnA) ¯ Temp.adjustment:Upper tempposition(A) switch ¯ Door/ Window :Close ¯ Compressor switch:ON (The lampturn

TEMPERATURE CONTROL SWITCH

FIGURE4.147

Refrigerant volume

ON)

FAN SWITCH SWITCH

Description

(~ Proper

theprocedure belowandcheckthe 3. Follow refrigerant volume bylooking thorough thesight glass (inspection window) on theupper part thereceiver dryer. a.Figure(~ showsthattherefrigerant volume isproper.

0

After theairconditioner isturned ON,little bubbles appear.

Therefrigerant becomes transparent, then turns a light milky white.

(~)Overcharged

X

b. Figure (~shows thattherefrigerant is over charged.

Thiswillmakebothhighandlow pressure extreme andexerta badinfluence onthepressure switch operation andtheair (~Insufficient conditioning system.

X

¢.Figure (~)shows thattherefrigerant insufficient.

Havetherefrigerant recharged at yourKOBELCO distributor.

NOTE ¯ Newrefrigerant (HFC-134a), whose characteristics are different fromconventional CFC-12, isusedinthis machine.

Do notmixHFC-134a withCFC-12. ¯ Keeptheairconditioner ready foruseallyearround.

Operate theairconditioner atleast onceevery weekfor several minutes to rotate thecompressor regardless of theseason.

Thiswillprevent therefrigerant gasfrom leaking fromthecompressor sealing.

©

After theairconditioner isturned ON,no bubbles appear.

After theairconditioner isturned ON, bubbles appear continuously.

gasis mixed Bubbles :Refrigerant with refrigerant fluid.

No Bubbles : Wholerefrigerant becomes fluid andtransparent.

Cloudy

@

4-57

:Refrigerant is separated fromoil.Thefluidbecomes a light milky white.

INSPECTION MACHINE MODEL: SK ITEM ENGINE OIL LEVEL

& MAINTENANCE

SERIALNO.:

CHECKLIST MACHINE HOURS:

OK MAINT. PERFORMED

ITEM

OK MAINT. PERFORMED

HYD. FUNCTION OPERATION

ENGINE COOLANT LEVEL

CHECK SWITCHES

CHECK FOR FLUID LEAKS

CHECK TRAVEL ALARM

CHECK BELT TENSION

CHECK SWING BRAKE

CHECK FUEL LEVEL

CHECK WARNING LIGHTS

DRAIN WATER SEPARATOR

CHECK BUZZER

CHECK AIR CLEANER

CHECK GAUGES

CHECK ENGINE ELECTRICAL

CHECK HORN

DRAIN WATER FROM FUEL

CHECK DISPLAY MONITOR

CLEAN PRE-FILTER BOWL

SWING REDUCTION OIL

CHANGE ENGINE OIL

SLEWING RING GEAR

CHANGE OIL FILTER

GREASE BATH LEVEL

CHANGE FUEL FILTER

SLEWING RING PINION

CHANGE WATER SEPARATOR

SLEWING RING SEAL

CHANGE COOLANT FILTER

SWIVEL JOINT SEALS

CHECK AIR INTAKE SYSTEM

DRAIN WATER FROM BATH

CHECK FAN ASSEMBLY

GREASE SLEWING RING

CHECK BELT TENSIONER

CHANGE

CHECK VIBRATION DAMPER

GREASEBATH

CHECK BOLTS/HARDWARE

CLEAN RADIATOR

CHECK FOR OIL LEAKS

CLEAN DEBRIS SCREEN

CHECK LINESFOR DAMAGE

CHANGE ENG COOLANT

CHECK STEPS

AIR CLEANER ELEMENTS

CHECK FRAME STRUCTURE

ADJUST VALVE CLEARANCE

CHECKTRACKS&

CHANGE ETHER CYLINDER

CHECK SPROCKET WEAR

LINKS

HYDRAULIC OIL LEVEL

CHECK IDLER WEAR

CHECK HYD FUNCTIONS

CHECK ROLLER WEAR

CHECK FOR OIL LEAKS

CHECK TRACK TENSION

CHECK HOSES/LINES

ADJUST TRACK TENSION

CLEAN SUCTION SCREEN

TRAVEL REDUCTION OIL

CHANGE RETURN FILTER

CHECK BOOM & ARM

PILOT MANIFOLD FILTER

BUCKET TEETH

CHANGE HYDRAULIC OIL

SIDE CUTTERS

CLEAN HYDRAULIC TANK

GREASE BOOM PINS

INSPECT ALL WIRING

GREASE ARM PINS

BATTERY ELECTROLYTE

GREASE BUCKET PINS

BATTERY SERVICE

CHECK COOLANT ADDITIVE Theseitem includenon-equipped partsby the machine specification.

MECHANIC: SIGNATURE:

4-58

DATE:

Section V- SPECIFICATIONS Tableof Contents

5-1- 5-12 GENERAL SPECIFICATIONS ................................................................................

5-1 Machine Dimensions ................................................................................

5-1 Attachment Working Ranges ............................................................................

5-2 Boom .......................................................................................

5-2 Arm ........................................................................................

5-2 Bucket ......................................................................................

5-2 Shoes .......................................................................................

5-3 Performance Specifications ...........................................................................

5-3 Travel Speed .................................................................................

5-3 Swing Speed .................................................................................

5-3 Gradeability .................................................................................

5-3 Engine ....................................................................................

5-3 Hydraulic Components ............................................................................

5-3 Machine & Components Weights ..........................................................................

5-4 ~ 5-7 Lifting Capacities (EU) .............................................................................

5-8- 5-11 Lifting Capacities (USA) .............................................................................

5-12 OPTIONAL ATTACHMENTS SPECIFICATIONS .......................................................................

5-12 Attachment Working Ranges ............................................................................

5-13 Bucket & Arm Combinations ............................................................................

5-13 TORQUE SPECIFICATIONS .................................................................................

5-13 Capscrews &Nuts .................................................................................

5-14 Nuts &Sleeves ..................................................................................

5-14 Flare Type Fitting Joints ............................................................................

5-14 Nylon Tube Fitting Joints ............................................................................

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

5-0

SectionV- SPECIFICATIONS 5.1 GENERAL SPECIFICATIONS The specifications foundin this sectionare given on tl~e StandardSK70SR HydraulicExcavatoras manufactured

by KOBELCO CONSTRUCTION

A. MACHINE DIMENSIONS- Figure 5.1 1. These dimensionsconsiderthe following: a. StandardBoom- 3.72 meter (12’-2"). bo StandardArm- 2.07 meter(6’-9"). c. Bucket-0.22m 3 (0.29cubic yard). d. Standard Shoe- 600mm (23.6")

MACHINERY CO., LTD. No modifications or optionsaretakenin to consideration in regardto these specifications.

5,510mm (18’-1") 4,350mm(14’-3") TRANSPORTATION POSITION ~ ~

1,160mm (3’-10")

~.

E E

C:) t,D J

~

1,140mm(3’-9") 2,860mm(9’-5")

2,470mm (8’-1")

Markeddimensiondo not include heightof shoelug.

5,790mm(19") FIGURE 5.1 10’668

B. ATTACHMENT WORKING RANGES- Figure 1. Standard Attachment Working Ranges:

5.2

(35’) ¯

a. BOOM-3.72 M (12’-2")

6,096 (20’)

Widthwith Side Cutters-650 mm (2’-2")

4,572 (15’)

Widthw/o Side Cutters-580 mm (1 ’-11") Weight-190 kg (420 Ibs)

(lO3

6710

B

MaximumDiggingReachat Ground 6570

21’-7"

(5’)

C

MaximumDiggingDepth

4520

14’-10"

D

MaximumDiggingHeight

7500

24’-7"

E

MaximumDumpingClearance

5430

17’-10"

F

MinimumDumpingClearance

2070

6’-9"

G

Max.Vertical WallDigging Depth

3970

13’-0"

H

MinimumSwingRadius

2090

6’-10"

/

1

MaximumDiggingReach

I

mm

D

3,048

SAE 22’-0"

A

-

7,620 (25’)

Struck0.18m3 (0.24cu yd)

FUNCTION

g "

- H

b. ARM- 2.07 M (6’-9") c. BUCKETSAE Heaped 0.22m3 (0.29 cu yd)

ITEM

,i

A

9,144 (30’)

1,524

0 -1,524

(-5’)

i

-3,048

(-lO’) -4’572 (-15’)

CAUTION

-6096

(-2o’)

Do not excavate with the machine in transport position. Such operation can cause attachment damage and cab interference.

-7620 (-25’) 10,668

9,144

(35’)(30’)

7,620 (25’)

6,096 (20’)

4,572 (15’)

FIGURE 5.2

5-1

3,048 (10’)

1,524 (5’)

i

SectionV- SPECIFICATIONS C. BOOM- Figure 5.3 1. Standard Boomis 3.72Meter(12’-2")

i,

A- Lengthis 3.715METER(12’-2") Center Lineto Center Lineof Pins.

B- Heightis 1085 mm (42.7") FromCenterline of BoomEndto Centerline of Arm Cylinder Boss.

C- Width is 360mm(14.2") From edgeto edge of BoomFoot.

WEIGHT-Approximately 390 kg (860 Ibs)

ARM

CYLINDER~

FIGURE 5.3 D. ARM- Figure5.4 1. Standard Armis 2.07mm (6’-9") A- Lengthis 2.07METER(6’-9") CenterLineto CenterLineof Pins.

B- Widthis 180mm(7.1") Fromedgeto edgeof Arm end.

WEIGHT-Approximately 180 kg (400 Ibs)

~-® A FIGURE 5.4

E. BUCKET-Figure 5.5 1. Standard Bucketis 0.22m 3 (0.29cu yd) A- Lengthis 0.98Meter(3’-3") B- Heightis 0.89Meter(2’-11") C-WidthWithoutSide Cuttersis 580mm (1’-11") D- WidthwithSideCutters650mm(2’-2") E- BucketWeightis 190kg (420Ibs)

I A

C D FIGURE 5.5

F. SHOES- FIGURE 5.6 1. StandardShoesfor the SK70SRare 600mm (23.6") Triple Grouser.

2. Quantity of shoes; SK70SR(39 per track)

FIGURE 5.6

5-2

Section V- SPECIFICATIONS H. MACHINE & COMPONENT WEIGHTS Thefollowing Weight Specifications arebasedon theStandard Machine withStandard Attachment.

G. PERFORMANCE SPECIFICATIONS Thefollowing Performance Specifications are basedon theStandard Machine withStandard Attachment.

1. Travel S }eed,SwingSpeed& Gradeability

1. ComponentWeights

SPECIFICATION

DESCRIPTION TRAVEL SPEED

COMPONENT

SK70SR

5.3 km per hr (3.3mph) in ~1~ mode.

COMPLETE MACHINE (STANDARD)

7,180(15,830)

3.4 km per hr ( 2.1 mph) in ~ mode.

UPPER FRAME ASSEMBLY

3,250(7,160)

SWING SPEED

12.5 RPM IN H-Mode/"HI"Idle.

GRADEABILITY

70% (35 °)

COUNTERWEIGHT

820(1,810)

CAB

210 (460) 92 (200)

BOOM CYLINDER* ENGINE*

2. Engine a.Major Engine Specifications.

ISUZU A-4JB1 4-Cycle, Water Cooled, Direct Injection X 102ram (3.66"X 4.01") Numberof CylindersBoreX Stroke 4-93mm Displacement 2.771 liter (169 cuin.)

Compression Ratio 18.2:1 40.4kw / 2,100 rpm Output Rating(ISO9249) (55PS/2,100 rpm) 19.2kgf.m/1,600 rpm MaximumTorque(ISO9249) (139Iboft/1,600 rpm) -2,345 rpm MaximumRPM at No Load-HighIdle 2,295 MaximumRPM at No Load-Low Idle 980- 1020rpm 1-3-4-2 Clockwise Rotation Ignition Order 17_+1 ° Before TopDead Point Injection Timing EngineMaker Model Type

RADIATOR* PUMP ASSEMBLY CONTROL VALVE

Intake ValveClearance Cold Exhaust ValveClearance Cold Electrical System Starting Motor Alternator Batteries EngineDry Weight* Thermostat Cooling Fan DriveMethod

HYDRAULIC TANK*

64 (140)

SWING MOTOR & REDUCTION UNIT LOWER FRAME ASSEMBLY

115(250)

TRAVEL MOTOR & REDUCTION UNIT

90 (200)

IDLER ASSEMBLY

44 (97)

LOWER ROLLER ASSEMBLY

15 (33)Xl0

UPPER ROLLER ASSEMBLY

4 (9)

TRACK TENSION ASSEMBLY

28 (60)

SPROCKET

27 (59)

NOTE BOOM ASSEMBLY Forprovision affecting thequalified engine complying with BOOM EPArequirements forexport toNorthAmerica, referto ARM CYLINDER* pages9-9and9-10.

PIN (Mounting the Arm & Arm Cyl) FLUIDS

HYDRAULIC

PUMPS

SWING MOTOR TRAVEL MOTOR CONTROL VALVES CYLINDERS (ALL) RETURN FILTER i OIL COOLER

67 (150) 2,820(6,220)

SLEWING RING

PIN(2 PCSformtgbucket cyl& bucket)

COMPONENT

44 (97) 44 (97) 42 (93) 53 (120)

0.4mm (.016") DOZER BLADE 0.4mm (.016") DOZER BLADE CYLINDERS * D.C.24 V TRACK LINK W/600mm (23.6") SHOEE 24 V-3.2KW 24 V-30A TRACK LINK 2- 12V- (136Ah) ATTACHMENT (STANDARD) 240kg(529Ibs) BUCKETASSEMBLY [0.22m 3 (0.29cu yd)] Begin toopenat 82°C(180°F).

ARM ASSEMBLY [2.07m (6’-9")] Fullopenat95°C(203°F).

E~450 (E)17.7") Suction Type Belt ARM[2.07m(6’-9")] Drive Pulley Ratio: 1.12 BUCKET CYLINDER* DryTypewithSafety Elements IDLER LINK *Less flywheel andelectrics.

BUCKET LINK

3. Hydraulic Components

240(530)

FUEL TANK*

SWIVEL JOINT

AirCleaner

Unit : kg(Ibs.)

21 (46) 280(620)

55(120) 530(1,170) 155 (340) 1,110(2,450)

190(420) 29O(640) 180(4O0) 44(97) 6 (13) 8 (17)X2 17 (37) 630(1,390) 390 (860) 72 (160) 16 (35) 130(290)

HYD OIL, ENG OIL

54 (119)

TYPE

FUEL

71 (156)

Tandem,VariableDisplacement, AxialPistonwith PilotGearPump.

WATER

5 (11) * DRY WEIGHT

AxialPiston AxialPiston 6 SpoolMultiple Control DoubleActing SafetyValvecontaining FilterType Air Cooled

USE ONLY LIFTING DEVICES AND EQUIPMENT WITH RATED CAPACITIESSUFFICIENTTO LIFT THE SPECIFIC COMPONENT(S) BEING REMOVED OR INSTALLED.

5-3

Section V- SPECIFICATIONS I. LIFTINGCAPACITIES(EU)

RATED OBJECT HANDLING CAPACITIES TABLE

KOBELCO CONSTRUCTION MACHINERY CO.,LTD.

SK70SR SHOE WIDTH 450mm HEIGHT (m)

t

LEFTPOINT(AXIS) Axis ARM(Seethefollowing table) BOOM(Seethefollowing table) COUNTERWEIGHT 820kg

WORKING CONDITIONS: - withnotool(bucket, clamshell..).

If object handling is performed with toolinstalled, theweight ofthetool shallbe deducted fromthe values ofthistable.

- withextended bucketcylinder.

- on a compact or horizontal, level ground.

WORKING CIRCUIT - in completeswingof the upperPRESSURE29420kPa structure HOLDING CIRCUIT PRESSURE 29420kPa

AXIS OF ROTATION

0

1

2

3

4

5

6

7

OUTREACH

(m)

8

THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH I BOOM LENGTH 3.72m J OUTREACHIN METERS ARM (BOOMFOOT HEIGH1 LENGTH LOADSIN KG (m) OUTREACH(m) 3 4.5 6 7.5 MAX REACH m Z2 1800 m m 1.65 LD= 1.99 Zl 1700 900 700 (5.42m) B B Z3 1700 m m Z2 2000 m 2.07 LD= 2.40 Zl 1700 900 600 (5.83m) Z3 1500

LD: BOOM POINT TO HOOK POINT DISTANCE

YT20TO1055P2

5-4

Section V- SPECIFICATIONS RATED OBJECT HANDLING CAPACITIES TABLE

KOBELCOCONSTRUCTION MACHINERY CO., LTD.

SK70SR SHOE WIDTH 450mm HEIGHT(m)

t

LEFT POINT (AXIS) Axis ARM (See the followingtable) BOOM (See the followingtable) COUNTERWEIGHT

820kg

WORKING CONDITIONS: -withno tool(bucket,clamshell..).

If objecthandling is performed with toolinstalled, theweightof the tool shallbe deductedfrom the values ofthistable.

- with extendedbucketcylinder.

- on a compactor horizontal, level

ground.

WORKING CIRCUIT PRESSURE 29420kPa

- in completeswing of the upper structure HOLDING CIRCUIT PRESSURE 29420kPa

AXIS OF ROTATION

0

1

2

3

5

4

6

7

8

OUTREACH (m)

THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH I BOOM LENGTH3.72mI ARM LENGTH

(m)

OUTREACH (~m I

Z2 1.65 LD= 1.99Zl Z3 Z2 2.07 LD= 2.40Zl Z3

3

OUTREACH IN METERS LOADS IN KG 4.5 6 7.5

1800 1900 1000 1700 2000 1800 1000 1500

B B

(BOOM FOOT HEIGHT) MAX

REACH D

B

800 (5.42m)

m

700 (5.83m)

m i

m

LD: BOOM POINT TO HOOK POINT DISTANCE

YT20T01057P2

5-5

Section V- SPECIFICATIONS RATED OBJECT HANDLING CAPACITIES TABLE

KOBELCOCONSTRUCTION MACHINERY CO., LTD. =

SK7OSR SHOE WIDTH 600mm HEIGHT(m)

LEFT POINT (AXIS)

t

Axis

I

ARM (See the following table) BOOM (See the following table) COUNTERWEIGHT

820kg

WORKING CONDITIONS: - withno tool(bucket, clamshell..).

If objecthandlingis performed with toolinstalled, the weightof the tool shallbe deductedfrom the values of thistable.

- with extendedbucketcylinder.

- on a compactor horizontal, level ground.

WORKING CIRCUIT PRESSURE 29420kPa - in completeswingof the upper structure HOLDING CIRCUIT PRESSURE 29420kPa

AXIS OF ROTATION

0

1

2

3

4

5

6

7

8

OUTREACH (m) Im~

THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH I BOOM LENGTH3.72mI ARM OUTREACH IN METERS (BOOMFOOTHEIGH] LENGTH LOADSIN KG (m) OUTREACH(m 3 4.5 6 7.5 MAX REACH I m m Z2 1800 B 1.65 LD= 1.99 Zl 1800 900 700(5.42m) m B Z3 1700 m B Z2 2000 B 2.07 LD= 2.40Zl 1800 900 600 (5.83m) m m Z3 1500 LD: BOOM POINT TO HOOK POINT DISTANCE

YT20T01056P2

5-6

Section V- SPECIFICATIONS RATED OBJECT HANDLING CAPACITIES TABLE

KOBELC0CONSTRUCTION MACHINERY C0., LTD.

SK70SR SHOE WIDTH 600mm HEIGHT(m)

LEFTPOINT (AXIS)

t

Axis ARM (See the following table) BOOM (See the following table) COUNTERWEIGHT

820kg

WORKING CONDITIONS: - withno tool(bucket, clamshell..).

If objecthandling is performed with toolinstalled, theweightof thetool shallbe deductedfrom the values ofthistable.

- with extendedbucketcylinder.

- on a compactor horizontal, level ground.

WORKING CIRCUIT PRESSURE 29420kPa - in completeswingof the upper structure HOLDING CIRCUIT PRESSURE 29420kPa

AXIS OF ROTATION

0

1

2

3

4

5

6

7

8

OUTREACH (m) illb"

THESE LOADS ARE VALID FOR THE HEIGHT OF THE CONSIDERED ZONE (Z.) FOR THE INTENDED OUTREACH I BOOM LENGTH 3.72m ARM OUTREACH IN METERS (BOOMFOOTHEIGH1 LENGTH LOADSINKG (m) OUTREACH 4.5 6 7.5 MAX REACH Im’~ 3 Z2 1800 1.65 LD= 1.99Z1 2000 1000 800 (5.42m) Z3 1700 Z2 2000 2.07 LD= 2.40Zl 1900 1000 700(5.83m) Z3 1500 LD: BOOM POINT TO HOOK POINT DISTANCE

YT20T01058P2

5-7

Section V- SPECIFICATIONS J. LIFTING CAPACITIES(USA) 1. LiftingCapacity Specifications are basedon theStandard Machinewith1.65Armand 450mm Shoes.

SK70SR LIFTING CAPACITIES Basedon a machineequippedwith Arm 5’-5"(1650mm) Bucket SAE heaped0.37cu yd (0.28a) Bucket Shoe 17.7"(450mm) TripleGrouserShoe

5’(1.5m)

1~ 20’ (6.1m) 15’ (4.6m) 10’ (3.0m)

Ib

k9 Ib

k9

* 9300 * 4200

* 9300 * 4200

* 9300 * 4200 * 5400 * 2400

* 9300 * 4200 * 5400 * 2400

Ib

kg

5’

Ib

(1.5m) GROUND LEVEL -5’ (-1.5m) -10’ (- 3.0m)

k9 Ib kg Ib kg Ib kg

q~~B

=

LOAD RADIUS 15’(4.6m)

10’(3.0m)

~

* 4500 * 2000 * 5500 * 2500 5300 2400 4900 2200 4800 2200 * 3600 * 1600

~

* 4500 * 2000 4800 2100 4200 1900 3800 1700 3800 1700 * 3600 * 1600

2900 1300 2700 1200 26OO 1100 2500 1100

2300 1000 2200 90O 2000 900 2000 900

1.Donotattempt tolift orhold anyload that isgreater than 4. Theabove rated loads arein compliance withBS1757:1986. these rated values attheir specified load radius andheight. Theydo notexceed 87%ofhydraulic lifting capacity or Weight ofallaccessories must be deducted from theabove 75%oftipping load. lifting capacities.

Rated loads marked withanasterisk (*)arelimited byhycapacity rather thantipping load.

2. Lifting capacities arebased onmachine standing onlevel draulic firmanduniform ground.

5. Operator should be fully acquainted withtheoperator’s instructions before operating thismaUsermustmakeallowance forjobconditions.

Sideloads andMaintenance sudden stopping of loads hazardous conditions, experi- chine andrules forsafeoperation ofequipment should be enceofpersonnel etc. adhered toatalltimes.

3.Ratings atbucket lifthook.

6. Capacities apply onlyto machine as original manufacturedand normally equipped

by KOBELCO CONSTRUCTIONMACHINERY CO..LTD. YT20TO1066P2

2. LiftingCapacity Specifications arebasedon the Standard Machinewith1.65Arm and600 mm Shoes.

SK70SR LIFTING CAPACITIES Basedon a machineequippedwith Arm 5’-5"(1650mm) SAE heaped0.37cu yd (0.283) Bucket Bucket Shoe 23.6"(600mm) TripleGrouserShoe

LOAD RADIUS ~~

*

* 9300 * 4200

,=

* 4200 * 5400 * 2400

~

~4~~

* 4500 * 2000 * 5500 * 2500 5600 2500 5100 2300

* 4500 * 2000 5000 2200 4400 2000 4000 1800

2300 * 3600 * 1600

1800 * 3600 * 1600

~=~

1300I 2800I 1300I 2700I 1200I

1100 2300 1000 2100 900

,00 ,00 0000 00

rated loads arein compliance withBS1757:1986.

1. Donotattempt tolift orhold anyload that isgreater than 4. Theabove 87%ofhydraulic lifting capacity or these rated values attheir specified load radius andheight. Theydonotexceed load.

Weight ofallaccessories must be deducted from theabove 75%oftipping Rated loads marked with an asterisk (*) are limited by hylifting capacities. draulic capacity rather than tipping load. __ 2.Lifting capacities arebased on machine standing on level should be fully acquainted withtheoperator’s 5. Operator firmanduniform ground. and Maintenance instructions before operating thismsUsermustmakeallowance forjobconditions.

Sideloads andrules forsafe operation of equipment should be sudden stopping ofloads hazardous conditions, experi- chine adhered toatalltimes. enceofpersonnel etc. apply onlyto machine as original manufac6. Capacities 3.Ratings atbucket lifthook. turedand normally equipped

by KOBELCO CONSTRUCTIONMACHINERY CO.,LTD. YT20T01065P2

5-8

SectionV- SPECIFICATIONS 3. Lifting Capacity Specifications are basedon theStandard Machine with1.65Arm+ DozerBladeand450mm Shoes.

SK70SR LIFTING CAPACITIES Based on a machine equipped with Arm 5’-5" (1650 mm) Bucket SAE heaped 0.37 cu yd (0.28 3) Bucket 17.7" (450 mm) Triple Grouser Shoe Shoe

LOAD RADIUS 1~5’(1.5m)o.~1 20’ (6.1m) 16’ (4.6m) 10’ (3.0m) 5’ (1.5m) GROUND LEVEL -5’ (- 1.5m) -10’ (- 3.0m)

Ib 9 k Ib 9 k Ib 9 k Ib 9 k Ib kg Ib kg Ib kg

* 9300 * 4200

* 9300 * 4200

* 9300 * 4200 * 5400 * 2400

* 9300 * 4200 * 5400 * 2400

~ * 4500 * 2000 * 5500 * 2500 5300 2400 4900 2200 4800 2200 * 3600 * 1600

10’(3~ ~

1~15’(4.6m)~:~1~~=~1~0,,.

* 4500 * 2000 5200 2300 4600 2000 4200 1900 4100 1800 * 3600 * 1600

2900 1300 2700 1200 2500 1100 2500 1106

2500 1100 2400 1000 2200 1000 2200 1000

withBS1757:1986.

1. Do notattempt toliftor holdanyloadthatis greater than 4. Theaboveratedloadsare in compliance Theydo not exceed87% of hydraulic liftingcapacity or theserated values at theirspecified loadradius andheight.

75%of tipping load.

Weightof all accessories mustbe deducted fromtheabove Rated loads marked with an asterisk (*) are limited by hylifting capacities.

2. Lifting capacities arebasedon machine standing on level draulic capacity rather thantipping load. shouldbe fullyacquainted withthe operstor’s firmand uniformground, 5. Operator and Maintenance instructions beforeoperating thismaUsermustmakeallowance for job conditions.

Sideloads chine and rules for safe operation of equipment shouldbe suddenstopping of loadshazardous conditions, experiadhered to at alltimes. enceof personnel etc.

6. Capacities applyonlyto machineas original manufac3. Ratings at bucket lifthook. tured and normally equippedby KOBELCO CONSTRUCTION MACHINERYCO., LTD. YT20T01062P2

4. Lifting Capacity Specifications arebasedon theStandard Machinewith1.65Arm+ DozerBladeand600mm Shoes.

SK70SR LIFTING CAPACITIES Based on a machine equipped with Arm 5’-5" (1650 mm) SAE heaped 0.37 cu yd (0.28 3) Bucket Bucket Shoe 23.6" (600 mm) Triple Grouser Shoe

LOAD,RADIUS I~ 5’ 20’ (6.1m) 16’ (4.6m) 10’ (3.0m) 5’ (1.5m) GROUND LEVEL -5’ (- 1.5m) -10’ (- 3.0m)

Ib 9 k Ib kg Ib kg Ib 9 k Ib k9 Ib kg Ib kg

(1~

* 9300 * 4200

* 9300 * 4200

* 9300 * 4200 * 5400 * 2400

* 9300 * 4200 * 5400 * 2400

1~15(4~

I~10’

(3~

* 4500 * 2000 * 5500 * 2500 5500 2500 5100 2300 5000 2200 * 3600 * 1600

* 4500 * 2000 5300 2400 4700 2100 4400 2000 4300 1900 * 3600 * 1600

3000 1300 2800 1200 2600 1200 2600 1200

I~

~

I~

~=~

2600 1200 2500 1100 2300 1000 2300 1000

withBS1757:1986.

1. Do notattempt toliftor holdanyloadthatisgreater than 4, Theaboveratedloadsare in compliance Theydo not exceed87% of hydraulic liftingcapacity or theserated values at their specified loadradius andheight.

75% of tipping load.

Weight of allaccessories mustbe deducted fromthe above Ratedloadsmarkedwithan asterisk (*)arelimited by hylifting capacities. draulic capacity rather thantipping load, 2. Lifting capacities are basedon machine standing on level 5. Operator shouldbe fullyacquainted withthe operator’s firmand uniformground. and Maintenance instructions before operating thismaUsermustmakeallowance for job conditions.

Sideloads chineand rulesforsafeoperation of equipment shouldbe suddenstopping of loadshazardous conditions, experiadhered to at alltimes. enceof personnel etc.

6. Capacities applyonlyto machineas original manufac3. Ratings at bucket lifthook, tured and normallyequipped by KOBELCOCONSTRUCTION MACHINERYCO., LTD. YT20T01061P2

5-9

SectionV- SPECIFICATIONS 5. LiftingCapacity Specifications arebasedon the Standard Machinewith2.07mArmand 450 mm Shoes.

SK70SR LIFTING CAPACITIES Based on a machine equipped with Arm 6’-9" (2070 mm) Bucket SAE heaped 0.29 cu yd (0.22 3) Bucket Shoe 17.7" (450 ram) Triple GrouserShoe

5’(1.5m)

~ 20’ (6,1m) 15’ (4.6m) 10’ (3.0m) 5’ (1.5m) GROUND LEVEL - 5’ (- 1.5m) -10’ (- 3.0m)

Ib k9 Ib kg Ib kg Ib kg Ib kg Ib kg Ib kg

10’(3.0m)

~

* 3400 * 1500

* 8000 * 3600 * 7700 * 3500

* 8000 * 3600 * 7700 * 3500

* 4900 * 2200 5400 2400 4900 2200 4800 2100 * 4800 * 2100

LOAD RADIUS 15’(4.6m)

~

* 3400 * 1500 3000 1300 2900 1300 2700 1200 2500 1100 2400 1100

* 4900 * 2200 4300 1900 3800 1700 3700 1600 3800 1700

2400 1100 2400 1000 2200 1000 2000 900 1900 800

1. Do notaHempt to liftor holdanyloadthatis greater than 4. Theaboveratedloadsarein compliance withBS1757:1986. theserated values st their specified loadredius andheight.

Theydo not exceed87% of hydraulic liftingcapacity or Weight of allaccessories mustbe deducted ftomthe above 75% of tipping load.

Ratedloadsmarked withan asterisk (*)are limited by hylifting capacities.

2. Lifting capacities arebasedon machine stending on level draulic capacity rather thantipping load. firmand uniformground.

5. Operator shouldbe fullyacquainted withthe operator’s Usermustmakeallowance for job conditions.

Sideloads and Maintenance instructions beforeoperating thismasuddenstopping of loadshazardous conditions, experichineandrulesfor safeoperation of equipment shouldbe enceof personnel etc. adhered to atalltimes.

3. Ratings st bucketlifthook.

6. Capacities applyonlyto machineas original manufactured and normally equippedby KOBELCO CONSTRUCTION MACHINERYCO., LTD. YT20T01064P2

6. LiftingCapacitySpecifications are basedon the Standard Machinewith2.07mArm and600 mm Shoes.

SK70SR LIFTING CAPACITIES Based on a machine equipped with Arm 6’-9" (2070 mm) Bucket SAE heaped 0.29 cu yd (0.22 3) Bucket Shoe 23.6" (600 mm) Triple Grouser Shoe

LOAD RADIUS ~ 5’ (1.5 m) ~10’ (3.0 m) ~15’ (4.6 m)~ 20’ (6.1m) 15’ (4.6m) 10’ (3.0m) 5’ (1.5m) GROUND LEVEL -5’ (- 1.5m) -10’ (- 3.0m)

Ib 9 k Ib kg Ib 9 k Ib 9 k Ib kg Ib 9 k Ib kg

* 3400 * 1500

* 8000 * 3600 * 7700 * 3500

* 8000 * 3600 * 7700 * 3500

* 4900 * 2200 5600 2500 5100 2300 5000 2200 * 4800 * 2100

=~

o,,,~ ~ =~=~ ~

* 3400 * 1500

* 4900 * 2200 4500 2000 4000 1800 3800 1700 4000 1800

* 3100 * 1400 3000 1400 2800 1300 2600 1200 2600 1100

2500 1100 2500 1100 2300 1000 2100 900 2000 900

withBS1757:1986.

1. Do notattempt to liftor holdanyloadthatisgreater than 4. Theaboveratedloadsarein compliance Theydo not exceed87% of hydraulic liftingcapacity or theserated values at their specified loadradius andheight.

75% of tipping load.

Weightof all accessories mustbe deducted fromthe above Ratedloadsmarked withan asterisk (*)are limited by hylifting capacities. draulic capacity rather thantipping load.

Lifting capacities arebasedon machine standing on level 5. Operator shouldbe fullyacquainted withthe operator’s firmand uniformground. and Maintenance instructions before operating thismaUsermustmakeallowance for job conditions.

Sideloads chineandrulesfor safeoperation of equipment shouldbe suddenstopping of loadshazardous conditions, experiadhered to at alltimes. enceof personnel etc.

6. Capacities applyonlyto machineas originalmanufac3. Ratings at bucket lifthook. tured and normally equippedby KOBELCO CONSTRUCTION MACHINERYCO., LTD. YT2OT01063P2

5-10

SectionV- SPECIFICATIONS 7. LiftingCapacity Specifications are basedon the Standard Machinewith2.07mArm+ DozerBladeand450mm Shoes.

SK70SR LIFTING CAPACITIES Basedon a machineequippedwith Arm 6’-9"(2070mm) SAE heaped0.29cu yd (0.223) Bucket Bucket Shoe 17.7"(450ram)TripleGrouser Shoe

LOAD RADIUS ~ 5’ (1.5 m) ~10’ 20’ (6.1m) 15’ (4.6m) 10’ (3.0m) 5’

Ib 9 k Ib 9 k Ib 9 k Ib

(1.5 m)

9 k

GROUND LEVEL -5’ (-1.5m) -10’ (-3.0m)

Ib 9 k Ib 9 k Ib kg

(3.0

m) ~~15’

* 3400 * 1500

(4.6

,~,=~ m)~=~

~

~,,~

~

e~l

* 3400 * 1500 3000 1300 2900 1300 2700 1200 2500 1100 2400 1100

2600 1200 2600 1100 2400 1000 2200 1000 2100 900

* 4900 * 4900 * 2200 * 2200 4700 5400 2400 2100 4900 4200 2200 1900 * 8000 * 8000 4700 4000 * 3600 * 3600 2100 1800 * 7700 * 7700 * 4800 4100 * 3500 * 3500 * 2100 1800 rated loads arein compliance with BS1757:1986. tolift orhold anyload that isgreater than 4. Theabove 1. Donotattempt these rated values attheir specified load radius andheight. Theydo notexceed 87%of hydraulic lifting capacity or 75% of tipping load.

Weight ofallaccessories mustbededucted fromtheabove Rated loads marked withanasterisk (*)arelimited byhylifting capacities. capacity rather than tipping load.

2.Lifting capacities arebased on machine standing on level draulic 6.Operator should be fully acquainted withtheoperator’s firmanduniform ground. and Maintenance instructions before operating thismaUsermustmakeallowance forjobconditions.

Sideloads sudden stopping of loads hazardous conditions, experi- chine andrules forsafeoperation ofequipment should be adhered toatalltimes. enceofpersonnel etc.

6. Capacities apply onlyto machine aa original manufac3.Ratings atbucket lift hook. turedandnormally equipped

by KOBELCO CONSTRUCTIONMACHINERY CO.,LTD. YT20T01060P2

8. LiftingCapacity Specifications arebasedon theStandard Machinewith2.07mArm+ DozerBladeand600mm Shoes

SK70SR LIFTING CAPACITIES Basedon a machineequippedwith Arm 6’-9"(2070mm) SAE heaped0.29cu yd (0.22~) Bucket Bucket 23.6"(600mm) TripleGrouserShoe Shoe

LOAD RADIUS ~ 20’ (6.1m) 15’ (4.6m) 10’ (3.0m) 5’ (1.5 In) GROUND LEVEL -5’ (-1.5m) -10’ (- 3.0m)

Ib 9 k Ib kg Ib 9 k Ib 9 k Ib k9 Ib kg Ib kg

5’

(1~,,~

~10’ * 3400 * 1500

* 8000 * 3600 * 7700 * 3500

* 8000 * 3600 * 7700 * 3500

* 4900 * 2200 5600 2500 5100 2300 4900 2200 * 4800 * 2100

(3~

~15’

(4..,~

~

* 3400 * 1500 * 4900 * 2200 4800 2200 4300 1900 4200 1900 4300 1900

3100 1400 3000 1300 2800 1200 2600 1200 2500 1100

2700 1200 2700 1200 2500 1100 2300 1000 2200 1000

rated loads arein compliance withBS1757:1986.

1. Donotattempt tolift orhold anyload that isgreater than 4. Theabove 87%ofhydraulic lifting capacity or these rated values attheir specified load radius andheight. Theydo notexceed 75% of tipping load.

Weight ofallaccessories must be deducted from theabove Rated loads marked withanasterisk (*)arelimited byhylifting capacities. draulic capacity rather than tipping load.

2. Lifting capacities arebased onmachine standing onlevel 6. Operator should be fully acquainted withtheoperator’s firmanduniform ground. andMaintenance instructions before operating thismaUsermustmakeallowance forjobconditions.

Sideloads andrules forsafe operation ofequipment should be sudden stopping of loads hazardous conditions, expari- chine adhered toatalltimes. ence of personnel etc, 6, Capacities apply only to machine as original manufac3.Ratings atbucket lifthook, turedand normally equipped

by KOBELCOCONSTRUCTIONMACHINERY CO.,LTD, YT20T01059P2

5-11

SectionV- SPECIFICATIONS 5.2 SPECIFICATIONSOPTIONAL ATTACHMENTS The followingWorkingRanges Specifications are

10’668 (35’)

basedon the StandardMachinewith OptionalAttachments.

A

9,144 (30’)

B

7,620

(25’) A. A’n’ACHMENT WORKING RANGES- Figure 5.7 6,096 (20’)

1. Attachment with: a. BOOM- 3.72 M (12’-2")

4,572

(15’)

b. ARM- 1.65 M (5’-5") c. BUCKETSAE Heaped 0.28m3 (0.37 cu yd) Struck 0.22m3 (0.29 cu yd)

3,048 (10’) 1,524 (5’)

Widthwith Side Cutters-750mm (2’-6") Width w/o Side Cutters-680mm (2’-3") Weight-200 kg (440 Ibs) ITEM A

FUNCTION MaximumDiggingReach

D

mm

SAE

6310

20’-8"

B

MaximumDiggingReachat Ground 6170

20’-3"

C

MaximumDiggingDepth

4100

13’-5"

D

MaximumDiggingHeight

7180

23’-7"

E

MaximumDumpingClearance

5120

16’-10"

F

MinimumDumpingClearance

2380

7’-10"

G

Max.Vertical WallDigging Depth

3540

11’-7"

H

MinimumSwingRadius

1750

5’-9"

-1,524 (~5’)

C -3,048

(-lO’) -4’572 (-15’) -6096 (-20’) -7620 (-25’) 10,668 9,144 7,620 6,096 4,572 3,048 1,524 (35’) (30’) (25’) (20’) (15’) (lO’) (51

FIGURE 5.7

2. Attachment with; a. BOOM- 3.72 M (12’-2") b. ARM- 1.65 M (5’-5") + EXTENSION ARM ¢. BUCKET SAE Heaped 0.22m3 (0.29 cu yd) Struck 0.18m3 (0.24 cu yd) Width with Side Cutters-650mm (2’-2") Widthw/o Side Cutters-580mm(1 ’-11") Weight-190 kg (420 Ibs) ITEM

mm

SAE

A

MaximumDiggingReach

FUNCTION

6760

22’-2"

B

MaximumDiggingReachat Ground 6630

21’°9"

C

MaximumDiggingDepth

4600

15’-1"

D

MaximumDiggingHeight

7520

24’-8"

E

MaximumDumpingClearance

5460

17’-11"

F

MinimumDumpingClearance

1900

6’-3"

G

Max.Vertical WallDigging Depth

4030

13’-3"

H

MinimumSwingRadius

1900

6’-3"

5-12

0

Section V- SPECIFICATIONS C. BUCKET & ARM COMBINATIONS BUCKET m3 (cu yd) SAE (JIS) (HEAPED)

ARM

JIS, SAE 1.65m 2.07m 1.65m (5’-5") (STRUCK) (5’-5") (6’-9") + EXTENSION

o 0.14(0.18)

0.12 (0.16)

O

01i8 (0.24) 0:14(0:18) i O 0.22(0.29)

O

0.18(0.24) I

0.=(0,29)

0.28(0.37) 0.35(0.46)

¯

0.26(0.34)

o

[

O - Normal Working O

E~ - Standard

O

O

¯ - LightDutyOnly

O

O

X - Do Not Use This Combination

A

A

X

X

5.3 TORQUE SPECIFICATIONS Thefollowing TorqueSpecifications areprovided forusewhenactualtorquevalueof a fastener is notknown.

A. CAPSCREWS & NUTS 1. MetricCoarseThreadStandard Tightening TorqueValues.Makecertainto tighten all Capscrews & Nutsto propertorquevalues.

Classification

4

T

7

T

10

NOMINALSIZE

NO LUBRICATION

M6

P=I

0.98__+0.1 (7.1:L-0.7) 1.5-+0.15 (10.8_+1.1) 0.45__+0.05 (3.2-+0.4) 0.38-+0.04(2.7-+0.3) 0.83-+0.08 (6.0±0.6) 1.77__+0.18 (12.8__+1.3

M8

P=1.25

(17.3-+1.4) 4.3_+0.4 (31,05-_2.9) 3.6-+0.4 (26.0+__2.9) 1.09_--H].11 (7.9_+0.8) 0.92+-0.09 (6.6+0.7)2.4+_0.2 2.0+0.2 (14.4_+1.4)

M10

P=1.5

4.0+-0.4 (28.9+_2.9) 8.5_+0.9 (61.3-+6.5) 7.2__+0.7 (52.0-+5.1) 2.2-+0.2 (15.9+_1.4) 1.83+0.18 (13.2+1.3)4.7+_0.5 (33.94__3.6)

M12

P=1.75

3.7_+0.4 (26.7+_2.9)3.2-+0.3 (23.1+-2.2) 8.1+_0.8 (58.5+5.8) 6.8_+0.7 (49.1+5.1) 14.6+1.5 (105+10.812.3+_1.2 (88.8_+8.7)

M14

P=2

5.9_+0.6 (42.6+_4.3)5.0-I--0.5 (36.1_+3.6) 12.8+_1.3 (92.5+9.4) 10.8-+1.1 (78.0-+7.9)23+~2 (166+__14) 19.5+_1.9 (140-+14)

M16

P=2

9.0-+-.09 (64.9_+6.5) 7.6__+0.7 (54.8+5.1) 19.5+_2.0 (140&-_14.4) 16,4_+1.6 (118_+11.5) 35+_4 (252+_28.9) 29-+3 (209+_21.6)

M18

P=2.5

12,4+_1.2 (89.6_+8.7) 10.5+_1.0 (75.8+_7.2)27_+3 (195+_22)

23+_2 (166-+14)

495-_5 (354+_36)

41+4(296+_2.9)

M20

P=2.5

17,5__+1,7 (126+_12,3) 14,7+_1.4 (106+_10,1)38_+4 (274+_29)

32+-3 (231+_22)

68+7(491_+51

57_+6(412~43)

M22

P=2.5

23+__2 (166,+14) 19.6-+2.0 (142-+14) 51+_5 (368_+36)

43_+4 (310-+29)

92_~9 (663_+65)

77-+7 (555_+58)

M24 P---3

30+-3 (217+__22)

24-+3 (173+_22)

65+_7 (469_+51)

53_+5 (383_+36) 118-+12 (852+_87) 96_+10(693_+72)

M27

44+4(318_+_29)

36±3(260+_22)

96,+10 (693+_72)

78+_8(563-+58)173,+17 (1250+-120) 140--+14 (1010±100)

60-+6(433±43)

50-4:5 (361_+36) 131_+13 (946_+94) 110-$-_11 (794_+79) 235,+24 (17004__170) 198+__20 (1430!-__140) 68±7(491_+51) 176+_18(1270-+130) 148_+15(1070-+110) 317+_32(2290+-200) 266+_2.7 (1920+_200)

M30

P=3 P=3.5

OIL LUBRICATION NO LUBRICATION

T

OIL LUBRICATION NO LUBRICATION

OIL LUBRICATION

M33

P=3.5

81+_8(585,+58)

M36

P=4

105,+10(758_+72) 88-+9 (636-+65) 227__+23 (1640±170)190+____19 (1370±140) 343,+34 (24805--250) 343-+34 (2480+_250)

TORQUE VALUE UNITkgf-m (ft.Iba.) 2. MetricFineThreadStandard Tightening TorqueValues,Makecertainto tighten allCapscrews & Nutsto propertorquevalues.

Classification

4

T

7

T

T

NOMINALSIZE

NO LUBRICATION

M8

1.15__+0.11 (8.3±0.8)0.97_+0.1 (7.0-+0.7)2.5:=H].2 (18.0±1.4) 2.1_+0.2 (15.2+1.4) 4.5+0.4 (32.5+-2.9)3.8_+0.4 (27.4+_.2.9)

P=I.0

OIL LUBRICATION NO LUBRICATION

10

OIL LUBRICATION NO LUBRICATION

OIL LUBRICATION

M10 P=1.25

2.3-+0.2 (16.6+1.4)1.91__+0.19 (13.8-+1.4) 4,9-+0.5 (35.4__+3.6) 4.2__+0.4 (30.3+__2.9) 8.9_4-0.9 (64.2+6.5)7.5-+0.7 (54.2+5.1)

M12

P=1.25

4.(k0.4 (28,9+~2.9)3.4_+0.3 (24.5±2.2)8.7_+0.9 (62.8-+6.5) 7.3_+0.7 (52.7+_5.1) 15.7-+1,6 (113+_13)13.2-+.1.3 (95.3±9.4)

M16

P=1.5

9.4_+0.9 (67.9_+6.5)7.9-+0.8 (57.0+-5.8) 20+_2 (144-+14) 17.2_-+1.7 (124-+12)37+_4 (267_+_29)

M20

P=1.5

19_+9 (137_+14)

15.8-+1.6 (114-+14) 41_+4 (296+_29)

34-+3 (246+_22)

M24

P=2

32+_3(231-+22)

27-+3 (195+_22)

58±6(419--+43) 126,+12 (9104____87) 105+_10(758+_72)

M30

P=2

65_+6 (469-+43)

54,+5 (390-+-_36)142±14 (1030~__100)118_+12(852_+87) 255+_26 (1840-+190) 21~1 (1530-+150)

M36

P=3

109+11(787+_79)

91,+9 (657_+65) 238+-_23 (1720+____170) 198-+20 (1430-+140) 428+_43 (3090-+310) 357-+36 (2580+_260)

70-+7 (506+_51)

74±7(535+_51)

31+_3(224+22) 62-+6(448-+43)

TORQUEVALUEUNIT-kgf-m(ft.Ibs.)

5-13

Section V- SPECIFICATIONS 3. Nuts& Sleeves

MANUFACTURER’S NAME

NIPPONA.M.C.

IHARA KOATSU

WORKING PRESSURE kgf/cm 2 (PSI)

350 (4980)

TUBE SIZE O.D.X THICKNESS mm (in)

OPPOSING FLATS mm DimensionB

10 X 1.5(0.394 X 0.059)

19

4.5:h0.5 (33_+4)

15 X 2.0(0.591 X 0.079)

27

15!2(108+14)

18 X 2.5(0.709 X 0.098)

32

18+~(130-+14)

22 X 3.0(0.866 X 0.118)

36

22+’) (159i-_14)

28 X 4.0(1.10 X 0.157)

41

28+_.,3 (203-~2)

35 X 5.0(1.38X 0.20)

55

35_+4.5 (253:!:29)

350 (4980)

4. FlareTypeFittingJoints Overtightening of FlareType(UnionNutType) metaljointsmay causedamageto nuts,seatsurfacesandprevent optimum sealing resulting in oil leaks.

1. PIPE THREADS Unit: kg-m (ft.

Ibs.) NOMINAL SIZE

TORQUE VALUE

1/4"

2.5-+0.3 (18.1__+1.8)

3/8"

5!0.5 (36.2+_3.6)

1/2"

6-+0.6 (43.4+4.3)

314"

12_+1.2 (86.8~8.7)

1n

14__+1.4 (101__+10)

1-1/4"

17__+1.7 (123-+12)

1-1/2"

21+’2.1 (152__+15)

g, 2

TORQUE VALUE kgf-m (ft.Ibs.)

5. N2 (Nylon) TubeFitting Joints 1. Clean tubeandmakecertain tubeendis trimmed smooth.

2.Insert tube into fitting until tube endissecurely seated infitting body.

3.Tighten thenutbyhand.

4.Usea spanner wrench, securely tighten nutby turning 1-1/4 turns.

PLASTIC SLEEVE

42+4.2(304!30) BODY NUT--

5-14

-- NYLON TUBE

NOTES

Section VI- TROUBLESHOOTING Tableof Contents

GENERAL TROUBLESHOOTING ...............................................................................

6-1- 6-3

/~

WARNING

/~

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS,

6-0

Section VI- TROUBLESHOOTING 6.1 GENERAL TROUBLSHOOTING Thistroubleshooting information covers thecomponents andsystems as described in thisoperators manual.

Should in depth troubleshooting, repair or SYS

PROBLEM

replacement of components or adjustment of valves berequired, contact an authorized KOBELCO Service Dealer forassistance.

PROBABLE CAUSE

1.Alloperating speeds area.Lowhydraulic oillevel sloworpower islost. b.Airleaking intothesuction pipe

POSSIBLE REMEDY

a.Fill oiltospecified level. a.Tighten suction pipehos~ clamp or replace hose. ¢. Hydraulic pumpdamaged a. Repair or replace d. Pilotgearpumpdamaged a. Repair or replace e.Mainrelief valve isnotadjusted correctly a.Adjust orreplace f.Pilot relief valve isnotadjusted correctly a.Adjust orreplace A specific cylinder 2. a. Cylinder sealis damaged a.Repair orreplace functions improperly or b.Control valve oroverload valve functions a. Repair or replace/Bleed losespower incorrectly orthere aresigns ofairinthecylinder airfromcylinder c.Pilot valve isdamaged a.Repair orreplace d.Pilot valve piping isloose a.Retighten 3.Thecylinder position willa.Cylinder sealisscored a.Repair orreplace notholdwithoperating b. Control valveor overload valveis damaged a.Repair orreplace ¢3 z lever inneutral. c.Overload valve isnotoperating a.Repair orreplace d.

Pilot valve is damaged a.

Repair orreplace IZ: doesnot a.Brake valve isnotworking 4.Machine a. Repair orreplace O swing. b.Hydraulic motor (swing)is notworking a. Repair orreplace or swinggearis damaged. ¢. Swingbearing is damaged. a. Repair orreplace d.Pilot valve isnotworking. a.Repair or replace e. Swingreduction unitisdamaged a.Repair or replace 5.Swing speed is slow. a.Brake valve isnotworking a.Repair or replace b.Control valve isnotworking. a.Repair or replace ¢.Hydraulic motor (swing) is notworking a.Repair orreplace d. Hydraulic pumpis notworking a.Repair orreplace sound occurs a. Insufficient lubrication of swing gearandbearings a. Grease 6.Abnormal whenswinging. b.Lowoillevel intheswing reduction unit a.Refill with proper oil stopped, thea. Brakevalvemalfunctions 7.Withswing a.Repair orreplace machine drifts andis b.Setpressure ofbrake valve isincorrect a.Adjust orreplace hard tocontrol. c.Brake lining isworn a.Repair orreplace 1.Machine doesnottravel a. Toomuchtracktension a.Adjust track tension smoothly. b.Dirty track links andshoes a.Clean tracks c.Brake valve isnotworking a.Repair orreplace d.Travel reduction unitisdamaged a.Repair orreplace 2.Traveling power is insufa. Hydraulic pumpis damaged a.Repair orreplace ficient. b. Poorengine performance a.Repair orreplace a: ¢.Mainrelief valve pressure issetincorrectly a.Adjust orreplace I-d.Lowhydraulic oillevel a.Fill toproper level ,e.Hydraulic motor (travel) isnotworking a.Repair orreplace f.Brake valve isnotworking a.Repair orreplace g.Sealinswivel joint isscored oroilisleaking a.Repair orreplace

6-1

Section VI- TROUBLESHOOTING POSSIB .E REMEDY PROBABLE CAUSE PROBLEM a.Adjust tension.

3.Machine doesnottravel a. Unequal tensions on tracks ,.J w b.Setpressures ofmainrelief valves unbalanced a.Adjust. ina straight line. a.Repair orreplace. c.Performances ofhydraulic travel motor has

SYS

I-

deteriorated riseinthe a.Oilcooler coreclogged 1.Temperature hydraulic oil temp. b.

Engine fan belt slipping i ..J ¢.Lowhydraulic oillevel nd.Wrong typehydraulic oilused >-

a. Clean a.Adjust orreplace a.Refill tospecified level Replace with correct, new a. oil a.Repair or replace a.Fill tospecified level a.Repair & fill toproper level a.Replace withproper oil a.Fill toproper level a.Repair & fill toproper level a.Tighten a.Cleancooling system a.Tighten toproper tension a.Flush system/fill tolevel a. Replace a. Replace elements a.Clean, repair orreplace

e.Hydraulic pumpisnotworking 1.Engine oilpressure istooa.Engine oillevel low low.(Buzzer sounds b.Oilleaking oilviscosity andicondisplays). ¢.Wrong a.

Low coolant #.

2.Abnormal riseinthe ¢/J leaking coolant temperature.b.Coolant c.Loose radiator cap (Buzzer soundsand LU I-icondisplays). d. Radiator coreclogged C~ e.

V-belt loose or damaged --I f.Rustorscale incoolant LU g.Faulty thermostat 3.Aircleaner clogged. a.Clogged aircleaner b. Hoses fromaircleaner toturbo clogged.

1.Starter doesnotturnor a. Connect turnsslowly whichdoesa. Battery disconnected a. Charge notstart theengine. b.Battery discharged c. Battery terminals disconnected, loose, orcorrodeda. Cleanandconnect a. Connect d. Ground cabledisconnected a.Change to proper oil e.Engine oilviscosity toothick (Cold Weather) 2.Starter turns butengine a.Refuel a.Insufficient fuel doesnotstart. a. Refer to pages3-2-3-4 = b.Improper starting procedure

a. Bleed(Seepage4-35-4-36) ¢.Air infuel line a. Replace element d.Clogged fuel filter w a. Replace elements e. Clogged aircleaner Z a.Check circuit circuit malfunctioning 3.Engine tends tostopat f.Airheater 1J,I a.

KOBELCO Serviceman lowspeed a. Lowidling RPM a. Replace element b.Fuelfilter clogged a. Replace elements ¢.Aircleaner clogged a. KOBELCOServiceman d.Improper valve clearance a. Replace element a.

Fuel filter clogged 4. No power a. Replace elements b.Aircleaner clogged c. Improper valve clearance a. KOBELCOServiceman d.Loose clamps ontheairinlet hose(with turbo charger) a.Tighten clamps a. Replace hose e.Cracked airinlet hose(with turbo charger)

6-2

Section VI- TROUBLESHOOTING SYS

PROBLEM 5. Engine overheats.

PROBABLE CAUSE POSSIBLE REMEDY a.Insufficient coolant a.Refill coolant b. Clogged radiator a.Clean cooling components c. V-belt to loose ordamaged a.Adjust orreplace belt d.Faulty thermostat a. Replace 6.Engine exhaust isblack, i a.Aircleaner clogged a. Replace elements b. Improper valveclearance a. KOBELCOServiceman 7. Poorfuelconsumption a.Fuelleak a. KOBELCOServiceman b.Aircleaner clogged a. Replace elements iii c. Loose clamps on suction hose(with turbo charger)a.Tighten clamps Z d. Cracked suction hose(with turbo charger) a. Replace w/newhose .=, 8.Excessive oilconsumpa. Improper oil a.Replace withcorrect oil tion. b.Oilleak a. KOBELCOServiceman c.Improper oilreplacement intervals a.Change atcorrect interval d. Improper warming-up operation a.Refer topage3-5 9.Engine oilpressure doesa.Lowoilvolume a.Fill tospecified level notrise. b.Oilleak a. KOBELCOServiceman ¢.Improper oilviscosity a.Replace withproper oil 10.Battery diesoften. a. Battery terminals disconnected loose, orcorrodeda.Clean & tighten terminals b.Lowbattery electrolyte a.Fill cells w/distilled water c. V-belt looseor damaged a.Adjust orreplace belt d.Defective battery a. Replace battery

6-3

Section VII- SCHEMATICS Tableof Contents

ELECTRICAL CIRCUIT DIAGRAM (A)...........................................................................

7-1 ELECTRICAL CIRCUIT DIAGRAM (B)...........................................................................

7-2 ELECTRICAL CIRCUIT DIAGRAM (C)...........................................................................

7-3

/~

WARNING

/~

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

7-0

NOTES

Section VIII- OPTIONAL EQUIPMENT Tableof Contents

HYDRAULIC BREAKER ...................................................................................

8-1- 8-3 SAFETY PRECAUTIONS ...................................................................................

8-4- 8-5 MAINTENANCE FORNIBBLER/BREAKER ..........................................................................

8-6 REINFORCEMENT OFATTACHMENT .............................................................................

8-6 EXTRA, EXTRA &BREAKER ................................................................................

8-7- 8-8 DOZER BLADE .......................................................................................

8-9- 8-13 VANDALISM GUARD .....................................................................................

8-14

/~

WARNING

/~

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT OR SYSTEMS.

8-0

Section VIII- OPTIONAL EQUIPMENT 8.1 HYDRAULIC BREAKER A. SELECTION OF THE HYDRAULIC BREAKER Whenmounting thebreaker onthehydraulic excavator, itisnecessary tomatch stability, hydraulic pressure, and theoillevel foreachbreaker.

Toselect hydraulic breakers, callyourdealer orservice shop.

B. BEFORE OPERATING THE HYDRAULIC BREAKER Consult yourKOBELCO distributor forthepiping orenforcement ofthearmwheninstalling thehydraulic breaker.

Thoroughly readthroughtheHydraulic BreakerOperation Manualandthe sectionPRECAUTIONS DURING OPERATION of thismanual, anduseduecaution so as notto damage themachine bodyor hydraulic breaker during operation.

C.

HYDRAULIC OIL LEVEL CHECK AND CONTAMINATIONPREVENTION Whenthehydraulic breaker is notinstalled onthemachine, attach theblank plugs to thetubeendonthearmtop endandthehoseendonthehydraulic breaker sidetoprevent dustandwater fromentering intothepiping.

Before starting operation, check thecapscrews on thetubefixing clamps forlooseness, andtheconnections of thetubes andhoses foroilleakage.

D. BASIC OPERATRION

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

I

1. StartMachine andplace theSafety LockLever in the"UNLOCKED" (Down) position.

SeeFigure8.1.

2. Movethrottle control tothe"HI" idleposition.

3. UsingBoom,ArmandBucket controls setthe Breaker orNibbler todesired position.

4. Release Control PedalLockRod.SeeFigure 8.2.

5. Makecertain Breaker or Nibbler is in desired position andagainst material tobebroken.

6, Place Right footonpedal anddepress withtoe toactivate Breaker orNibbler.

SeeFigure 8.2.

7. Operate Breaker orNibbler forone(1)minute thenrelease pedal.

WARNING

SAFETY LOCK IN UNLOCKED (DOWN) POSITION

IJ /-

FIGURE8.1 PUSH LOCK FORWARD

ROD

|

ITO"ELE’SE I ",, I~

\~.,~ \ I BACKWARD ~ ~ I TO LOCKPEDAL DEPRESS WITH ACIVATE

OPERATION OF BREAKER OR NIBBLER LONGER THAN ONE (1) MINUTE INTERVALSCOULD CAUSE PREMATURE WEAR OR DAMAGE TO THE ATTACHMENT AND THE MACHINE. IF MATERIALIS NOT BREAKING,REPOSITION BREAKER OR NIBBLER AND REPEAT OPERATIONIN ONE (1) MINUTE INTERVALS.

LEVER

PEDAL TOE

~/" TO

""~ ~

~’

FIGURE8.2

NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

8-1

Section VIII- OPTIONAL EQUIPMENT E,

Breaker andnibbler selector switch Thismachine is provided withbreaker single circuitandnibbler andbreaker Bidirection flowcircuit.

Tousebreaker ornibbler, select circuit appropriate tothespecification through switch ontherear sideofdriver’s seat.

SeeFigure 8.3.

1.Switch position Specification Circuit Breaker Single flow Nibbler Bidirection flow Switc~(~osition

I

v

CAUTION

v

ICA’

Never turnswitch on (conflux) tooperate breaker. maycausedamageof machine.

FIGURE8.3

F. Control pedal 1.Hydraulic breaker single circuit Release pedal lockontherightfront sideof driver’s seattooperate pedal.

SeeFigure 8.4.

CAUTION Precaution forpedal operation Theoperation varies in thespecifications, so before operating, readtheOperator Manual carefully.

Footpedaldepressing section Operating condition.

Depress toesection.

Breaker starts operation.

Pedal inneutral position. Breaker stops operating. .

Nibbler andbreaker combined (conflux) circuit.

Release pedal lockon theright frontsideof driver’s seattooperate pedal.

SeeFigure 8.4.

PUSH LOCK

J

J ROD FORWARD[ [TO RELEASE J~

Hydraulic breaker Footpedaldepressing section Operating condition.

Pedal inneutral position. Breaker stops operating.

Depress toesection.

Breaker starts operation.

Nibbler Footpedal depressing section Operating condition.

Depress toesection.

Nibbler close Depress heelsection.

Nibbler open

DEPRESS PEDAL I WITH TOE TO ACIVATE

FIGURE8.4

NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

8-2

Section VIII- OPTIONAL EQUIPMENT G,

Settingselector valve.- Figure8.5 For machinesprovidedin nibblerand breaker specification, theselector valveinstalled on the backof boomis required to be switched to theposition corresponding tothespecification.

®

NOTE ¯ Inappropriate switching of selector valvemay cause decrease of workefficiency andoperating speeddue to inferioroperation, and alsocausedamageof machine.Securely switchselector valve. ¯ Be sureto switchselector valve1 or 2 timesa month periodically.

1. TOOLS USED SELECTOR CIRCUIT VALVE

!

TOOLS STAMP

® .

H,

MAIN

SPANNER (24mm)

(BOOM)

ALLEN WRENCH (5mm)

SETTING PROCEDURE a. Use a allenwrenchto loosenand remove thesocket bolt. bo Usea wrenchto turntheselector valveto theproper position. c. Afterthevalveis in theproperposition, tighten thesocket bolt. d° Markings of theselector valveareshownbelow.

B : Breaker N1 : Independent flowof Nibbler N2 : Bi direction ofNibbler

Settingstopvalve.- Figure8.6 Stopvalveon armtopendis usedto stophydraulicoilflowing.

Free: Hydraulic oilflows.

Stop: Hydraulic oilstopsflowing.

Beforeremovingattachment, set stopvalveto "STOP"position.

1. TOOLS USED SELECTOR CIRCUIT VALVE

SOCKET BOLT

/USE BREAKER

USE NIBBLER

FIGURE 8.5

= k=4====

==

TOOLS

MAIN (~)

(ARM)

SPANNER (24mm)

FREE

STOP FIGURE 8.6

8-3

Section VIII- OPTIONAL EQUIPMENT 8.2 SAFETY PRECAUTIONS The following SafetyPrecautions shouldbe usedin conjunction withallothersafety precautions foundin thismanual.

X

READ, UNDERSTAND AND FOLLOW ALL SAFEY PRECAUTIONS AND OPERATING PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT FIGURE 8.7 A,

USE FOR INTENDED PURPOSE- FIGURE 8.7 Usetheattachment onlyforitsintended purpose.

If not usedin accordance withthe manufactures instructions, theexcessive pressure exerted on the boom,armandframestructure of themachine will causepremature failureof the components.

B°

PASSENGERS Neverallowpassengers on the attachment or machine.

C°

PROTECTIVE EQUIPMENT- FIGURE 8.8 Install protective guards on themachine andclose theallwindow to protect theoperator fromflying debris.

Alsotheoperator andallpersonnel in the vicinity of themachine shouldwearprotective gear suchas Safetyshoes,HardHat,Glovesand Face Shieldor Goggles.

D°

FIGURE 8.8

CYLINDERS- FIGURE 8.9 Do not operator Boom,Armor Bucketcylinders to strokeends when usinga breakerattachment.

Doingthiscancauseunduestresson thecylinder rodsandresultin damage.

E. AVOID CONTINUOUSOPERATION - FIGURE 8.10 OperatetheBreakeror Nibblerin one (1)minute intervals.

Operation forlongerthanone(1)minute at a timecancausehighoiltemperatures anddamagetheaccumulators, cylinder sealsandpossibly pump damage.

FIGURE 8.9

FIGURE 8.10

8-4

Section VIII- OPTIONAL EQUIPMENT F. HOSE SURGE-FIGURE8.11 Should thehydraulic hoses begintosurgeorvibrateabnormally during operation of a Breaker or Nibbler, immediately stopoperation andcontact an Authorized KOBELCOService dealerforassistance.

Thisproblem oftenisa result in damaged accumulators andcanalsoresult invalve failure.

FIGURE8.11

X

/-,-_._.___

G. DO NOT USE DROPPINGFORCE- FIGURE 8.12 Never usethedropping force of theattachment to break or drive objects.

Thiswillcauseextensive damage to theattachment andmachine structure.

FIGURE8.12 H. DO NOT USE SWING FORCE- FIGURE 8.13 Never usetheswing force ofthemachine forpushingorsliding objects.

Thiswillcause premature failure of theattachment andothermachine components.

,..;:

X FIGURE8.13 I. DO NOT LIFT-FIGURE8.14 Never useanoptional attachment toliftortransportobjects or material.

Doingso cancauseextensive damageto theattachment, themachine structures andcause injury ordeath.

X FIGURE8.14

J. WORKING RANGES- FIGURE 8.15 Neveroperate an optional attachment overthe sides of themachine.

Onlyoperate overthefront orrearofthetracks.

UNACCEPTABLE

WORK

RANGE

ACCEPTABLE WORK RANGE

UNACCEPTABLE

WORK

FIGURE8.15

8-5

RANGE

Section VIII- OPTIONAL EQUIPMENT 8.3 MAINTENANCE A,

FOR BREAKER/NIBBLER

It is necessary to perform thefollowing maintenanceschedule in regard to Hydraulic OilandFiltersalongwithnormalinspection andmaintenance as described in Section IV of thismanualforthe Breaker/Nibbler Optional Attachment.

,

/

~.~) /~/ I DEPRESSRUBBER \\~ ~////~1 CAP TO RELEASE

I

FIGURE 8.16

COMPONENT LOCATION CHANGE HYDRAULIC OIL HYDRAULIC TANK RETURN FINER HYDRAULIC TANK

REPLACEMENT SCHEDULE 1ST MAINTENANCE 2ND MAINTENANCE REGULAR MAINTENANCE EVERY 600 HOURS 25 HOURS 100 HOURS EVERY 200 HOURS

8.4 REINFORCEMENT OF ATTACHMENT The use of machinewith breakerand nibblermay causedamageof attachment.

So contactour representative or service shopto reinforce arm.

8-6

Section VIII- OPTIONAL EQUIPMENT 8.5 EXTRA (GRAPPLE, CLAMSHELL, ETC)AND EXTRA & BREAKER A. BASIC OPERATION

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

=

1. StartMachineandplacetheSafetyLockLever in the "UNLOCKED" (Down)position.See Figure8.17. control tothe"HI"idleposition.

2. Movethrottle 3. UsingBoom,Arm and Bucketcontrolsset the Attachment to desired position.

4. Use the Boom,Arm and BucketControls to position theattachment.

5. PlaceRightfooton pedalanddepress withtoe to closeattachment anddepressbackof pedal withheelto openattachment.

SeeFigure8.18. is complete or operator is re6. Afteroperation quiredto leavethe machine, placepedallock rodin thelocked position, SeeFigure 8.18,position attachment inhydraulic oilcheckposition, movethrottle control to "LO"idleposition.

I

IN UNLOCKED (DOWN) POSITION

FIGURE 8.17 PUSH LOCK ROD FORWARD TO RELEASE

DEPRESSPEDAL WITHTOE TO . ACTIVATE

~~~ EXTRASPEC

Throttle

Supplementary Explanation Formachineprovided in extra& breakerspecification, beforestarting operating, unlock leftcontrol pedal.See Figure8.18.

NEVER LEAVE THE OPERATOR CAB WITH ENGINE RUNNING.

POS OC OO TO RELEASE "~

i~

D EV~2cHETSTvOaE TO

FIGURE 8.18

8-7

Section VIII- OPTIONAL EQUIPMENT B. SETrlNG THE SELECTOR VALVE FIGURE 8.19 (ENGINE OFF)

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT.

\

1. Boom SelectorValves a. Locatethe two (2)Selector Valveson the Boom.See Figure8.19. b. Remove theSocket Boltwithan allenwrench. c. Usinga spannerwrench, turntheselectors untilthestamped letter "E"is aligned with thesocketboltmounting hole. d.Reinstall thesocket boltandtighten securely.

~B \’. \

I

TURN SELECTOR TO "E"SETTING

REMOVE SOCKET BOLT

I

® Arm SelectorValves . a. Locatethe two(2) Selector Valveson the Arm.See Figure8.20. b. RemovetheSocketboltwithan allenwrench. c. Usinga spannerwrench, turntheselectors untilthestamped letter "E"is aligned with thesocketboltmounting hole. d. Reinstall thesocket boltandtighten securely.

ff [,~1STAM P

® NO

USE BREAKER

USE EXTRA

FIGURE 8.19

~._~_.-~____~-= ---~. _~= NOTE AllSelector ValvesMUSTbe turnedto the"E"position or theEXTRAAttachment willnotfunction properly.

3. TOOLS USED SELECTOR POSITIOIk VALVE

®&®

BOOM &ARM

TOOLS

SPANNER (24mm) ALLEN WRENCH (5mm)

/

!®

2 f i..,,,.i STAMP ,f

r’-,

® NO

USE BREAKER

FIGURE 8.20

8-8

USE EXTRA

Section VIII- OPTIONAL EQUIPMENT 8.6 DOZER BLADE A. Outline Bladeis attached on lowerframewithpin,andis usedforbackfilling andleveling afterdigging works by operating dozercylinder through theaidof dozer control leverin cabandmovingbladeup anddown.

Forangledozer,thebladecanbe inclined at angle of 25 degreeto armin addition to theabovefunctions.

Also,extension bladewhichis ableto extend length to max.300mm is available.

FIGURE 8.21

B. DOZER BLADE CONTROL LEVELER

WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND OPERATION PROCEDURES FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE OR ANY ATTACHMENT. DOZER BLADE I CONTROL LEVER

The DozerBladeControlLeveris locatedon the rightsideof theRighthandOperator Console basicfunction istoliftorlower thedogerblade.

1. StartMachineandplacetheSafetyLockLever in the "UNLOCKED" (Down)position.

See Figure8.21.

2. Movethrottle control to the"HI"idleposition.

3. UsingBoom,Arm and Bucketcontrolsset the Attachment to desired position.

4. PulltheBladeControl Lever to liftup theBlade, SeeFigure8.22.

5. PushtheBladeControlLeverforwardto lower the Blade,See Figure8.22.

ALWAYS PLACE ATTACHEMTS ON THE GROUND AND LOCK UP THE SAFETY LEVER BEFORE LEAVING THE CAB.

I

THROTTLE CONTROL

DOZER BLADE CONTROL FUNCTION IS LIVE AT ALL TIMES. THAT IS, EVEN WITH THE SAFETY LOCK LEVER IN LOCK UP POSITON.

m j=l

®

! @ FIGURE 8.22

8-9

SectionVIII- OPTIONALEQUIPMENT C.

Safetyprecautions A. Precautionon blade.

Be careful thatbladedoesnotcontact boomcylinderandbucket whileworking withbladefrontside.

See Figure8.23.

X

i/ FIGURE 8.23 B°

Precaution whenplacingattachment nearside.

Be careful so thatbucketandbladedo notcontact whenplacing frontattachment nearsidein travel or transportation position.

SeeFigure 8.24.

FIGURE 8.24 C.

Precaution on bladeso as not to collidewith rock,etc.

It maycausepremature failure of bladeandcylinder.SeeFigure8.25.

×

FIGURE 8.25

8-10

Section VIII- OPTIONALEQUIPMENT D. DOZER BLADE SPECIFICATIONS Thespecifications foundin thissection aregiven on the StandardSK70SRHydraulicExcavatoras manufactured by KOBELCO CONSTRUCTION MACHINERYCO., LTD. No modifications or optionsaretakenintoconsideration in regard tothese specifications.

A=

MACHINE DIMENSIONS - Figure 8.26 1. Thesedimensions consider the following: a. Standard Boom-3.72 meter(12’-2"). b. Standard Arm-2.07 meter(6’-9"). c. Bucket-0.22m 3 (0.29cubicyard). d. Shoe-600 mm (23.6")TripleGrouser.

6,230mm(20’-5")

FIGURE 8.26 B. DOZER BLADE WORKING RANGES - Figure 8.27

DOZER BLADE WORKING RANGES E_---v¢,O

1,880mm(6’-2")

E E;" O’~’O4~..,

FIGURE 8.27

8-11

Section VIII- OPTIONAL EQUIPMENT E. STRAIGHT & ANGLE DOZER SPECIFICATIONS- FIGURE 8.28

/;;;i ~II(IL~

FIGURE 8.28 ITEM

STRAIGHT DOZER (g TYPE)

STRAIGHT DOZER (A TYPE)

ANGLE DOZER WITHOUT EXTENSION WITH EXTENSION

LENGTH(From the center of the mm(4’-6")R1,630 mm (5’-4") fixing pin tothe tip ofarm theblade) R1,380 mm(4’-6")IR1,380

<

2,320 mm(7’-7") + 300mm(11.8")

WIDTH

2,470 mm(8’-1 ")

2,320mm(7’-7")

<

HEIGHT

470mm (18.5")

470mm (18.5")

500mm (19.7")

WEIGHT

360kg(790Ibs.) 340kg (750Ibs.)

480kg(1,060 Ibs.)

,(

500kg(1,110 Ibs.)

SET PRESSUREOF MAIN RELIEF 19.6MPa{200kgf/cm 2} VALVE SET PRESSURE OF OVERLOAD RELIEFVALVE

27.5MPa{280kgf/cm 2}

F. Handlingof angledozer.- Figure8.29 Changebladeanglein thefollowing procedure.

1. Removecapscrew(~, nut (~), and pin, then also removethe housed-inlink (~. Return capscrew(~, nut (~ and pin (~ to original position.

2. Removecapscrew(~)andnut (~), and removepin(~). shownin drawing 3. Shiftlink(~)totheposition movingblade(~, connect frame(~, insertpin (~)andattachcapscrew (~ andnut

/

, ? iF ////J/TH~ ////z~IIII

C

±

VIEWI FIGURE 8.29

8-12

SectionVIII- OPTIONALEQUIPMENT G°

DOZER BLADE LUBRICATION- FIGURE 8.30 Lubricate DozerbladePinsevery100hoursof engineoperation.

UseExtreme Pressure MultiPurpose Grease No.2EP TypeGrease.

Lubricate allpoints until grease purges.

1. Dozzer Cylinder RodandHead.

2. DozerBladeLinkpin

FIGURE8.30

8-13

Section VIII- OPTIONAL EQUIPMENT 8.7 VANDALISM GURAD A. The KOBELCOSK70SRCab is equippedwith special studsto accommodate installation of the KOBELCOVandalismGuard.See Figure8.31.

FIGURE 8.31 B°

When mountingthe VandalismGuardto the machine, beginwithPanel1 andinstall to cabin sequence (1,2,3, etc.).SeeFigure8.32.

1

7

6

4

5

C. Whenremovingguardfromthe cab,removein reverseorderof installation (14,13,12,etc.).

See Figure 8.32.

14

13

12

11

10

9

FIGURE 8.32 D. Storageof the Vandalism Guardis locatedright sidewallof cab.SeeFigure8.33.

FIGURE 8.33

8-14

8

NOTES

Section IX- SPECIAL PROCEDURES Tableof Contents

GENERAL .........................................................................................

9-1 RELEASING TRAVEL MOTOR BRAKES ...........................................................................

9-1- 9-4 LOWERING ATTACHMENT WITHENGINE FAILURE ....................................................................

9-5 RELEASING SWING BRAKE .................................................................................

9-6- 9-8

/~

WARNING

/~

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.

9-0

Section IX-SPECIAL PROCEDURES 9.1 GENERAL The SK70SRmachineincorporates automatically applied springbrakesystems in thetravelmotors and swingmotors.Thesesystemswillautomatically engagethe brakeswhenengineis stoppedmaking it impossible to movethemachine.

Thissection containstherequired procedures forreleasing thetravel motorbrakes,the swingmotorbrakeand lowering the attachment to thegroundshouldsuddenengine failure be experienced.

FATTACHMENTS

ON

--1 LCHOCK BLOCKS AT FRONT AND REAR OF EACH TRACK

READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN I THIS MANUAL BEFORE ATTEMPTING ANY I !

OPERATION, INSPECTION, MAINTENANCE OR I REPAIR OF THIS MACHINE, ATTACHMENT OR ANY OF ITS SYSTEMS.

WARNING MAKE CERTAIN CHOCK BLOCKS ARE SECURE AT I FRONT AND REAR OF EACH TRACK BEFORE I ATTEMPTING TO RELEASE BRAKES. I NEVER STAND IN THE PATH OF THE TRACKS I WHEN RELEASING BRAKES. I FIGURE 9.1

WARNING THE PROCEDURES FOUND IN THIS SECTION SHOULD BE PERFORMED BY A WELL TRAINED EXPERIENCED SERVICE TECHNICIAN WHO IS FAMILIAR WITH THE KOBELCO SK70SR MACHINES, 9.2 RELEASING TRAVEL MOTOR BRAKES A. Tools & EquipmentRequired 1. Four(4)ChockBlocks.

2. One(1)AllenwrenchforDrainplug.

3. Hammer and Punch one each.

4. Drilling devicefor2mmdiameter. drainpans.

5. Two(2)3.4Liter(0.9Gal)capacity 6.Threadsealant.

(ForDrainandCheck/Fill Plugs) 7. Rubberor SoftFacedMallet.

FIGURE 9.2 B. Procedures NOTE Makesureto alignthe plugson the TravelMotorCovers perpendicular to the ground,as shownon Figure 9.3,beforeshutting off theengine.

1.PlaceChockBlocksat Frontand Rearof each trackto preventmachinefrommovingwhen brakesare released.

SeeFigure9.1.

FIGURE 9.3

9-1

Section IX- SPECIAL PROCEDURES 2.Lowerattachments to ground.

See"9.3LoweringAttachment" forproper procedures, page 9-4- 9.5.

3. TurnKeySwitch "OFF"andremoveKey.See Figure 9.2.

Check/Fill Plugfromeachtravel mo4. Remove torusing the8 mm allen wrench.

5.Place a clean 5 liter (1.3Gallon) capacity drain panunder eachtravel motor drain plugandremovedrainplugusing the8 mm allenwrench.

SeeFigure 9.4.

6.After alloftheengine oilhasdrained, cover the drain pansto prevent contamination andmove themto an areaawayfromthemachine.

7. Findthemating partof ringandpunchat a point of theoutside ofthehub,approximately 20mminward fromthetipofringfordrilling purpose.

SeeFigure 9.5.

8. Drill through 2mmholefromtheoutside ofhub toward ringusing electric drill.

SeeFigure 9.6.

///~// 15 LITER(1.3 GAL)

I CAPACITY ORAIN PAN

FIGURE9.4

i6

HUB RING

’ING f

-- MATING PART

FIGURE9.5

/~1

CAUTION

I/~

Becareful nottodamage lipof cover plate.

Any damage tothelipcould result ina engine oilleak.

/~1

CAUTION

F

]/~

Whenremoving thefollowing components itwillbe necessary tohavea clean areafreeofdirtandgritto laythesecomponents.

FIGURE9.6

9-2

Section IX-SPECIAL °

PROCEDURES

Puta steelbarintotheholeandpushring.

SeeFigure9.7.

10.Holdthetipof ringsticking outof thecover anddrawtheringoutof theringgroove of the hub.

11.FixPT 3/8eyeboltstothetwotapped holesof cover(to whichsocketplugsand fixedusu ally).

FIGURE 9.7

12.Placethehookanda wireslingin thePT 3/8 eyebolts, liftit byhoistandremove thecover.

SeeFigure9.8.

13.Removethe coversfrombothtravelreduction unitsto exposetheplanetary gears.SeeFigure9.9A.

CAUTION Be awareof and protecthandsfrompinchareaswhen removing and instaling planetary gearsor anyother componentwhichmay causepersonal.

O-RING 14.UsingSnapRingPliers, removethesnapring fromthe"Shaft" SeeFigure9.9B. 15.Carefully remove"InputGear"fromtheshaft by handandlayit aside.

16. RemoveshaftfromCoupling.

17. RemoveballfromShaft.

18. RemoveCouplingfromShaft.

19.Install coverplates ontohousings andfixring intotheringgroove of hub.

20.Install FillandDrainPlugsintocoverplates andreplace engine oilintotravel reduction units through Fill/Check portto proper level.

20 havebeenperformed 21.Aftersteps4 through on bothtravel reduction units, themachine may be towed to an area whererepairscan be made.

22.Afterrepairs aremadereinstall the"Input Gear" in reverse order.

COVER

FIGURE 9.8

FIGURE 9.9A

9-3

EYE BOLT (PT3/8)

Section IX- SPECIAL PROCEDURES NOTE Referto Section IV,page4-6and4-7forproper oils specification andcapacity.

~?~

JAW ~\,,~, I\REMOVE SNAP RINGI

NOTE Install newO-ring sealson CoverPlates afterall repairs arecompleted.

SeeFigure9.8.

I SHAFTJ ~

[INPUT GEAI~

FIGURE 9.9B

9-4

Section IX- SPECIAL PROCEDURES 9.3 Lowering Attachment When Sudden Engine FailureOccurs Shouldsudden enginefailure occur,follow theinstructions belowto placetheattachment on the ground.

NOTE Rotation of theengine withtheStarter Motoris necessaryin orderto lowertheattachment to theground.

If rotation oftheengine is notpossible, contact an authorized KOBELCOservicetechnician for service andassistance.

FIGURE 9.10

MAKE CERTAIN THE AREA AROUND THE MACHINE IS CLEAR OF PEOPLE AND OBJECTS BEFORE ATTEMPTING THESE PROCEDURES. 1. Locatethe Engineemergency StopControlat thelowerR.H.corner of theseatbaseandpull control out.SeeFigure9.10.

2. Place the SafetyLock Lever in the "UNLOCKED"(Down)position.

See Figure9.11.

3, SoundHornto alertpeoplein theareaof machinemovement.

Key to the "START"posi4. Turnthe Keyswitch tion,usingstarter motortorotate theengine.

I FIGURE9.11

CAUTION Onlyoperate theStarter Motorin 20 secondintervals andallow3 - 5 minutes between intervals to allowthe starter motorto cool.

5. Whileengineis rotating, slowlyandcarefully move the R.H. ControlLeverforward(Boom Down)and lowerBoomcompletely to ground.

SeeFigure9.12.

6. AfterBoomis completely down,operatethe Arm, Bucketand SwingControlsto release hydraulic pressure inthesecircuits.

7. LocateHydraulic TankAirBreather on top of hydraulic tank.Removecap and depressstem untilallinternal hydraulic tankpressure isreleased.

See Figure9.13.

FIGURE 9.12

~

DEPRESSRUBBERCAP TO RELEASEPRESSURE

WARNING USE CAUTION WHEN REMOVING OR REPAIRING HYDRAULIC COMPONENTS AS HYDRAULIC PRESSURE MAY EXIST OR BE TRAPPED IN CIRCUITS.

FIGURE 9.13

9-5

Section IX-SPECIAL PROCEDURES 9.4 RELEASING SWING BRAKE

WARNING MAKE CERTAIN THAT THE ATTACHMENTIS ON THE GROUND TO HELP PREVENT SUDDEN ROTATION OF THE UPPER STRUCTURE BEFORE ATTEMPTING TO RELEASE THE SWING BRAKE. REFER TO PAGES 9-4 ~ 9-8 FOR ATTACHMENT LOWERING PROCEDURES, A. Tools& Equipment Required 1.Handtools required forremoval ofhydraulic tubes, hoses andfittings.

2.Plugs andcapsfortubes, hoses andfittings.

3.12mmAllenwrench.

4.5mmAllenwrench.

5.Overhead Lifting Device capable oflifting and holding 45kg(100Ibs).

6.Plenty ofclean, dryshoprags.

7.Torquewrenches.

B. Procedures 1.Lowerattachment to ground.

Referto pages 9-4- 9-6forproper procedures inlowering the attachment. allhosesandtubesfromtheSwing 2.Remove MotorTopPlate andSwing ValvetogainaccesstotheTopPlate Mounting Bolts.

See Figure 9.14. theproper plugs andcapsontohoses, 3.Install tubes andfittings toavoid thepossibility ofcontamination entering thehydraulic system.

See Figure 9.15.

FIGURE9.14

INSTALL PROPER CAPS AND PLUGS ON HOSES, TUBES AND FITTINGS TO HELP PREVENT CONTAMINATION ENTERING THE SYSTEM

FIGURE9.15

CAUTION Useonlyplugsandcapsdesigned toproperly sealthe specf c hose, tubeorfttngtheyaretobe nstaedon.J FIGURE9.16 4.Thoroughly clean thetopof theSwingMotor andSwing Valve removing alldirtanddebris.

NOTE Place a large quantity ofclean, dryshopragsaround the Swing Motortohelpcatch anyoverflow ofhydraulic oil fromtheremoval of theTopPlate.

5.Loosen thefour(4)TopPlate Mounting Bolts withthe12mmAllenWrench.

See Figure 9.17.

FIGURE9.17

9-6

Section IX- SPECIAL PROCEDURES 6.Remove two(2)TopPlateMounting Boltsfrom corners opposite ofeachother.

SeeFigure 9.18.

7.Attach overhead lifting device tothelifting eye andremove mostoftheslack fromthecable or chain.

8.Carefully remove theremaining two(2)bolts fromtheTopMounting Plate.

NOTE TheTopPlate willraise fromspring pressure as thelast two(2)boltsareremoved.

Somemovement of theupper framemaybe experienced as thespring tension is released.

FIGURE9.18

9. Using theoverhead lifting device, carefully lift theSwingMotorTopPlateandSwingValve assembly offof andawayfromtheSwing Motor.

±1

CAUTION

Donotallow anydirtordebris toenter theswing motor orsettle onthetopplate.

10.Carefully remove allbrake springs andplace ina container filled with fresh, clean hydraulic oil.Then, sealthecontainer toprevent contamination.

SeeFigure 9.19.

11.Align theholes ofthedistributor plate inthe swing motor until theyarelocated toward the front andbackoftheswingmotor housing.

SeeFigure 9.20. place thetopplate overtheSwing 12.Carefully Motor andalign thedowel pinsofthetopplate withtheholes inthedistributor plate.

See Figure 9.21. andslowly lower theTopPlate into 13.Carefully position ontheSwing Motor andinstall, by hand, thefour(4)TopPlate Mounting Bolts.

14.Carefully andslowly lower theTopplate into position ontheSwing Motor andinstall, by hand, thefour(4)TopPlate Mounting Bolts.

I

FIGURE9.19

FIGURE9.20

CAUTION

Makecertain theTopPlateDowelPinsandthe Distributor Plate Holes meshtogether.

FIGURE9.21

9-7

Section IX- SPECIAL PROCEDURES 15.Securely tighten thetopplate mounting bolts insequence.

Donottorque atthispoint.

16.RemovetheSwingValveSpoolHousing Mounting Boltswith5mmAllenWrench.

See Figure 9.22.

17.Carefully remove theSwingValveSpool.

See Figure 9.29.

Place spool ina container filled withfresh, clean hydraulic oilandsealthecontainer toprevent contamination.

CAUTION TheSwingSpoolmaybe underresidual hydraulic pressure.

Pressurized hydraulic oilcancause severe injury.

Usecarewhenremoving spool.

Wear approved Safety glasses orfaceshield andhardhat whenworking on thisequipment.

FIGURE9.22

theSwing ValveSpool Housing and 18.Install securely tighten mounting bolts.

Donottorque atthis point.

NOTE Be careful notto damage thespoolhousing "O"-Ring.

SeeFigure 9.24.

19.Aftersteps 1 - 18 havebeencompleted, attacha towing vehicle to thelower frame of thedisabled machine andjogthelowerframe until theattachment isina position toallow towing of themachine.

20.After themachine hasbeenpositioned fortowing,reinstall theSwing Valve Spool andBrake Springs inreverse order.

Thiswilllockthe upper frame intoposition fortowing.

21.Release Travel MotorBrakes, as described in Section 9.2.Raise or remove attachment, and towmachine to an areawhererepairs canbe made, orontoa truck fortransport.

FIGURE9.23

FIGURE9.24

9-8

NOTES

Section X- SPECIFICATIONS(EPA ENGINE) Tableof Contents

EPAENGINE MAJOR SPECIFICATIONS ..........................................................................

10-1 10-2 ~ 10-4 WARRANTY STATEMENT ...................................................................................

10-0

SectionX- SPECIFICATIONS (EPA ENGINE) 1. EPA EngineMajorSpecifications.

Model A- 4JB1 (IN-LINE INJECTION PUMP TYPE) A-4JB1 ISUZU engine model name WSZXL02.7DNA Enginefamily 27DNA-1 Enginecode Water-Cooled, Fourcycle,in-lineoverhead valvetype Enginetype Direct Injection Combustiontype 4 - 93 X 102(3.66X 4.01) mm (in) No.of cylinders - boreX stroke 2.771(169.1) Enginedisplacement lit(cid) 18.2to1 Compression ratio 1 -3 -4 -2 Firing order kW / rpm 46.1/ 2600 Max.ratedpower: SAE NET 41.1 Fuelflowat max.ratedpower (mm/ stroke) 190.0/ 1800 Nm / rpm Max.torque: SAE NET 45.4 Fuelflowat max.torque (mm/ stroke) Enginemodification Exhaustemission controlsystem Bosch,A type Injection pump Variable speed,Mechanical type Governor Multi-hole type Injection nozzles Specified fuel Dieselfuel(ASTMD975No.2-D) 24 - 3.2 (V-kW) Starter 24 - 30 (V-A) Alternator CC or CD Specified engineoil (APIgrade) lit(qts) Lub.oilvolume (Oilpan) 8.0(8.5)- 6.0(6.4) lit(qts) 5.0(5.3) Coolantvolume(Engineonly) 240.0(109.9) kg(Ib) Enginedry weight Overall length 756.7(29.79) mm (in) Engine Overall width mm (in) 618.0(24.33) dimensions Overall height mm (in) 711.0(27.99) 0.4(0.0157) mm (in) Valveclearance (cold) MPa (psi) 18.1(2625) Nozzleinjection pressure ° 14 Injection timing B.T.D.C. (Static) NA Makerand typeof turbocharger

NOTE Theenginefamilycodein thistableis changed as follows yearby year.

YEAR 1998 1999 2OOO 2001 2OO2 2003

A-4JB1 WSZXL0 2.7DNA XSZXL0 2.7DNA YSZXL0 2.7DNA 1SZXL0 2.7DNA 2SZXL0 2.7DNA 3SZXL0 2.7DNA

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Section X- SPECIFICATIONS(EPA ENGINE)

Heavy Duty Non-Road Engine (50- 750hp) EmissionControlSystem WarrantyStatement EMISSION RELATED SYSTEM DEFECT WARRANTY American Isuzu Motors Inc.warrants to theinitial ownerandsubsequent ownerofa certified non-road diesel engine (powering non-road machines andequipment), thatsuchengine is: 1. Designed, built, andequipped soasto conform, atthetimeofsale, withallapplicable regulations adopted bythe United States Environmental Protection Agency (EPA) andtheCalifornia AirResource Board.

2. Freefromdefects inmaterials andworkmanship inspecific emission related parts fora period offive(5)years 3,000 hours ofoperation whichever occurs first, after dateofdelivery totheinitial owner.

Ifan emission related partfails during thewarranty period, it willberepaired orreplaced.

Anysuchpartrepaired or replaced under warranty is warranted fortheremainder ofthewarranty period.

During thetermof thiswarranty, American IsuzuMotors Inc.willprovide, through a ISUZUEngine dealer or other establishment authorized

by American Isuzu Motors Inc., repair or replacement ofanywarranted partatno charge tothe non-road engine owner.

In anemergency, repairs maybe performed at anyservice establishment, or bytheowner, using anyreplacement part.

American IsuzuMotors Inc.willreimburse theowner fortheir expenses, including diagnostic charges forsuchemergency repair.

These expenses shall notexceed American Isuzu Motors Inc.suggested retail price forallwarranted parts replaced, andlaborcharges basedonAmerican IsuzuMotors Inc.recommended timeallowance forthewarranty repair andthegeographically appropriate hourly labor rate.

A partnotbeing available within 30daysora repair notbeing complete within 30daysconstitutes anemergency.

Asa condition of reimbursement, replaced parts andreceipted invoices mustbepresented at a place ofbusiness ofan authorized ISUZUEngine Dealer or otherestablishment authorized

by American IsuzuMotors Inc. Thiswarranty covers thefollowing emission related partsandcomponents. ¯ Charge AirCooling System (IfEquipped) ¯ FuelInjection System ¯ Intake Manifold ¯ Exhaust Manifold ¯ Turbocharger System ¯ Miscellaneous hoses, clamps, connectors andsealing devices usedin theabove systems.

Iffailure ofoneofthese components results infailure ofanother part, bothwillbecovered bythiswarranty.

AnyReplacement partmaybe usedformaintenance or repairs.

Theowner should ensure thatsuchpartsareequivalent in design anddurability to genuine ISUZU parts.

Useofnon-genuine ISUZUparts doesnotinvalidate thewarranty.

However, American Isuzu Motors Inc.is notliable forparts which arenotgenuine ISUZU parts.

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Section X- SPECIFICATIONS(EPA ENGINE) LIMITATIONSAND RESPONSIBILITIES These warranties aresubject tothefollowing:

AMERICAN ISUZU MOTORS INC. RESPONSIBILITIES During theemission warranty period, ifa defect inmaterial orworkmanship ofa warranted partorcomponent is found.

American Isuzu Motors Inc.willprovide: ¯ New,Remanufactured, orrepaired partsand/or components required to correct thedefect.

Note:Itemsreplaced underthiswarranty becometheproperty of American IsuzuMotorsInc. ¯ Labor, during normal working hours, required tomakethewarranty repair.

Thisincludes diagnosis andlabor toremove andinstall theengine, ifnecessary.

OWNER RESPONSIBILITIES During theemission warranty period, theowner isresponsible for: ¯ Theperformance ofallrequired maintenance.

A warranty claim willnotbe denied because thescheduled maintenance wasnotperformed.

However, if thelackof required maintenance wasthereason fortherepair, then theclaim willbedenied. ¯ Premium of overtime labor costs. ¯ Costs toinvestigate complaints which arenotcaused by a defect in American Isuzu Motors Inc.material or workmanship. ¯ Providing timely notice ofa warrantable failure andpromptly making theproduct available forrepair.

LIMITATIONS American IsuzuMotors Inc.isnotresponsible forresultant damages to an emission related partor component resulting from: ¯Anyapplication or installation American Isuzu Motors Inc.deems improper asexplained in theInstruction Manual. ¯Attachments, accessory items, orparts notauthorized foruseby American IsuzuMotors Inc. ¯ Improper off-road engine maintenance, repair, or abuse. ¯ Owner’s unreasonable delay inmaking theproduct available after being notified ofa potential product problem.

Thiswarranty isinaddition toAmerican Isuzu Motors Inc.standard warranty, applicable totheoff-road engine product involved.

Remedies under thiswarranty arelimited totheprovision of material andservices as specified herein.

American Isuzu Motors Inc.isnotresponsible forincidental orconsequential damages suchasdowntime or loss-use ofengine poweredequipment.

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Section X- SPECIFICATIONS (EPA ENGINE) CUSTOMER ASSISTANCE - EMISSION CONTROL SYSTEM WARRANTY: American IsuzuMotorsInc.aimsto ensurethattheEmission ControlSystems Warranty is properly administered.

In theeventthatyoudo notreceive thewarranty service to whichyoubelieve youareentitled undertheEmission Control Systems Warranty, callor write: American IsuzuMotorsInc. EngineOperations 41280 BRIDGE ST. NOVI, MI 48375-1301 Te1.:248-426-4200 Authorized Dealersare recommended for majormaintenance and repairworkas theyare staffedwithtrained personnel, propertoolsand are awareof the latestmaintenance methodsand procedures.

Ownersand otherswho desireto perform theirownworkshouldpurchase a Service Manualandobtaincurrent service information fromtheir ISUZUEngnieDealer.

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NOTES

KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. Part Number North American English 245 E NORTH AVENUE Printed in U.S.A. CAROL STREAM, IL 60188 U.S.A

S2YT00002ZE-03 NA October 03 Bur