Kobelco SK850 Super Acera Tier 3 Excavator Operator's Manual PDF

OPERATOR’S MANUAL HYDRAULIC EXCAVATOR

SK850 SUPER ACERA TIER 3

S2LY00001ZE06 Issued April, 2010 KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A.

English Part Number S2LY00001ZE06 Printed in U.S.A. • Rac

APPLICABLE: SK850 . . . . . . . . . . . . . . . . LY01-00101~

SK850 SUPER ACERA TIER 3 CRAWLER EXCAVATOR OPERATOR’S MANUAL APPLICABLE NO. LY01-00101 Part Number: S2LY00001ZE06

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

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

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

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

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

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

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

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

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

and STOP if used, are RED.

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

machine on a job site.

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

WARNING_01_NA

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

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

Wash hands after handling.

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

Rac S2LY00001ZE06 NA Issued April 2010

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Right, Left, Front, and Rear of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Cab and Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Switch and Meter Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Operating Levers and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Machine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Control Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Using Auto Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Practices to Improve Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Machine Operation in Adverse Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Recommendation for Longer Undercarriage Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Bucket Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Use of Optional Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fluids and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Daily Inspection & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 120 hour maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 I

250 hour maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 500 hour maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Periodical Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Maintenance for Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 Attachment and Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SK850 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SK850 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION TO THE OWNER SK850-LC CRAWLER EXCAVATOR

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

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

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

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

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

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

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

The operator has read and understands the instructions given in this manual and the Operator’s Manual.

The operator possesses a valid local vehicle permit and/or other applicable local age work permits.

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

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

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

1-1

CHAPTER 1 - GENERAL INFORMATION

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

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

1

6

6

4

3

5

5

2 Figure 1

DC03H142

1. FRONT 2. REAR

1-2

3. RIGHT HAND SIDE 4. LEFT HAND SIDE

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

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

12

11

13 10 14 15 8 9 27 6

17

16

21 34 4

22 30 18 19 33

24 1

20

32

29 5 26

3 7

31

23 25

28

2

Figure 2

DC03H141

MACHINE COMPONENTS

1. ENGINE 2. HYDRAULIC PUMP 3. ENGINE MUFFLER 4. MAIN CONTROL VALVE 5. HYDRAULIC OIL TANK 6. FUEL TANK 7. SWING MOTOR 8. HAND RAIL 9. BOOM CYLINDER

10. BOOM 11. ARM CYLINDER 12. ARM 13. BUCKET CYLINDER 14. IDLER LINK 15. BUCKET LINK 16. BUCKET 17. OPERATOR CAB 18. TRACK SHOE ASSEMBLY

19. TRACK IDLER 20. TRACK SPRING 21. ENGINE AIR CLEANER 22. CAT WALK 23. STEP 24. UPPER ROLLER 25. ACCESS DOOR 26. SWING RING 27. ELECTRIC GREASE PUMP

28. TRAVEL MOTOR 29. BATTERY 30. ENGINE RADIATOR 31. POWER DIVIDER 32. ENGINE HOOD 33. COUNTERWEIGHT 34. OIL COOLER

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE

ENGINE

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

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

Figure 4

DC03H139

ENGINE ➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS Figure 3

DC03H140

PRODUCT IDENTIFICATION PLATE

COMPONENT SERIAL NUMBERS ➤ Hydraulic Pump

➤ Model

➤ Swing Reduction Gear

➤ Serial Number

➤ Travel Reduction Gears

➤ Manufacturing Year

➤ Travel Control Valve ➤ Attachment Control Valve ➤ Swing Control Valve

1-4

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

CHAPTER 2

SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 emergency exit Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Counterweight Lifting Eyes - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Working Above Ground - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Lifting Fuel Tank - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Working Above Ground - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Adjusting Track Tension - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Stop Engine - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hot Coolant - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Booster Cable - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 California Proposition 65 - Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Handling Pilot Hoses - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Hot and Rotating Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Hot Parts - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Swing - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Operating Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Attachment Operation By Foot Pedal - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Nibbler & Breaker Hydraulic Oil Maintenance (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Machines Equipped with Pattern Control Change Valve (Optional) - Warning . . . . . . . . . . . . . . . . . . . . . . . 2-21 Work Mode Selection - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Do Not Pinch Your Hand(s) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Lock Front Window at the Housed Position - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Swing Brake Release - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Nibbler & Breaker Operation (Optional) - Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Keep Clear Of Machine - Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-2

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

Failure to comply could result in death or serious injury.

M171C

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

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

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

• The first panel indicates the nature of the hazard.

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

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

and STOP if

SAFETY AREA

1

Figure 1

BS06H091

2

OPERATOR’S MANUAL STORAGE SPACE Figure 2

BC02N198

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

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

1. WORKING AREA 2. SAFETY AREA

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

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

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

2-3

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

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

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

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

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

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

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

RH99G001

Figure 3

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a h o l e by h a n d a n d / o r w i t h a u t o m a t i c va c u u m equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS PERSONNEL

MOUNTING AND DISMOUNTING PRECAUTIONS

• Be prepared for emergencies. Always have a first

• Use the hand holds and steps with at least three

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

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

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

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

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

See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

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

who

has

the

GENERAL

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

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

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

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

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

STARTING AND STOPPING PRECAUTIONS

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

Sound the horn, if equipped, before starting.

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

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer before starting the machine.

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

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

• Do not bypass the machine’s neutral-start system. The neutral-start repaired if it malfunctions.

system

must

be

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

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

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

• DO NOT use the bucket or attachment to lift

• Park the machine on level ground whenever

• Make sure that all protective guards, canopies,

possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

persons or carry riders on the machine. doors, etc. are in place and secure.

• Remove all loose object stored in the machine.

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

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

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CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• Remove the starter key or disconnect switch

• When roading a machine, know and use the

when leaving the machine parked or unattended.

signaling devices required on the machine.

Provide an escort for roading where required.

OPERATING PRECAUTIONS

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

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

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

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

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

• Use the recommended transport devices when roading the machine.

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

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

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

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

• Operate and drive the machine with care and at

• Check all controls in a clear area and make sure

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Dust, fog, smoke, etc., can decrease your vision

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

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

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

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

2-6

the machine is operating correctly. and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

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

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

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

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

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

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• If you have extreme conditions, such as a fire,

• Disconnect the battery before working on the

etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

electrical system. Know the consequences of disconnecting any electronic or computer devices.

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

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

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

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

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

MAINTENANCE PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

DC04E084

Figure 4

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

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

• Observe proper maintenance procedures.

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

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

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

• Wear gloves to protect hands when handling cable.

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

• When the battery electrolyte is frozen, the

FUEL HANDLING PRECAUTIONS

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

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

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

• Do not fill the fuel tank completely to the top.

Allow room for expansion.

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

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

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

BURN PREVENTION

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately Failure to comply could result in death or serious injury.

M144B

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

Ventilate when charging or using in enclosed area.

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

M422A

2-8

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

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

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

TRANSPORTING PRECAUTIONS K n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n t necessary for transporting this machine on a road or highway.

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

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

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

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

FIRE PREVENTION Remove all trash or debris from the machine each day. Check the engine area and exhaust system SEAT BELT PRECAUTIONS

1 DC04D572

Figure 6

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

2 SPECIFIC PRECAUTIONS TO THIS MACHINE Figure 5

DC04D529

1. RIGHT HAND BELT STRAP 2. LATCH MECHANISM

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

• Do not use tractive force of the machine for loading the bucket attachment nor to push or pull any objects.

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

• Do not use swinging force of the machine for

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

• Do not perform “hammering” operation with the

WARNING

• Do not use this machine for anything other than

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

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to comply could result in death or serious injury.

operations. bucket. its intended purpose.

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

• Do not over exert the machine’s capacities.

• Never pull standing objects toward the machine.

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

M422A

ROPS/FOPS PROTECTION This machine does not have a ROPS (roll over protection str ucture) or FOPS (falling object protection structure). The machine is intended for general earth moving/excavating only. If the machine is to be used in any other manner, it is imperative that it be retrofitted with a protective structure meeting the standard for ROPS and/or FOPS as dictated by the Society or Automotive Engineers (SAE) minimum performance criterion to protect the operator.

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS Safety decals are placed on your machine as a guide for your safety. Walk around the machine, and note the content and location of these decals before operating your machine.

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

CE-NA000

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

CE-NA000

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

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

384270A1A

Figure 7

This symbol instructs you to refer the Operator’s M a n u a l fo r f u r t h e r i n fo r m a t i o n r e g a r d i n g maintenance, operational guidelines, etc.

BC00G075

Figure 8

This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

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

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

The color associated with Danger is RED.

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

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

• The first panel indicates the nature of the hazard.

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

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

2-10

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

BS06J019/YN20101221

Figure 9/

WORKING ABOVE GROUND - WARNING Located on fuel tank and side cover (three required) - Part Number 2432T6111

GRAPHIC3/GRAPHIC12

Figure 10

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS LIFTING FUEL TANK - WARNING Located on top of fuel tank (rear right corner) - Part Number YN20T01028P1

GRAPHIC3/YN20T01028P1

Figure 11

WORKING ABOVE GROUND - WARNING Located on engine access cover (two required) - ZL11M02708

GRAPHIC3/BS06J021

2-12

Figure 12

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS ADJUSTING TRACK TENSION - CAUTION Located on crawler frame (two required) - YN20T01813P1

GRAPHIC6/GRAPHIC13

Figure 13

HOT PARTS - CAUTION Located on engine hood (two required) - Part Number YN20T01220P1

GRAPHIC8/YN2050122P1

Figure 14

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP ENGINE - WARNING Located on top of engine radiator - Part Number YN20T01009P1

GRAPHIC7/YN20T01009P1

Figure 15

HOT COOLANT - WARNING Located on top of engine fan shroud - Part Number YN20T01010P1

GRAPHIC7/YN20T01010P1

2-14

Figure 16

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS BOOSTER CABLE - WARNING Located on cab rear side cover - Part Number YN20T01015P2

GRAPHIC5/YN20501015P2

Figure 17

BOOSTER CABLE - WARNING Located on cab rear side cover - Part Number YN20T01338P1

GRAPHIC5/YN20T01338P1

Figure 18

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS CALIFORNIA PROPOSITION 65 - WARNING Located on cab rear side cover - Part Number YN20T01495P1

GRAPHIC5/YN20T01495P1

Figure 19

HANDLING PILOT HOSES - CAUTION Located on cab rear side cover - Part Number YN20T01872P1

GRAPHIC5/YN20T01872P1

2-16

Figure 20

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS HOT AND ROTATING PARTS - CAUTION Located on engine hood - Part Number YN20T01012P1

GRAPHIC8/YN20T01012P1

Figure 21

HOT PARTS - CAUTION Located on engine oil filter bracket - Part Number YN20T01867P1

GRAPHIC8/YN20501867P1

Figure 22

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SWING - DANGER Located on each side of the rear counterweight (2 Required) - Part Number YN20T01003P2

GRAPHIC4/PE20T01014P1

2-18

Figure 23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS OPERATING WARNINGS Located inside cab - Part Number YN20T01863P1

GRAPHIC11/ YN20101863P1

WARNING - AUTOMATIC TWO SPEED TRAVEL WARNING - MACHINE MAY MOVE SUDDENLY WARNING - EXTREME HIGH PRESSURE IN TRACK ADJUSTMENT NOTICE - STOPPING ENGINE WITHOUT COOL DOWN

Figure 24 WARNING - RELEASING POWER BOOST SWITCH CAUTION - ATTACHMENT INTERFERENCE WITH CAB DANGER - ELECTRICAL POWER CONTACT WARNING - READ AND UNDERSTAND OPERATORS MANUAL

2-19

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

GRAPHIC9/PY20TP1062P1

Figure 25

NIBBLER & BREAKER HYDRAULIC OIL MAINTENANCE (OPTIONAL) - CAUTION Located inside cab, on right window glass lower corner - Part Number YN20T01930P1

GRAPHIC9/YN20T01930P1

2-20

Figure 26

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS MACHINES EQUIPPED WITH PATTERN CONTROL CHANGE VALVE (OPTIONAL) - WARNING Located inside cab on right window glass lower corner - Part Number YN20T01039P1

GRAPHIC9/YN20501039P1

Figure 27

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

GRAPHIC9/YN20501836P1

Figure 28

2-21

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS DO NOT PINCH YOUR HAND(S) - CAUTION Located inside cab, on right rear window and on seat stand (2 Required) - Part Number YN20T01339P1

GRAPHIC9/YN20501339P1

Figure 29

LOCK FRONT WINDOW AT THE HOUSED POSITION - CAUTION Located inside cab R.H. - Part Number ZL11MM06008

GRAPHIC9/GRAPHIC24

2-22

Figure 30

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

BS06J029 /YN201639PA

Figure 31

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

GRAPHIC9 /YT201054P1

Figure 32

2-23

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS KEEP CLEAR OF MACHINE - DANGER Located on both sides of the arm (2 Required) - Part Number YN20T01337P1

GRAPHIC10/GRAPHIC15

2-24

Figure 33

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

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

MOVE LOAD IN HORIZONTALLY

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

RAISE LOAD VERTICALLY

DC04E040

Figure 36

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

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 34

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

LOWER LOAD VERTICALLY

DC04E041

Figure 37

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

RAISE BOOM

DC04E039

Figure 35

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

DC04E042

Figure 38

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

2-25

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

LOWER BOOM

DC04E043

Figure 39

DC04E046

Figure 42

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

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

SWING LEFT

ARM OUT

DC04E044

Figure 40

DC04E047

Figure 43

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

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

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 41

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

2-26

DC04E048

Figure 44

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

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

COUNTER ROTATE RIGHT

DC04E049

Figure 45

DC04E052

Figure 48

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

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

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 46

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

DC04E053

Figure 49

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

TRAVEL REVERSE TURN LEFT

DC04E051

Figure 47

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

DC04E054

Figure 50

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

2-27

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS STOP

TURN RIGHT

DE04E055

Figure 51

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

DC04E058

Figure 54

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

EMERGENCY STOP

MOVE THIS MUCH

DC04E059 DC04E056

Figure 52

Figure 55

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

Fa c e m ac hi n e op e ra to r, ra i s e b ot h a r m s ou t horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

MOVE SLOWLY

STOP ENGINE

DC04E057

Figure 53

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

2-28

DC04E060

Figure 56

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CHAPTER 3

INSTRUMENTS AND CONTROLS TABLE OF CONTENTS OPERATOR CAB AND OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Locking/Unlocking Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Opening and Closing Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Removing and Storing Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Opening and Closing Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Opening and Closing Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 document pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Front and Rear Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Back Reclining Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Forward & Backward Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Stand Forward & Backward Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Arm Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Head Rest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Adjustment of Seat Stand Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator Cab Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Components & Controls Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Right Hand Operator Console and Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Buzzer Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 windshield Wiper & Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Screen Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Screen display switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Auto Accel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 L.C.D. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 A. Normal Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 B. Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Warning level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LCD Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Monitor Time Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Pump Flow Rate Adjustment (A mode / B mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Draining Hydraulic System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Power Boost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 24 Volt Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Location for Optional Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Cup Holder and Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 How to Select Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 How to Adjust the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 right Hand Operator Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Climate Control - Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS air outlet diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 basic Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 CONTROL PANEL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Hydraulic Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Conflux/Single Flow Change Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Swing Parking Brake Release Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 OPERATING LEVERS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Left Hand (LH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 Right Hand (RH) Operator Control Lever (ISO/SAE Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 Pattern Control Change (BHL Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 Left and Right Travel Levers & Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR CAB AND OPERATOR SEAT LOCKING/UNLOCKING CAB DOOR

1

1 Figure 3

DC04D505

Figure 1

DC04D503

1. DOOR LOCK

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

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

1. DOOR RELEASE LEVER

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

WARNING To provide secure hand and foot mobility, preventing slipping and possible injury, always face the machine when mounting and dismounting.

Failure to comply could result in death or serious injury.

CAB DOOR LATCH

R131B

1 Figure 2

DC04D504

1. DOOR LATCH

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

1 Figure 4

DC04D506

1. PULL RELEASE LEVER

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

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPENING AND CLOSING WINDSHIELD Front window (upper) can be stored in ceiling.

WARNING

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

A falling window can cause injury to you or others.

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

M1709

REMOVING AND STORING LOWER FRONT WINDOW

1 1 2

Figure 5

BS06J091

1. LOCK LEVER 2. UPPER CENTER HANDLE

Figure 7

DC04D509

1. Pull lock lever down on front window upper section to unlock the window.

1. LOWER FRONT WINDOW

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

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

1

2

3

1

Figure 6

BS06J092

1. LOCK LEVER 2. CENTER HANDLE 3. WINDSHIELD STORED IN CEILING POSITION

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

WARNING Make sure to secure front window with locks when placed in the upper position. Failure to comply could result in death or serious injury.

3-4

3 2 2

2

Figure 8

DC04D510

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

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS EMERGENCY EXIT

OPENING AND CLOSING DOOR GLASS

1 1

2

2

Figure 9

DC04D511

2

1. CAB DOOR UPPER GLASS 2. LOCK

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

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

OPENING AND CLOSING SUNROOF

Figure 11

BS08B172

1. FRONT INSIDE CAB DECAL 2. REAR INSIDE CAB DECAL

1. Be proactive and familiarize yourself with the emergency exits and escape hammer. If it is impossible to open the cab door in an emergency, escape can be made through the front window. Read the steps for opening the front window in this section.

1 Figure 10

DC04D512

1. SUN ROOF IN CLOSED POSITION

1. Pull the levers on the left and right of the sunroof.

Push the handle up and the sunroof will open and will be held in place with gas struts.

2. To close, pull in with handle. Do not force. Move left and right levers into lock position.

1

BS08D258

Figure 12

If it is not possible to escape through the front window, use the emergency hammer (1), and break the rear window. If both of these alternate escapes are blocked, open and use the sunroof.

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

CAB DOME LIGHT

1 2 1 Figure 13

BS06H100

1. CAB DOME LIGHT

Figure 15

DC04D529

1. BUCKLE 2. RED BUTTON

1. Turn Cab Dome Light “ON” by pushing the Dome Light Switch downward.

2. Turn “OFF” by pushing switch all the way up.

3. Place Dome Light Switch in the “CENTER” position and the light will be operated by the door switch. When door is opened the light will come “ON” and when the door is closed the light will turn “OFF”.

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

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

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

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

DOCUMENT POUCH

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

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

1

WARNING

Figure 14

BS06H091

1. DOCUMENT POUCH

Always wear seat belt while sitting in operator seat.

Always check condition of seat belt and seat belt mounting hardware to make certain seat belt is in good condition and properly secure. Failure to comply could result in death or serious injury.

M422B

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

3-6

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BACK RECLINING ADJUSTMENT

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

7

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

1 3

2 4

5

4 BS08D259

6

Figure 16

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

• Rotate the weight adjustment knob (1) until

DC04D523

Figure 17

5. ARM REST ADJUSTMENT 6. ARM REST CONTROL DIAL 7. HEAD REST

weight close to operator’s weight is at the top end of the dial.

• Lower arm rest (5) and turn adjustment wheel (6)

• Pull height adjustment lever (2) up to raise or

• Move head rest (7) forward or backward to

lower rear of seat.

• Push height adjustment lever (2) down to raise or

until arm rest is in desired position. desired reclining angle. Raise or lower head rest to desired height.

lower front of seat.

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

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

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL LEVER ADJUSTMENT

HYDRAULIC SAFETY LOCK LEVER

2 1 B A C

BS08B476-01

Figure 18

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

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

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

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

Figure 19

BS06H080

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

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

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

M1710

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

3

4

5

6 7 8

20

9 2

11 10

1 12

21

13 25 14 15 16 17 22

18 19

23 A

24 Figure 20

BS06H114

COMPONENTS 1. LEFT HAND OPERATOR 7. HOUR METER CONTROL LEVER (HORN SWITCH) 2. SAFETY LOCK LEVER 3. LEFT TRAVEL PEDAL 4. LEFT TRAVEL LEVER 5. RIGHT TRAVEL LEVER 6. RIGHT TRAVEL PEDAL

13. THROTTLE 19. CIGARETTE LIGHTER POTENTIOMETER 14. WORKING LIGHT SWITCH 20. SWING PARKING BRAKE 8. GAUGE CLUSTER (BOOM, DECK) RELEASE SWITCH 15. CONFLUX / SINGLE FLOW 9. CUP HOLDER 21. FUSE & RELAY BOX CHANGE SWITCH (OPTION) 10. ASH TRAY 16. RADIO 22. OPERATOR SEAT 11. RIGHT HAND OPERATOR 17. AIR CONDITIONER 23. LIFE HAMMER CONTROL LEVER CONTROL PANEL 12. STARTER KEY SWITCH 18. OPTIONAL SWITCHES 24. 12 VOLT SUPPLY 25. TRAVEL ALARM SWITCH (OPTION)

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB AND COMPONENT NOMENCLATURE

2. Throttle Potentiometer

The Operator Cab Nomenclature (see Figure 20), points out locations of operator controls. Study these areas and locate these components on the machine.

Specific information regarding these components follows.

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

WARNING

Notice:

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

M1087

All personnel associated with this machine should read and understand this information BEFORE beginning any work with or on this equipment.

RIGHT HAND OPERATOR CONSOLE AND MONITOR

a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 4 seconds, and if the position of the throttle potentiometer is higher than 1050 rpm, the auto acceleration actuates automatically and engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto acceleration speed, the engine speed is maintained to the throttle potentiometer position.

Auto Accel/Decel Function:

1. Ignition Switch

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

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

Figure 21

BS06H116

1. IGNITION SWITCH 2. THROTTLE POTENTIOMETER

The Ignition Switch is located on the right hand operator console and has four operating functions.

OFF - When key is turned to this position, the e n g i n e s t o p s a n d e l e c t r i c a l p owe r to th e machine’s electrical system is stopped after approximately 3 seconds.

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

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

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

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

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR

11

1

2 3

10 6 4

9

8

5

7 Figure 22

BS06H115

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

7. WIPER SWITCH 8. TRAVEL SPEED SELECT SWITCH 9. AUTO ACCEL SWITCH 10. SELECT SWITCH 11. L.C.D. DISPLAY

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS WORK MODE SWITCH

BS06H065 BS06H065

Figure 23

When the engine starts, it is set to the last engaged mode. To select the proper work mode select one of the machine’s four modes. Modes can be set according to the work conditions. The work modes are H B A and S. After initial start-up, the mode last used will be retained. Always check the mode selected conforms to intended work.

Figure 24

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

B mode is for breaker work S mode is for standard digging and loading. It also saves fuel consumption keeping performance in balance with the workload.

A mode is for demolition work with nibbler After starting the engine, select the work mode desired. The mode in use at work operation is retained when the machine is restarted.

Check that the attachment in use conforms to the work mode prior to starting work.

Operation under the improper work mode may cause damage to the machine.

If the work mode lamp flickers, it indicates the wrong work mode choice.

NOTICE: When working with the breaker, make certain the B mode is selected. Working with the breaker in any other mode may cause damage to the hydraulic equipment and breaker.

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS BUZZER STOP SWITCH

WINDSHIELD WIPER & WASHER SWITCH

2

BS06H065

Figure 25

1 BS06H066

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

To stop the sound, press the Buzzer Stop button.

Can also be used to cancel travel alarm during traveling.

1. Wiper Switch

To stop the buzzer sound when a war ning is displayed on the monitor, press the buzzer stop switch and the buzzer will stop. If the engine coolant temperature is too high, or various sensors of mechatro controller (self-diagnosis) fail, the alarm sounds intermittently. and can not be stopped.

2. Washer Switch

Figure 26

• Pressed once - Wiper moves intermittently.

• Pressed again - Wiper moves continuously.

• Pressed once more - Wiper stops moving.

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

The washer fluid reservoir is located under the floor plate in cab.

• Remove floor mat to access floor plate and reservoir.

NOTICE: Make certain the washer reservoir has washer fluid before operating washer. Operating washer without fluid can damage the washer fluid motor.

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS SCREEN CHANGE SWITCH

A

1

2 B

4

BS06H102 / BS06H071

3

Figure 27

After turning the key switch on or starting the engine, the display screen (A) is changed each time that the display switch (B) is pushed. This will display the remaining time until the next service interval for each of the displays shown on the screen.

1. Remaining time until oil change.

2. Remaining time until fuel filter change.

3. Remaining time until hydraulic filter change.

4. Remaining time until hydraulic oil change.

NOTICE: If the change screen switch (B) is not operated for 30 seconds keeping the screen for maintenance displayed, the screen will automatically return to the main screen.

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS AUTO ACCEL SWITCH

TRAVEL SPEED SELECT SWITCH

Figure 29

BS06H067

Figure 28

BS06H068

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

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

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

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

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

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

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

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

WARNING

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

WARNING: Do not use high 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. Failure to comply could result in death or serious injury.

M1697

M1609

WARNING

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

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS L.C.D. DISPLAY

A4. Engine Lubrication Time 256 hours remain until the next engine oil change in this example.

This icon shows the total time since remaining, counting down until the oil should be changed at 500 hours.

A5. Fuel Filter Time 256 hours remain until the next fuel filter change in this example.

This icon shows the total time remaining, counting down until the fuel filter should be changed.

Figure 30

DC04D540

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

A. NORMAL DISPLAYS A1. System Status Display This icon will display after key switch is turned “ON” and all machine system and components are checked by CPU and found to be good working order.

A2. Day Time Display Five seconds after the system status is shown on the LCD, the time will be displayed on the monitor. See “Monitor Time Adjustment” in this section for details on how to set the 24 hour clock feature.

A3. Engine R.P.M. Display Actual engine speed. When auto accel is deactivated, RPM shown corresponds to the throttle potentiometer position.

3-16

A6. Hydraulic Filter Time 256 hours remain until the next hydrau lic o il filte r changes.

This icon shows the total time remaining, counting down until the hydraulic oil filter should be changed.

A7. Hydraulic Oil Time 256 hours remain until the next hydraulic oil change.

This icon shows the total time remaining, counting down until the hydraulic oil should be changed.

A8. Travel Independent Mode Display This icon will displays when the travel independent select switch is on. When you are not using this function, make cer tain the switch is in the OFF position.

CHAPTER 3 - INSTRUMENTS AND CONTROLS B. Warning Displays Priority of Group

A

B

Warning Level

Screen

Condition

1

DATA COMMUNICATION ERROR

Data from the mechatro controller is not received.

1

SWING BRAKE DISENGAGED

The swing parking brake switch is turned ON.

1

ENGINE STOP

Engine is stopped after Engine oil pressure Low Warning.

1

SELECTOR VALVE FAILURE

Selector valve malfunction

2

FINISH WARM-UP

After finishing warming up control

The warming of the engine and hydraulic oil is complete

2

LOW ENGINE OIL PRESSURE

Low Engine oil pressure Disconnection

Stop engine immediately and check oil level

3

HIGH ENGINE WATER TEMPERATURE

The engine water is more than 105° C (221° F)

Slow engine to idle for cool down. If engine does not cool down turn engine off and check coolant level

3

DRAIN WATER SEPERATOR

Water in water separator is increased

Drain water separator

3

CLOGGED AIR FILTER

The Air Filter is clogged

Check Air Filter and clean. Replace if necessary

3

(SELF DIAGNOSIS SCREENS)

According to the self diagnosis control

Contact your Kobelco Service Dealer

3

LOW ENGINE WATER LEVEL

Water in engine coolant reservoir is low.

Turn engine off and add coolant

4

CHARGE ERROR

Battery Error (high voltage, low voltage, or not charging

Check battery and alternator

4

LOW FUEL LEVEL

Fuel level is low

Fill fuel tank

Remedy

Contact your Kobelco Service Dealer

5

AUTO WARM UP

When auto warming up is in operation

Do not start engine until auto warm up is complete

5

CHANGE ENGINE OIL

Remaining time before engine oil change

Use specified engine oil and quantities

WARNING LEVEL 1. These may effect safety and the machine performance 2. These warn that the machine control mode is switched.

3. Equipment/system failure.

4. Normal priority warning.

5. Low priority message BUZZER SOUNDS 1. Constant 2. Beep ON 0.2 sec. OFF 0.3 sec.

3. Beep ON 0.5 sec. OFF 0.5 sec.

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS B1. I.T.C.S. Controller CPU Display

B4. Engine Pre-Heat Complete Display

This icon will display when a problem exists in the I.T.C.S. ( I n t e l l i g e n t To t a l C o n t r o l System).

This icon is displayed when the PREHEAT is completed.

The monitor alarm will sound continuously.

Turn key switch “OFF”, wait for 4 seconds until the system shuts down completely, then turn the switch back to “ON” to reset the CPU program.

Should this icon remain on display, stop operation, shut down the engine. Contact a Ko b e l c o Construction technician for repair.

If alarm will not cancel by the buzzer stop switch, turn the k e y sw i t c h t o t h e O F F p o s i t i o n , a n d w a i t fo r 4 seconds until the electrical system turns completely off.

Restar t the engine.

Continuous preheat after this icon is displayed could cause damage to the engine. DO N OT O P E R AT E THE P R E H E AT P O S I T I O N O F THE KEY SWITCH FOR MORE THAN 20 SECONDS.

B2. Swing Parking Brake Release Display Turn the “Swing Parking Brake Release Switch” on the rear side of operator’s seat to the “RELEASE” position, and this warning is displayed.

While this war ning is displayed, the swing parking brake does not actuate. This switch should be used only in t h e eve n t o f e m e r g e n c y.

Contact a Ko b e l c o Construction technician for repair.

B3. Engine Pre-Heating Display This symbol is displayed when the water temperature is 50° F (10° C) or lower.

T h i s d i s p l ay g o e s o u t a t completion of pre-heating, at which time FINISH PREHEAT is displayed.

B5. Engine Oil Pressure Display This icon will display and the alarm will sound should the Engine Oil Pressure drop b e l o w a s a fe o p e r a t i n g pressure.

Stop the engine immediately and check engine oil level. Fill engine to proper level with approved oil. If engine has LOW OIL PRESSURE, it will automatically go to “LO” Idle, and immediately shut down.

This icon will display only if alternator is charging.

B6. Engine Coolant Temperature Display This icon will display and the alarm will sound should the Engine Coolant Temperature r ise above safe operating temperature.

Reduce engine RPM to idle and stop operation until engine coolant temperature rea ches a sa fe o pera ting temperature range.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS B7. Engine Air Cleaner Display This icon will display should the Engine Air Cleaner Element(s) ( F I LT E R S ) become too dir ty to allow proper air flow to the engine.

Should this icon display, stop engine immediately and clean or replace engine air cleaner element(s) as required.

This icon will Display only if alternator is charging.

B8. Over Load Alarm Display (Europe only) This icon will display and the buzzer will sound should the Boom Cylinder Circuit P r e s s u r e ex c e e d t h e s e t specified pressure.

Should this icon display and the buzzer sound, immediately stop all operation, stop engine and contact an authorized dealer for service assistance.

B9. Battery Charging System Display T h i s i c o n w il l d i s p l ay th e electrical charging system not functioning properly.

Should this icon display, have the electrical charging system repaired immediately.

I c o n d i s p l ay s o n l y w h e n engine is running with normal oil pressure and a problem occurs in the charging system.

B10. Fuel Level Display This icon will display should the Fuel Level is low.

Should this icon display, refill fuel tank immediately using approved diesel fuel.

B11. Hydraulic Oil Level Display This icon will display should the Hydraulic Oil Level in hydraulic oil reser voir fall below safe operating level.

S h o u l d t h i s i c o n d i s p l ay before starting engine, place m a c h i n e i n H y d ra u l i c O i l Check position and check hydraulic oil level. Refer to M a i n t e n a c e S e c t i o n fo r p r o p e r i n s tr u c t i o n s t o f i l l hydraulic reservoir to proper l ev e l u s i n g a p p r o v e d hydraulic oil.

This icon will not display during machine operation and a loss of hydraulic oil is experienced.

B12. Engine Coolant Level Display This icon will display should the Engine Coolant Level fall below safe operating level.

S h o u l d t h i s i c o n d i s p l ay before star ting the engine, check and fill coolant level in the radiator and coolant reservoir.

This icon will not display if alternator is charging and a sudden loss of coolant is experienced.

B13. Engine Oil Level Display This icon is displayed when the engine oil level of the engine oil pan is low.

Check the engine oil level immediately and make up the shortage of the engine oil.

This icon will not display with engine running and a loss of engine oil is experienced.

B14. Attachment Boost Pressure Display This icon will display when the Power Boost Switch on the r i g h t h a n d j oy s t i c k i s depressed.

This icon is displayed only when this system is activated during operation.

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS B15. Heavy Lift Pressure Display This icon will display when the Heavy Lift Switch is in the “ON” position.

This icon is displayed only when this system is activated during operation.

B16. Auto Warming Up display T h i s i c o n i s d i s p l aye d t o indicate the war ming up operation of the engine and hydraulic oil when this system is activated.

B17. Auto Warming Up Finish Display This icon is displayed when the warming up of the engine and hydraulic oil is finished or when the warming up system is forced to stop.

The monitor alarm will sound continuously for 5 seconds.

B18. Replace Engine Oil Display This icon display every 500 hours of machine operation to remind operator of scheduled engine oil change.

Buzzer will sound and can be reset by pushing the buzzer stop switch twice.

The recommended oil change interval for the engine is every 500 hours of operation.

Proceed with oil change and make sure to recalibrate the engine oil change interval.

B19. Hydraulic Pressure Drain Display This icon will display when the hydraulic system pressure drain is activated. The alarm will sound intermittently during the draining process.

B20. Hydraulic Pressure Drain Fail Display This icon will display when the hydraulic system pressure drain process fails. The alarm will sound continuously.

Turn the key switch OFF to cancel the alarm and repeat hy d r a u l i c p r e s s u r e d r a i n procedure before servicing the machine.

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD CONTRAST ADJUSTMENT

A

B

C

D

E

A

F

BS06H076 / BS06H077

Figure 31

1. Turn key switch on and display main screen (A), and press select switch and display SWITCH STATUS CLOCK CONTRAST select screen (B).

2. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to SWITCH STATUS CLOCK CONTRAST screen (C) and then press select switch and the ADJUST CLOCK ADJUST CONTRAST screen (D) is displayed.

3. In operations press UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to ADJUST CLOCK ADJUST CONTRAST and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (E) is displayed.

4. Press select switch and the ADJUST CONTRAST 55555 screen (F) is displayed.

5. Vary the values by pressing the desired figure in operations UP ARROW (washer switch) and DOWN ARROW (wiper switch). The available setting range is in 9 steps from “11111” to “99999”. (Example) 11111 (faint) to 99999 (clear). *Initial setting value is 55555.

6. Press select switch and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to the main screen (A).

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS MONITOR TIME ADJUSTMENT

A

B

C BS06H076 / BS06H078

A

D

E Figure 32

1. Turn key switch on and display main screen (A) for the operator, and press select switch and display “SWITCH STATUS CLOCK/CONTRAST” select screen (B).

2. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “CLOCK/CONTRAST” screen (C) and then press select switch and the “ADJUST CLOCK ADJUST CONTRAST” screen (D) is displayed.

3. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to “ADJUST CLOCK” and then press select switch and the “ADJUST CLOCK” screen (E) is displayed.

4. Select any of “Y-M-D-H-M” in operation of UP ARROW (washer switch) and DOWN ARROW (wiper switch) and vary the values in operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch).

5. After adjustment, press the select switch and the adjusted values are stored as memory and time setting is completed, and then the screen returns to the main screen (A).

3-22

CHAPTER 3 - INSTRUMENTS AND CONTROLS AUTO WARM UP Use this feature to warm-up the engine oil and hydraulic oil in cold temperatures.

A

B

C

F

D

E

2 1 BS06H-95 / BS06H076

1. Turn the key switch to the ON position, the main display screen (A) will illuminate.

2. Press the select switch (1) and the “CLOCK/CONTRAST” screen (B) is displayed.

3. Press the select switch (1) again and the “AUTO WARM-UP OFF” screen (C) is displayed.

4. Press the select switch (1) again to highlight “OFF” (D) in the “AUTO WARM-UP OFF” screen.

5. Switch the “AUTO WARM-UP OFF” to “ON” (E) by pressing the up arrow (Washer switch) (2).

Figure 33

NOTICE: 1. If a pilot control lever is activated while the warm up system is active, the warm up system is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

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

6. Press the select switch (1) to set the “AUTO WARM-UP ON” (F).

7. Turn key switch OFF to save the “AUTO WARM-UP ON” setting. When the engine is s t a r t e d i n c o l d t e m p e r a t u r e s t h e “ AU TO WARM-UP” operation will start automatically.

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

8. During the engine oil and hydraulic oil warming the “AUTO WARM-UP” will be displayed in the multi-function display.

9. When the “AUTO WARM-UP” is complete the buzzer will sound for approximately 5 seconds and the multi-function display will have “FINISH WARM-UP” in the display.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Pump Flow Rate Adjustment (A mode / B mode) 1. Screen change switch 2. Buzzer stop switch 3. Work mode select switch 4. Washer switch 5. Wiper switch 6. Travel speed select switch 7. Auto accel switch 8. Select switch

BS06H076 / BS06H244

Figure 34

Dependent on the type of attachment (nibbler or breaker) it is necessary to change the flow rate and relief pressure for the service circuit. Change these rates as necessary. Contact your dealer for setting assistance.

1. Turn key switch on and display main screen (A).

2. The display in the lower left corner of the screen can be changed from S, H, B, or A” each time the MODE switch is pressed where the main screen (A) is displayed.

3. Select “A” and A mode screen (B) is displayed, or “B” and B mode screen (C) is displayed.

4. Press the select switch (8) in either A or B mode display screens and the value of flow rate reverses to black, and screen (D) is displayed.

5. To increase flow, press the up arrow (washer switch), or to decrease flow press the down arrow (wiper switch).

6. When the desired setting has been selected, press the select switch (8) and the flow rate is set to the displayed value.

3-24

CHAPTER 3 - INSTRUMENTS AND CONTROLS RESETTING MAINTENANCE INTERVALS The machine is equipped with a multi-display which r e f l e c t s t h e r e m a i n i n g t i m e fo r t h e replacement/change of engine oil, fuel filter, hydraulic oil filter, and hydraulic oil.

When the remaining time elapses, replace or change components, then reset the maintenance interval to restart maintenance count down. See steps below for oil change reset. Other maintenance intervals follow the same steps Engine Oil Default . . . . . . . . . . . . . . . . 500 hours Fuel Filter Default . . . . . . . . . . . . . . . . 500 hours Hydraulic Filter Default . . . . . . . . . . . 1000 hours Hydraulic Oil Default . . . . . . . . . . . . . 5000 hours STEP

PROCEDURE

BS08D533

Figure 35

DISPLAY

Turn ignition key on 1

2

Press screen change switch once.

Display will change from clock to display for oil change. Continue to press for fuel filter, hydraulic filter, hydraulic oil change.

Press the select switch once and the display for revert to zero.

3

4

5

If it is necessary to adjust the interval by 10 hours, press the washer switch.

Press the wiper switch to reduce the time

To return to the initial set time, press the buzzer stop switch once, then press the select switch once, and set time will be stored.

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS

SWITCH AND METER LOCATIONS 15

10

19 11 14 16 1

9

13 2 3 4

6 5 7 8 12 A

BS08D262

1. STARTER KEY SWITCH 2. THROTTLE POTENTIOMETER 3. WORK LIGHT SWITCH (BOOM, DECK) 4. CONFLUX/SINGLE FLOW CHANGE SWITCH 5. AIR CONDITIONER CONTROL PANEL 6. RADIO 7. CAP FOR OPTIONAL SWITCH 8. CIGARETTE LIGHTER 9. HORN SWITCH 10. HOURMETER 11. SWING PARKING BREAK RELEASE SWITCH 12. 12 VOLT POWER SUPPLY 13. TRAVEL ALARM SWITCH (OPTIONAL) 14. MONITOR

3-26

Figure 36

CHAPTER 3 - INSTRUMENTS AND CONTROLS WORK LIGHT SWITCH

BS08B185

CIGARETTE LIGHTER

Figure 37

BS08B252

Figure 39

Press the switch and the work lights on the boom (left) and deck (right) will illuminate. Press the bottom of the switch and the lights will turn off.

The cigarette lighter is located on the right wall of the cab. Do not use the cigarette lighter as a power supply for 12 volt accessories. It is a 24 volt outlet.

12 VOLT POWER SUPPLY

CONFLUX/SINGLE FLOW SWITCH

BS08B253

Figure 38

The 12 volt power supply is located beside the rear side cover. Remove the cover from the power supply and insert a 12 volt male socket. Replace cover after use.

ULY00020011E01

Figure 40

This switch will change the flow of hydraulic fluid from single flow to the conflux flow for nibbler work. Press the top of the switch to change to conflux flow. Do not use this nibbler configuration when using a breaker attachment. Use single flow for breaker attachment work.

Do not set this switch to double pump flow, unless the attachment (e.g.: breaker) requires more than one pump flow. If in doubt, contact your authorized dealer.

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS POWER BOOST SWITCH

HOUR METER

1

1 Figure 41

BS06H106

Figure 43

DC04D547

1. HOUR METER

1. POWER BOOST SWITCH

The hour meter indicates the total time the engine has run. It meters the time continuously as long as the engine is running.

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

HORN SWITCH

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

WARNING Do not use Power Boost for lifting operations.

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

24 VOLT CIGARETTE LIGHTER

Figure 42

BS08B254

HORN SWITCH

Located on the left hand control lever, this is a momentary push button. Always sound the horn before starting the engine to alert personnel the machine is going to be operated.

1

Figure 44

BS06H093

WARNING Sound the horn before you start the engine to alert those around you, before you operate the machine.

Failure to comply could result in death or serious injury.

M1121

1. CIGARETTE LIGHTER

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

NOTICE: Do not use the cigarette lighter as a power source for 12 volt accessories. It is a 24 volt outlet.

Plugging a 12 volt accessory into volt connector may result in shortage and/or Fire.

3-28

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

1

a. Stop the engine.

1 Figure 45

BS06H093

1. LOCATION FOR OPTIONAL SWITCHES

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

CUP HOLDER AND ASHTRAY

1

2

BS06H097 / BS06H098

Figure 47

1. SWING PARKING BRAKE RELEASE SWITCH Figure 46

BS06H094

1. CUP HOLDER 2. ASHTRAY

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

b. Locate the switch to release the swing parking brake, located on the left side behind the seat and move it to its release position. c. Start the engine and move the machine to a safe place.

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

3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS 12 VOLT POWER SUPPLY

FUSE BOX

1 2

1

Figure 49

BS06H104

1. FUSE BOX COVER

Figure 48

BS06H105

1. 12V POWER SUPPLY 2. COVER

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

The power supply is for use of common auto accessories such as a fan or other accessories requiring 12 volt (DC) power. Pull cover away from 12 volt power supply and insert 12 volt male socket into power supply. Replace cover after use.

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

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

GREASE GUN HOLDER

Figure 50

RH09H005

GREASE GUN HOLDER

A grease gun is provided with the machine. Store the grease gun on the holder located inside the access cover on the left side of the machine.

3-30

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATING LEVERS AND CONTROLS LEFT HAND (LH) OPERATOR CONTROL LEVER (ISO/SAE PATTERN)

Figure 51

DC04D562

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

M1716

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

• FORWARD - Variable speed ARM out.

• BACKWARD - Variable speed ARM in.

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

RIGHT HAND (RH) OPERATOR CONTROL LEVER (ISO/SAE PATTERN)

DC04D563

Figure 52

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

• FORWARD - Variable Speed BOOM down.

• BACKWARD - Variable speed BOOM up.

• LEFT - Variable speed BUCKET in (Digging).

• RIGHT - Variable speed BUCKET out (Dump).

• CENTER - Neutral position.

NOTICE: An optional Pattern Control Change Valve is available. Contact your authorized dealer for more information. If your Excavator already has this valve installed follow the following instructions (BHL Pattern) regarding its operation.

3-31

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

1

1

Figure 54

BS07M475

1. PATTERN CHANGER VALVE

3. Open the air cleaner compartment door, locate the pattern changer valve and change valve’s handle position from I (ISO/SAE) to D (BHL).

DC04C344

Figure 53

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

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

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

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

M1713

NOTICE: Whenever a change is made to the machine’s control pattern, also change the pattern decal card in the cab to match the new pattern.

1

Figure 55

DC04D565

1. ISO/SAE PATTERN DECAL CARD

3-32

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

1

Figure 56

DC04D566

1. BHL PATTERN DECAL CARD

DC04D567

Figure 58

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

D. Right Hand Control Lever (BHL Pattern)

1 DC04A001

Figure 57

1. HYDRAULIC PATTERN DECAL CARD HOLDER

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

DC04D568

Figure 59

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

3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT AND RIGHT TRAVEL LEVERS AND PEDALS

3 2

4 5

1

6

Figure 60

BS06H089

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

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

• FORWARD - Variable speed forward track movement.

• BACKWARD - Variable speed reverse track movement.

• CENTER - Neutral position.

3-34

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO

The radio is located on the right side control panel.

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

1

Figure 61

BS06H093

RADIO CONTROLS LY01-00101 - LY01-001122 The following describes the different available radio functions:

Figure 62

DC04D548

SWITCH

FUNCTION AND USAGE

1

Power switch control

2

Tone control

3

FM & AM selector

4

Display change selector

5

Preset selector buttons

6

Time set

7

LCD display

8

Volume control BS09B05B

Figure 63

VOLUME CONTROL/POWER CONTROL Use the knob (1) to adjust volume of the radio. This knob is also the power control. Push the knob to turn the radio off or on.

AM/FM SWITCHING Use the AM/FM (3) key to switch between frequency bands.

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS HOW TO SELECT STATIONS a. How to select the radio station manually: Press the power switch to turn ON the radio and press the station selector buttons up or down to select the desired radio station. This radio functions in two main frequency bands: AM and FM. When the frequency band reaches the upper or lower limit, the radio automatically switches to the opposite limit: from the upper to the lower or vice versa.

BS09B054

Figure 65

HOW TO ADJUST THE CLOCK 1. Use the time setting keys H, M, RST after the radio is turned on and the time is displayed.

2. Press the RST key for 1 second or more and the time display will flicker and change in the time setting mode.

Figure 64

BS09B053

b. How to preset the radio stations: Once the desired radio station is selected manually, press any of the preset station buttons (1 ~ 6) for more than 1.5 seconds to record it in i t s r e s p e c t i ve m e m o r y. T h e r e c e p t i o n i s tem porar ily lost du r ing th e me mor ization process. Once the reception is recovered, the station is preset on the desired preset station button. Repeat this procedure to preset a total of 6 different radio stations.

The radio is preset to the following stations: Key

AM (kHz)

FM1 (MHz)

FM2 (mHz)

1

522

76.0

76.0

2

603

76.4

76.0

3

954

85.6

76.0

4

1386

76.0

76.0

5

522

76.0

76.0

6

522

76.0

76.0

NOTICE: The preset stations are cancelled when the radio is removed for maintenance or the batteries are disconnected.

3. Set the hour by using the H key and the minutes by using the M key. The value of the hour and minute will increase each time the H and M keys are pressed.

4. When the hour display is at 12 press the H key and the value will return to 1. When the minute display is at 59, pressing the M key will return to the) value. Note that the hour is not carried.

5. After setting is complete, press the RST key for 1 second or more, and the time set is complete and the display will illuminate.

NOTICE: The radio LCD screen will return to normal functioning after 5 seconds of inactivity on the time control button.

BS09B05B

Figure 66

DISPLAY FUNCTION Use DISP (4) key to switch between radio frequency display and time display.

3-36

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO CONTROLS LY01-00112

Figure 67

BS09B057A

1. Power Switch

5. Preset Key

2. AM/FM Switch

6. DISP (display change) Key

3. Volume Control

7. Sound Control Key

4. UP/DOWN Key

8. Display (time/frequency)

POWER CONTROL Press the power switch 91) and the power is switched from OFF to ON. The band AM or FM will display initially and will then switch over to a time display.

BS09B057B

Figure 68

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS DISPLAY SWITCHING To change the display from the frequency display to the time display, press the DISP key (6).

The display will show either the time or the frequency, dependent upon which display is selected.

BAND SWITCHING Press the AM/FM key (2) in order to switch the band from AM to FM frequency.

When the frequency band is switched, the station last received will be automatically selected.

SELECTING STATIONS The radio stations can be selected by:

• Manual turning • Auto select station • Preset Memory

BS09B05B

3-38

CHAPTER 3 - INSTRUMENTS AND CONTROLS MANUAL PRESET Press on the 6 PRESET buttons (5) for one second or more. The current station being received will be memorized in the preset button chosen.

PRESET MEMORY Press one of the 6 PRESET buttons (5) for 0.5 second or less and the frequency which is memorized in the present number and its reception is available.

BS09B060

Figure 69

3-39

CHAPTER 3 - INSTRUMENTS AND CONTROLS VOLUME CONTROL To turn the volume level up, press the + side of the volume control key (3). To reduce volume, press the side of the volume control key. The level of volume is displayed along with station, balance, treble, bass.

After adjustments, the panel will return to frequency or time display.

SOUND CONTROL Adjust the balance and tone with. Balance will adjust the right and left speakers. BAS Make adjustments when the SOUND control key is pushed. Choose the item to adjust. will control bass, and TRE will control treble.

3-40

CHAPTER 3 - INSTRUMENTS AND CONTROLS TIME SET

BS09B05B

Figure 70

Press the display key (6) for one second or more while the time is displayed. The HOUR display will flicker.

To increase the hour, press the up key (4). To decrease the hour press the down key (4).

Press the DISP key (6) again and the MINUTE display will flicker. Press the up or down keys (4) to set minutes.

Press the DISP key (6) again, and time setting will be complete.

NOTICE: The radio antenna is located on the machine cab. Retract the antenna before transporting or storing the machine.

3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND OPERATOR CONSOLE

Basic Use

Climate Control - Air Conditioner

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

3

a. Press the AUTO control switch to control air capacity and blower outlet automatically, and set the temperature from 18.5°C (65.3°F) to 31.5°C (88.7°F). The AUTO indicator in the LCD display will come on.

2

1

The outlet temperature, outlet opening and fan speed are adjusted automatically so the temperature of the cab adjusts to the set temperature.

2

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

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

2 BS06H079

Figure 71

1. AIR CONDITIONER CLIMATE CONTROL PANEL 2. AIR OUTLETS 3. SOLAR SENSOR

The Air Conditioner Climate Control provides a comfortable operator compartment environment as well as adjustable control of cab temperature. It removes moisture from humid air and reduces window glass fogging.

The Climate Control - AC unit is installed under the operator’s seat.

3-42

b. Select proper mode manually through recirculate and fresh air capacity selector switch and compressor switch ON - OFF.

CHAPTER 3 - INSTRUMENTS AND CONTROLS c. When the main power switch is OFF, the system will retain the previous setting in memory. Therefore, when the main power sw i t c h i s p r e s s e d a g a i n , t h e C l i m a t e Control-AC will come on in the auto control mode.

Control Panel Functions A. Main Power Switch and Display

2

C. Temperature Setting Switch and Display

2

1 Figure 72

DC04D550

1. MAIN POWER SWITCH 2. LCD DISPLAY

a. LCD display is illuminated when the Climate Control-AC is operating. When the Climate Control-AC is stopped, LCD will turn off. b. Press main power switch, and all functions for the Climate Control-AC will switch ON or OFF. Each time when this switch is pressed, the f u n c t i o n sw i t c h e s O N a n d O F F. W h e n switched ON, the Control Climate-AC starts operating at the last setting before switching OFF. B. Auto Control Switch and Display

2

3

1 Figure 74

DC04D550

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

a. The set temperature is indicated in digits on LCD display. Temperature range is 18.5°C (65.3°F) to 31.5°C (88.7°F). b. Press the two temperature set switches simultaneously for 5 seconds to change the display from °C to °F or vice-versa. c. Press the temperature set switch DOWN or UP to change the set temperature. The temperature goes up or down by 0.5°C (0.9°F) in graduation. The set temperature may be raised or lowered by continued pressing of the switch. d. The set temperature 18°C (64.4°F) is the lowest cooling temperature, and 32°C (89.6°F) is the highest heating temperature. Control beyond either of these limits is not possible.

1 Figure 73

DC04D550

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

a. Press the main power switch to activate the Climate Control-AC and the LCD display will illuminate. b. Press control switch AUTO, and fan speed and air outlet are automatically controlled, and AUTO indicator lamp on LCD display is illuminated.

3-43

CHAPTER 3 - INSTRUMENTS AND CONTROLS E. Defroster Switch and Display

D. Air Outlet Mode Selector Switch and Display

2

2 1

1 Figure 77

DC04D550

1. DEFROSTER SWITCH 2. LCD DISPLAY

Figure 75

DC04D550

1. AIR OUTLET MODE SELECTOR SWITCH 2. LCD DISPLAY

a. Press Defroster Switch to display the defroster indicator.

a. Air outlet position is indicated by the arrow on LCD display.

b. Press Air Outlet Mode selector Switch, and it returns to air outlet mode just before pressing defroster switch.

b. Press Air outlet Mode Switch when the auto display light is on, and the display mode is fixed, AUTO indicator lamp on LCD display goes out, and AUTO control of the air outlet opening is released. Press it again, and the level is change to: VENT

BI-LEVEL

FOOT

c. Press Defroster Switch when the AUTO display is indicated, AUTO indicator lamp on LCD display goes out and the auto control of air outlet opening is released.

F. Fresh and Recirculate Air Selector Switch and Display

FACE

1

DC04D551

2

Figure 76 DC04D550

Figure 78

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

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

.

3-44

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

2

1

DC04D552

Figure 79

DC04D550

1. COMPRESSOR SWITCH 2. LCD DISPLAY

Figure 80

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

a. Press the Compressor Switch (1), and the snow flake icon will be indicated on LCD display (2). b. Press it again, the compressor turns off, and its indicator icon on the LCD display goes out.

H. Fan Speed Selector Switch and Display

2

1 DC04D550

1. FAN SPEED SELECTOR SWITCH 2. LCD DISPLAY

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

Display

Fan Speed

LCD 4 bars are lit up.

MAXIMUM

LCD 3 bars are lit up.

HIGH

LCD 2 bars are lit up

MEDIUM

LCD 1 bar is lit up.

LOW

3-45

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-46

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4

OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Stopping Engine - Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting Machine Engine with Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Connecting Booster Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Boosting Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Starting Disabled Machine Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Disconnecting Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 MACHINE WARM UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warm Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warm Up of Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Manual Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Warming Up of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Hydraulic Oil Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CONTROL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating Pattern Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Unlocked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Locked Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Work Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Work Mode selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Machine Travel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Operating Both Travel Levers Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Use of Travel Speed Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Turning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Counter Rotating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Travel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Machine Attachment and Swing - ISO/SAE pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Swing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Using Power Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 USING AUTO ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 PRACTICES TO IMPROVE EFFICIENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Use Arm in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Operate Boom Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Bucket Teeth Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Maximum Digging Force position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Cleaning Sand & Soil from Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Stop Swing Motion Early . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4-1

CHAPTER 4 - OPERATING INSTRUCTIONS Back Filling & Leveling with Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Operating the Shovel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 MACHINE OPERATION IN ADVERSE WEATHER CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation in High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation in Sandy and Dusty Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation at Seashore or Salty Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operation in Humid Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 RECOMMENDATION FOR LONGER UNDERCARRIAGE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 BUCKET SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 USE OF OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Selection of the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Before Operating the Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Hydraulic Oil Level Check and Contamination Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 Nibbler/Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Basic Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 Getting the Most Out of Your Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 Extra (Grapple, clamshell, etc.) and Extra & Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 Setting Boom Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 Setting Attachment Selector Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Ground Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Retracting and Expanding Crawler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Expanding Crawler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Retracting Crawler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Prepare Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41 Care During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41 Removing Machine from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

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

Before operating this machine: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr ican ts ar e suita ble for p reva iling conditions. See Chapter 6 - Maintenance and Adjustments.

2. Carry out the daily maintenance operations.

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

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

5. Check the track assemblies.

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2 - Safety and Decals.

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

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

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

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

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

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

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

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

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

10. Remove any obstructions which hinder visibility.

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

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

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

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

The operator must be alone on the machine.

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

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

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

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

8. Modify your driving to suit the type of work and working conditions.

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 10. Operate all controls gradually to ensure smooth machine operation.

STARTING AND STOPPING MACHINE ENGINE

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

STARTING ENGINE

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

1. Sit comfortably in the operator’s seat, making certain you can reach all the pedals and controls.

Fasten the seat belt.

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

2. Move throttle control to “LO” position.

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

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

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

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

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

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

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

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

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

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

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

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

STOPPING THE MACHINE

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

20. See Parking the Machine when you park the machine.

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

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

BS08D271

Figure 1

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

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

3. Turn Key Switch to OFF position.

4. Set the safety lock lever in the LOCKED position.

4-4

CHAPTER 4 - OPERATING INSTRUCTIONS

STARTING AND STOPPING MACHINE ENGINE IN COLD CLIMATES

STARTING MACHINE ENGINE WITH BOOSTER CABLES CONNECTING BOOSTER CABLE

STARTING ENGINE

WARNING

1. Move throttle control to “LO” position.

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

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

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

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

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

NOTICE:

• After starting the engine, use the auto warm up system described in Machine Warm Up in this chapter, and warm the engine and hydraulic oil.

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

• When cranking engine, check for the absence of “blue” or “white” smoke from the exhaust.

STOPPING THE MACHINE

Improper booster cable connections can cause an explosion resulting in personal injury.

Always follow the correct procedures when connecting and disconnecting the booster cables.

Failure to comply could result in death or serious injury 1. Move vehicle or machine to be used for boosting as close to the batter y box of the disabled machine as possible.

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

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

WARNING Wear hard hat, approved safety glasses or face shield, gloves and other safety equipment when working with batteries. Failure to comply could result in death or serious injury

WARNING AVOID ACID BURNS Battery electrolyte is an acid and can cause injury or blindness if it contacts with skin or eyes.

Wear eye protection and protective clothing when handling or servicing batteries.

BS08D271

Figure 2

1. Move machine to a firm, level area and place the attachment in the hydraulic oil check position with attachments resting safely on the ground.

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

3. Turn key switch to OFF position.

If electrolyte contacts skin or eyes, flush affected areas immediately with clean water and seek medical attention. Failure to comply could result in death or serious injury

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

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS DISCONNECTING BOOSTER CABLES

3

1

2

3

1

2

4 4 1

2

3

4

DC04D588

Figure 3

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

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

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

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

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

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

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

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

4-6

4 DC04D588

3

2

1 Figure 4

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

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

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

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

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

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

NOTICE: When disconnecting booster cables always disconnect negative (-) cable first from frame of disabled machine.

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE WARM UP AUTO WARM UP NOTICE: The auto warm up system will not activate if the ambient temperature is above 10°C (50°F).

1. Warm Up of Engine WARMING UP is displayed on the multi display after operating the engine for 10 minutes at auto accel speed (1050 rpm). When the accel dial set value is the value for deceleration or lower, the engine speed returns to the speed set by the accel dial (throttle potentiometer).

2. Warm Up of Hydraulic Oil

• Operation of pump max. flow rate at the

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

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

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

M1716

engine speed 1050 rpm for 3 minutes.

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

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

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

3. Warming Up Complete After an elapsed time of about 26 minutes of warming of hydraulic oil, or when the hydraulic oil temperature switch turns OFF, the warming up indication WARMING UP on the multi-display disappears and concurrently buzzer sounds for 5 seconds.

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

NOTICE: 1. If a pilot control lever is activated while the warm up system is active, the war m up is disconnected. The warm up system will restart after 10 seconds of neutral condition in the pilot control system.

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

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

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC OIL WARM-UP

DC04D595

Figure 5

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

Figure 7

DC04D474

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

WARNING While operating the machine with cold hydraulic oil, the operator may experience slow or unexpected movement of functions Damage to the hydraulic components may result due to the cold oil not providing adequate lubrication.

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

M1717

DC04D473

Figure 6

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

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS

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

OPERATING PATTERN DECAL The CONTROLS decal located inside the right side window of the operator cab. Study this decal and understand the directions each control can be operated and the functions associated with each movement. Detailed instructions for each control and its functions are explained on the following pages of this chapter.

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

M1717

BS06H096

Figure 8

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS

HYDRAULIC CONTROLS SAFETY LOCK LEVER 1. Unlocked Position

2

1 1 Figure 9

DC04D475

1. TRAVEL MOTOR

Figure 11

BS06H080

Always be aware of the travel motor position before operating the machine. Practice with the machine using its hydraulic controls and travel levers in an open, unobstructed area.

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

Figure 10

WARNING Normal positioning of the machine for the purpose of determining Front, Rear, Forward, Reverse are with the travel motors located behind the operator’s cab.

Failure to comply could result in death or serious injury M1726

1. UNLOCKED POSITION 2. LOCKED POSITION

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

2. Locked Position Before leaving the operator cab, place the safety lock lever in the LOCKED (up) position by pulling lever up.

With safety lock lever in the LOCKED (up) position, no hydraulic operation is possible and this allows easy access in and out of the operator seat.

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

M1710

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

M1727

4-10

CHAPTER 4 - OPERATING INSTRUCTIONS WORK MODE SWITCH

Press the work mode selector switch, and modes H, B, A, or S can be selected. The work mode selected will be displayed in the lower left hand screen of the monitor.

The initial default mode from the factory is the H mode. After operating the machine, the last mode selected when the machine is shut down will be the start-up mode when the machine is restarted.

Check to be certain the mode conforms to the work being performed. Operating with the improper work mode can damage the machine.

Figure 12

BS06H065

If the work mode lamp flickers, it indicates the wrong work mode choice.

NOTICE: For breaker work, always use the B mode.

Working with the breaker in any other mode can cause damage to the hydraulic equipment and/or breaker.

S - Standard mode H - Heavy duty work mode A - Nibbler/Crusher attachment B - Breaker attachment .

WORK MODE SELECTION TABLE Distinction

Remarks

H - Heavy Mode

H will appear in lower left corner of LCD.

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

B - Breaker Mode

B will appear in lower left corner of LCD.

When an attachment, like breaker, etc., is required, the max. flow rate is adjustable. All other modes get full flow regardless of the flow setting for Breaker Mode.

A - Nibbler Mode

A will appear in lower left corner of LCD.

When the nibbler attachment (crusher) is used for demolition work.

S - Standard Mode

S will appear in lower left corner of LCD.

Used for standard work and loading operations.

Control Mode

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE TRAVEL CONTROLS

2. Use of Travel Speed Select Switch

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

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

BS06H067

DC04D477

Figure 13

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

Figure 15

a. For fast travel speed, depress and release the travel speed select switch once befo re operating the travel controls. This puts the travel motors in “FAST” travel speed and the lamp for “FAST” on the gauge cluster display will illuminate. b. To return to “SLOW” travel speed, stop travel and depress and release travel speed select switch once.

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

3. Turning Machine

DC04D478

Figure 14

b. Pull both travel levers or press the pedals toward operator seat and machine will travel “REVERSE”. c. Return both travel levers to “NEUTRAL” (center) position and machine will stop travelling. Parking brakes are automatically applied when travel levers are in neutral position.

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

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

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

4-12

DC04D479

Figure 16

a. Push the left travel lever toward front of machine to turn machine to the RIGHT in forward motion.

CHAPTER 4 - OPERATING INSTRUCTIONS 4. Counter Rotating Machine

DC04D480

Figure 17

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

DC04D481

DC04D483

Figure 20

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

Figure 18

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

DC04D484

Figure 21

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

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

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

DC04D482

Figure 19

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

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

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

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

4-13

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

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

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

a. Make certain the travel motor location is known before performing any travel operation.

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

b. Travel on firm, level surfaces as much as possible.

MACHINE ATTACHMENT AND SWING - ISO/SAE PATTERN

c. When traveling on rough terrain, travel in SLOW speed with engine at a low idle. d. Travel with the travel motors in the back of the machine for long distance travel.

The following operation instruction are to be used with hoe bucket attachment only. If other attachment are being used, consult the operators manual for the particular attachment.

e. When traveling or operating machine on snow or icy surfaces, clean track shoes frequently to prevent clogging.

WARNING

5. Travel Safety

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

Avoid these areas.

6. Operating the Machine in Water

DC03N003

4-14

Figure 22

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

Failure to comply could result in death or serious injury.

M1087

CHAPTER 4 - OPERATING INSTRUCTIONS 1. Boom Operation Operation of the Boom is performed by pushing and p u l l i n g t h e R i g h t C o n t r o l L eve r fo r wa r d a n d backward. Boom speed is determined by how far the lever is activated.

DC04D487

Figure 25

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

DC04D485

Figure 23

a. Pulling right control lever BACK raises boom.

DC04D488

Figure 26

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

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

DC04D486

Figure 24

3. Bucket Operation

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

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

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

BS06H081

Figure 27

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

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

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 28

DC04D489

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

Figure 29

DC04D490

DC04D491

Figure 30

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

DC04D492

Figure 31

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

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

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

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

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

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

Sound horn before beginning swing operation.

Failure to comply could result in death or serious injury.

M106F

NOTICE: Use operations.

4-16

swing

flashers

during

swing

CHAPTER 4 - OPERATING INSTRUCTIONS

USING AUTO ACCELERATION

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

1

1

Figure 33

BS06H064

1. THROTTLE POTENTIOMETER

Figure 32

DC04D493

1. POWER BOOST SWITCH

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

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

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

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

AUTO ACCEL OPERATION AND CONTROL a. In operation, when the pilot pressure from the hand and pedal control levers does not act for 4 seconds, if the position of the throttle potentiometer is higher than 1050 rpm, the auto accel actuates automatically and the engine speed returns to 1050 rpm. b. When the throttle potentiometer is positioned lower than the auto accel speed, the engine speed is maintained to the throttle potentiometer position.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS

PRACTICES TO IMPROVE EFFICIENCY USE ARM IN ACTION

DC04E074

MAXIMUM DIGGING FORCE POSITION

Figure 34

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

OPERATE BOOM SMOOTHLY

DC04E077

Figure 37

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

CLEANING SAND & SOIL FROM BUCKET

DC04E075

Figure 35

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

BUCKET TEETH DIRECTION

DC04E078

Figure 38

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

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

DC04E076

Figure 36

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

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE SHOVEL

STOP SWING MOTION EARLY

DC04E079

Figure 39

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

DC04E081

Figure 41

Digging with the shovel differs slightly from digging with backhoe.

1. Using the arm cylinder, scrape the ground.

BACK FILLING & LEVELING WITH FRONT ATTACHMENT

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

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

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

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

DC04E080

Figure 40

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

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

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

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

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

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

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

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

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

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

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

2. Clean radiator, oil cooler and debris screen often t o p r eve n t d a m a g e o r ove r h e a ti n g o f t h e machine.

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

3. Keep all belts properly tensioned.

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

4-20

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

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

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

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

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

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

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

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

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATION AT SEASHORE OR SALTY CLIMATE

OPERATION IN HUMID CLIMATE

1. Thoroughly wash machine daily to help avoid corrosion of machined areas, electrical components and cylinder rods.

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

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

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

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

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

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

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

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

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

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

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

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

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

BUCKET SELECTION GUIDE Bucket selection is extremely impor tant to a machine’s productivity, durability, and stability.

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

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

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

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

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

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

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

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

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

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

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS

USE OF OPTIONAL ATTACHMENT

1

Example: Some couplers can increase tooth tip radius up to 12 inches. If this is used with 48” tooth tip radius, effective bucket breakout force can be reduced 25%, a 5% reduction in effective arm force, a reduction in lift capacities of up to 272 kg (600 lbs).

It is also impor tant to mention that some quick couplers offer a great advantage, particularly when lifting loads. Some quick couplers allow the operator to quickly remove the bucket for lifting purposes; therefore, increasing lifting capacity, height and visibility. Always follow coupler manufacturing instructions for safe operation.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine.

EXAMPLE:

Figure 42

DC04D574

1. BUCKET QUICK COUPLER

If a machine is equipped with optional attachments such as a bucket quick coupler, and/or thumbs (either hydraulic or mechanical), applicable bucket sizes and suspended loads must be reduced in direct proportion to the weight or combined weight of these attachments. Failure to consider the added weight of such attachments will cause stability complaints.

Additionally the weights of such attachments must be considered when the Lift Chart is referred to before lifting a load. See Lift Charts in the Specification’s Section.

N OT I C E : U s e o f q u i c k c o u p l e r s fo r b u c k e t interchangeability will reduce effective arm digging force and particularly bucket breakout force due to an increase of tooth tip radius.

4-22

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

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS HYDRAULIC BREAKER

4. Basic Operation

1. Selection of the Hydraulic Breaker When mounting a breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the oil flow for each breaker. To select hydraulic breakers, contact your authorized dealer.

2. Before Operating the Hydraulic Breaker Consult your authorized dealer for the hydraulic lines needed for the boom and arm when installing a hydraulic breaker. Replace the hydraulic return filter according to the replacement schedule table listed on MAINTENANCE FOR NIBBLER/BREAKER in the MAINTENANCE AND ADJUSTMENT Section.

Thoroughly read the Hydraulic Breaker Operation Manual and SAFETY PRECAUTIONS from this Section, as well as the Safety Precaution’s Section in this Manual to avoid damaging the machine or hydraulic breaker during operation. Select the appropriate hydraulic flow for the breaker by following the instruction detailed in the NIBBLER/BREAKER BASIC MACHINE OPERATION in this section.

3. Hydraulic Oil Level Check and Contamination Prevention When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the Arm-Bucket end and the hose end on the on the hydraulic breaker side to prevent dust and water from entering into piping.

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

M1087

1

Figure 43

BS06H080

1. SAFETY LOCK LEVER

a. Start machine and place the hydraulic safety lock lever in “UNLOCKED” (down) position.

Before starting operation, check the cap screws on the tube fixing clamps for looseness, and the connection of the tubes and hoses for oil leakage.

BS06H082

Figure 44

b. Make sure to select the Breaker Mode. Move throttle control to HI idle position. c. Using boom, arm and bucket controls set the breaker or nibbler to desired position.

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING PEDAL

NIBBLER/BREAKER

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M100B

WARNING

Figure 45

Before operating this machine, review and understand all Safety Precautions in the Safety Section of this manual. Failure to comply could result in death or serious injury.

e. Make certain breaker or nibbler is in desired position and against material to be broken.

M1416

DC04E082

d. Release control pedal lock rod.

f. Place right foot on pedal and depress with toe to activate breaker or nibbler. g. Operate breaker or nibbler at one (1) minute intervals.

NOTICE: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute intervals .

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

M1710

4-24

MACHINE SET-UP A. Setting return flow selector valve. a. Use a 5 mm allen type wrench to loosen and remove the socket head capscrew. b. Use a 24 mm wrench to turn the selector valve to the proper position. c. After the valve is set in the proper position, install the 5 mm socket head capscrew and tighten it.

CHAPTER 4 - OPERATING INSTRUCTIONS BASIC MACHINE OPERATION

SETTING STOP VALVE.

1

1 Figure 46

DC04D498

1. NIBBLER AND BREAKER STOP VALVE

NOTICE: Make sure to relieve hydraulic system and tank pressure as instructed in Releasing Hydraulic System And Tank Pressure in Section 6. a. Locate the stop valves on both sides of the Arm. b. Use a 24 mm wrench to turn the stop valve to the proper position.

NOTICE: Make sure to switch the position of the stop valves to the “CLOSED” position before removing the attachment.

BS06H093 / BS06H090

Figure 47

1. CONFLUX/SINGLE FLOW CHANGE SWITCH

The standard machine is equipped with a bi-directional auxiliary hydraulic valve, which is optional. The double pump flow switch is provided on the right side control panel to select a single or double pump flow to the auxiliary system.

• Press switch Forward when using the nibbler for demolition work.

• Press switch Backward when using the breaker.

NOTICE: Never turn switch on bi-directional flow (two pump flow) to operate Breaker. It may cause damage to the machine.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS CONTROL PEDAL

B (BREAKER) MODE

Hydraulic Breaker Single Circuit

BS06H082

Figure 48

If an optional attachment such a breaker, etc. are used, the flow rate can be automatically controlled.

Adjust the maximum flow rate by the following procedure: Each time the work mode is pressed, the work mode indicator will show in the lower left side of LCD display in order of “H”, “B”, “A”, or “S”.

Figure 49

DC04E083

Release pedal lock on the right front side of driver’s seat to operate pedal.

• Turn key switch on.

NOTICE: Pedal operation varies upon specifications.

Make sure to read the operator’s manual carefully before operating optional attachment.

• Select the Breaker “B” mode.

Pedal Operation - Breaker Only

Adjustment of maximum flow rate:

• Press the up or down arrows to increase or

Foot Pedal Depressing Section

Operating Condition

Flow rate display:

Depress toe section

Breaker starts operation

The flow rate stored last time is displayed. Maximum flow rate is displayed as standard value.

Pedal in neutral position

Breaker stops operating

decrease the flow rate.

• Press the up arrow to increase the flow rate setting or press the down arrow to decrease the flow rate setting.

• Press the select switch again to store the desired flow rate value, and the adjust mode is cancelled.

4-26

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 50

DC04D575

Figure 52

DC04D576

If the machine is equipped with optional hand control grip levers, operate as shown.

If the machine is equipped with optional control grip levers, operate as shown.

NIBBLER AND BREAKER COMBINED (CONFLUX)

NOTICE: Operation of Breaker or Nibbler longer than one (1) minute intervals could cause premature wear or damage to the attachment and the machine. If material is not breaking, reposition Breaker or Nibbler and repeat operation in one (1) minute intervals.

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

M1710

DC04E083

Figure 51

Release pedal lock on the right front side of driver’s seat to operate pedal.

Pedal Operation - Breaker Foot Pedal Depressing Section

Operating Condition

Pedal in neutral position

Breaker stops operating

Depress heel section

Breaker starts operation

Pedal operation - Nibbler Foot Pedal Depressing Section

Operating Condition

Depress toe section

Nibbler close

Depress heel section

Nibbler open

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS SAFETY PRECAUTIONS The following safety precautions should be used in conjunction with other safety precautions found in this manual.

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

Failure to comply could result in death or serious injury.

When operating attachments that produce flying debris, it is highly recommended to procure and install protective guards on the machine and close all windows to protect the operator from flying debris.

Also the operator and all personnel in the vicinity of the machine should wear protective gear such as safety shoes, hard hat, gloves and face shield or goggles.

CYLINDERS

M1087

USE FOR INTENDED PURPOSE

DC04E063

Figure 55

DO NOT OPERATE boom, arm or bucket cylinders at stroke ends when using a breaker attachment. Doing this can cause undue stress on the cylinder rods and result in damage.

DC04E061

Figure 53

AVOID CONTINUOUS OPERATION

Use the attachment only for its intended purpose. If not used in accordance with the manufacturer’s instructions, the excessive pressure exerted on the boom. arm and frame structure of the machine will cause premature failure of the components.

PASSENGERS Never allow passengers on the attachment or machine.

PROTECTIVE EQUIPMENT

DC04E064

Figure 56

Operate the Nibbler/Breaker in one (1) minute intervals. Operation for longer than one (1) minute at a time can cause high oil temperatures and damage the accumulators, cylinder seals and possibly pump damage.

DC04E062

4-28

Figure 54

CHAPTER 4 - OPERATING INSTRUCTIONS DO NOT LIFT

HOSE SURGE

DC04E065

Figure 57

DC04E068

Figure 60

I f hy d ra u l i c h o s e s b e g i n t o s u r g e o r v i b ra t e abnormally during operation of a Breaker or Nibbler, immediately stop operation and contact an authorized dealer. This can be the result of damaged accumulators and can also result in valve failure.

Never use optional attachment to lift or transport objects or materials. Doing so can cause extensive damage to the attachment, the machine structures or cause injury or death due to slipping or dropping of load due to improper attachment.

DO NOT USE DROPPING FORCE

WORKING RANGES

DC04E066

Figure 58

Never use the dropping force of the attachment to break or drive objects. This will cause extensive damage to the attachment and machine structure.

DC04E069

Figure 61

Never operate an optional attachment over the sides of the machine. Only operate over the front or rear of the tracks.

DO NOT USE SWING FORCE

DC04E067

Figure 59

Never use the swing force of the machine for pushing or sliding objects. This will cause premature failure of the attachment and other machine components.

4-29

CHAPTER 4 - OPERATING INSTRUCTIONS GETTING THE MOST OUT OF YOUR BREAKER

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

Failure to comply could result in death or serious injury.

M1087

BREAKER PROPER POSITIONING

DC03M065

Figure 62

Always position the Breaker perpendicular to the material you intend to break. The Breaker can be vertical, horizontal, or anywhere in between, as long as the tool is perpendicular to the surface and the pressure applied is in the same direction of the tool.

APPLIED PRESSURE ON BREAKER The Breaker must have sufficient pressure between the tool and the surface of the material intended to break to allow the shock wave to flow through the tool and to the material being broken. The applied pressure has to be constantly adjusted by combining the boom, arm, and bucket functions so that the breaker follows the tool at all times during breaker operation.

4-30

When the excavator boom is lowered, it normally follows a curved path, which changes the original perpendicular position of the breaker. Keep adjusting t h e o p e ra to r ’s c o n t r o l s t o m a i n t a i n c o n s t a n t per pendicularity between the breaker and the surface of the material being broken. The applied pressure should be sufficient to avoid the breaker t o o l f r o m b o u n c i n g o n t h e r o ck r a t h e r t h a n transmitting the shock wave into it. The applied pressure should not lift the machine high off the ground, since the excavator can drop suddenly, as the breaker breaks through the material, and harmful shock loads will be transmitted through the entire machine.

CHAPTER 4 - OPERATING INSTRUCTIONS BREAKING OVERSIZE ROCKS

SURFACE ROCK DEMOLITION

DC03M067

Figure 64

Use the breaker just as if it were a hand held breaker, or a plain hammer and chisel. Adjust the breaker’s position according to the work to be done, and take small bites at a time. The only difference between a hand held breaker and the hydraulic excavator breaker is the size of the rocks that can be broken.

Do not try to break too much at one time.

DC03M066

Figure 63

Do not attempt breaking oversize boulders from the center. It is much more efficient to break these type of rocks from the edges. Do not break into smaller pieces than necessary. There is a direct relationship between the size of the boulders and the size of the breaker. It is inefficient to break large rocks with small breakers and vice versa.

4-31

CHAPTER 4 - OPERATING INSTRUCTIONS 9. DO NOT OPERATE breaker for more than a minute at a time.

EXCAVATING AND TRENCHING

10. Lubricate breaker every 30 minutes. Keep tool lubricated at all times.

DC03M068

Figure 65

Lay back side walls a bit at the time so that they do not interfere with the breaker housing. To lessen the opportunity for side loading, approach each wall from the opposite side by positioning the excavator perpendicular to the trench.

RULES TO REMEMBER Use the following rules for correct breaker operation: 1. Make sure to adjust the proper hydraulic flow according to the breaker specifications.

2. Place tool against material to be broken at 90° angle to work surface.

3. Use the boom, arm, and bucket controls to press firmly against surface, keeping perpendicularity while operating the breaker.

4. As material breaks, stop breaker quickly to prevent idle strokes.

5. Reposition breaker if material does not break after 15 seconds of operation.

6. Do not bend or pry with the breaker tool while operating.

7. DO NOT OPERATE breaker with attachment cylinders at full extension.

8. DO NOT OPERATE breaker submerged in water.

4-32

CHAPTER 4 - OPERATING INSTRUCTIONS EXTRA (GRAPPLE, CLAMSHELL, ETC.) AND EXTRA & BREAKER

SETTING ATTACHMENT SELECTOR VALVES

MACHINE SET-UP

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

Failure to comply could result in death or serious injury.

M1087

SETTING BOOM SELECTOR VALVES

DC03M070

Figure 67

a. Locate the two (2) selector valves on the arm. b. Use a 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until stamped letter “E” is aligned with the socket head cap screw mounting hole. d. Reinstall the 5 mm socket head cap screw and tighten securely.

NOTICE: All selector valves MUST be turned to the “E” position or the EXTRA ATTACHMENT WILL NOT FUNCTION PROPERLY. DC03M069

Figure 66

a. Locate the two (2) selector valves on the boom. b. Use 5 mm allen type wrench and remove the socket head cap screws. c. Using a 24 mm wrench, turn the selectors until the stamped letter “E” is aligned with the socket head cap screw mounting hole. d. Reinstall the 5 mm socket head cap screw and tighten securely.

4-33

CHAPTER 4 - OPERATING INSTRUCTIONS BASIC OPERATION

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

Failure to comply could result in death or serious injury.

M1087

1

Figure 68

BS06H080

1. SAFETY LOCK LEVER

a. Start machine and place the hydraulic safety l o ck l eve r i n t h e “ U N L O C K E D ’ ( d ow n ) position. b. Move throttle control to the HI idle position.

Figure 70

BS06H214 / BS06H216

e. Unlock pedal and place right foot on pedal.

Depress with toe to close attachment and depress back of pedal with heel to open attachment. f. After operation is complete or operator is required to leave the machine, place pedal lock rod in the locked position, operate the attachment in hydraulic oil check position, move throttle control to LO idle position, and place the Nibbler/Breaker selector switch in the neutral position.

1

BS06H088

Figure 69

1. NIBBLER/BREAKER SELECTOR SWITCH

c. Place the Nibbler/Breaker selector switch, located on the RH control console, to the operating position being performed. d. Use the boom, arm, and bucket controls to position the attachment.

4-34

WARNING Set the pedal lock to the “LOCKED” position while the breaker or nibbler is not used. Unexpected contact with the pedal in the “UNLOCKED” position may cause serious injury or death. Failure to comply could result in death or serious injury.

M1603

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTATION GROUND TRANSPORTATION MACHINE PREPARATION a. Know the total weight, length, width and height of the machine being transported.

f. Use only a trailer with a rated capacity sufficient to transport the machine.

b. The crawler frame must be retracted before transporting the machine.

g. Make certain trailer has ramps or a ramp is available for loading and unloading the machine.

c.

h. Place a cover over the exhaust pipe of the machine and secure to avoid water entering the engine, and possible turbo damage.

d. Know route to be traveled. Investigate bridges, overpasses, height of road signs on route. e. Obtain any permits required from proper g o v e r n m e n t a g e n c i e s fo r m a c h i n e transportation.

RETRACTING AND EXPANDING CRAWLER FRAME EXPANDING CRAWLER FRAME

3 WARNING Crawler Frame must be expanded before machine can be used. Failure to expand the crawler frame could result in machine tipping over and resulting in serious injury or death. Failure to comply could result in death or serious injury.

1

2

NOTICE: DO NOT loosen bolts of plate on the crawler frame.

Figure 72

3

1

1. BOLTS 2. SPACERS 3. PLATE

3. Attach cables to crawler frame as shown. Use pads to keep cables and frame from damage.

2

2 Figure 71 1. BOLTS 2. SPACERS 3. PLATE

3 2 1

1. Remove bolts and spacers on side to be expanded. DO NOT remove bolts and spacers from opposite side of machine.

2. Swing upper frame 90 degrees to the crawler frame so that the upper structure is at right angle.

Figure 73 1. CABLES 2. PADS 3. RATCHET LEVER WINCH

4-35

CHAPTER 4 - OPERATING INSTRUCTIONS 4. Attach cables to bucket. Use pads to keep cables from being damaged.

5. Attach a ratchet lever winch to cables as shown.

6. Lower bucket to ground and raise frame to where the track is 50 mm (1.97 in) above the ground.

1

2 3

2 1

Figure 76 1. BOLTS 2. SPACERS 3. PLATE

RETRACTING CRAWLER FRAME Figure 74 1. CABLES 2. PADS

1. Remove all bolts and spacers from crawler frame on side to be retracted.

2. Swing upper structure 90 degrees to one side so upper structure is at a right angle to lower frame.

3. Operate right and left travel levers in reverse alternately like a pivot turn to retract crawler frame.

NOTICE: Raise boom and move arm inward to adjust the center of gravity to the counterweight side of machine.

4. Install 8 bolts and spacers in crawler frame to secure as shown in Figure 5. Torque bolts to 2800± 280 Nm (2066± 207 lb ft).

5. Repeat steps 1 through 4 for other side.

Figure 75

7. Use two people to operate the ratchet lever winch so the crawler frame is expanded equally, until the crawler frame contacts the stop on the main frame.

8. Secure crawler frame using 26 bolts (13 on front of crawler frame and 13 on back of crawler frame) and spacers. Torque bolts to 2800± 280 Nm (2066± 207 lb ft).

9. Repeat steps 1 through 8 for other side of machine.

4-36

WARNING Crawler Frame must be expanded before machine can be used. Failure to expand the crawler frame could result in machine tipping over and resulting in serious injury or death. Failure to comply could result in death or serious injury.

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE DIMENSIONS

900MM 35’4”

DC03N007

Figure 77

650 mm (25.6 in) 750 mm (29.5 in) TRACK

S2LY00001ZE05-243

Figure 78

4-37

CHAPTER 4 - OPERATING INSTRUCTIONS 900 mm (35.4 in) TRACK

Figure 79

S2LY00001ZE05-244

Figure 80

S2LY00001ZE05 245-1

Boom with Arm Cylinder Boom LxHxW

Figure 81

S2LY00001ZE05 245-2

Arm with Bucket Cylinder 8250 mm (27 ft 1 in)

8620 x 2270 x 1100 (28 ft 3 in x 7 ft 5 in x 3 ft 7 in)

With arm cylinder

8220 kg (18,120 lb)

Boom cylinder rod pin (two)

63 kg (139 lb)

Top pin

98 kg (216 lb)

Arm - 3.6 m (11 ft 10 in) 5190 x 1270 x 705 mm (17 ft x 4 ft 6 in x 2 ft 4 in)

LxHxW With arm cylinder

4350 kg (9590 lb)

Arm 4.4 mm (14 ft 5 in) LxHxW With arm cylinder

6000 x 1430 x 705 mm (19 ft 8 in x 4 ft 8 in x 2 ft 4 in) 4350 kg (9590 lb)

Assembly includes weights listed below

4-38

Rod pin

46 kg (101 lb)

Bucket link pin

94 kg (207 lb)

Bucket pin

94 kg (207 lb)

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 82

S2LY00001ZE05 246-1

Counterweight

Figure 85

S2LY00001ZE05 246-4

Bucket

LxHxW

3350 x 1540x 845 (11 ft 0 in x 5 ft 1in x 2 ft 9in)

Weight

13300 kg (29320 lb)

Figure 83

S2LY00001ZE05 246-2

LxHxW

2250 x 1800 x 1980 (7 ft 5 in x 5 ft 11 in x 6 ft 6 in)

Weight

2560 kg (5640 lb)

Figure 86

S2LY00001ZE05 246-5

Handrail

Boom Cylinder LxHxW

2940 x 390 x 845 (9 ft 8 in x 1ft 3 in x 1 ft 3 in)

Weight

2280 kg (6030 lb)

LxHxW With arm cylinder

995 x 905 x 46 (39.2 ft x 35.6 ft x 1.8 ft) 11.2 kg (24.7 lb)

Figure 84

S2LY00001ZE05 246-3

Cat Walk LxHxW

4490 x 200 x 420 (14 ft 9 in x 0 ft 8 in x 1 ft 5 in)

Weight

71.5 kg (158 lb)

4-39

CHAPTER 4 - OPERATING INSTRUCTIONS LOADING THE MACHINE

WARNING Operating the machine too fast and not centering it on the transport device and ramps could cause an accident. When moving the machine on or off of the transport device, trailer or ramps, operate slowly and keep the machine centered. Failure to follow these instructions could cause death or serious injury. Failure to comply could result in death or serious injury.

1

CM113A

Figure 88

DC04C344

1. Apply parking brakes on tractor and trailer and chock trailer wheels before attempting to load or unload machine.

4. Set travel speed to LOW 1st speed.

2. Lower ramps of trailer.

5. Move throttle control to low idle position.

3. Start the machine.

6. Turn Auto Accel function OFF.

NOTICE: Remove bucket, boom, arm, and counterweight before loading machine on truck for transportation. Contact your authorized Dealer for proper procedures when disassembling and assembling machine.

7. Place hydraulic safety “LOCKED” (up) position.

DC03K084

4-40

Figure 87

1. SAFETY LOCK LEVER

lock

lever

in

the

8. Turn machine “OFF”, remove key and lock all doors, filler caps and access panels.

CHAPTER 4 - OPERATING INSTRUCTIONS SECURING MACHINE TO TRAILER

DC04D581

Figure 89

9. Use cable or wire rope with sufficient capacity to secure front and rear of the machine to trailer.

Chock the tracks, use the lower frame front and rear brackets to secure machine to trailer. Also, make sure to secure front and rear of each track.

10. Securely fasten all loose parts, as well as removed parts from the machine to the trailer or transporting platform.

4-41

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE PREPARE MACHINE Perform the following procedure to prepare the machine for long term storage.

1. Perform all inspection and maintenance proce dure s as de scr ibed in Mainte nance Section.

2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace or repair all damaged or worn parts.

1

NOTICE: Protect CPU and all electrical components from water and steam when cleaning the machine.

3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside the fuel tank. Make sure to use an anti-algae additive in the fuel tank.

4. Move machine to an indoor location for storage.

2 2

2 Figure 90

DC04D586

1. MACHINE IN STORAGE POSITION 2. CYLINDER RODS HEAVILY GREASE TO PREVENT CORROSION DURING STORAGE

5. Operate bucket and arm completely “IN” extending cylinders. then lower boom until attachment is resting on the floor.

6. Coat cylinder rods with heavy coat of grease to prevent corrosion during storage.

7. Remove batteries and store in a well ventilated, warm area.

CARE DURING STORAGE 1. Every 30 days during storage, it will be necessar y to star t and run the machine to circulate the fluids through the systems. Before starting, clean cylinder rods and after running, re-grease cylinder rods.

NOTICE: Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach normal operating temperatures.

4-42

REMOVING MACHINE FROM STORAGE 1. Perform all inspection and maintenance procedures as described in the Maintenance Section before bringing machine out of storage for normal operation.

2. Remove drain plugs from the travel motors and swing gear reduction units to drain off any moisture which may have accumulated during storage.

3. Carefully and closely inspect all hydraulic hoses after long per iods of stora ge for signs of deterioration. Replace all hoses showing these signs.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CHAPTER 5

LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS FLUIDS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Required Fluids/Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Travel Motor Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operating Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Upper Attachment Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Swing Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Required Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Transmission Component Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Use of Bio-degradable Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Biodiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Biodiesel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND FILTERS REQUIRED FLUIDS/LUBRICANTS AND CAPACITIES

UPPER ATTACHMENT PINS

ENGINE

Capacity -------------------------- As required in each pin

Type of Oil -------------------------------- EP Grease EP/2

Type of Oil ------------------------ Engine Oil SAE 15W40 Capacity:

NOTICE: See ATTACHMENT LUBRICATION in Chapter 6 for proper lubrications.

Engine Oil Pan (H Level) -----55.0 liters (15.0 gal) Engine Oil Pan (L level) ----- 43.0 liters (11.0 gal) Total Engine Oil Volume --- 64.0 liters (17.0 gal)

SWING BEARING Type of Oil -------------------------------- EP Grease EP/2

NOTICE: See ENGINE OIL LEVEL in Chapter 6 for proper oil filling and/or checking engine oil level.

HYDRAULIC

Capacity --------- As required (1 place - swing 90° x 4) NOTICE: See SWING BEARING LUBRICATION in Chapter 6 for proper lubrication.

Type of Oil ----------------------------Hydraulic Oil AW 46 Capacity: Hydraulic Tank -----------------522 liters (138.0 gal) Hydraulic System ------------856 liters (226.0 gal)

TRACK TENSION ADJUSTMENT Type of Oil -------------------------------- EP Grease EP/2 Capacity ---------------------------- As required (2 places)

NOTICE: See HYDRAULIC OIL LEVEL in Chapter 6 for proper filling and/or checking hydraulic oil level.

SWING MOTOR REDUCTION UNIT Type of Oil ------------------------- SAE 90 GL4 Gear Oil Capacity --------------------21.5 liters (5.7 gal) Each x 2 NOTICE: See SWING MOTOR REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

NOTICE: See TRACK TENSION in Chapter 6 for proper procedures in injecting grease.

SWING RING GEAR Type of Oil ------------ Lithium base grease with MOS2 Capacity------------------- 63.6 ± 6.4Kg (140.0 ± 14 lbs) NOTICE: See SWING RING GEAR LUBRICATION in Chapter 6 for proper lubrications.

TRAVEL MOTOR REDUCTION UNIT Type of Oil ------------------------- SAE 90 GL4 Gear Oil Capacity ------------------ 22.0 liters (5.8 gal) Each x 2 NOTICE: See TRAVEL MOTORS REDUCTION UNIT OIL in Chapter 6 for proper filling and/or checking oil level.

POWER DIVIDER Type of Oil--------------------------SAE 90 GL4 Gear Oil Capacity -------------------------------5.0 liters (1.3 gal) OPERATING LEVER Type of Oil -------------------------------- EP Grease EP/2 Capacity ------------------------- As required in each joint NOTICE: See CONTROL LEVER JOINT LUBRICATION in chapter 6 for proper lubrications.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Radiator

REQUIRED FILTERS

Coolant --------------- Ethylene-glycol Coolant Solution

NOTICE: Refer to the Parts Manual for the correct part numbers to order.

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

Capacity: Radiator --------------------------37.5 liters (10.0 gal) Cooling System ---------------76.0 liters (20.0 gal) NOTICE: See ENGINE COOLANT CHANGE in Chapter 6 for proper coolant filling and/or coolant level check.

HYDRAULIC

• Return Filter Element for Standard Machine • Return Filter Element for Breaker and N&B • Tank Suction Strainer • Tank Breather Filler Element • Pilot Line Filter ENGINE

• Engine Oil Filter FUEL TANK Type of Fuel --------------------- Diesel Fuel grade No. 2 Capacity --------------- Fuel Tank - 960 liters (254 gal) NOTICE: See FUEL LEVEL in Chapter 6 for proper filling and/or checking the fuel level.

• Air Cleaner Inner Element • Air Cleaner Outer Element FUEL

• Engine Fuel Filter • Priming Pump Gauze Filter OPERATOR CAB

• A/C Fresh Air Filter • A/C Recirculate Air Filter NOTICE: Refer to MAINTENANCE AND ADJUSTMENT Chapter 6 in this Manual for the Locations and proper procedures in replacing filters.

5-4

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICANT SPECIFICATIONS The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various climate and certain conditions.

CLIMATE ZONE

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

FRIGID -30°C~15°C (-22°F~59°F)

FRIGID -20°C~30°C (-4°F~86°F)

FRIGID-WARM -25°C~40°C (-13°F~104°F)

WARM -5°C~40°C (23°F~104°F)

VERY HOT 5°C~55°C (41°F~131°F)

ISOVG22

ISOVG32

ISOVG32S

ISOVG46

ISOVG68

CLIMATE ZONE

LUBRICANT

ENGINE OIL A.P.I. CLASSIFICATION FOR SERVICE CD)

FRIGID -30°C~30°C (-22°F~86°F)

WARM -5°C~40°C (23°F~104°F)

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

SAE10W30

SAE15W40*

SAE15W50

*Note: All engines shipped from factory with SAE15W40 engine oil.

CLIMATE ZONE

LUBRICANT

FUEL

FRIGID -15°C ~ -25°C (5°F ~ -13°F)

WARM -5°C ~ -15°C (23°F ~ 5°F)

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

WINTERIZED ASTM D975 No.1

ASTM D975 No.2

ASTM D975 No.2

LUBRICANT

For ROLLERS and IDLERS

ENGINE OIL A.P.I. Classification for Service CD - SAE15W40

(For General Purpose Lubrication)

LUBRICANT

For Swing Motor Reduction Unit and Travel Motor Reduction Units

ENGINE OIL (For General Purpose Lubrication)

A.P.I. Classification for Service CD - SAE15W40

LUBRICANT

GENERAL LUBRICATION

SWING GEAR SUMP (BATH)

GREASE

Extreme Pressure Multi Purpose Grease No.2 EP Type Grease

N.L.G.I. No. 2 Lithium Base with MOS2 Grease

FLUID ENGINE COOLANT (50% MIXTURE)

ANTIFREEZE (LLC) -34°C (-29.2°F) Mixture ratio should protect to 5°C (9°F) lower than the coldest temperature the machine will experience. Take into consideration Wind Chill Factors.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

HYDRAULIC FLUID Use hydraulic fluid specifically designed for high pressure applications. Your dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions.

GREASE The type of grease to use depends on ambient temperature. Use a quality extreme pressure multipurpose No. 2 grease.

ENGINE OIL CI-4 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, flush the hydraulic system that was filled with mineral oil twice. This is a requirement before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

ENVIRONMENT Before you service this machine and dispose of oil, f l u i d s, a n d l u b r i c a n ts, a l way s re m e m b e r t he environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.

FUEL STORAGE

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out with approved lubricants.

Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

USE OF BIO-DEGRADABLE OILS

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

When using Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

5-6

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CHAPTER 6

MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Disposal of Hazardous Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hot Surface & Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Warm Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Tag-Out Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Inspect Waste Oils and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Seals & O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Prevent Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Machine Access Compartments and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Releasing Hydraulic System and Tank Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Guidelines for Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Special Considerations for Hand Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Replacing Ground Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Machine Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 DAILY INSPECTION & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Radiator and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Fan and Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Steps and handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 50 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Drain Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Fuel Tank Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 120 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Swing Motor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Travel Reduction Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Checking Radiator Cap and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 .Engine Accessory Belt Wear and Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Air Conditioner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 500 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Travel Motor Reduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Swing Reduction Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Checking and Cleaning Fuel Tank Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Checking the Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Lubricate Machine and Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Control Lever Joint Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Lubricate Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Air Conditioning Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 1000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Power Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Coolant Corrosion Resistor Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Engine Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 2000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Engine Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43 cleaning suction strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 Pilot Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47 Swing Gear REduction Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48 5000 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50 PERIODICAL INSPECTION ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Dust Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 Frame Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Tracks and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Track Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Boom & Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-55 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Bucket, Arm, & Link Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56 Reversing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-57 Removing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58 Installing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59 Bucket Teeth and Side Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59 Hydraulic Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Boom Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Arm Cylinder Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Fuel Lines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61 Hydraulic Suction Tubes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62 MAINTENANCE FOR NIBBLER/BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 Releasing Travel Motor Brakes Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 Lowering Attachment When Sudden Engine Failure Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-66 Radiator, Oil Cooler and Debris Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-68

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 ATTACHMENT AND COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 installing boom cyclinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Attaching Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Installing Hydraulic Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Installing Boom Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Attaching Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Installing Arm Cylinder rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Installing Bucket Cylinder and Nibbler Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Installing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Mounting Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Counterweight Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Counterweight Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Counterweight Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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

M1087

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

DC04B668

Figure 1

1. An inspection and maintenance schedule should be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule helps to keep the machine in optimum operating condition.

2. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine. Use these procedures when performing inspection and maintenance. Also, refer to the inspection and maintenance charts for general service interval recommendations.

3. Use only oils, fluids, lubricants, filters and replacement parts supplied by your authorized dealer to keep machine in optimum operating condition.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

GENERAL SAFETY DISPOSAL OF HAZARDOUS WASTE

TAG-OUT MACHINE

Dispose waste oils, fluids, lubricants, filters, and other hazardous waste properly.

NOTICE: Dispose of all hazardous waste in accordance with government environmental regulations, laws, and codes.

KEEP MACHINE CLEAN

DC04B671

Figure 4

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

DC04B669

Figure 2

INSPECT WASTE OILS AND FILTERS

Thoroughly clean machine before perfor ming inspection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also reduce r isk of hydraulic sys tem contamination when the machine is clean.

HOT SURFACE & FLUIDS

DC04B672

Figure 5

Before disposal, inspect all waste oils, fluids, and filters for debris and foreign material. Cut open the filters to determine any abnormal wear.

SEALS & O-RINGS DC04B670

Figure 3

Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a machine has been stopped. Allow machine to cool before performing maintenance procedure.

WARM ENGINE OIL Engine should have a temperature between 20°C ~ 40°C (68°F ~ 104°F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change temperature.

6-6

Always replace seals and O-rings with new parts.

Never reuse a seal or O-ring during reassembly of components. Make sure to lubricate all new seals with the appropriate oil before installation.

STOP ENGINE Never attempt any MAINTENANCE with engine running. Always stop the engine and allow machine to cool.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WEAR SAFETY EQUIPMENT Wear hard hat, safety goggles or face shield, work gloves, safety shoes, and well fitting work clothes when perfor ming inspection and maintenance procedures on this machine.

PREVENT CONTAMINATION

WARNING ALWAYS disconnect the battery (both terminals) before welding on any part of the machine. Always wash your hands after battery components. Failure to comply could damage sensitive electrical components, death or serious injury.

M866A

FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

NOTICE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

Figure 6

DC04B673

Always cap or plug lines when hydraulic components are removed to help prevent hydraulic system contamination that can be caused by dirt, dust, and debris entering a line or port.

NOTICE: Never allow a hydraulic line or component to become contaminated. Always use proper caps and plugs.

CLEANING PARTS Use only approved cleaning solvents and proper equipment to clean parts.

3. In cases where welding is required, consult your authorized dealer for proper procedures. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding. Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

STEPS AND HAND HOLDS 1. Inspect all mounting steps and hand holds on the machine to make sure they are clean and in safe working condition daily.

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

WARNING Improper use of solvents can result in fire or explosion. Do not use gasoline or low flash point solvents. Clean only in a well ventilated area away from sources of sparks or flame, including any appliances with a pilot light. Failure to comply could result in death or serious injury.

M1629

WELDING SAFETY 1. Turn key switch to OFF position.

2. Remove negative (-) cable from battery terminal.

3. Attach the welder ground cable within 1 m (39 in.) from component being welded.

4. Do not clamp the welder ground cable close to or in location where ground could be separated by bearings or seals.

NOTICE: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition free of grease, oil, mud, ice, and snow.

MACHINE ACCESS COMPARTMENTS AND DOORS The machine has a several machine compartment doors. Use the ignition key to lock and unlock these compartments.

The batteries, radiator, oil cooler and air cooler are located behind the left compartment door.

The engine air cleaner, oil check and fill are located in the main engine compartment.

Always use the struts to secure the doors in an open position. When closing doors, make certain doors are securely closed, and no tools or other objects are left on or in the door compartments.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RELEASING HYDRAULIC SYSTEM AND TANK PRESSURE

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1333

Figure 9

BS06H208

4. Shift the right and left travel control levers forward and backward, also operate the right and left control levers to full strokes several times.

1

Figure 7

DC04B674

1. Move the machine to firm level ground and place the attachments on the ground in the oil check position.

2. Put the machine in drain mode to drain pressure.

Figure 10

S2LY00001ZE06 233-1

a. Depress air release button (1) of the hydraulic tank breather to release tank pressure and proceed to ser vice or change auxiliar y attachments .

WARNING 1 Figure 8

DC04A001

Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

M1502

1. SAFETY LOCK LEVER

3. Lower the safety lock lever to unlock the hydraulic system. Turn the engine off.

6-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Service intervals

As Required (AR)

Every 8 hours

Every 50 hours

page

Intervals in hours

clean

check

replace

lubricate

drain

6-26

Fan and air conditioning drive belt

6-33

Air filter

AR

6-36

Fuel tank filter

AR

6-53

Steel track shoe bolt torque

AR

6-14

Engine oil level

8

6-14

Coolant level

8

6-16

Hydraulic reservoir level

8

6-14

Radiator and oil cooler

8

8-12

Track shoe bolt torque

Run-in

8

8-15

Bolt and nut torque

Run-in

8

6-15

Fan/alternator belt tension

8

6-17

Steps and handholds

8

6-13

Attachment

6-18

Oil change and filter

Run-in

6-20

Hydraulic return filter

Run-in

6-21

Hydraulic drain filter

50

6-22

Drain fuel tank sediment

50

7-6

Battery electrolyte level

50

7-6

Battery check

50

6-23

Power Divide oil

120

6-23

Swing motor level

120

Travel reduction unit oil level & fill

120

6-24

Air intake

120

6-55

Adjust track tension

120

6-25

Radiator cap and hoses

250

6-26

Fan and radiator belt

250

6-27

Air conditioner belt

250

6-28

Air conditioner filter

6-53

Track shoe bolt torque

250

8-15

Bolt and nut torque

250

6-26

Fan/alternator belt tensioner

250

Every 120 hours 6-24

Every 250 hours

Service points

INITIAL NEW MACHINE

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

AR

AR

50 50 50

250

6-9

Service intervals

page

INITIAL NEW MACHINE

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Service points

Intervals in hours

clean

check

replace

6-29

Engine oil

50

500

6-29

Engine oil filters

50

500

6-31

Fuel filter

500

6-32

Fuel pre-filter

500

6-33

Engine air cleaner

6-34

Travel motor reduction oil

500

Every 500 hours 6-35

Swing reduction gear oil

500

Every 1000 hours

Every 2000 hours

Every 5000 hours

lubricate

drain

500

6-36

Fuel tank strainer

500

6-37

Engine RPM

6-37

Control lever lubrication

6-38

Air conditioning refrigerant

6-19

Machine Grease Points

500

6-64

Turntable bearing

500

6-39

Engine valve clearance

6-13

Attachment

6-39

Primary air filter element

250

1000

6-39

Secondary air filter element

250

1000

6-40

Hydraulic return filters

6-41

Power Divider

6-42

Corrosion cartridge

6-42

Engine mounting bolts

6-49

Hydraulic Fluid (Breaker/nibbler)

6-43

Engine coolant

6-46

Suction strainer

2000

6-47

Pilot line filter

2000

6-48

Swing reduction oil

2000

6-34

Travel reduction oil

2000

6-49

Change hydraulic oil

5000

500 500 500

Contact your authorized dealer 1000

1000 120

1000 1000

1000 1000 2000

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTICE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen to serve as a reminder that service work is due. See “Systems display and control panel” in the “Controls/Instruments/Accessories” Section.

NOTICE: RM = See Repair Manual or contact an authorized dealer.

6-10

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS GUIDELINES FOR ATTACHMENT LUBRICATION Lubricate attachment pins according to the intervals indicated in the Maintenance Chart. Use extreme pressure multipur pose grease No. 2 EP type.

Lubr icate all points until grease purges. The lubr ication inter vals are based on a standard excavator (see Specifications Section for the definition of Standard Excavator) working in an average duty cycle. Average duty cycle is defined as “Most typical digging application, road construction in natural bed clay, digging 50% ~ 60% of the daily work schedule”.

SPECIAL CONSIDERATIONS FOR HAND LUBRICATION

3

1

4

2

1

Figure 12

DC04C281

1. BUSHING 2. PIN 3. HAND LUBE FILL 4. LOAD AREA

3

2 DC04C280

Figure 11

1. BUSHING 2. PIN 3. ROUGH SURFACE REQUIRING BREAK-IN.

New pins and bushings, including new machines and repairs require special break-in procedures. While both pin and bushing have a special ground finish, they still have to be mated to each other to eliminate the machining high points.

Because of these high spots, it is recommended that the front attachment or the repaired area be lubricated a minimum of once every eight (8) hours for the first one hundred (100) hours for a standard machine working in an average duty cycle. All other machine should be lubricated every 4 hours for the first twenty (20) hours and every eight (8) hours for the next eighty (80) hours of operation. This lubrication procedure will reduce the possibility of a premature pin or bushing failure during the break-in period.

While grease grooves in the bushings allow grease to move around the bushing, it does not insure that grease gets on all of the bushing surfaces. Any load on the joint will prevent the grease from getting to the wear surfaces in the loaded area. Due to the fact that a hand operated grease dispenser does not provide the volume of grease that a power system does, there is a greater possibility of bushing galling, unless the standard lubr ication procedure is modified. See the pin load and grease cavity illustration shown above. No matter how much grease is pumped into the pin bushing cavity with a hand grease gun, the grease will tend to escape to the outside before filling the grease cavity. To avoid this situation, the front attachment should be repositioned during the lubrication process, to move the load area and allow the grease to cover the entire grease cavity between the pin and bushing.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING GROUND TOOLS It is very important to keep bucket teeth and side cutters properly tightened. Loose or missing bolts will increase loads and eventually cause tool failure.

Extended operation with loose hardware can cause the bolts to stretch and wear on the support mounting holes. Heating of hardware and support mounting holes will cause the same effect. Follow these general guidelines to insure proper tightness of hardware on bucket teeth and side cutters.

• When installing new cutting edges, end bits, side cutters, and bucket teeth, make sure that all supporting surfaces are free of dirt, paint, debris, rust, scale or weld splatter. All mating surfaces must be clean and flat to insure that maximum clamping force is obtained.

• Make sure that all bolts and nut threads are clean and dry. DO NOT APPLY ANY TYPE OF LUBRICANT.

• When installing end bits, start at the center and work toward the outside edges.

• Always torque bolts according to specifications.

• For best results, strike all head bolts with a heavy hammer to seat bolts properly before final torque.

6-12

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

• When new parts are used, the mating surfaces will seat more uniformly and the bolts torque will be less than the standard value after a short period of operation. Make sure to check all bolts for proper tightness on new parts after eight (8) hours of operation.

• Lower maintenance costs by replacing, turning, or rotating cutting edges before they reach their wear limits.

• When finding loose bolts, check bolts for elongation and support mount holes for wear.

Replace bolts and repair any wear on support mount hole if needed. Torque bolts according to specifications.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MACHINE ATTACHMENT LUBRICATION During the initial 50 hours of operation during the run-in period, grease bucket, boom, arm cylinder and dozer every 8 hours. After the initial run-in period, grease boom, arm, cylinders (boom hoist and arm) every 250 hours.

Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the bucket/attachment on the ground. Turn the engine off. Lubricate the following points.

A

8

9

11

10

Figure 15

S2LY00001ZE06 193-01

8. Arm foot left side

1

9. Arm foot right side Figure 13

DC04C305

1. Boom cylinder head pins.

10. Arm cylinder rod pin 11. Bucket cylinder head

13

7

6 5 4 2

15

3 12

14 Figure 14

DC04C306

2. Boom foot (center) Pin

DC04C309

Figure 16

12. Bucket cylinder rod pin.

3. Boom foot pin

13. Top bucket link pin.

4. Boom foot pin

14. Idler link to arm pin and arm to bucket pin

5. Boom cylinder rod pin

15. Arm top pin.

6. Boom cylinder rod pin 7. Arm cylinder head pin

WARNING The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

M1719

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DAILY INSPECTION & MAINTENANCE Check oil level every day or each 8 hour shift. Oil should be changed at 50 hour run-in period and at every 500 hours thereafter. It may be necessary to change the oil at 250 hours if a lower quality fuel is used. Develop a program of regular oil testing and sampling.

WARNING Wear goggles, safety shoes, hard hat, work clothes and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

M1070

ENGINE COOLANT LEVEL Check coolant level every 8 hours. Coolant should be changed at 2000 hours. The coolant reservoir tank is located on the left side of the engine compartment.

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm level ground and place the bucket/attachment on the ground.

Turn the engine off.

2. Check coolant reservoir located on left side of machine inside engine compartment. Proper coolant level is between FULL and “LOW” marks.

If necessary to add coolant, remove reservoir cap and fill to proper level with fresh coolant mixture.

ENGINE OIL LEVEL

1

1

2

Figure 18

BS07M117

1. RADIATOR CAP Figure 17

BS07M101

1. ENGINE OIL DIPSTICK 2. OIL FILL CAP

3. If no coolant is shown in reservoir, check coolant level in radiator. Fill radiator with proper coolant mixture and replace cap. Then refill reservoir to proper level.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

WARNING

2. Pull engine dipstick, clean it with a clean, dry, lint free cloth. Reinsert into engine. Pull out again to visually inspect the engine oil level on dipstick.

Oil level should be within the range of H-L as indicated on the dipstick.

3. If necessary to add oil, remove oil filler cap and fill engine oil to proper level.

NOTICE: After adding oil, check oil level again, replace filler cap and dipstick and close engine cover.

6-14

Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

M646

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ENGINE FLUID LEAKS

ENGINE ELECTRICAL

1. Inspect complete engine for signs of fluid leaks.

Figure 21

DC04C292

Figure 19

DC04C286

2. When inspecting around pressure lines and hoses use a stiff piece of cardboard.

1. Visually and manually inspect all engine electrical wiring, connectors and components for signs of damage and malfunction.

2. Repair or replace all damaged or malfunctioning wiring, connectors and components before resuming operation of the machine.

WARNING Operating the machine with damaged or malfunctioning electrical components can cause serious damage to the machine and serious injury to personnel. Failure to comply could result in death or serious injury.

M1725

Figure 20

DC04C287

FUEL LEVEL

WARNING Never use your hand to check for leaks. High pressure fluid leaks will penetrate the skin and cause severe injury. Failure to comply could result in death or serious injury.

M1736

RADIATOR AND OIL COOLER

2

Visually check radiator and oil cooler area for build-up of debris. Leaves, branches, debris can be a fire hazard on a hot engine.

1 DC04C294

FAN AND ALTERNATOR BELT Check the fan and alternator belt for slippage or wear on a daily basis. Replace any cracked or frayed hose.

Check tension of hoses periodically. See checking belt tension in this chapter.

Figure 22

Turn ON the ignition key and the fuel gauge in the cluster will indicate the fuel tank level.

To refuel the machine, use the ignition key to unlock the cap (if locked) and remove the fuel tank cap. Do not remove the fuel screen for fueling. Refill fuel tank to full mark to reduce air volume (condensation).

Failure to do so could create problems such as rusting and fuel freezing.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC OIL LEVEL

1 2 Figure 23

DC04B674

Figure 25

DC04B339

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

3. To add hydraulic oil, always release tank pressure. Depress air release button to release hydraulic tank pressure. (See releasing pressure in this section for further information). .

4

2

1

3 Figure 24

DC04C297

2. Check the sight glass through the opening of the hydraulic tank side cover.

WARNING For safe operation on inclines, the hydraulic oil level must be maintained between proper level and upper limit mark. DO NOT OPERATE machines on inclined surfaces with a slope greater than 35°.

Failure to comply could result in death or serious injury.

S2LY00001ZE06 233-03

Figure 26

1. CAP SCREW 2. COVER PLATE 3. O-RING 4. KEY

M1718

4. Slowly remove the six mounting bolts from the hydraulic suction filter cover plate.

WARNING When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. Failure to comply could result in death or serious injury M1303A

6-16

5. Add hydraulic oil, filling hydraulic tank to the proper level.

NOTICE: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

6. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic oil and install the O-ring.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 7. Install cover plate, cap screws and washers.

Tighten the cap screws to torque specification.

Torque to 46.5 ± 4.6 Nm (34 ±3.4 lb ft). lock compartment

STEPS AND HANDHOLDS

WARNING Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1716

NOTICE: Always use clean hydraulic oil. Use caution to avoid contamination during filling.

WARNING Hydraulic fluid is under extreme pressure. Make certain all pressure is released in the hydraulic system. Failure to comply could result in death or serious injury.

M1295

DC04A040

Figure 28

1. Inspect daily all mounting steps, handholds, and mirrors on the machine to make sure they are clean and in safe working condition.

HYDRAULIC FUNCTIONS

2. Repair or replace all damaged parts or components before allowing any operation of the machine.

NOTICE: Use steps and handholds when mounting and dismounting the machine. Keep steps, handholds, and step rails clean and in safe working condition.

Figure 27

BS06H208

Check all hydraulic controls for proper functionality before operating the machine.

WARNING Never operate the machine with faulty control or function. Make all necessary repairs before allowing any operation. Failure to comply could result in death or serious injury.

M1726

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

50 HOUR MAINTENANCE ENGINE OIL AND FILTER ELEMENT (INITIAL) Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation. It may be necessary to change the oil at 250 hours if a lower quality fuel is used. Develop a program of regular oil testing and sampling.

NOTICE: One new oil filter is shipped with the machine in the support kit. This is to be used at the 50 hour oil & filter change.

2

1 Figure 31

DC04C310

1. BELLY PAN COVER 2. BELLY PAN COVER BOLTS Figure 29

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.f

3. Remove bolts and engine belly pan covers 4. Locate the engine oil drain valve and place an empty oil container [58.0 l (15.3 gal) capacity] under the engine.

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

1

Figure 32

BS07M102

ENGINE OIL DRAIN VALVE

5. Open the engine oil drain valve and let the engine oil drain completely.

Figure 30

BS07M117

1. ENGINE OIL FILLER CAP

2. Raise the engine cover and secure it open.

Remove the oil filler cap.

6-18

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

Figure 33

BD06H022

6. Use a filter wrench and turn counter clockwise to remove the oil filters.

7. To install the oil filter, apply a thin coat of engine oil to the gasket of the new oil filters, fill the filters partially with engine oil and then secure the filter by tightening 3/4 ~ 1 complete turn by hand after the gasket comes in contact with the oil filter head.

NOTICE: Check the waste oil. If there are metal flakes in the oil, contact your authorized Dealer. Do not reuse the oil filters.

Figure 35

BS07M101

1. ENGINE OIL DIPSTICK

13. Check oil level and close engine cover.

14. Reinstall engine belly pan covers and tighten bolts to 83.3 N-m (38 Ft-lbs).

8. Clean oil drain plug and install it. Tighten securely.

9. Refer to LUBRICATION, FILTERS, and FLUIDS Section for the proper oil to use and fill engine oil to proper level.

WARNING Clean all spilled oil to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1209

1

Figure 34

BS06K465

1. ENGINE OIL FILLER CAP

10. Add oil and install oil filler cap. Clean up all spilled oil.

11. Keep others away from machine, start engine, run for 5 minutes. While running, check for oil leaks.

12. Should any oil leaks be found, stop engine, check for the source of leakage, and repair immediately and refill with proper oil.

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER Replace the hydraulic return filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 1000 hours thereafter. If breaker is, used replace return filter every 250 hours.

NOTICE: If Breaker is used replace return filter every 250 hours.

1 2 Figure 37

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

4. Stop the engine. Depress air release button to release hydraulic tank pressure.

5. Stop the engine. Depress pressure release button to release hydraulic tank pressure.

Figure 36

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

3. Open the cover to the hydraulic tank and secure with the strut. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

6-20

Figure 38

RH09H012

MOUNTING BOLTS

6. Slowly remove the mounting bolts. The filter cover plate is under spring tension.

7. Remove the six mounting bolts from the hydraulic return cover plate.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DRAIN FILTER CARTRIDGE

1

2

1

5 3

3 6 4

Figure 40

S2LY00001ZE06 233-03

Replace the hydraulic drain filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 2000 hours thereafter.

Figure 39

BS06H083

1. BOLT 2. COVER PLATE 3. O-RING 4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

8. Remove O-ring, spring, bypass valve, and return filters.

9. Install the new return filters.

10. Install the bypass valve and spring.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

11. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install the O-ring.

12. Install cover plate, bolts, and lock washers.

Tighten the bolts to torque specification.

3. Open the cover to access the filter and secure with the strut. Clean any dirt from the filter.

4. Remove cartridge (1) by turning left with filter wrench.

5. Apply oil thinly to filter cartridge seal and hand tighten filter and cover to base. Tighten another 2/3 turn.

6. Close and lock access door cover.

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL TANK DRAIN Drain water and deposits from the fuel tank every 50 hours or weekly.

1 Figure 41

BS07M103

1. FUEL TANK DRAIN VALVE

performed in the morning.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Place a suitable container under the drain hose (2) to catch the discharged fuel.

3. Slowly loosen the drain valve (1) to drain water and sediment. When clean fuel begins to flow, tighten the drain valve.

4. Check for fuel leakage after tightening drain valve. If fuel is leaking, stop the engine, and consult your authorized dealer for repair.

WARNING Drain fuel, using a suitable container, in a well ventilated area away from any source of flame or sparks, including any appliances with a pilot light.

Failure to comply could result in death or serious injury.

M1398.

6-22

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

120 HOUR MAINTENANCE POWER DIVIDER

SWING MOTOR OIL LEVEL

1.

2.

2.

1.

Figure 42

BS07M112

1. FILL PLUG

2. DIPSTICK

Check the oil level in the swing motor when the hourmeter registers 120 hours. The oil should be changed when the hourmeter registers 5000 hours and every 5000 hours thereafter.

1

1. SITE GLASS

Check the oil level in the engine power divider when the hourmeter registers 120 hours. The oil should be changed when the hourmeter registers 1000 hours and every 1000 hours thereafter.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Check oil level at the sight gauge. If the pointer is above the red circle, the oil is at its optimum level.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Check gear oil level with dip stick (1). If addition of oil is necessary, remove the plug from oil fill port and fill to full level with specified gear oil.

Refer to Lubricant Capacities in Chapter 5.

3. Return the dipstick to its original position. Clean the fill plug with light oil, tape with teflon tape, and install the plug securely.

3. If addition of oil is necessary, see changing power divider oil in the section at 1000 hour maintenance.

6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL REDUCTION UNITS

AIR INTAKE SYSTEM Inspect all hoses and clamps of the air intake system, including turbo charger and intercooler when the hourmeter registers 120 hours and every 120 hours thereafter. The manifold and intake system should be checked by your author ized dealer when the hourmeter registers 1000 hours.

3.

2.

1.

2 Figure 43

DC04C334

1. DRAIN PLUG 2. LEVEL PLUG 3. FILL PLUG

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. When parking the machine, make certain the drain port (1) is at the bottom.

3. Remove the oil level fill plug (2) and check oil level is at bottom of level plug. If addition of oil is necessary, see changing travel reduction gear oil in this section and fill as required in plug (3).

1

Figure 44

BS06M264

1. HOSE CLAMPS

2. AIR HOSE

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Stop the engine. Open the engine cover, secure it open, and inspect all hoses for damage.

Tighten all hose clamps.

3. Replace any damaged hose before allowing any machine operation.

6-24

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

250 HOUR MAINTENANCE CHECKING RADIATOR CAP AND HOSES Inspect the radiator cap and hoses every 250 hours of engine operation. If replacing radiator cap, make certain to replace with authorized part with correct PSI rating.

1

2

3

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

3

1 Figure 45

BS07M108

1. RADIATOR HOSE CLAMP 2. RADIATOR CAP

3. RADIATOR HOSE

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Stop the engine. Raise the engine cover and secure it open.

3. Check the hoses for leakage due to loose clamps, or crack and worn hoses.

4. Tighten any loose clamps.

5. Should you need to replace any cracked or worn hoses, proceed as follows:

6-25

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS .ENGINE ACCESSORY BELT WEAR AND TENSION Visually check the belts every day. Belt tension should be checked after when the hour meter registers 250 hours and every 250 hours thereafter.

1

2.

1.

4

2

4.

3 3.

BS07M106/BS07M105

1. ALTERNATOR 2. A/C COMPRESSOR BELT

Figure 46 3. CRANK PULLEY 4. ALTERNATOR BELT

Figure 47

BS07M105/BS07M106

1. ALTERNATOR 2. ADJUSTING BOLT

3. ALTERNATOR BELT 4. ADJUSTING NUT

BELT

DEFLECTION

Measure belt tension on longest span of belt. Apply a 58.8 N (13 lbf) pressure on the Alternator and Fan belts, and 25.1 N (6 lbf) pressure on the Air Conditioner belt. Measure the belt deflection and compare to the Belt Deflection table.

Alternator

NOTICE: Be careful when moving the alternator. Do not damage the stator coil section located between the alternator’s front and rear housing.

With the engine off, measure belt tension on longest span of belt. Apply a 58.8 N (13 lbf) pressure on the belts and measure the belt deflection and compare to the Belt Deflection table.

With the engine off, measure belt tension on longest span of belt. Apply a 58.8 N (13 lbf) pressure on the belts and measure the belt deflection and compare to the Belt Deflection table.

6-26

Air Conditioner

10 mm ~ 15 mm (0.4”~ 0.6“) 3 mm ~ 4 mm (0.1”~0.2”)

FAN BELTS Check fan belts for excessive wear and cracks and replace them if needed. When replacing a twin type V-belt, replace them both. If only one belt is replaced, it may fail due to the excessive loading. To adjust the fan belts, proceed as follows:

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Air Conditioning Compressor Belt

4

Check belt for excessive wear and cracks and replace as needed. Measure belt tension on longest span of belt. Apply 25.1 N (6 lbf) pressure on the Air Conditioner belt. Measure the belt deflection and compare to the Belt Deflection table.To adjust the AC compressor belt, proceed as follows:

1

4

5 1

2 3 Figure 48

BS07M107

1. ALTERNATOR 2. ADJUSTING BOLT 3. IDLER PULLEY NUT

2

3 4. A/C COMPRESSOR 5. IDLER PULLEY

a. Loosen mounting cap screw and adjusting nut on the alternator. b. Loosen or tighten adjusting bolt to adjust fan belt to the specified tension, and tighten mounting nut and adjusting nut properly.

TIGHTENING TORQUE

Figure 49

BS07M106

1. IDLER PULLEY 2. ADJUSTING BOLT

3. IDLER PULLEY NUT 4. A/C COMPRESSOR

a. Loosen the idler pulley nut. b. Loosen or tighten adjusting bolt. c. Tighten idler pulley nut. d. After adjustment, start engine and run it at low idle for about 5 minutes with AC turned ON. Then recheck belt tension.

Adjusting Nut: 46.5 N·m (34 lbf-ft) c. After adjustment, start engine and run it at low idle for 5 minutes. Then recheck belt tension.

6-27

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR CONDITIONER FILTER Inspect the fresh air filter and the recirculation air filter every 250 hours of engine operation.

NOTICE:

• If the working environment is extremely dusty, it is recommended reducing the inspection schedule to at least half of the above specified working hours.

1

• The fresh air filter is a paper filter. DO NOT WASH. Wear safety glasses. Clean with air only. Do not clean more than 10 times or replace it every 2 years.

• Wear safety glasses. Clean the recirculation air filter with compressed air or by washing and rinsing.

2

• Do not wash the recirculation air filter with any organic solvent, such as: gasoline, trichlene, paint thinner, etc.

REMOVING THE FILTERS

BS06H207

1. RECIRCULATE AIR FILTER

Fresh Air Filter a. Remove cover on the left rear side of operator seat and pull up.

Figure 51 2. FRESH AIR FILTER

b. With handle remove the fresh air filter (2) for inspection and cleaning or replacement. c. After cleaning or replacement, use this procedure in reverse for assembling.

Recirculation Air Filter

1

a. Move floor mat on left front side of operator seat. b. Pull out recirculating air filter.

After cleaning or replacement, use this procedure in reverse for assembling.

Figure 50

BD06H019

1. COVER

6-28

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

500 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER

1

Change the engine oil and filter on a new machine after the first 50 hours of operation. Then change the engine oil at every 500 hours of operation. It may be necessary to change the oil at 250 hours if a lower quality fuel is used. Develop a program of regular oil testing and sampling.

Figure 53

BS07M117

1. ENGINE OIL FILLER CAP Figure 52

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.f

2. Raise the engine cover and secure it open.

Remove the oil filler cap.

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

2

1 Figure 54

DC04C310

1. BELLY PAN COVER 2. BELLY PAN COVER BOLTS

3. Remove bolts and engine belly pan covers 4. Locate the engine oil drain valve and place an empty oil container [58.0 l (15.3 gal) capacity] under the engine.

6-29

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

Figure 57

BS06K465

1. ENGINE OIL FILLER CAP

10. Add oil and install oil filler cap. Clean up all spilled oil.

Figure 55

BS07M102

ENGINE OIL DRAIN VALVE

5. Open the engine oil drain valve and let the engine oil drain completely.

11. Keep others away from machine, start engine, run for 5 minutes. While running, check for oil leaks.

12. Should any oil leaks be found, stop engine, check for the source of leakage, and repair immediately and refill with proper oil.

1

BD06H022

Figure 56

6. Use a filter wrench and turn counter clockwise to remove the oil filters.

7. To install the oil filter, apply a thin coat of engine oil to the gasket of the new oil filters, fill the filters partially with engine oil and then secure the filter by tightening 3/4 ~ 1 complete turn by hand after the gasket comes in contact with the oil filter head.

NOTICE: Check the waste oil. If there are metal flakes in the oil, contact your authorized Dealer. Do not reuse the oil filters.

8. Clean oil drain plug and install it. Tighten securely.

9. Refer to LUBRICATION, FILTERS, and FLUIDS Section for the proper oil to use and fill engine oil to proper level.

6-30

Figure 58

BS07M101

1. ENGINE OIL DIPSTICK

13. Check oil level and close engine cover.

Reinstall engine belly pan covers and tighten bolts to 83.3 N-m (38 Ft-lbs).

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACE FUEL FILTER The fuel filter should be replaced at 500 hours. The fuel filter should not be reused. It must be replaced. a. Place an empty container below fuel filters.

1

1

2 3 Figure 60

BS06H086

1. FUEL FILTER 2. O-RING Figure 59

BS06H084

3. FUEL FILTER BOWL

6. Remove fuel filter bowl from bottom of filter.

1. FUEL FILTER

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Allow the machine to cool. Open the engine door and remove the lower cover.

3. Close fuel shut off valve. Place the filter wrench on the filter cartridge (1), turn counterclockwise, and remove the filter.

4. Wipe off any dirt on the seal face of filter base to avoid contamination.

7. With a clean, dry cloth, clean the filter support mount surface.

8. Lubricate O-ring for fuel filter bowl and attach to new fuel filter.

9. Lubricate the O-ring seal with diesel fuel and install filter by hand (do not use wrench), and tighten 3/4 ~ 1 turn after the O-ring seal has made contact with support mount surface.

10. Open fuel shutoff valve.

11. Open air bleeder plug on top of filter support housing and use primer pump to fill filter with clean fuel.

5. Remove O-ring seal from the filter support mount.

6-31

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BLEEDING AIR FROM FUEL SYSTEM

REPLACING FUEL PRE-FILTER

If air contaminates the fuel system, the engine may become hard to start or malfunction. Bleed the air whenever the water separator is drained, or the fuel filter elements are replaced.

1

4

2

Figure 61

BS06H084

1. FUEL PRE-FILTER

1

1. Close fuel shutoff valve.

2. Loosen air bleeder plug and drain valve and drain fuel from fuel pre-filter.

3

3. Use filter wrench and turn counter clockwise to remove filter.

4. With a clean, dry cloth, clean the filter support mount surface.

5. Lubricate the O-ring with diesel fuel and install filter by hand, (do not use wrench), and tighten 3/4 to 1 turn after O-ring has made contact with support mount surface.

6. Tighten drain valve.

7. Open fuel shutoff valve.

8. Open air bleeder plug on top of filter support housing and use primer pump to fill filter with fuel.

Figure 62

BS06H087

1. FUEL FILTER 2. PRIMING PUMP

3. DRAIN VALVE 4. AIR PLUG

1. Loosen the air plug located on top of the fuel filter support mount.

2. Push button by hand to supply fuel until air bubbles stop coming out of the air plug.

NOTICE: Use paper towel or rags to contain any fuel spill.

3. Tighten the air plug when no more bubbles are present.

WARNING Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1302

4. Continue pumping even after tightening the air plug. Stop pumping with the handle in the lower position and tighten the knob completely.

NOTICE: The air in the injection pump will automatically be forced out when the engine starts.

5. Run engine at low idle for 5 minutes to check and make sure there is no fuel leakage.

WARNING Clean up all spilled fuel to prevent fires. Dispose of hazardous waste according to environmental laws and regulations. Failure to comply could result in death or serious injury.

M1302

6-32

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR CLEANER Clean the engine air cleaner when the hourmeter registers 500 hours and every 500 hours thereafter.

Change both filters when the hourmeter registers 1000 hours or after cleaning six times. The air restriction indicator will not signal if the element is torn or improperly sealed.

1 2

Figure 65

DC04C290

1. WING NUT 2. AIR CLEANER INNER ELEMENT

1 5. Remove the wing nut and air cleaner inner element from the housing. ]

BS07M096/BS07M098

Figure 63

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Open engine air cleaner access door.

3. Remove air cleaner cover (1).

Figure 66

DC04C291

6. To clean the outer element, use compressed air less than 2.8 bar (40 psi) up and down along the folds of the filter element interior to remove clogged dust or other contaminants.

WARNING

2

Always wear eye and face protection when using compressed air or water. Failure to comply could result in death or serious injury Figure 64

M1611

4. Remove the air cleaner outer element(2) from the housing.

7. After cleaning, use light to check the inside of the element for tearing, pinholes, or cracking.

Replace with new element if necessary.

DC04C289

8. Assemble elements in the reverse order of disassembly.

9. Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element.

Failure to do so could cause engine damage.

6-33

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRAVEL MOTOR REDUCTION OIL Change the travel reduction units oil on a new machine after the first 500 hours of engine operation.

Change every 2000 hours thereafter.

WARNING Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. Failure to comply could result in death or serious injury.

WARNING Never change oil or filters on a machine that has just finished working. Allow sufficient time for the machine to cool down before performing any maintenance. Failure to comply could result in death or serious injury.

WARNING Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations. Failure to comply could result in death or serious injury.

DC03N027

Figure 68

3. Remove oil FILL/LEVEL, and DRAIN plugs to drain oil into the container.

4. After oil has been drained out completely, clean “DRAIN” plug. Use teflon tape on DRAIN plug for additional sealing and install plug. Tighten securely.

1 2 DC04C388

3 Figure 67

DC04C334

1. FILL PLUG 2. LEVEL PLUG

3. DRAIN PLUG

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

1. Operate travel until “DRAIN” plug is positioned at 6:00 o’clock. Oil FILL/LEVEL plug should be on the top side at about 10:00 o’clock.

2. Stop engine and place an empty container under the drain plug.

6-34

Figure 69

5. Add SAE 90W Gear oil through the oil FILL/LEVEL opening until oil starts flowing out of the port.

6. Clean oil FILL/LEVEL plug. Use teflon tape on plug for additional sealing and install plug.

Tighten plug securely.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SWING REDUCTION GEAR OIL

1

Change the Swing Reduction Unit oil on a new machine after the first 500 hours of engine operation.

Then, change every 2000 hours.

WARNING Hot oil and/or components can burn. Oil must be at operating temperature when draining. Avoid contact with oil or components. Failure to comply could result in death or serious injury.

M623

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

Figure 71

BS07M112

1. DIPSTICKS

4. Remove the dipstick and fill the unit with oil.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper capacities and oil specifications.

1 Figure 70

BS07M112

1. DRAIN PORTS

2. Locate drain ports under the center opening of the lower frame. Place an empty container under drain ports and remove plugs allowing oil to drain into container 3. Clean the drain plugs. Use teflon tape on plugs for additional sealing and install it. Tighten securely.

DC04C337

Figure 72

5. Using the dipstick, confirm that the oil level is within the designated range.

6. Clean the fill plug. Use teflon tape on plug for additional sealing and install it. Tighten securely.

6-35

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE ENGINE RPM

CHECKING AND CLEANING FUEL TANK STRAINER

BS06H082 DC04C387

Figure 73

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

Figure 75

1. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system by pressing the switch located on the monitor.

2. Keep others clear of machine. Start the engine and set the engine to the High Idle position.

2. Remove fuel cap.

3. Check cap (1) and seal for damage. If damaged, replace with new cap.

DC04C398

Figure 76

3. Press the Monitor’s display screen change switch ONCE to switch to the Tachometer Mode display.

DC04C386

Figure 74

4. Remove strainer and clean with light oil. Replace strainer into tank opening, securing in place.

5. Replace cap and lock with starter key.

4. Compare RPM value displayed on the LCD to the machine specifications. If RPM value differs from specification, contact your authorized dealer.

NOTICE: See SPECIFICATIONS Section for proper engine RPM specifications.

LUBRICATE MACHINE AND ATTACHMENTS See the beginning of this section for lubrication points at the 500 hour lubricating interval.

6-36

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CONTROL LEVER JOINT LUBRICATION LUBRICATE CONTROL LEVER

2

1

3

4

3

4 BS09B064

Figure 77

Lubricate the control lever when the hour meter registers 500 hours. Use a small amount of grease and apply to the pins (1) and rotating cup (2).

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. To remove boot, insert a flat blade screwdriver into the space between the boot (3) and plastic housing (4). Release the cover from 4 pins one by one.

3. After lubrication, reattach boot (3) to housing (4).

6-37

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS AIR CONDITIONING REFRIGERANT 1. Keep others clear of machine. Start the engine.

2. Set the engine speed to the Middle speed position.

4

1

3

Figure 80

BS07M100

1. SIGHT GLASS

1

2

a. Figure (A) shows that the refrigerant volume is proper.

Figure 78

DC04C384

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

1. TEMPERATURE SETTING SWITCH 2. MAIN POWER SWITCH 3. COMPRESSOR SWITCH 4. AIR CAPACITY SELECTOR SWITCH

3. Set machine to the conditions shown when checking the refrigerant.

• Air Conditioner ---------- ON • Fan Switch --------------- HI position (Max.) • Temp. Adjustment Switch -- Lower Temp • Door/window ------------ Close • Compressor Switch --- ON (The lamp lit up)

c. Figure (C) shows that the refrigerant is insufficient. Have the refrigerant recharged at your authorized dealer.

NOTICE:

• New Refrigerant HFC-134a is used in this machine. Do not mix HFC-134a with CFC-12.

• Operate the air conditioner at least once every week for several minutes to rotate the compressor regardless of the season. This will prevent the refrigerant gas from leaking from the compressor sealing.

• Air Conditioning Unit should only be serviced by a qualified technician.

DC04C383

Figure 79

4. Check the refrigerant volume by looking through the sight glass (inspection window) on the upper part of the receiver-dryer.

6-38

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1000 HOUR MAINTENANCE ENGINE VALVE CLEARANCE Check and adjust the engine valve clearance every 1000 hours of the engine operation. Contact your Kobelco Construction Dealer’s Service Department for assistance.

AIR CLEANER

1

Figure 83

DC04C289

1. AIR CLEANER OUTER ELEMENT

5. Remove the air cleaner outer element from the housing.

Figure 81

BS07M096/BS07M098

NOTICE: The air restriction indicator will not signal if the element is torn or if the air cleaner compartment is not sealed properly. If “REST’D AIR CLEANER” icon is displayed, inspect, clean, and/or replace the air cleaner elements.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Open engine air cleaner access door.

1 2

Figure 84

DC04C290

1. WING NUT 2. AIR CLEANER INNER ELEMENT

3. Remove air cleaner cover (1).

6. Remove the wing nut and air cleaner inner element from the housing.

7. Replace both primary and secondary filter. DO NOT clean secondary filter. It must be replaced.

8. Reassemble in reverse order.

1

9. Make sure to properly place the O-ring seal on the wing nut sleeve for the outer filter element.

Failure to do so could cause engine damage.

Figure 82

BD06H021

1. AIR CLEANER COVERS

4. Remove air cleaner cover.

6-39

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS HYDRAULIC RETURN FILTER Replace the hydraulic return filter when the machine is new at 50 hours during the run-in period. The hydraulic return filter should be replaced every 1000 hours thereafter. If breaker is, used replace return filter every 250 hours.

NOTICE: If Breaker is used replace return filter every 250 hours.

1 2 Figure 86

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

4. Stop the engine. Depress air release button to release hydraulic tank pressure.

5. Stop the engine. Depress pressure release button to release hydraulic tank pressure.

Figure 85

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Make certain to remove all hydraulic pressure from the system.

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

3. Open the cover to the hydraulic tank and secure with the strut. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

6-40

Figure 87

RH09H012

MOUNTING BOLTS

6. Slowly remove the mounting bolts. The filter cover plate is under spring tension.

7. Remove the six mounting bolts from the hydraulic return cover plate.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS POWER DIVIDER

1

2

Change the oil in the power divider when the hourmeter registers 1000 hours.

5

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

3

2. Make certain to relieve all hydraulic pressure.

3 6 4

3. Place an empty container that will hold 6.0 liter (1.6 gal.) under drain plug.

4. Remove drain plug (1). Allow oil to completely drain into container.

5. Clean and dry drain plug and reinstall. Torque to 98± 9.8 Nm (72± 7.2 lb ft).

6. Remove fill plug (2) and fill with SAE 90W gear oil until the pointer (3) is above the red circle of the level gauge.

Figure 88

BS06H083

7. Clean and dry fill plug, wrap with teflon tape and reinstall fill plug. Torque plug to 98± 9.8 Nm (72± 7.2 lb ft).

1. BOLT 2. COVER PLATE 3. O-RING 4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

1

8. Remove O-ring, spring, bypass valve, and return filters.

9. Install the new return filters.

10. Install the bypass valve and spring.

11. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install the O-ring.

3

2 Figure 89 1. FILL PLUG 2. DRAIN PLUG 3. SITE GLASS

6-41

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS COOLANT CORROSION RESISTOR CARTRIDGE

ENGINE MOUNTING BRACKET

Change the corrosion resistor car tridge on the engine when the hourmeter registers 1000 hours and every 1000 hours thereafter.

1

3,4

2 2 1

2

3,4

3 1 3,4

1

2 1

2 S2LY00001ZE05 218-01

Figure 90

S2LY00001ZE05 220-01

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Open the engine compartment and loosen bolt (1). Close valve (3) to turn off coolant flow.

3. Using a filter wrench, turn counterclockwise to remove the cartridge (2) from the filter head.

4. Clean the filter mount, coat the sealing surface of the new cartridge lightly with engine oil and install the cartridge.

5. Install the cartridge by hand. Do not use the filter wrench to reinstall cartridge. Turn the cartridge by hand until it contacts with sealing surface of filter head, then tighten 2/3 of a turn more.

6. Close valve (3) and align marks. Tighten lock bolt (1) after replacement torquing to 40 ± 4 Nm (30 ± 3 lbf).

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

6-42

2

3,4 Figure 91

Check the engine mounting bracket when the hour meter registers 1000 hours and every 1000 hours thereafter.

If there is any damage or deterioration to bracket (1) or the rubber mount (2), contact your authorized dealer.

If there is no visible damage, check the torque of bolts (3 and 4), tightening to specifications. Bolt torques for the machine can be found in Chapter 8 Specifications.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

2000 HOUR MAINTENANCE ENGINE COOLANT CHANGE

1

WARNING Be cautious of hot fluids and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. Allow sufficient time for the engine to cool down before changing fluids. Failure to comply could result in death or serious injury.

Figure 93

BS07M108

1. RADIATOR CAP

Figure 92

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

2. Raise the engine cover, secure it open, and place a rag or paper towel on the radiator cap.

Slowly remove the cap. The system could be under pressure.

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

B097

2

Figure 94

BS07M110

2. RADIATOR LOWER ACCESS COVER

3. Locate the lower cover (2) beneath the radiator.

6-43

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS .

3

5 Figure 95

BS07M109

3. RADIATOR DRAIN VALVE Figure 97

GRAPHIC2A

4. Remove cover to obtain access to the radiator drain hose and drain valve (3). Place an empty container, with sufficient capacity for engine coolant, below the radiator drain hose. Turn valve counter clockwise to open drain.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS section for proper engine coolant and capacity.

6. Locate the engine coolant drain plug (5).

Remove it to drain remaining coolant in engine block. Use a funnel with hose attached to direct the drained coolant toward the container.

7. After draining, close the drain valve and install the drain plug. Fill cooling system with clean water.

3

BS06H082

4 Figure 96

DC04C310

Figure 98

8. Turn the key switch to ON position. Do not start the engine. Deactivate the Auto Accel system by pressing the switch located on the lower side of monitor.

4. LOWER ENGINE COVERS

5. Remove the engine lower covers (4)

9. Keep others away from the machine. Start the engine and bring engine cooling temperature to about 90°C (194°F). Then run engine at low idle.

Remove engine drain plug, open radiator drain plug, and simultaneously feed fresh water into radiator until draining water comes out clear (about 10 minutes flushing is sufficient).

10. When flushing is completed, stop engine and also stop water flow. Drain engine cooling system completely. Close drain valve and install drain plug.

11. Prepare a mixture of radiator detergent according to the manufacturing specs. and pour the solution into the radiator.

6-44

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 12. Repeat step 8 and start the engine, but run it at low idle for 30 minutes before draining and flushing.

13. After flushing is completed, use teflon tape on the engine drain plug for additional sealing.

Install plug and tighten securely.

14. Close the radiator drain valve.

15. Add a mixture of engine coolant according to specifications indicated in the ENGINE C O O L A N T M I X T U R E t a b l e . R e fe r t o LUBRICATION, FILTERS, AND FLUIDS section for proper system capacity.

ENGINE COOLANT MIXTURE Expected Minimum Temp.

Long Life Coolant

-14.5°C (5.9°F)

30% mixed

-34°C (-29.2°F)

50% mixed

NOTICE:

• Change contaminated and foamy coolant with new coolant mixture as soon as possible.

• Cooling water other than long life coolant should be changed two times a year, in Autumn and Spring.

16. Install radiator cap. Start engine and run it at low idle for 5 minutes. Check and make sure there is no leakage.

17. Install engine and radiator lower covers. See Specification section for proper torque values.

18. Repeat steps 8, start the engine and run engine at high idle for 5 minutes to bleed out any air from the cooling system.

19. Return throttle to low idle and stop engine. Wait about 3 minutes and check engine coolant reservoir for proper level.

6-45

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING SUCTION STRAINER The hydraulic tank suction strainer should be cleaned when the engine hour meter registers 2000 hours and every 2000 hours there after.

1

3 2 4 5

6 Figure 99

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

Figure 101 Figure 102

DC04C376

1. BOLT 2. LOCK WASHER 3. COVER

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

4. O-RING 5. SUCTION STRAINER 6. STRAINER O-RING

4. Clean any dirt from the filter area to avoid contaminating the hydraulic system.

5. Loosen the cap screws and lock washers.

Remove cover. Be careful not to accidently drop bolts or nuts into the tank during this procedure.

M587

5

2. Open the cover to the hydraulic tank and secure with the strut.

1

BS08C441

Figure 103

6. Remove strainer (5) and clean with light oil or by washing. If damaged, replace.

7. Check O-rings (4) and (6) for wear or damage. If damaged, replace O-rings.

2

Figure 100

8. Insert strainer (5) into suction tube. Install cover (3) with cap screws (1) and lock washers (2).

Torque to: 46.5 ± 4.6Nm (34 ± 3.4 lbf ft).

3. Release all pressure from the hydraulic system.

Press the valve 5 to 7 times together with the breather cap (1).

9. Start the engine and operate at low idle for 5 to 7 minutes. Operate each cylinder and swing.

Retur n the machine to the hydraulic level checking position. Stop the engine and check the hydraulic oil. If level is low, add oil.

BS08D367

1. PRESSURE RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

6-46

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2000 HOUR MAINTENANCE

1 PILOT LINE FILTER Clean the pilot valve filter when the hour meter r e g i s t e r s 2 0 0 0 h o u r s a n d eve r y 2 0 0 0 h o u r s thereafter.

The P port of right and left pilot valves (for operation and travel) and the solenoid valve are equipped with a connector with a filter. Dirt that adheres on the filter will decrease oil flow.

2

Figure 105

BS08D367

1. PRESSURE RELIEF BUTTON 2. HYDRAULIC TANK BREATHER

2. Release all pressure to the hydraulic system.

Figure 104

RH09H009

WARNING

2

WARNING: Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1393

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

3 1 S2LY00001ZE06 229-01

1 Figure 106

3. Loosen manifold block case (1) with 24mm spanner wrench.

4. Clean removed parts and fit new element (2) and new O-ring (3) into casing.

5. Attach casing to the filter base securing with spanner. Torque to 25-34 Nm (18.4 - 25.1 lbf).

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

M587

6-47

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SWING GEAR REDUCTION OIL

1

Change the Swing Reduction Unit oil on a new machine after the first 500 hours of engine operation.

Then, change every 2000 hours.

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

M1933

Figure 108

BS07M112

WARNING

1. DIPSTICKS

Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations. Failure to comply could result in death or serious injury.

4. Remove the dipstick and fill the unit with oil.

NOTICE: Refer to LUBRICATION, FILTERS, AND FLUIDS Section for proper capacities and oil specifications.

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

DC04C337

5. Using the dipstick, confirm that the oil level is within the designated range.

1 Figure 107

BS07M112

1. DRAIN PORTS

2. Locate drain ports under the center opening of the lower frame. Place an empty container under drain ports and remove plugs allowing oil to drain into container 3. Clean the drain plugs. Use teflon tape on plugs for additional sealing and install it. Tighten securely.

6-48

Figure 109

6. Clean the fill plug. Use teflon tape on plug for additional sealing and install it. Tighten securely.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

5000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL NOTICE: The following procedures are to be used for a normal oil change for the hydraulic tank oil only.

NOTICE: If it is necessary to change the hydraulic oil viscosity, change hydraulic oil due to hydraulic component failure, or change main pump, contact an authorized dealer.

WARNING Be cautious of hot fluids, and surfaces. Wear goggles, safety shoes, hard hat, work clothes, and work gloves to perform inspection and maintenance on this machine. Allow hydraulic oil to cool before changing. Failure to comply could result in death or serious injury.

Figure 111

DC04A001

1. SAFETY LOCK LEVER

4. Make sure the safety lock lever is in the unlock (down) position.

Figure 110

DC04B674

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

NOTICE: Warm up changing hydraulic oil.

1

hydraulic

system

before

Figure 112

BS06H208

5. Move the attachment control levers several times.

1

2. Shut off the engine.

3. Turn the key switch to the ON position. DO NOT START THE ENGINE.

S2LY00001ZE06 233-1

Figure 113

1. AIR RELEASE BUTTON

6. Depress air release button to release hydraulic tank pressure.

6-49

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1 Figure 114

S2LY00001ZE06 233-02

1 S2LY00001ZE06 233-02

Figure 116

12. Remove drain plug to drain tank completely.

1. DRAIN PLUG

7. Hydraulic system capacity: 522 L (138 gal).

8. Place container of suitable size under the hydraulic tank drain plug.

13. Clean drain plug and reinstall. Torque to 108 ± 10 Nm (80 ± 7.4 lbf).

14. Replace all hydraulic filters when changing hydraulic fluid.

15. Filler hydraulic tank with hydraulic oil through filler port.

3,4 5

1 S2LY00001ZE06 234-01

Figure 115

S2LY00001ZE06 233-03

9. Clean surface around hydraulic tank to prevent contamination.

10. Loosen the mounting bolts (3) and washers (4) from tank upper cover. Remove cover (5). Use care not to drop bolts or washers into the tank.

Do not allow any foreign matter to drop into tank to prevent contamination.

11. Drain the hydraulic tank using a siphoning pump.

WARNING Clean up all spilled oil. Dispose of all hazardous waste in accordance with government environmental regulations. Failure to comply could result in death or serious injury.

6-50

Figure 117

16. Make certain oil level is correct. Check sight gauge.

17. Replace filler port O-ring and cover. If O-ring is deter iorated, replace O-r ing with new component.

18. Torque bolts to: 46.1 ± 4.9 Nm (34 ± 3.6 lbf).

19. Start engine and run at low idle for several minutes. Operate each cylinder and swing.

Return the machine to the hydraulic level check position and recheck oil level. Check for any leaks.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

PERIODICAL INSPECTION ITEMS DUST SEALS

Inspect dust seals in all pin connections frequently.

The attachment incorporates several dust seals that should be periodically checked for damage and excessive wear.

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

8

1

7 6

5 2

9 3

4

DC04C367

1. BOOM FOOT DUST SEALS (2 PCS) 2. ARM TO BOOM DUST SEALS (2 PCS) 3. ARM TO IDLER LINK DUST SEALS (2 PCS) 4. BUCKET CYLINDER TO BUCKET LINK DUST SEALS (4 PCS) 5. ARM TO BUCKET DUST SEALS (2 PCS)

Figure 118 6. BOOM CYLINDER HEAD DUST SEALS (2 PCS) 7. BOOM CYLINDER ROD DUST SEALS (2 PCS) 8. ARM CYLINDER HEAD AND ROD DUST SEALS (4 PCS) 9. BUCKET LINK (AT BUCKET) DUST SEALS (2 PCS)

NOTICE: Refer to the Parts Catalog for replacement Dust Seals Part Number.

ATTENTION: If excessive wear is found, refer to the Machine’s Shop Manual or Service Manual for specific instructions in regards to disassembly and assembly. Contact your Kobelco Construction Dealer’s Service Department for assistance if necessary.

6-51

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FRAME STRUCTURE 1. Carefully inspect the entire frame structure for signs of damage, broken welds, etc.

3

1

2 Figure 119

DC04C366

1. DUST SEAL

2. BUSHING

Figure 120

DC03K221

3. BOSS

Install the seals as shown. Make certain that the pin surface and tapered end are smooth and free from burrs or imperfections that could cause damage to the new seals.

NOTICE: Remove any excessive grease from the attachment pin connecting areas to inspect welding.

2. Repair or replace all frame components found to be damaged before allowing any operation of the machine.

3. In cases where welding is required, consult an authorized Dealer for proper procedures. Use only certified welding personnel familiar with structural welding methods to perform repairs requiring welding. Never allow current to flow through a joint such as between a pin, bushing, bearing, seal and/or between upper and lower structures.

WARNING Disconnect batteries before welding on this machine.

Connect welder ground cable within 1 m (3’ 3”) of area to be welded. Failure to comply could result in death or serious injury.

M1067

6-52

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Sprockets

TRACKS AND COMPONENTS 1. Track Shoes

1

2

1

Figure 123

DC04C301

Figure 121

DC04A040

1. SPROCKET 2. SPROCKET BOLT

1. TRACK SHOES

A. Visually inspect track shoes for signs of excessive wear or damage.

A. Inspect sprockets for excessive wear and damage.

B. Have all repair or replacement work done by an authorized Dealer.

B. Should the sprockets require service, contact an authorized Dealer.

C. Check shoe mounting bolts and nuts. If loose, remove bolt, clean thread, apply engine oil and torque to 853 ± 27 N-m (628 ± 36 ft-lbs).

C. Check and make sure all sprocket bolts are properly torqued.

2. Track Links

NOTICE: If any sprocket bolt is loose: 1. Remove bolt and clean threads.

2. Apply Loctite #262 to the bolt.

3. Torque to 55 kgf·m (397 lbs-ft)

1

Figure 122

DC04C300

1. TRACK LINK

A. Inspect link for signs of excessive wear or damage.

B. Have all repair or replacement work done by an authorized Dealer.

6-53

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK TENSION

4. Idlers

1

Figure 124

DC04C302

1. IDLER

A. Inspect Idlers for excessive wear and damage.

B. Should the Idlers require service, contact an authorized Dealer.

NOTICE: Every 8 hours of operation, make sure to check Idlers and Rollers for leakage and repair as needed. Contact your authorized dealer for assistance.

Figure 126

DC04C304

1. On a firm level surface operate swing, arm, bucket, and boom controls until machine is set up as shown. Stop the engine.

WARNING

5. Rollers

Support lower frame with suitable blocks. Failure to comply could result in death or serious injury.

M1288

2. Measure the sag in the center of the track, between the bottom of the track frame and the track shoe surface.

Proper Tension: 380 - 410 mm (15.0-16.0 inches)

1 Figure 125

DC04C303

1. ROLLERS

A. Inspect Rollers for excessive wear and damage.

B. Should the rollers require service, contact an your authorized dealer.

DC04C307

Figure 127

3. To increase track tension, inject extreme pressure No. 2 grease into idler adjustment grease fitting with a grease gun until proper tension is reach.

4. To decrease track tension, carefully loosen grease fitting 3/4 of a turn to allow grease to escape.

6-54

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BOOM & ARM

WARNING Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing severe injury. Keep face and body away from grease fitting area. Never loosen grease fitting more than one (1) complete turn. If grease does not release after one (1) turn of the fitting, call your authorized dealer for assistance. Failure to comply could result in death or serious injury.

1. Inspect Boom and Arm structures for signs of excessive wear and damage.

M1720

5. Tighten grease fitting to 6 kgf·m (45 lbf-ft) torque.

6. Keep others away from machine start engine and operate the travel motor for the track being adjusted, back and forth. Recheck track tension and adjust if needed.

7. Keep others away, start and lower machine to the ground.

8. Perform steps 1 through 6 on the opposite track if needed.

Figure 128

DC03K221

NOTICE: Remove any excessive grease from the attachment pin connecting areas for inspection.

2. Should repair or replacement be necessary, contact an authorized Dealer for assistance.

NOTICE: Visually check every eight (8) hours for excessive lateral play between boom and arm, and arm and bucket connections. Measure clearances every fifty (50) hours. Refer to shop manual for details regarding attachment lateral clearance.

WARNING Should welding be necessary, disconnect batteries before welding on this machine. Connect welder ground cable within 1 m (3’ 3”) of area to be welded.

Failure to comply could result in death or serious injury.

M1067

6-55

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS BUCKET

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B.

1. Bucket, Arm, & Link Clearance Frequently check clearance between Bucket and Bucket Link and/or between Arm and Bucket to make sure it is within specifications. If clearance is greater than 1.2 mm (0.05”) adjust clearance. Proceed as follows to correct excessive play:

Figure 131

DC03K235

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove the load from pins. d. Carefully slide out, partially, main mounting arm and bucket link to bucket.

pins

e. Insert shims as needed to correct any excessive play. Refer to Parts Catalog for proper Part Numbers. f. Align the shims with pin holes and insert pins into position. Be careful not to damage the seals.

Figure 129

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

2 1 Figure 132

DC04C364

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

g. Install retaining bolt with nut and jam nut.

2 1 Figure 130

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nut, nuts, and retaining bolt.

6-56

h. Roll O-ring onto the grooves between Bucket/Arm, and Bucket/Bucket Link.

NOTICE: Inspect O-rings for damage or excessive wear. If worn or damaged replace with new parts to protect the seals, pins, and surfaces from dirt and debris which can cause premature failure.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Reversing Bucket

Figure 135

DC03K232

Figure 133

DC04C363

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

f. Rotate bucket 180° or move machine.

1 2

2 1

Figure 136

DC03K233

1. ARM PIN FOR FRONT BUCKET OPERATION 2. ARM PIN FOR BACK HOE BUCKET OPERATION Figure 134

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

b. Roll O-rings onto the bucket bosses. c. Remove jam nuts, nuts and retaining bolts from both pins.

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

d. Carefully slide out main pins mounting arm and bucket link to bucket.

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove load from pins. e. Clean pins and pin holes, and apply grease on pins and holes surfaces.

g. Install arm and bucket link in their respective positions. h. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage the seals. i. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin. Be careful not to damage the seals.

6-57

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Removing the Bucket

2 1 Figure 137

DC04C364

Figure 139

DC04C363

1. O-RING SEAL 2. RETAINING BOLT, NUT, & JAM NUT

j. Install retaining bolts with nuts and jam nuts on both pins.

a. Move the machine to a firm level surface and place the bucket on the ground, making certain that the bucket is stable.

k. Roll O-rings onto grooves between bucket/arm, and bucket/bucket cylinder link.

NOTICE: Slowly cycle bucket, check for interference with arm, particularly if a lifting eye is welded on bucket bottom. Be careful not to confuse the bucket shoveling operation with that of the backhoe.

2 1 Figure 140

DC04C362

1. O-RING SEAL 2. RETAINING BOLT, RETAINING NUT, & JAM NUT

b. Roll O-rings onto bucket bosses. c. Remove jam nuts, retaining bolts.

BS06H081

retaining

nuts,

and

Figure 138

WARNING: Bucket can contact and damage cab when machine is equipped with certain attachments.

Check clearance between bucket and cab before operation. Exercise care when operating a bucket near cab.

DC03K235

Figure 141

NOTICE: You may have to start the engine and operate the boom and arm slightly to remove load from pins.

6-58

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS d. Carefully remove main pins mounting arm and bucket link to bucket. Be careful not to damage the dust seals.

4. Installing the Bucket a. Make certain that the bucket is stable on firm level ground. b. Install O-rings onto bucket bosses. c. Clean pins and pin holes, and apply grease on pin and holes surfaces.

1

e. Operate the boom and arm to match the bucket pin holes with the arm hole connection.

Insert pin carefully to avoid damaging the seals. f. Install retaining bolts with nuts and jam nuts on both pins, leaving 1 mm gap between the nut and pin boss. g. Roll O-rings onto grooves between bucket/arm and bucket/bucket link. h. Apply sufficient grease to the bucket pin connections.

5. Bucket Teeth and Side Cutters Frequently, check bucket tooth points and side cutters for wear and looseness. The life of the bucket teeth and side cutters can not be determined by wor king hours, but rather by application and operating conditions. a. Parts Description.

6

Figure 142

DC04C361

1

1. BUCKET LINK

WARNING

4

7

DO NOT use fingers to align pin holes. Fingers could be cut off. Follow instructions provided. Failure to comply could result in death or serious injury. d. Move the bucket cylinder to match the bucket pin holes with the bucket link hole. Insert pin.

Be careful not to damage seals.

1

3 2

5

Figure 144

DC03K237

1. ADAPTER NOSE 2. TOOTH POINT 3. RUBBER LOCK PIN 4. LOCKING PIN

5. SIDE CUTTER 6. CAP SCREW 7. NUT

NOTICE: Contact your Kobelco Construction Dealer for assistance in regards to parts for the specific bucket installed on your machine.

3

2 Figure 143

DC03K236

1. ARM 2. BUCKET 3. PIN

6-59

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS b. Replace the bucket teeth when their cutting edge and/or when hole for retaining pin on tooth are excessively worn.

c. Replacing the side cutters.

1 DC03K239

Figure 145

DC03K238

Figure 146

c.1 - Remove all sand and soil adhered around the side cutters capscrews. c.2 - Use an impact wrench to remove the capscrews, then remove the side cutters.

1. WOOD BLOCK

b.1 - Place a wood block under the bucket teeth support lip and remove all sand and soil adhered to the teeth pin connection areas.

WARNING Do not strike teeth with hammer. This can cause chips to fly causing injury. Failure to comply could result in death or serious injury. b.2 - Use a hammer and a punching tool to hammer out the locking pin. Be careful not to damage the rubber lock pin. b.3 - Inspect the locking pin and rubber lock pin. Replace them if the locking pin is too shor t or the rubber lock pin is in poor condition. b.4 - Clean the surface of the adapter nose with putty knife. b.5 - Fit tooth point onto adapter nose. b.6 - Push the rubber lock pin into the hole of the adapter nose. b.7 - Hammer the locking pin until it is aligned with the point surface.

6-60

DC03K240

Figure 147

c.3 - Clean the mounting surface and install a new side cutter with new cap screws and nuts. c.4 - Torque the cap screws with nuts to 100 ± 5 kgf·m (722 ± 36 ft-lbs).

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Arm Cylinder Hoses and Tubes

HYDRAULIC LINES, TUBES, AND HOSES S i n c e t h e r e i s n o d e f i n i t e t i m e t a bl e fo r t h e replacement of hydraulic lines, tubes, and hoses, inspect the following periodically for tightness and signs of damage. Replace all damaged lines, tubes, and hoses with new parts. Refer to the Parts Catalog for correct part numbers. when ordering.

Do not bend, strike or damage high pressure lines.

Do not install bent or damaged lines, tubes, or hoses.

Replace all damaged lines, tubes, and hoses immediately to avoid any fire hazard.

Tighten all loose fittings and connections to the proper torque value.

Clean up all fuel and oil spills immediately to prevent fires, slipping, accidents, attachment dropping, etc.

Never use hands to check for leaks.

Carefully inspect all lines, tubes, and hoses for:

• Fittings and connections damaged or leaking.

• Outer covering of hoses worn, cut or damaged exposing wire reinforcement.

1

Figure 149

DC04C358

1. ARM CYLINDER TUBE & HOSES

Inspect arm cylinder head and rod hoses and tubes for damage, wear and loose connections.

4. Bucket Cylinder and Nibbler/Breaker Hoses & Tubes

• Hose swelling or “ballooning”.

• Evidence of hose being kinked or collapsed.

• Steel protective covering worn or damaged.

• Loose fittings and connections.

1

Make certain all clamps, guards, and heat shields are in place and secured. This will help prevent vibration, excessive wear of components and excessive heat during operation.

1. Heater Hoses Inspect the heater hose between heater and engine for signs of damage and wear.

2

2. Boom Cylinder Hoses and Tubes Figure 150

DC04C367

1. BUCKET CYLINDER TUBE & HOSES 2. NIBBLER/BREAKER TUBE & HOSES

Inspect bucket cylinder head and rod hoses and tubes for damage, wear and loose connections.

Inspect also the Nibbler/Breaker tubes and hoses if equipped.

5. Fuel Lines and Hoses Inspect fuel lines and hoses for damage, wear and loose connections. Repair or replace fuel lines and hoses before operating the machine.

1 Figure 148

DC04C359

1. BOOM CYLINDER HOSES

Inspect boom cylinder head and rod hoses and tubes for damage, wear and loose connections

6-61

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Rear View Mirrors

6. Hydraulic Suction Tubes and Hoses

1 Figure 151

DC04C356

1. SUCTION HOSE

Inspect all hydraulic tubes and hoses for damage, wear and loose connections.

DC04A040

Figure 152

Inspect the rear view mirror. Make certain both sides rear view mirrors and internal rear view mirror are in place, proper ly adjusted, clean, and in good condition. If loose tighten the mounting hardware.

WINDSHIELD WASHER FLUID RESERVOIR Fill the windshield washer fluid reservoir as required using approved windshield washing fluid.

1. Open left side door of machine with key switch key.

2. Pull cap off and fill with proper windshield washer fluid.

3. Replace cap and close left side door and lock.

6-62

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE FOR NIBBLER/BREAKER It is necessary to perform the following maintenance schedule in regard to Hydraulic Oil and Filters along with the normal inspection and maintenance.

2. Depress air release button to release hydraulic tank pressure.

REPLACEMENT SCHEDULE Item

Location

1st 2nd Regular Maintenance Maintenance Maintenance

Hyd. Oil Hyd. Tank

-

-

Every 600 Hours

Return Hyd. Tank Filter

50 Hours

250 Hours

Every 250 Hours

WARNING

1

Never change oils or filters on a machine that has just finished working. Allow machine to cool first until oils and fluids are warm not hot. Release hydraulic tank pressure before working with any hydraulic components. Failure to comply could result in death or serious injury.

Figure 155

DC04B340

1. COVER MOUNTING BOLTS

WARNING Slowly remove the mounting bolts. The filter cover plate is under spring tension. Failure to comply could result in death or serious injury.

3. Remove the six mounting bolts from the hydraulic return cover plate.

Figure 153

DC04B674

1. Move machine to firm level ground and place attachment in oil level check position.

1 Figure 154

DC04B339

1. AIR RELEASE BUTTON

WARNING Gasses from hydraulic tank may be hot. Wear safety equipment. Failure to comply could result in death or serious injury.

6-63

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

1

5

2

3 3

6

4

Figure 156

BS06H083

1. CAP SCREW 2. COVER PLATE 3. O-RING

4. SPRING 5. BYPASS VALVE 6. RETURN FILTERS

4. Remove O-ring, spring, bypass valve, and return filter.

NOTICE: Make sure to use the correct return filter on machine using breaker. Refer to Parts Manual for correct part number when ordering parts.

5. Install the new return filter.

6. Install the bypass valve and spring.

7. Clean and inspect the O-ring. Replace O-ring if damaged. Lubricate the O-ring with hydraulic fluid and install O-ring.

8. Install cover plate, cap screws, and lock washers.

Tighten the cap screws to torque specification.

6-64

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

SPECIAL PROCEDURES GENERAL The SK850 machine incorporate automatically applied spring brake systems in the travel motors and swing motor. These systems will automatically engage the brakes when the engine is stopped, making it impossible to move the machine. These sections contain the required procedures for releasing the travel motor brakes, the swing motor brake and lowering the attachments to the ground should sudden engine failure be experienced.

RELEASING TRAVEL MOTOR BRAKES MANUALLY A. Tools & Equipment Required 1. Four (4) chock blocks.

2. One (1) 14 mm Allen type socket wrench.

3. One (1) 8 mm Allen type socket wrench.

4. Two (2) 22.0 liter (5.8 gal) capacity drain pans.

5. Two (2) M10-1.5 x 30 mm lifting eyes.

6. Two (2) M12-1.75 x 20 mm Lifting eyes.

WARNING Read, understand and follow all safety precautions and procedures found in this manual before attempting any operation, inspection, maintenance, or repairs of this machine, attachment or any of its system. Failure to comply could result in death or serious injury.

7. Overhead lifting device capable of lifting and holding 45 Kg (100 lbs).

8. Torque wrench 10~16 kgf·m (72~116 ft-lbs) capacity or better.

9. Thread sealant (for drain and check/fill plugs), and loctite #515 for cover bolts.

M1087

10. Rubber or soft face mallet.

The procedures found in this section should be performed by a well trained experienced service technician who is familiar with machine. Failure to comply could result in death or serious injury.

6-65

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS B. Procedures

NOTICE: Rotation of the engine with the starter motor is necessary in order to lower the attachment to the ground. If rotation of the engine is not possible, contact an authorized Kobelco Construction service technician for service and assistance.

WARNING Make certain the area around the machine is clear of people and objects before attempting these procedures. Failure to comply could result in death or serious injury.

1

1 Figure 157

DC04C354

1. CHOCK BLOCK

1. Position travel motors with drain plug down.

2. Lower attachment to ground. Refer to LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS in this section for proper procedures.

1

WARNING Make certain chock blocks are secure at front and rear of each track before attempting to release brakes. Never stand in the path of the tracks when releasing brakes. Failure to comply could result in death or serious injury.

M1773

3. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released.

4. Turn key switch to OFF position and remove key.

5. Place a clean 22.0 liter (5.8 gal) capacity drain pan under each travel motor drain plug.

Figure 158

DC04A001

1. SAFETY LOCK LEVER

7. Place the safety lock lever in the UNLOCKED (down) position.

8. Sound horn to alert people in the area of machine movement.

9. Turn key switch to START position to use starter motor to rotate the engine.

NOTICE: Operate the Starter Motor in 20 second intervals and allow 3~5 minutes between intervals to allow the Starter Motor to cool.

6. Remove oil “FILL/LEVEL” and “DRAIN” plugs to drain oil into the container.

WARNING Reduction unit may be under pressure. Remove plugs slowly. Failure to remove plug slowly could result in serious injury or death. Failure to comply could result in death or serious injury.

M1783

NOTICE: If the Reduction Unit drain plug is not at its lowest point (6:00 o’clock) for draining, drain as much oil as possible through the plug orifices.

DC04C343

LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS S h o u l d s u d d e n e n g i n e fa i l u r e o c c u r, fo l l o w procedures to place the attachment on the ground.

6-66

Figure 159

10. While engine is rotating, slowly and carefully move the RH control lever forward (boom down) and lower boom completely to the ground.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 11. After Boom is completely down, leave the key switch in ON position, operate the arm, bucket and swing controls to release hydraulic pressure in these circuits. Turn key switch off.

1 2 Figure 160

DC04B339

1. AIR RELEASE BUTTON 2. HYDRAULIC TANK BREATHER

12. Locate hydraulic tank air breather on top of the hydraulic tank. Remove cap and depress air release button until all internal hydraulic tank pressure is released.

WARNING Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button on the breather to release all pressure in the system.

Failure to observe these instructions can cause injury. See, Releasing pressure in the hydraulic system. Failure to comply could result in death or serious injury.

M1106

6-67

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RADIATOR, OIL COOLER AND DEBRIS SCREEN

LUBRICATING RADIATOR DRIVE

Clean radiator after every 50 hours of operation using pressurized air.

1. Stop the engine. Open radiator compartment door and engine cover and secure them open to clean the radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler.

NOTICE: When working in extremely dusty environments, it is recommended to check the radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler at the end of the working shift and clean regardless of working hours.

1

2

2. Remove radiator lower access cover from bottom of machine.

3. Rinse all dirt and debris from engine compar tment. Reinstall debris screen and radiator lower access cover.

NOTICE: Be careful not to bend or damage cooling fins of the radiator, A/C condenser, oil cooler, inter cooler, or fuel cooler. Replace debris screen if damage is found. Repair damaged cooling fins of radiator, oil cooler, A/C condenser, inter cooler, and fuel cooler.

S2LY00001ZE06 234-2

Figure 161

1. Clean grease nipple (1) on radiator drive.

2. Using a hand held grease gun, lubricate at grease nipple (2) until grease comes from relief valve (2).

3. Wipe off excess grease. DO NOT use an electric grease pump, as it may damage the oil seal of drive.

6-68

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LUBRICATING OIL COOLER DRIVE

1

2

S2LY00001ZE06 235-01

Figure 162

1. Clean grease nipple (1) on oil cooler drive.

2. Using a hand held grease gun, lubricate at grease nipple (2) until grease comes from relief valve (2).

3. Wipe off excess grease. DO NOT use an electric grease pump, as it may damage the oil seal of drive.

6-69

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

DISASSEMBLY AND ASSEMBLY Because of the physical size of the machine, it may • Relieve all hydraulic pressure on the machine require disassembly and assembly for a number of reasons such as transport, work environment, etc.

Disassembly and assembly of the machine should only be performed by skilled technicians.

and be aware if there are accumulators on the machine.

• Cap all hydraulic hoses and ports when

• Disassembly and/or assembly should only be

removing hydraulics from the machine to prevent contamination.

carried out on a firm, level surface. Keep all unauthorized personnel clear of the area.

• When lifting machine components, pad properly

• A designated lead is an optimum way to handle a

• Never lift machine or components over people or

disassembly and assembly procedure. Always obey the lead and/or signal personnel.

• Make certain hoisting equipment is of adequate size and there is ample room for a crane to maneuver.

• Attach identification tags to components for

to prevent damage. objects. Do not allow anyone to enter under lifted objects.

• Never use fingers or hands to align holes.

• Always do a inspection of the machine prior to any disassembly or assembly.

reassembly purposes.

EXTERNAL COMPONENTS

2

1

3 S2LY00001ZE06 265-1

Figure 163

S2LY00001ZE06 266-1

Figure 165

MUFFLER

MACHINE STEPS AND HANDRAILS

The muffler should be removed when transporting the machine.

Steps and handrails should be removed from machine when transporting.

Steps (3) will extrude from the width of the trailer bed.

Remove all four sets of steps by removing fastening bolts. When replacing steps, apply Loctite #62 to bolts and torque to: 279 ± 28.5 Nm (206 ± 21 lbf)

S2LY00001ZE06 265-2

Figure 164

The muffler should be stored inside the side access door near the hydraulic tank when transporting the machine. After unloading machine, reattach muffler to deck making certain it is tightly fastened.

6-70

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ATTACHMENT AND COUNTERWEIGHT INSTALLING BOOM CYCLINDER

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

M110B

WARNING Figure 167

S2LY00001ZE06 267-2

Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

4. Align boom cylinder head with boss hole on frame side and check clearance (a). Adjust clearance so the total of space on both sides is within range of 0.6 - 1. mm (0.024 - 0.039 inches). This total is with shims inserted in the pin.

2 4

1 S2LY00001ZE06 267-1

2

3 Figure 166

1. Make certain the right and left cylinders are in the correct position. Do not reverse the cylinders.

The hydraulic hoses/connections should be positioned at the lower side.

Figure 168

S2LY00001ZE06 267-3

5. Align pin hole (3) of boom cylinder with pin hole (4). Drive pin in. Use care not to damage seal.

1

2. Apply grease to pins (1).

3. Using auxiliary crane, hoist the left boom cylinder (2).

6 S2LY00001ZE06 267-4

5 Figure 169

6. Tighten pin retainer plate (5) with bolt (6). Apply Loctite #242 and torque to; 219 ± 22 Nm (162 ± 16 lbf).

6-71

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

13

7

7

Figure 170

S2LY00001ZE06 267-4

7. Support the installed boom cylinder on the left with support (7). Install right side boom cylinder follow steps 2 through 5.

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

M587

S2LY00001ZE06 267-4

Figure 171

8. Make certain all hydraulic pressure is removed from the system.

9. Gradually loosen bolts of boom cylinder piping and hose plug before making connect between boom cylinder piping and machine piping.

10. Fit O-rings (9) to the four hoses (8) between boom cylinder and body on both right and left side. Tighten half-clamps (10) with bolts (11) and spring washers (12). Torque to 103 ± 10 Nm (76 ± 7 lbf).

6-72

S2LY00001ZE06 267-4

Figure 172

11. Make certain support is secure. Release air from the boom cylinder. Run the engine at low idle, extend and retract the cylinder rod (13) of the boom cylinder slowly. Repeat the back and forth extension of the cylinder rod (13) until it moves smoothly.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ATTACHING BOOM

1

WARNING Always inspect the lifting equipment, lifting points on the machine to insure they are in safe condition. If worn or damaged, DO NOT USE. Use of improper lifting equipment could allow the load to shift or fall causing death or serious injury.

4

M1147

WARNING To prevent personal injury or machine damage, use appropriate lifting equipment and straps rated for the load. Always use the appropriate equipment when unloading the components from a truck or installing the components on the machine. Keep all other persons away when moving or unloading the components. Failure to comply could result in death or serious injury.

M828A

Figure 174

S2LY00001ZE06 269-2

3. Align boom foot pin with pin Hole (1) on the body side.

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

4. To make adjustment easier, trace the outline boom on the inside of center frame (4). Use the tracing as a guide.

2

S2LY00001ZE06 269-1

Figure 173

1. A crane and suitable lifting equipment capable of lifting boom weight is necessary to attach boom.

Make certain all hydraulic pressure is removed from the system.

2. Apply grease to boom pin.

S2LY00001ZE06 269-3

Figure 175

5. Align boom foot boss with boss hole on frame side. Check clearance (a). Adjust clearance so the sum of clearance on both sides is 0.5 mm (0.02 in) or less with shims inserted in with the pin.

6-73

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING HYDRAULIC HOSE

2

3

3 1

5

4

Figure 176

S2LY00001ZE06 267-4

6. Using sledge hammer, drive pin (3) in.

S2LY00001ZE06 270-2

Figure 178

1. Make certain all hydraulic pressure has been released from the system. Move the control lever several times to release remaining pressure.

5

2. Gradually release pressure by slowly loosening bolts from the boom cylinder piping.

3

3. Fit O-ring (2) to hose (1) between machine and boom (arm, bucket, nibbler and breaker circuit) and tighten half-clamp (3) with bolt (4) and spring washer (5). Torque to: 169 ± 11 Nm (125 ± 8.1 lbf).

6 S2LY00001ZE06 270-1

Figure 177

7. Install pin (3) with retainer plate (5) and bolts (6).

Tighten bolts. Apply Loctite #242. Torque to: 932 ± 93 Nm (687 ±69 lbf).

6-74

4. Operate the boom up and down. Make certain that each hose does not come into contact with machine frame and connections are secure and do not leak.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING BOOM CYLINDER ROD

2

1

4

3

3

Figure 180

S2LY00001ZE06 271-1

Figure 179

S2LY00001ZE06 271-1

3. Drive pin (4) and then attach pin retainer plate (5) to the left side of pin (rod attached side).

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

3

5

B020A

WARNING To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

6 S2LY00001ZE06 2701-3

M110B

1. The boom cylinders must be hoisted by crane.

Make certain all lifting devises are of adequate strength.

Figure 181

4. Torque bolt to 219 ± 22 Nm (162 ± 16 lbf). apply Loctite A#242.

5. Install cylinder rod on the right side following the procedures 1 through 4.

2. Hoist the left boom cylinder (3) with the crane.

With the engine running at low speed, extend and retract the cylinder rod (1) while moving boom cylinder (3) up and down by crane. Align cylinder rod pin hole with pin hole (2) on the boom side.

6-75

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ATTACHING ARM

2

3 4 5

1 Figure 182

S2LY00001ZE06 272-1

WARNING To prevent personal injury or machine damage, use appropriate lifting equipment and straps rated for the load. Always use the appropriate equipment when unloading the components from a truck or installing the components on the machine. Keep all other persons away when moving or unloading the components. Failure to comply could result in death or serious injury.

S2LY00001ZE06 272-2

Figure 184

3. Drive pin (6). Adjust clearance so the clearance (a) between (boom (1) and arm (3) is 0.5 mm (0.02 in) or less with shims.

4. Tighten pin retainer plate (4) with bolt (5). Torque to: 426 ± 42 Nm (314 ± 31 lbf). Apply Loctite #242.

M828A

1. Apply grease to joint pin of boom and arm.

2. Hoist arm (3) by crane and align pin hole (2) of arm (3) with pin hole of boom (1).

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

6

5

4,5 S2LY00001ZE06 272-2

6-76

Figure 183

S2LY00001ZE06 272-7

Figure 185

5. Lower arm slowly, perpendicular to the ground.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING ARM CYLINDER ROD

4 1 3

Figure 188

S2LY00001ZE06 273-3

Figure 186

S2LY00001ZE06 273-1

1. Air from arm cylinder must be released to prevent damage to seal.

5. Apply grease to pin (4) and drive the pin. Adjust clearance so the sum of clearance (a) between arm cylinder rod and arm is within the range of 0.6 to 2.0 mm (0.024 to 0.079 in).

2. Run engine at low speed, hoist arm cylinder.

3. Extend and retract cylinder rod (1) of arm cylinder slowly. Repeat procedure until cylinder rod (1) moves smoothly.

4 5

3

2

6

4 3

S2LY00001ZE06 273-4

Figure 189

6. After pin (4) is in place install pin retainer plate (5) with bolt (6). Torque bolt to: 426 ± 42 Nm (314 ± lbf). apply Loctite #242.

S2LY00001ZE06 273-2

Figure 187

4. Extend and retract arm cylinder rod (1) while moving arm cylinder (2) up and down by crane. align cylinder rod pin hole (3) with pin (4) on the arm side.

6-77

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING BUCKET CYLINDER AND NIBBLER HOSE

1

2 3 4 5

1

2 3 4 5

WARNING Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

M587

S2LY00001ZE06 274-2

Figure 191

3. Fit O-ring (2) to connection of boom tube and arm hose (1). Connect hoses (1) for the bucket and nibbler circuits on both right and left sides with half-clamp (3), bolt (4) and lock washer (5).

4. Torque to 147 ± 15 Nm (108 ± 11lbf).

S2LY00001ZE06 270-14

Figure 190

1. Stop engine, move control lever several times, and release the remaining pressure from hydraulic piping.

2. Release the pressure by gradually loosening bolts of cover for plugs on the boom top end and on the arm hose side before connecting piping of boom top end to the arm with hose. Remove cover for plug.

S2LY00001ZE06 270-1

Figure 192

5. Remove air from bucket cylinder. Run the engine at low speed.

6. Extend and retract cylinder rod of bucket cylinder slowly.

7. Repeat until cylinder rod moves slowly.

6-78

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLING BUCKET

7 5

6

8

4

8 3 2

3

Figure 194

S2LY00001ZE06 275-2

Figure 193

S2LY00001ZE06 275-1

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

4. Align pin hole (5) of link with pin hole (2) of bucket, extracting and retracting bucket cylinder rod.

5. Drive pin (6) and tighten double nuts (8) to secure pin retainer bolt (7) with pins 93) (6).

6. Torque to: 181 ± 20 Nm (134 ± 15 lbf).

B020A

WARNING Do not get under boom cylinder when replacing pin or working on machine. Cylinder could unexpectedly drop. Failure to comply could result in death or serious injury.

B020A

1. Fit O-ring to bucket boss.

2. Start engine and raise arm (1) top end about 2.5 m (8 feet) from ground.

Figure 195

S2LY00001ZE06 275-3

3. Hoist bucket (2) with crane aligning pin hole (3) of bucket with pin hole (4) of arm. Drive pin (3).

A

S2LY00001ZE06 275-4

Figure 196

7. Adjust clearance of bucket. Check that clearance (A) is 1.2 mm (0.05 in) or less.

8. Move O-ring between bucket and arm. For further information, see installing bucket in this section.

6-79

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOUNTING COUNTERWEIGHT WARNING: Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass 29320 lbs (13300 kg). Failure to comply could result in death or serious injury.

5

A

1

3

6

S2LY00001ZE06 275-4

2

4 Figure 199

3. When counterweight is in place, tighten bolts temporarily in the order shown.

4. Bolt width 65 mm (2.56 in) 5. Tighten bolts fully after all bolts are placed.

Tighten in same order.

6. Torque bolts 3.92 ± 0.39 kNm (2892 ± 276 kbf(,

Figure 197

S2LY00001ZE06 276-1

1. Park the machine on a firm, level surface with attachments resting on the ground. Turn the engine off. Place the safety lock lever in the locked position. Keep all unauthorized personnel clear of the area.

7. Connect both right and left swing flashers and rear work lights to main harness on machine.

MAINTENANCE AND TESTING Air may enter the hydraulic system. Do not work the machine until air has been removed.

1. Remove air from hydraulic circuit by extending and retracting each hydraulic cylinder 5 or 6 times.

2. Check that each cylinder, piping, hose is free from any hydraulic leaks and that all bolts are in place and properly torqued.

3. Check pin retainers and locking pins:

1 S2LY00001ZE06 276-2

Figure 198

2. Hoist counterweight (1) by crane and fit it to frame.

• Boom foot pin • Boom cylinder rod, bottom pin • Boom arm joint pin • Arm cylinder rod pin • Bucket cylinder rod pin • Bucket link joint pin 4. Check hydraulic oil level.

5. Check crawler tension 6. Check each machine operation.

7. If any abnormality is discovered, during the final check, correct any problem or contact your authorized dealer.

6-80

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

OPTIONAL EQUIPMENT COUNTERWEIGHT COMPONENTS

6

10

7 1

1 8

3 2

9

4

5

Figure 200

S2LY00001ZE06 286-1

Number

Component

Number

Component

1

Hoist Cylinder

2

Tilt Cylinder

3

Chain Assembly

4

Counterweight Removal Switch

5

Tilt/Hoist Switch

6

Link Assembly

7

Arm Assembly

8

Hook Device

9

Stopper (tilt)

10

Stopper (hoist)

6-81

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS COUNTERWEIGHT REMOVAL SYSTEM WARNING: Improper operation of the counterweight removal system can result in serious injury or death. Do not operate this system unless you have read and understand these instructions. If you have any doubt about your ability to perform these instructions, consult your authorized dealer.

COUNTERWEIGHT REMOVAL

• Always perform counterweight removal on firm, level surface.

• Always make certain the crawlers are not retracted. The machine is less stable when crawlers are retracted and can tip under certain conditions.

• Make certain the travel motors and machine are aligned correctly. Do not remove counterweight if the cab and counterweight are perpendicular to the travel motor.

Figure 201

DC04B674

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground, and place the front attachments on the ground, the throttle control in low idle. Place a DO NOT OPERATE tag on the machine controls in a visible position.

1

• Do not operate the remote removal switch while removing the counterweight bolts.

• Make certain the center of the counterweight is aligned with the counterweight removal system.

• If removing counterweight with crane, lift the counterweight slightly then move horizontally to avoid interference with the counterweight removal system.

S2LY00001ZE06 288-2

Figure 202

2. Turn the counterweight removal switch (1) located on the right control stand to on. This will actuate the counterweight removal system.

2 DC04A001

Figure 203

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

6-82

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass 29,320 lbs (13,300 kg). Failure to comply could result in death or serious injury.

A

C

4 B

3

Figure 206

CTWLOWER

A. EXTERNAL CONTROLLER B. COUNTERWEIGHT TILT ROCKER SWITCH C. COUNTERWEIGHT LIFT/HOIST SWITCH

S2LY00001ZE06 288-4

Figure 204

8. Using the external controller for the lifting system, change the position of the lift/hoist switch to the hoist position. Depress the top of the rocker switch to lift the counterweight cylinders.

4. The counterweight control cable (3) and remote control (4) are located in the grease pump compartment. Remove the cable and control from the holder.

6

5

S2LY00001ZE06 289-1

Figure 205

5. The counterweight cable connection is located on the left side of the machine. Open the connection cover and connect control cable (3) and remote control (4) to the cable connector (5).

6. Before starting to remove the counterweight, make certain that the lifting chain is not loose. Do not remove bolts until this check has been made.

7. Make certain the lifting device is adequate to lift the counterweight mass and chains.

S2LY00001ZE06 290-1

Figure 207

9. Apply slight pressure to the hoist chain (6). Make certain the counterweight removal system is in a vertical position. Correct if necessary by moving the tilt cylinder up or down.

6-83

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

A

C

7

B

CTWLOWER

Figure 209

A. EXTERNAL CONTROLLER B. COUNTERWEIGHT TILT ROCKER SWITCH C. COUNTERWEIGHT LIFT/HOIST SWITCH

8 S2LY00001ZE06 290-2

Figure 208

12. Using the external controller for the lifting system, change the position of the lift/hoist switch to the hoist position. Depress the top of the rocker switch to lift the counterweight cylinders.

WARNING: Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight mass 29,320 lbs (13,300 kg). Failure to comply could result in death or serious injury.

10. Do not allow anyone to work under the counterweight. To remove the counterweight, use a power wrench with 65 mm socket to loosen the four bolts (7) that hold the counterweight in place.

11. Remove the two bolts (8). Remove the four previously loosened four bolts (7).

WARNING: Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

NOTICE: Excavator functions are disabled when the counterweight switch is in the ON position.

6-84

DSCN1964

Figure 210

13. Lift the counterweight all the way up until the lift cylinders reach their maximum height.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

9

DSCN1963

Figure 213

16. This will allow the counterweight cylinders to tilt down and separate the counterweight from the back of the machine. Make cer tain the tilt cylinder is fully retracted before lowering the counterweight.

S2LY00001ZE06 291-2

Figure 211

14. The hoist cylinder will raise until it contacts the hoist stop.

CTWSWITCHUP

Figure 214

17. Change the position of the of the Lift/Hoist switch to the down position and press the bottom of the rocker switch in order to lower the counterweight.

CTWSWITCH2

Figure 212

15. Change the position of the Lift/Hoist Switch (3) to the tilt position and press the bottom of the Tilt Rocker Switch.

6-85

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

9

Figure 217

S2LY00001ZE06 293-3

21. Press the upper side of the rocker switch (Up) to tilt the counterweight cylinders.

S2LY00001ZE06 292-1

Figure 215

13

18. Lower the counterweight to the ground or transporting bed.

S2LY00001ZE06 293-2

10

11 12 S2LY00001ZE06 293-1

Figure 216

19. After making certain the counterweight is stable, disconnect the counterweight by removing pins from the counterweight chain. Install the pins back into the chain.

20. Use the external controller to reposition the cylinders and chain. Remove the exter nal controller and store securely in the compartment behind the operator’s seat. Close and secure the compartment access door.

6-86

Figure 218

22. Hold the upper side of the rocker switch until the counterweight lifting device (13) is raised vertically.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 26. Deactivate the counterweight removal system by pressing on the bottom of the counterweight removal switch (4) located on the right console.

Turn the engine off.

13

S2LY00001ZE06 294-1

Figure 219

23. After the counterweight lifting device (13) is fully raised, retract the host cylinder to lower the cylinder. Attach the chain on the hook (14).

24. Install pin (11) and insert the beta pin (12) to hold the chain in place. Install the chain on the other side following the same procedure.

WARNING: Make certain all access doors are securely closed and all tools are removed from the machine. Failure to comply could result in death or serious injury.

CTWSWITCH2

Figure 220

25. Turn the counterweight removal switch OFF. Turn the engine Off. Disconnect the control cable and store. Remove the Do Not Operate tag.

6-87

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS COUNTERWEIGHT INSTALLATION

4

Figure 223

CTWSWITCH2

Figure 221

DC04B674

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground, and place the front attachments on the ground, the throttle control in low idle. Shut off the engine.

Place a Do Not Operate tag on the machine controls in a visible position.

3. Press the counterweight removal installation switch. Located on the right console panel, this switch will activate the counterweight system.

Make certain the cancellation lever is in the lock (UP) position, before leaving the cab.

NOTICE: Excavator functions are disabled when the counterweight switch is in the ON position.

15

11 12 14 1 Figure 222

DC04A001

1. SAFETY LOCK LEVER

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

WARNING: Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight 22,050 lbs (10,002 kg). Failure to comply could result in death or serious injury.

DMG1961

Figure 224

4. Open the pump compartment locate the connection for the remote controller cable. Plug the connect cable in as in steps 1-5 in removal directions. Remove pin 12 from pin (22) and uncouple chain hook (14). If pin (11) is difficult to remove, loosen chain tension.

6-88

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WARNING: Make certain all access doors are securely closed and all tools are removed from the machine prior to operation. Failure to comply could result in death or serious injury.

9 Figure 227

CTWSWITCH2

Figure 225

CTWLOWER

5. Using the external controller for the lifting system, change the position of the lift/hoist switch to the tilt position. Depress the top of the rocker switch to lift the counterweight cylinders.

10

11 12 13

S2LY00001ZE06 296-3

S2LY00001ZE06 296-1

Figure 226

6. Switch the Tilt/Hoist switch to the Tilt side and press the DOWN side of the rocker switch. Lower to counterweight lifting device (13) to a horizontal position.

Figure 228

7. Place the counterweight on the ground and loosen the tension of the chain (1) slightly. Install the pin (11) and insert the beta pin (12). Install the other chain on the other side of the counterweight following the same steps.

6-89

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 12. Make certain the mounting hole of the counterweight is in line with the mating surface of the machine.

13. Clean the two counterweight mounting bolts (18) and tighten the bolts temporally with washers 919) 14. Temporary tightening torque: 300 Nm (221 lbf) 15. Pass the four counterweight mounting bolts (20) and 4 washers (21) through the bolt hole and tighten with 4 nuts (22) as shown in figure.

16. Temporary tightening torque: 300 Nm (221 lbf).

CTWSWITCHUP

Figure 229

8. Change the position of the Lift/Hoist switch to the hoist position and press the UP side until the counterweight lifting device is raised vertically.

17. Switch the Tilt/Hoist switch (9) to the Hoist side and press the DOWN side of the rocker switch to loosen chain tension slightly.

18. Tighten the six counterweight bolts to the specified torque.

9. Switch the Tilt/hoist switch to the hoist side and press the DOWn side of the rocker switch to lower the counterweight.

19. Turn OFF the counterweight removal switch.

10. Lower the counterweight until it meets the mating rear seat.

21. Disconnect control cable and store in proper location.

11. Visually confirm the position of the counterweight is correct.

22. Using the wrench, tighten the 8 mounting bolts for the two covers under the engine.

WARNING: Keep fingers clear of the mating surface of the counterweight and machine upperstructure. Do not allow anyone under or around the counterweight removal and installation system or counterweight during counterweight removal. Make certain all lifting devices are in good condition and capable of handling the counterweight 22,050 lbs (10,002 kg). Failure to comply could result in death or serious injury.

WARNING: Keep fingers and hands clear of mating surfaces of counterweight and machine upper structure. Failure to comply could result in death or serious injury.

6-90

20. Turn off engine and remove the DO Not Operate tag.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

22 18 2

21

20

21 4 2 6 3 1 5

Figure 230

S2LY00001ZE06 298-1

Standard Counterweight 10,400 kg (22,980 lbs)

Optional counterweight 13,400 kg (29,540 lbs)

Bolt No.

Bolt No.

Torque kNm (lbf)

Torque kNm (lbf)

18

3.92 ± 0.39 (2890 ± 290)

18

3.92 ± 0.39 (2890 ± 290)

20

3.92 ± 0.39 (2890 ± 290)

20

3.92 ± 0.39 (2890 ± 290)

6-91

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS COUNTERWEIGHT MAINTENANCE

S2LY00001ZE06 300-1

2

Lubricate chains with a spray lubricant each 250 hours or monthly and each time the counterweight is installed. To lubricate the chains, raise the lift cylinders as directed in the removal/installation procedures, leaving some slack in the chains. Coat the chains with spray lubricant.

4

3

1 S2LY00001ZE06 299-1

Figure 231

Always ke ep the coun te rweigh t removal and installation cylinders, pins, and bushings properly lubricated. Lubricate the counterweight cylinder pins and bushings each 500 hours of operation. Use extreme pressure multipurpose grease Number 2 to lubricate each pivot point (1-4).

6-92

Figure 232

Always check the chains for wear and damage.

Never use chains which are damaged.

CHAPTER 7 - ELECTRICAL

CHAPTER 7

ELECTRICAL TABLE OF CONTENTS ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Mechatro Controller (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL COMPONENTS ALTERNATOR Ask your Dealer to check the Alternator.

1

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Ask your Dealer to check the Starter Motor.

Make sure that the terminal protectors are correctly installed.

FUSES NOTICE: Fuses are also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Figure 1

BS06H104

Follow this procedure to replace “blown” or “faulty” fuses.

1. Move seat and seat base completely forward.

1. FUSE BOX COVER

Open the fuse compartment and remove fuse box cover from fuse box.

2. Locate and remove faulty fuses. Replace any fuse needed with the same type and amperage.

WARNING Never replace a faulty fuse with a higher amperage fuse. Never use a jumper in place of a fuse. Never splice accessories directly into fuse terminals.

Failure to comply could result in death or serious injury.

M1728

3. Refer to fuse box cover for fuse amperage and their functions.

7-3

CHAPTER 7 - ELECTRICAL

BS06H108

Figure 2

BS06H110

Figure 3

7-4

CHAPTER 7 - ELECTRICAL FUSIBLE LINK

MECHATRO CONTROLLER (CPU)

1

2 1

Figure 4

S2LY00001ZE05 92-01

If no power is available when the ignition key is turned on, check the fusible link. Inspect and replace the link if necessary.

S2LY00001ZE05 92-3

Figure 6

The Mechatro Controller and fuse/relay box are located at the rear of the operator seat. Be careful not to splash liquid or drinks on the controllers. If there is a malfunction of the controller, contact your authorized dealer. Do not attempt to self service this unit.

2 S2LY00001ZE05 92-02

Figure 5

1. Open the battery relay box door (1) on the rear side of the cab with the ignition key.

2. Remove the fusible link (2) if faulty. Replace with a new part.

3. Make certain connection is good and close battery relay door and lock.

7-5

CHAPTER 7 - ELECTRICAL BATTERIES NOTICE: Batteries is also shown on MAINTENANCE AND ADJUSTMENT, Chapter 6 in this Manual.

Perform complete battery service on a new machine after the first 50 hours of engine operation. Then, check electrolyte (acid) every 50 hours and perform maintenance every 250 hours.

.

WARNING Wear safety clothes, goggles or face shield, gloves and safety shoes when working with batteries.

Work in a well ventilated area.

Battery electrolyte (acid) is corrosive. If it comes in contact with skin, eyes or clothing, flush with large amount of water and seek immediate medical attention.

Battery electrolyte (acid) produces hydrogen gas that is highly explosive. Keep away sparks, fire or flames and do not smoke when working with batteries. Failure to comply could result in death or serious injury.

M144C

Figure 8

BS06H237

2. Remove battery cell caps and visually inspect electrolyte (acid) level. Proper level is 10 ~ 15 mm (0.4” ~ 0.6”) above cell plates.

3. If necessary, fill each cell to proper level with DISTILLED WATER ONLY. 4. Remove cables from terminals and clean with hot water. Coat each terminal with a thin layer of petroleum jelly. Clean cables in the same manner and reinstall onto battery.

5. If cables are found to be in poor condition, replace with new parts immediately.

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

BS06H238

Figure 7

1. Batteries are located on the left side of the machine in the air filter compartment.

7-6

84-109

CHAPTER 7 - ELECTRICAL 6. Use a hydrometer to check the specific gravity of each cell. Compare readings to the chart below.

NOTICE: Use hydrometer manufacturer’s instruction.

according

to

its

8. When the battery requires charging: a. Disconnect battery cables from terminals. b. Remove all cell caps.

ATMOSPHERIC TEMPERATURE CHARGE 20°C (68°F)

0°C (32°F)

-10°C (14°F)

100%

1.26

1.27

1.28

90%

1.24

1.25

1.26

80%

1.22

1.23

1.24

75%

1.21

1.22

1.23

c. Check for proper electrolyte (acid) level. d. Connect charger leads to the proper battery terminals.

NOTICE: Make certain not to cross Positive (+) and negative (-) terminals when connecting charger. e. Stop charge if battery overheats. f. Periodically check the specific gravity of the batteries with a hydrometer. Stop charging batteries when 100% charged.

NOTICE: Battery life can be shortened by over charging and over discharging of the battery.

Replace any battery that will not hold charge or difficult to charge.

2

1

BS06H238

Figure 9

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

7. When disconnecting batteries, remove the negative (-) cable first. When connecting batteries, connect the negative (-) cable last.

7-7

CHAPTER 7 - ELECTRICAL

NOTES

7-8

CHAPTER 8 - SPECIFICATIONS

CHAPTER 8

SPECIFICATIONS TABLE OF CONTENTS SK850 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Working Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Digging Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Attachment Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Bucket Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 SK850 PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Travel Speed, Swing Speed & Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 600 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-10 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 600 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-10 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 800 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-11 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 800 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-11 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . 8-12 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes . . . . . . . . . . . . . . . 8-12 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Capscrews & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 ORS Joint (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Nuts & Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 N2 (Nylon) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Torque Values For Most Common Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Weight of Materials Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Some Conversion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Units of Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

CHAPTER 8 - SPECIFICATIONS

SK850 GENERAL SPECIFICATIONS The specifications found in this section are given on the Standard SK850 Hydraulic Excavator as manufactured by Kobelco Construction: Boom 8.25 m (27’ 1”), Arm 3.6 m (11’ 10”), and 3.5 m3 (4.58 yd3) SAE Bucket. No modification or options are taken into consideration in regard to these specifications.

MACHINE DIMENSIONS

900 MM 35’4”

Figure 1

DC03N007

WORKING WEIGHT TRIPLE GROUSER

TRIPLE GROUSER

TRIPLE GROUSER

Track Shoe Width - mm (in)

650 (25.6)

750 (29.5)

900 (35.4)

Overall Working Width - m (ft - in)

4,200 (13.9)

4,300 (14.1)

4,450 (14.7)

Overall Transport Width - m (ft - in)

3,400 (11.2)

3,500 (11.6)

3,800 (12.6)

78,450 (172,980)

78,820 (173,800)

79,390 (175,050)

Working Weight - kg (lbs)

Bucket Weight: 2,610 kg (5,750 lbs)

DIGGING FORCES ARM LENGTH SAE Rating

11’ 10” (3.6 m)

Bucket Digging Force

*352 kN (79,133 lbs)

Arm Crowding Force

*298 kN (66,993 lbs) * Power boost engaged

ARM LENGTH ISO Rating

11’ 10” (3.6 m)

Bucket Digging Force

*401 kN (90,148 lbs)

Arm Crowding Force

*310 kN (69,691 lbs) * Power boost engaged

8-3

CHAPTER 8 - SPECIFICATIONS ATTACHMENT WORKING RANGES

Figure 2

DC03K130

ARM

Units: ft-in (m) WORKING RANGES (SK850)

11’ 10” (3.6 m) 4.58 yd3 (3.5 m3)

14’ 5” (4.4 m) 4.58 yd3 (3.5 m3)

A

Maximum digging reach

45’ 4” (13.83 m)

47’ 9” (14.56 m)

A’

Maximum digging reach at ground level

44’ 5” (13.55 m)

46’ 11” (14.29 m)

B

Maximum digging depth

29’ 2” (8.9 m)

31’ 10” (9.7 m)

C

Maximum digging height

39’ 9” (12.11 m)

40’ 6” (12.35 m)

D

Maximum dumping clearance

27’ 4” (8.34 m)

28’ 1” (8.57 m)

E

Minimum dumping clearance

12’ 0” (3.67 m)

9’ 5” (2.86 m)

F

Maximum vertical wall digging depth

22’ 1” (6.74 m)

24’ 6” (7.48 m)

G

Minimum front swing radius

20’ 10” (6.34 m)

20’ 10” (6.34 m)

H

Height at minimum swing radius

35’ 8” (10.87 m)

35’ 8” (10.87 m)

J

Digging depth for 8’ (2.4 m) flat bottom

28’ 8” (8.75 m)

31’ 5” (9.58 m)

8-4

CHAPTER 8 - SPECIFICATIONS BUCKET SELECTION CHART SK850 Bucket Selection Chart

Application

Hoe Bucket

Capacity yrd3 (m3)

Width ft-in (m)

Weight lbs (kg)

4.58 (3.5)

6’ 7” (2.0)

6.02 (4.6)

8’ 4” (2.53) 3

Arm 3.6 m (11’ 10”)

4.4 m (14’ 5”)

5,750 (2,610)

M

L

6,880 (3,120)

M

M

3

H - Used with material weight up to 1,780 kg/m (3,000 lb/yrd ).

M - Used with material weight up to 1,483 kg/m 3 (2,500 lb/yrd3).

L - Used with material weight up to 1,186 kg/m3 (2,000 lb/yrd3).

X - Not recommended.

ARM WITH BUCKET CYLINDER

DC04B663

BUCKET

Figure 3

Figure 4

DC04B664

3

3

Standard Arm is 3.6 m (11’ 10”)

Standard Bucket is 3.50 m (4.58 yd )

A - Total length is 5.19 m (17’ 0”)

A - Length is 2.25 m (7’ 5”)

B - Total height is 1.37 m (4’ 6”)

B - Height is 1.80 m (5’ 11”)

C - Width is 0.705 m (2’ 4”)

D - Width with side cutters is 1.98 m (6’ 6”)

Weight - Approximately 4,350 kg (9,950 lbs)

Weight - Approximately 2,560 kg (5,640 lbs)

8-5

CHAPTER 8 - SPECIFICATIONS BOOM WITH ARM CYLINDER

DC04B662

Standard Boom is 8.25 m (27’ 1”) A - Length is 8.62 m (28’ 3”) B - Height is 2,270 mm (7’ 5”) C - Width is 1,100mm (3’ 7”) Weight - Approximately 8,220 kg(18,120 lbs)

8-6

SHOES

Figure 5 DC03K215

Figure 6

1. Standard Shoes for SK850 are 29.5” (750 mm) triple grouser.

Height of grouser: 2.0” (50 mm).

2. Quantity of shoes: 51 per track.

CHAPTER 8 - SPECIFICATIONS

SK850 PERFORMANCE SPECIFICATIONS The following performance specifications are based on the standard machine with standard attachment.

TRAVEL SPEED, SWING SPEED & GRADEABILITY SK850 Travel Speed

4.2 km/hr (2.6 mph) in high speed 2.7 km/hr (1.7 mph) in low speed

Swing Speed

8.4 RPM in M-Mode/High Idle

Gradeability

70% (35°) Limited by engine lubrication

Drawbar Force

637 kN (143,203 Lbf)

ENGINE Engine Make

Komatsu LTD.

Model

SAA6D140E-5

Type

Diesel - 4 cycle, water cooled, direct injection with intercooler & turbocharger

No. of Cylinder - Bore x Stroke

6 cyl. - 140 mm x 165 mm (5.50” x 6.50”)

Displacement

15.241 Liters (930 cu. in)

Output Rating

370 kW (496 HP) @ 1,800 rpm

Maximum Torque

2197 N·m (1620 Lb-ft) @ 1,350 rpm

Cooling System

Circulating by a centrifugal pump.

Lubrication System

Pressurized oil fed by a gear pump.

Air Cleaner

Dry type with safety element

Electric System

24 V DC

Starting Motor

24 V - 5.0 kW

Alternator

24 V - 60Amps

Batteries

2 x 12V - (190 AmpHr)

Cold Start Assist

Electric Type

8-7

CHAPTER 8 - SPECIFICATIONS

HYDRAULIC COMPONENTS Hydraulic Pumps

2 x 504 l/min. (2 x 133.1 gpm) Tandem, variable displacement axial piston pump with 30.0 l/min. (7.9 gpm) Pilot Gear Pump at 4.9 MPa (710 psi).

Swing Motor

Axial piston, fixed displacement 179 l/min. (47 gpm) @ 27.9 MPa (4,050 psi)

Travel Motors

Axial piston, variable displacement. Max. displacement of 210 l/min (55 gpm) at 35.8 MPa (5,200 psi), 32.8 rpm in high speed and 48.8 rpm in low speed.

Control Valve

6 spools in the main control valve

Cylinders (All)

Double action

Oil Filtration

Hydraulic oil filtration is performed through a replaceable element and a suction strainer.

Oil Cooler

Air forced ventilation through finned tubbing.

OPERATING PRESSURES Pilot System

51 (725)

Swing

306 (4352)

Travel

336 (4779) 336 (4779)

Main Excavating Circuits Units: kgf/cm

8-8

2 (psi)

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPACITIES 1. Do not attempt to lift any load that exceeds the rated values at their specified load radius and height.

2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface.

Operator must make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings, attachment, etc.

3. Rating at bucket lift hook.

4. The rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J1097. They do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with asterisk (*) are limited by hydraulic capacity rather than tipping load.

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

5. Capacities apply to the machine as originally manufactured and normally equipped by Kobelco Construction.

NOTICE: The operator must consider the weight of any device utilized for lifting to properly calculate the total lifting capacity of the machine. example: 1. If the excavator uses the same bucket size indicated in the Lifting Chart, and a lifting cable, etc. weighing 100 kg (220 lbs) is used for lifting, then you have to subtract this additional 100 kg (220 lbs) from every value indicated in the Lifting Chart accordingly.

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

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

CE-NA000

Lifting Capacities Chart Legends:

A - Reach swing center line to bucket hook (Load Radius).

B - Bucket hook height above/below ground.

C - Lifting capacities in pounds (lb) and kilograms (kg).

Front Lifting.

Side Lifting.

8-9

CHAPTER 8 - SPECIFICATIONS STANDARD LIFT - MACHINE WITH 3.6 M ARM, 3.5 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES SK850 Lifting Capacities based on machine with: Boom: 27’ 1” (8.25 m) Arm: 11’ 10" (3.6 m) Bucket: 4.58 yd3 (3.5 m3) Shoes: 35.4” (900 mm) triple grouser shoe

At Maximum Reach

A 10’ 0” (3.0 m) 15’ 0” (4.6 m) 20’ 0” (6.1 m) 25’ 0” (7.6 m) 30’ 0” (9.1 m) 35’ 0” (10.7 m) B

C

30’ 0” (9.1 m)

lb kg

25’ 0” (7.6 m)

lb kg

*25600 *11610

*25600 *11610

*24510 *11110

20’ 0” (6.1 m)

lb kg

*27730 *12570

*27730 *12570

15’ 0” (4.6 m)

lb kg

10’ 0” (3.0 m)

RADIUS

*66720 *30260

*22690 *10290

32’ 9” (9.98 m)

*24510 *11110

*22860 *10360

*22860 *10360

35’ 6” (10.82 m)

*25520 *11570

*25520 *11570

*23660 *10730

22850 10360

37’ 4” (11.39 m)

*45680 *20710

*45680 *20710

*35960 *16310

*35960 *16310

*30460 *13810

*30640 *13810

*27060 *12270

25020 11350

*25090 *11380

20890 9470

38’ 6” (11.74 m)

lb kg

*53630 *24320

*53630 *24320

*40600 *18410

*4060 *18410

*33300 *15100

31010 14060

*28770 *13050

23970 10870

*26340 *11940

19780 8970

38’ 11” (11.87 m)

5’ 0” (1.5 m)

lb kg

*59110 *26800

54690 24800

*44380 *20120

39060 17710

*35780 *16220

29520 13390

*30300 *13740

23030 10440

*27370 *12410

19380 8790

38’ 8” (11.80 m)

Ground Level

lb kg

-5’ 0”(1.5 m)

lb kg

*40700 *18450

-10’ 0” (-3.0 m)

lb kg

-15’ 0” (-4.6 m) -20’ 0” (-6.1 m)

8-10

*66720 *30260

*22690 *10290

*45890 *20810

*45890 *20810

*61550 *27910

52900 23990

*46720 *21180

37550 17030

*37470 *16990

28440 12900

*31310 *14200

22340 10130

*28590 *12960

19700 8930

37’ 10” (11.53 m)

*40700 *18450

*61470 *27870

*61470 *27870

*61420 *27850

52290 23710

*47370 *21480

36820 16690

*38030 *17240

27860 12630

*31390 *14230

22000 9970

*29990 *13600

20880 9470

36’ 2” (11.03 m)

*57970 *26290

*57970 *26290

*77890 *35320

*77890 *35320

*59000 *26750

52510 23810

*46160 *20930

36750 16670

*37050 *16800

27800 12600

*31570 *14310

23320 10570

33’ 9” (10.29 m)

lb kg

*77370 *35090

*77370 *35090

*70000 *31740

*70000 *31740

*54030 *24500

53450 24240

*42610 *19320

37350 16940

*33670 *15270

28370 12870

*33250 *15080

28030 12710

30’ 3” (9.22 m)

lb kg

*76260 *34580

*76260 *34580

*57930 *26270

*57930 *26270

*45350 *20560

*45350 *20560

*35190 *15950

*35190 *15950

*34700 *15730

*34700 *15730

25’ 3” (7.69 m)

*28370 *12860 22700 10290 *24890 *11290 17880 8100 *22440 *10170 16890 7660 41’ 2” (12.56 m)

*35660 *16170 28020 1270 *29780 *13500 21810 9890 *12600 *11610 17360 7870 *25310 *11480 17070 7740 40’ 4” (12.30 m)

*36850 *16710 27160 12320 *30460 *13810 21250 9630

*36730 *16660 26830 12160 *29970 *13590 21090 9560

*34780 *15770 27050 12270

23010 10430 33’ 4” (10.18 m)

29510 13380 28’ 11” (8.82 m)

*32670 *14810

22’ 6” (6.87 m)

*29720 *13480

*31430 *14250

*32670 *14810

36’ 7” (11.15 m)

38’ 10” (11.84 m)

17910 8120

*33480 *15180

39170 17760

*41510 *18820

55280 25070

*55330 *25090

41’ 5” (12.62 m)

17300 7840

*20310 *9210

18550 8410

*23840 *10810

23810 10800

*26540 *12030

*30630 *13890

*30630 *13890

*37150 *16850

*37150 *16850

*48590 *22030

*48590 *22030

*65130 *29530

*65130 *29530

lb kg

10’ 0” (3.0 m)

41’ 0” (12.50 m)

18280 8290

*18870 *8550

19280 8740

*22730 *10310

*24600 *11150

*24600 *11150

*27540 *12490

*27540 *12490

*32180 *14590

*32180 *14590

lb kg

15’ 0” (4.6 m)

39’ 11” (12.17 m)

*17940 *8130

*17940 *8130

*22850 *10360

*22850 *10360

*24660 *11180

*24660 *11180

lb kg

20’ 0” (6.1 m)

*17460 *7910 35’ 7” (10.86 m)

*17470 *7920 38’ 2” (11.64 m)

*17460 *7910

*19360 *8780

*21590 *9790

*17470 *7920

*19360 *8780

lb kg

30’ 0” (9.1 m)

*21590 *9790

lb kg

25’ 0” (7.6 m)

RADIUS

C

B

At Maximum Reach

40’ 0” (12.2m)

35’ 0” (10.7 m)

30’ 0” (9.1 m)

25’ 0” (7.6 m)

20’ 0” (6.1 m)

15’ 0” (4.6 m)

10’ 0” (3.0 m)

5’ 0” (1.5 m)

A

SK850 Lifting Capacities (Heavy Lift) based on machine with: Boom: 27’ 1” (8.25 m) Arm: 11’ 10" (3.6 m) Bucket: 4.58 yd3 (3.5 m3) Shoes: 35.4” (900 mm) triple grouser shoe

19700 8930

*28080 *12730

*26610 *12070

29350 13310

37240 16890

36120 16380

35710 16190

35960 16310

36940 16750

*44610 *20230

*46140 *20920

*45940 *20830

*43690 *19810

*38570 *17490

52650 23880

51420 23320

51720 23460

*49440 *22420

*37770 *17130

*59520 *26990

*44080 *19990

51180 23210

*44080 *19990

*59290 *26880

*56050 *25400

*71630 *32480

*71630 *32480

*60580 *27470

*49440 *22420

*37770 *17130

*74580 *33820

*64710 *29350

*49210 *22320

*74580 *33820

*64710 *29350

*49210 *22320 *47000 *21310

*35980 *16310

*49610 *22500

*65210 *29570

*84390 *38270

*57100 *25890

*35980 *16310

*49610 *22500

*65210 *29570

*84390 *38270

*47000 *21310

*29390 *13330

*40950 *18570

*53710 *24360

lb kg

5’ 0” (1.5 m)

*57100 *25890

*29390 *13330

*40950 *18570

lb kg

*53710 *24360

Ground Level

-5’ 0” (-1.5 m) lb kg

-10’ 0” (-3.0 m) lb kg

lb kg

lb kg

-15’ 0” (-4.6 m) lb kg

-20’ 0” (-6.1 m)

-25’ 0” (-7.6 m)

CHAPTER 8 - SPECIFICATIONS

HEAVY LIFT - MACHINE WITH 4.46 M ARM, 3.5 M3 BUCKET, 900 MM TRIPLE GROUSER SHOES

8-11

CHAPTER 8 - SPECIFICATIONS

TORQUE SPECIFICATIONS The following Torque Specifications are provided for use when actual torque value of a fastener is not known.

CAPSCREWS & NUT METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES Make certain to tighten all Capscrews & Nuts to proper torque values.

Metric Coarse Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M6

P=1

0.45 ± 0.05 (3.2 ± 0.4)

0.38 ± 0.04 (2.7 ± 0.3)

0.98 ± 0.1 (7.1 ± 0.7)

0.83 ± 0.08 (6.0 ± 0.6)

1.77 ± 0.18 (12.8 ± 1.3)

1.5 ± 0.15 (10.8 ± 1.1)

M8

P=1.25

1.09 ± 0.11 (7.9 ± 0.8)

0.92 ± 0.09 (6.6 ± 0.7)

2.4 ± 0.2 (17.3 ± 1.4)

2.0 ± 0.2 (14.4 ± 1.4)

4.3 ± 0.4 (31.0 ± 2.9)

3.6 ± 0.4 (26.0 ± 2.9)

M10

P=1.5

2.2 ± 0.2 (15.9 ± 1.4)

1.83 ± 0.18 (13.2 ± 1.3)

4.7 ± 0.5 (33.9 ± 3.6)

4.0 ± 0.4 (28.9 ± 2.9)

8.5 ± 0.9 (61.3 ± 6.5)

7.2 ± 0.7 (52.0 ± 5.1)

M12

P=1.75

3.7 ± 0.4 (26.7 ± 2.9)

3.2 ± 0.3 (23.1 ± 2.2)

8.1 ± 0.8 (58.5 ± 5.8)

6.8 ± 0.7 (49.1 ± 5.1)

14.6 ± 1.5 (105 ± 10.8)

12.3 ± 1.2 (88.8 ± 8.7)

M14

P=2

5.9 ± 0.6 (42.6 ± 4.3)

5.0 ± 0.5 (36.1 ± 3.6)

12.8 ± 1.3 (92.5 ± 9.4)

10.8 ± 1.1 (78.0 ± 7.9)

23 ± 2 (166 14)

19.5 ± 1.9 (140 ± 14)

M16

P=2

9.0 ± 0.9 (64.9 ± 6.5)

7.6 ± 0.7 (54.8 ± 5.1)

19.5 ± 2.0 (140 ± 14.4)

16.4 ± 1.6 (118 ± 11.5)

35 ± 4 (252 ± 28.9)

29 ± 3 (209 ± 21.6)

M18

P=2.5

12.4 ± 1.2 (89.6 ± 8.7)

10.5 ± 1.0 (75.8 ± 7.2)

27 ± 3 (195 ± 22)

23 ± 2 (166 ± 14)

49 ± 5 (354 ± 36)

41 ± 4 (296 ± 29)

M20

P=2.5

17.5 ± 1.7 (126 ± 12.3)

14.7 ± 1.4 (106 ± 10.1)

38 ± 4 (274 ± 29)

32 ± 3 (231 ± 22)

68 ± 7 (491 ± 51)

57 ± 6 (412 ± 43)

M22

P=2.5

23 ± 2 (166 ± 14)

19.6 ± 2 (142 ± 14)

51 ± 5 (368 ± 36)

43 ± 4 310 ± 29)

92 ± 9 (663 ± 65)

77 ± 7 (555 ± 58)

M24

P=3

30 ± 3 (217 ± 22)

24 ± 3 (173 ± 22)

65 ± 7 (469 ± 51)

53 ± 5 (383 ± 36)

118 ± 12 (852 ± 87)

96 ± 10 (693 ± 72)

M27

P=3

44 ± 4 (318 ± 29)

36 ± 3 (260 ± 22)

96 ± 10 (693 ± 72)

78 ± 8 (563 ± 58)

173 ± 17 (1250 ± 120)

140 ± 14 (1010 ± 100)

M30

P=3.5

60 ± 6 (433 ± 43)

50.5 ± 5 (361 ± 36)

131 ± 13 (946 ± 94)

110 ± 11 (794 ± 79)

235 ± 24 (1700 ± 170)

198 ± 20 (1430 ± 140)

M33

P=3.5

81 ± 8 (585 ± 58)

68 ± 7 (491 ± 51)

176 ± 18 (1270 ± 130)

148 ± 15 (1070 ± 110)

317 ± 32 (2290 ± 200)

266 ± 27 (1920 ± 200)

M36

P=4

105 ± 10 (758 ± 72)

88 ± 9 (636 ± 65)

227 ± 23 (1640 ± 170)

190 ± 19 (1370 ± 140)

409 ± 41 (2960 ± 300)

343 ± 34 (2480 ± 250)

TORQUE VALUE UNIT: kgf-m (ft-lbs)

8-12

CHAPTER 8 - SPECIFICATIONS METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES Tighten all Capscrews & Nuts to proper torque values.

Metric Fine Thread Standard Tightening Torque Values 4.8 T

Classification NOMINAL SIZE

7T

10.9 T

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

NO LUBRICATION

OIL LUBRICATION

M8

P=1

1.15 0.11 (8.3 ± 0.8)

0.97 ± 0.1 (7.0 ± 0.7)

2.5 ± 0.2 (18.0 ± 1.4)

2.1 ± 0.2 (15.2 ± 1.4)

4.5 ± 0.4 (32.5 ± 2.9)

3.8 ± 0.4 (27.4 ± 2.9)

M10

P=1.25

2.3 ± 0.2 (16.6 ± 1.4)

1.91 ± 0.19 (13.8 ± 1.4)

4.9 ± 0.5 (35.4 ± 3.6)

4.2 ± 0.4 (30.3 ± 2.9)

8.9 ± 0.9 (64.2 ± 6.5)

7.5 ± 0.7 (54.2 ± 5.1)

M12

P=1.25

4.0 ± 0.4 (28.9 ± 2.9)

3.4 ± 0.3 (24.5 ± 2.2)

8.7 ± 0.9 (62.8 ± 6.5)

7.3 ± 0.7 (52.7 ± 5.1)

15.7 ± 1.6 (113 ± 13)

13.2 ± 1.3 (95.3 ± 9.4)

M16

P=1.5

9.4 ± 0.9 (67.9 ± 6.5)

7.9 ± 0.8 (57.0 ± 5.8)

20 ± 2 (144 ± 14)

17.2 ± 1.7 (124 ± 12)

37 ± 4 (267 ± 29)

31 ± 3 (224 ± 22)

M20

P=1.5

19 ± 9 (137 ± 14)

15.8 ± 1.6 (114 ± 14)

41 ± 4 (296 ± 29)

34 ± 3 (246 ± 22)

74 ± 7 (535 ± 51)

62 ± 6 (448 ± 43)

M24

P=2

32 ± 3 (231 ± 22)

27 ± 3 (195 ± 22)

70 ± 7 (506 ± 51)

58 ± 6 (419 ± 43)

126 ± 12 (910 ± 87)

105 ± 10 (758 ± 72)

M30

P=2

65 ± 6 (469 ± 43)

54 ± 5 (390 ± 36)

142 ± 14 (1030 ± 100)

118 ± 12 (852 ± 87)

255 ± 26 (1840 ± 190)

212 ± 21 (1530 ± 150)

M36

P=3

109 ± 11 (787 ± 79)

91 ± 9 (657 ± 65)

238 ± 23 (1720 ± 170)

198 ± 20 (1430 ± 140)

428 ±43 (3090 ± 310)

357 ± 36 (2580 ± 260)

TORQUE VALUE UNIT: kgf-m (ft-lbs)

ORS JOINT (O-RING SEALING TYPE) ORS Joint (O-ring Sealing Type)

Hose mouth ring and Coupling

NOMINAL SIZE

OPPOSING FLATS mm

TORQUE VALUE kgf-m (ft.-lbs)

1 - 14 UNS

30 - 32

14 ± 1.4 (101 ± 10)

1 - 3/16 12 UN

36 - 41

18 ± 1.8 (130 ± 13)

1 - 7/16 12 UN

41 - 46

21 ± 2.1 (152 ± 15)

WORKING PRESSURE kgf/cm2 (psi) 350 (4980) 385 (5475) Power Boost

8-13

CHAPTER 8 - SPECIFICATIONS NUTS & SLEEVES Nuts and Sleeves

MANUFACTURER’S NAME

WORKING PRESSURE kgf/cm2 (psi)

350 (4980) Travel line only

NIPPON A.M.C.

350 (4980) Travel line only

IHARA KOATSU

FLARE TYPE FITTING JOINTS Flare Type Fitting Joints

TUBE SIZE O.D. X THICKNESS mm (in)

OPPOSING FLATS mm Dimension B

TORQUE VALUE kgf-m (ft.-lbs)

10 X 1.5 (0.394 X 0.059)

19

4.5 ± 0.5 (33 ± 4)

15 X 2.0 (0.591 X 0.079)

27

15 ± 2 (108 ± 14)

18 X 2.5 (0.709 X 0.098)

32

18 ± 2 (130 ± 14)

22 X 3.0 (0.866 X 0.118)

36

22 ± 2 (159 ± 14)

28 X 4.0 (1.10 X 0.157)

41

28 ± 3 (203 ± 22)

35 X 5.0 (1.38 X 0.20)

55

35 ± 4.5 (253 ± 29)

N2 (NYLON) TUBE FITTING JOINTS N2 (Nylon) Tube Fitting Joints

Overtightening of flare type (Union Nut Type) metal joints may cause damage to nuts, seat surfaces, and prevent optimum sealing resulting in oil leaks.

NOMINAL SIZE (PIPE THREAD)

TORQUE VALUE

1/4”

2.5 ± 0.3 (18.1 ± 1.8)

3/8”

5 ± 0.5 (36.2 ± 3.6)

1/2”

6 ± 0.6 (43.4 ± 4.3)

3/4”

12 ± 1.2 (86.8 ± 8.7)

1”

14 ± 1.4 (101 ± 10)

1-1/4”

17 ± 1.7 (123 ± 12)

1-1/2”

21 ± 2.1 (152 ± 15)

2”

42 ± 4.2 (304 ± 30) Unit: kgf-m (ft.-lbs)

8-14

1. Clean Tube and make sure certain tube end is trimmed smooth.

2. Insert tube into fitting until tube end is securely seated in fitting body.

3. Tighten the nut by hand.

4. Use a spanner wrench, securely tighten nut by turning 1-1/4 turns.

CHAPTER 8 - SPECIFICATIONS TORQUE VALUES FOR MOST COMMON BOLTS [Bolt Size] Units: kgf-m (ft-lbs) Location

Qty

SK850

5

Fuel Tank sending unit mounting

[M5] 0.2 ± 0.01 (1.4 ± 0.1)

6

A/C condenser mounting

[M6x50] 0.46 (3.3)

1

Hyd. tank sending unit mounting

15 ± 2 (108 ± 14)

6

A/C pulley mounting on damper

[M8x16] 4 (29)

4

Coolant reservoir mounting

1.1 ± 0.1 (8 ± 0.7)

4

A/C compressor mounting

[M8x100] 1.1 ± 0.1 (8 ± 0.7)

1

A/C idler pulley nut

[M10] 4 - 5.5 (29 - 40)

2

Pilot pump mounting bolts

[M10] 4 ± 0.4 (29 ± 3) Apply Loctite # 262

8

Hydraulic oil tank cover mounting

[M10] 4.7 ± 0.6 (34 ± 4)

2

Swing grease bath inspection cover mounting

[M10} 3 ± 0.6 (22 ± 4)

8

Swivel joint dust cover mounting

[M10} 1.5 ± 0.3 (11 ± 2)

6

Muffler support bracket mounting

[M10] 4 ± 0.4 (30 ± 3)

16

Engine mounting (engine body side)

[M10] 6.6 ± 0.4 (48 ± 3) Apply Loctite # 262

4

Travel lever mounting

[M10] 2.4 ± 0.3 (17 ± 2)

3

Stepping motor mounting

[M10] 1.9 (14) Apply Loctite # 242

12

Hydraulic pump housing to engine block mounting

[M10] 6.6 ± 0.6 (48 ± 4) Apply Loctite # 262

35

Lower cover mounting

[M10] 5.3 ± 0.6 (38 ± 4)

2

A/C compressor cover mounting

[M10x45] 6.2 (45)

10

Travel motor cover mounting

8.4 ± 0.8 (61 ± 6) Apply Loctite # 262

16

Cab support mounting bolts

4.7 (34)

3

Swivel joint mounting

11 ± 1 (79 ± 7) Apply Loctite # 262

4

Nuts for cab mounts

19 (137)

4

Idler and idler adjuster connection

[M16] 28.5 ± 3 (206 ± 22) Apply Loctite #262

4

Hydraulic oil tank and fuel tank mounting

[M16] 22 ± 2 (159 ± 14) Apply Loctite # 262

4

Radiator bottom support mounting

[M12] 12.3 ± 1.2 (89 ± 9)

1

Swivel joint locking nut

[M16] 15.9 ± 2 (115 ± 14)

8

Hydraulic pump coupling mounting

[M16] 22 ± 1 (159 ± 7) Apply Loctite # 262

8

track guide mounting

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Engine mounting (Upper frame side)

[M18] 23 ± 2 (166 ± 14) Apply Loctite # 271

44

Sprocket mounting

[M18] 40.4 ± 4(292 ± 29) Apply Loctite # 262

56

Lower roller caps

[M18] 40.4 ± 4 (292 ± 29) Apply Loctite # 262

4

Hydraulic pump mounting

[M20] 44 ± 4 (318 ± 29) Apply Loctite # 262

12

Swing reduction unit mounting

[M20] 55 ± 6 (397 ± 43) Apply Loctite # 262

36

Swing bearing inner race mounting

[M20] 57.4 ± 5.8 (415 ± 42) Apply Loctite # 262

33

Swing bearing outer race mounting

[M20] 40 ± 4 (289 ± 29) Apply Loctite # 262

184

Shoe bolt mounting

[M20] 86.8 ± 5 (628 ± 36)

4

Upper roller mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

34

Travel motor mounting

[M20] 55 ± 5.5 (397 ± 40) Apply Loctite # 262

4

Counterweight mounting

130 ± 13 (939 ± 94) Apply Loctite # 242

8

Side cutter mounting

[M24] 95 - 105 (686 - 758)

8-15

CHAPTER 8 - SPECIFICATIONS [Bolt Size] Units: kgf-m (ft-lbs) Location

Qty

SK850

2

Idler adjuster grease fitting mounting

[5/8”-18UNF] 5.9 ± 1 (43 ± 7)

2

Connector for heater hoses

2.5 (18) Apply three bond # 1110B

1

Nut on breather valve

1 - 1.4 (7 - 10)

4

Breather mounting bolts

0.48 (3.5)

1

Hydraulic tank plug

16.5 (119) Apply teflon tape

4

Top nuts for U-bolts muffler mounting

1.1 ± 0.1(8 ± 1)

4

Bottom nuts for U-bolts muffler mounting

0.9 ± 0.1 (6.5 ± 1)

1

Engine temperature sensor

2.5 ± 0.6 (18 ± 4) Apply three bond # 1110B

2

A/C hose connection on Compressor

2.4 ± 0.2 (17 ± 1.4)

2

A/C hose connection on Condenser

1.0 ± 0.1 (7.2 ± 0.72)

4

Cover mounting on swing motor

[M20] 43.8 (317)

1

Swing reduction unit oil plug

5.7 (41) Apply teflon tape

2

Oil plugs on travel reduction unit cover

5.7 (41) Apply teflon tape

WEIGHT OF MATERIALS TABLE lb/yrd3

kg/m3

Wood chips

700

420

Peat, dry

750

440

Cinders

950

560

Peat, wet

1170

690

Top soil

1600

950

Coal

1780

1050

Caliche

2100

1250

Earth, loam

2100

1250

Shale

2250

1330

Sand, dry

2400

1420

Clay, dry

2500

1480

Earth, dry

2550

1510

Limestone, broken or crush

2600

1540

Earth, wet

2700

1600

Clay, wet

2800

1660

Rock, granite, blasted & broken

2800

1660

Sand, moist

2850

1690

Sand and gravel, dry

2900

1720

Sand, wet

3100

1840

Sand and gravel, wet

3400

2020

Material (Loose Weight)

8-16

CHAPTER 8 - SPECIFICATIONS SOME CONVERSION UNITS

UNITS OF PRESSURE

UNITS OF WEIGHT

Units of Pressure From

Units of Weight From

Into

Multiply by

kg

lb

2.2

lb

kg

0.454

kg/cm2

Into

Multiply by

psi

14.223

Pa (Pascal)

9.807

Atm

0.06805

Bars

UNITS OF LENGTH psi

From

Into

Multiply by

Divide by

meters

feet

3.28

-

mm

inches

-

25.4

inches

mm

25.4

-

0.0703

Pa (Pascal)

6894.76

psi

145.04

kg/cm

Units of Length

0.06895 2

MPa (MegaPascal)

UNITS OF VOLUME

UNITS OF POWER Units of Volume Units of Power

Into

Multiply by 0.264

0.7457

Gal (US Liquid)

1.341

in3

61.02

yard3

0.00131

quarts

1.0567

ounces (US)

33.81

From

From

Into

Multiply by

HP

kW

kW

HP

Liters

UNITS OF FLOW Units of Flow Into

Multiply by

m3

0.765

Lit/min

3.79

in3

46656

Lit/sec

0.0631

ft3

27

cm3/min

3785.4

cm3

764554.9

ft3/min

0.1337

liters

764.555

ft3/min

0.0353

Gal/min

0.264

Gal/sec

0.004403

yard3/min

0.001308

From

Gal/min (US liquid)

Liter/min

Yard3

UNITS OF TORQUE Units of Torque From

N-m

lbf-ft

Into

Multiply by

lbf-ft

0.738

kgf-m

0.1019716

lbf-ft

0.737561

lbf-in

8.85075

kgf-m

0.1382552

N-m

1.35582

lbf-in

12

8-17

CHAPTER 8 - SPECIFICATIONS

NOTES

8-18

CHAPTER 9 - INDEX

Chapter 9

INDEX Symbols “Tag-Out” Machine .............................................. 6-6

Control Decal ......................................................4-10 Counter Rotating Machine ..................................4-15

A

D

Air Cleaner ................................................ 6-33, 6-39 Air Conditioning Compressor Belt ..................... 6-27 Air Intake System .............................................. 6-24 Alternator ............................................................. 7-3 Arm ...................................................................... 8-5 Arm Cylinder Hoses and Tubes ......................... 6-61 Arm Operation ................................................... 4-17 Attachment Lubrication ...................................... 6-13 Attachment Working Ranges ............................... 8-4 Auto Warm Up ..................................................... 4-8

Decals ................................................................2-10 Digging Forces .....................................................8-3 Disposal of Hazardous Waste ..............................6-6 Document Pouch ..................................................3-6 Dust Seals ..........................................................6-52

B Back Filling & Leveling with Front Attachment .. 4-21 Basic Operation of Hydraulic Controls ............... 4-12 Batteries .............................................................. 7-6 Before Operating the Hydraulic Breaker ............ 4-25 Before Operating the Machine ............................. 4-3 Boom ................................................................... 8-6 Boom & Arm ...................................................... 6-55 Boom Cylinder Hoses and Tubes ...................... 6-61 Boom Operation ................................................ 4-16 Bucket ......................................................... 6-56, 8-5 Bucket Cylinder and Nibbler/Breaker Hoses & Tubes 6-61 Bucket Operation ............................................... 4-17 Bucket Selection Chart ........................................ 8-5 Bucket Selection Guide ..................................... 4-23 Bucket Teeth and Side Cutters .......................... 6-59 Bucket Teeth Direction ...................................... 4-20 Bucket, Arm, & Link Clearance .......................... 6-56 Burn Prevention ................................................... 2-8 Buzzer Stop Switch ........................................... 3-13

C Cab Dome Light ................................................... 3-6 Cab Door Latch ................................................... 3-3 Change Hydraulic Oil ......................................... 6-50 Checking and Cleaning Fuel Tank and Strainer 6-36 Checking the Engine RPM ................................ 6-37 Cleaning Parts ..................................................... 6-7 Cleaning Sand & Soil from Bucket .................... 4-20 Cleaning Suction Strainer .................................. 6-46 Connecting Booster Cable ................................... 4-6

E Engine .......................................................... 1-4, 8-7 Engine Accessory Belt Wear and Tension .........6-26 Engine Coolant Change .....................................6-43 Engine Coolant Level .........................................6-14 Engine Coolant Tank & Engine Air Cleaner Access Doors ...........................................................3-30 Engine Electrical .................................................6-15 Engine Fluid Leaks .............................................6-15 Engine Lubrication Cumulative Time ..................3-16 Engine Oil and Filter Element ................... 6-18, 6-29 Engine Oil Level .................................................6-14 Engine Oil Type ....................................................5-6 Engine Valve Clearance .....................................6-39 Environment .........................................................5-6 Extra (Grapple, clamshell, etc.) and Extra & Breaker 4-32

F Fan Belts ............................................................6-26 Fire Extinguisher ..................................................2-8 Flare Type Fitting Joints .....................................8-14 Frame Structure ......................................... 6-7, 6-53 Fresh Air Filter ....................................................6-28 Fuel Filter Cumulative Time ...............................3-16 Fuel Handling Precautions ...................................2-7 Fuel Level ...........................................................6-15 Fuel Lines and Hoses .........................................6-61 Fuel Tank Drain ..................................................6-22 Fuses ....................................................................7-3

G General Information ..............................................1-1 Ground Transportation .......................................4-35 Guidelines for Attachment Lubrication ....... 6-9, 6-11

H Hand Signals ......................................................2-25 9-1

CHAPTER 9 - INDEX Hazardous Chemical Precautions ....................... 2-8 Heater Hoses ..................................................... 6-61 Heavy Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes ....... 8-11 Hot Surface & Fluids ............................................ 6-6 How to Handle Life Hammer ............................... 2-9 Hydraulic Breaker .............................................. 4-25 Hydraulic Components ........................................ 8-8 Hydraulic Filter Cumulative Time ....................... 3-16 Hydraulic Functions ........................................... 6-17 Hydraulic Lines, Tubes, and Hoses ................... 6-61 Hydraulic Oil Cumulative Time .......................... 3-16 Hydraulic Oil Level ............................................. 6-16 Hydraulic Return Filter ....................................... 6-40 Hydraulic Suction Tubes and Hoses ................. 6-62

I Identification Numbers ......................................... 1-4 Idlers .................................................................. 6-54 Inspect Waste Oils and Filters ............................. 6-6 Installing the Bucket .......................................... 6-59

K Keep Machine Clean ........................................... 6-6 Key Switch ......................................................... 3-10

L L.C.D. Display .................................................... 3-16 Lifting Capacities ................................................. 8-9 Locking/Unlocking Cab Door ............................... 3-3 Lowering Attachment When Sudden Engine Failure Occurs ......................................................... 6-66

M Machine Attachment and Swing ........................ 4-16 Machine Components .......................................... 1-3 Machine Dimensions ........................................... 8-3 Machine Operation in Adverse Weather Conditions ..

4-22 Machine Storage ............................................... 4-41 Machine Travel Controls .................................... 4-14 Machine Warm Up ............................................... 4-8 Maintenance Precautions .................................... 2-7 Manual Warm Up ................................................. 4-8 Maximum Digging Force position ...................... 4-20 Metric Coarse Thread Standard Tightening Torque Values ......................................................... 8-12 Metric Fine Thread Standard Tightening Torque Values ......................................................... 8-13 Model, Serial Number, and Year of Manufacture 1-4 Monitor ............................................................... 3-11 9-2

Mounting and Dismounting Precautions ...............2-5

N N2 (Nylon) Tube Fitting Joints ............................8-14 Nibbler/Breaker ..................................................4-26 Nuts & Sleeves ...................................................8-14

O Opening and Closing Door Glass .........................3-5 Opening and Closing Sunroof ..............................3-5 Opening and Closing Windshield .........................3-4 Operate Boom Smoothly ....................................4-20 Operating Both Travel Levers Together .............4-14 Operating Pattern ...............................................4-10 Operating Pattern Decal .....................................4-10 Operating Precautions ..........................................2-5 Operating Pressures ............................................8-8 Operating the machine .........................................4-3 Operating the Machine in Water .........................4-16 Operating the Shovel ..........................................4-21 Operation at Seashore or Salty Climate .............4-22 Operation in Extreme Cold .................................4-22 Operation in Extreme Heat .................................4-22 Operation in High Altitudes .................................4-22 Operation in Humid Climate ...............................4-23 Operation in Sandy and Dusty Areas .................4-22 Operator Precautions ...........................................2-4 Operator Seat Adjustments ..................................3-7 Operator’s Compartment Controls and Accessories .

3-9 ORS Joint (O-ring Sealing Type .........................8-13

P Personal Safety ....................................................2-3 Practices to Improve Efficiency ..........................4-20 Prevent Contamination .........................................6-7 Pump Flow Rate Adjustment ..............................3-24

R Radiator, Oil Cooler & Debris Screen .................6-68 Radio ..................................................................3-35 Rear View Mirrors ...............................................6-62 Recirculate Air Filter ...........................................6-28 Recommendation for Longer Undercarriage Life ......

4-23 Releasing Hydraulic System and Tank Pressure .6-8 Releasing Travel Motor Brakes Manually ...........6-65 Removing and Storing Lower Front Window ........3-4 Removing Machine from Storage .......................4-41 Removing the Bucket .........................................6-58 Required Filters ....................................................5-4

CHAPTER 9 - INDEX Required Fluids/Lubricants and Capacities ......... 5-3 Reversing Bucket .............................................. 6-57 Right Hand Operator Console and Monitor ....... 3-10 Right, Left, Front, and Rear of the Machine ........ 1-2 Rollers ............................................................... 6-54 Roll-Over Protective Structure (If equipped) ........ 2-8

S Safety Area .......................................................... 2-3 Safety Rules ........................................................ 2-3 Screen Change Switch ............................. 3-14, 3-26 Seals & O-Rings .................................................. 6-6 Seat Belt Precautions .......................................... 2-9 Seat Height Adjustment ....................................... 3-7 Seat Reclining Adjustment .................................. 3-7 Securing Machine to Trailer ............................... 4-40 Selection of the Hydraulic Breaker .................... 4-25 Shoes .................................................................. 8-6 SK350-8 Performance Specifications .................. 8-7 Special Considerations for Hand Lubrication .... 6-11 Specific Precautions to this Machine ................... 2-9 Sprockets ........................................................... 6-54 Standard Lift - Machine with 3.45 m Arm, 1.91 m3 Bucket, 900 mm Triple Grouser Shoes ....... 8-10 Starter Motor ........................................................ 7-3 Starting & Stopping Machine Engine with Temperature above 0°C (32°F) ..................... 4-4 Starting & Stopping Machine Engine with Temperature below 0°C (32°F) ..................... 4-5 Starting and Stopping Precautions ...................... 2-5 Starting Boosting Machine Engine ...................... 4-6 Starting Disabled Machine Engine ...................... 4-7 Starting Engine ............................................. 4-4, 4-5 Starting Machine Engine with Booster Cable ...... 4-6 Steps and Handrails .......................................... 6-17 Stop Engine ......................................................... 6-6 Stop Swing Motion Early ................................... 4-21 Stopping Engine - Normal Conditions .......... 4-4, 4-5 Swing Operation ................................................ 4-18

Travel Safety ......................................................4-16 Travel Speed Select Switch ...............................3-15 Travel Speed, Swing Speed & Gradeability .........8-7

U Units of Flow .......................................................8-17 Units of Length ...................................................8-17 Units of Power ....................................................8-17 Units of Pressure ................................................8-17 Units of Torque ...................................................8-17 Units of Volume ..................................................8-17 Units of Weight ...................................................8-17 Use Arm in Action ...............................................4-20 Use of Optional Attachment ...............................4-24 Use of Travel Speed Select Switch ....................4-14 Using Power Boost .............................................4-18 Utility Safety .........................................................2-4

W Warm Engine Oil ..................................................6-6 Warming of Hydraulic Oil ......................................4-8 Warming Up of Engine .........................................4-8 Water Separator .................................................6-68 Wear Safety Equipment .......................................6-7 Weight of Materials Table ...................................8-16 Welding Safety .....................................................6-7 Windshield Washer Fluid Reservoir ...................6-62 Wiper Switch ......................................................3-13 Work Mode selection Table ................................4-13 Work Mode Switch ................................... 3-12, 4-13 Working Weight ....................................................8-3

T Throttle Potentiometer ....................................... 3-10 Torque Specifications ........................................ 8-12 Torque Values For Most Common Bolts ........... 8-15 Track Links ........................................................ 6-53 Track Shoes ...................................................... 6-53 Track Tension .................................................... 6-55 Tracks and Components ................................... 6-53 Transportation ................................................... 4-35 Transporting Precautions .................................... 2-8 Travel Independent Mode Display ..................... 3-16 9-3

CHAPTER 9 - INDEX

9-4